ABB IRB 460 Series Product Manual
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ABB IRB 460 Series Product Manual

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IRB 460

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Summary of Contents for ABB IRB 460 Series

  • Page 1 ROBOTICS Product manual IRB 460...
  • Page 2 Trace back information: Workspace R18-2 version a18 Checked in 2018-11-20 Skribenta version 5.3.012...
  • Page 3 Product manual IRB 460 - 110/2.4 IRC5 Document ID: 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved. Specifications subject to change without notice.
  • Page 4 The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    Mechanically restricting the working range of axis 1 ........Robot in cold environments ................. 2.6.1 Start of robot in cold environments ............Electrical connections ..................2.7.1 Robot cabling and connection points ............Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 6 Replacing motor, axis 6 ................Gearboxes ....................... 4.6.1 Replacing the axis 1 gearbox ..............4.6.2 Replacing the axis 2 gearbox ..............4.6.3 Replacing the axis 3 gearbox ..............Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 7 Standard tools ....................Special tools ....................Lifting accessories and lifting instructions .............. Spare parts Spare part lists and illustrations ................Circuit diagrams Circuit diagrams ....................Index Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 8 This page is intentionally left blank...

  • Page 9: Overview Of This Manual

    Prerequisites Maintenance/repair/installation personnel working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Product manual scope The manual covers covers all variants and designs of the IRB 460. Some variants and designs may have been removed from the business offer and are no longer available for purchase.
  • Page 10 Replacing the tilthouse unit on page 188. • Procedures for Removal and Refitting updated in section Replacing the upper arm on page 209. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 11 The maximum allowed deviation in levelness of the base plate and foundation is changed, see Securing the base plate on page • Minor corrections. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 12 Published in release R18.2. The following updates are done in this revision: • Added locating hole position in tool flange view. Published in release R18.2. The following updates are done in this revision: • Updated references. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 13: Product Documentation

    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.
  • Page 14 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. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 15: How To Read The Product Manual

    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. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 16 This page is intentionally left blank...

  • Page 17: Safety

    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 complete system, nor does it cover all peripheral equipment that can influence the safety of the entire system.
  • Page 18 Unauthorized modifications of the originally delivered robot are prohibited. Without the consent of ABB, it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength of the robot could be affected.

  • Page 19: Protective Stop And Emergency Stop

    1.1.2 Protective stop and emergency stop 1.1.2 Protective stop and emergency stop Overview The protective stops and emergency stops are described in the product manual for the controller. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 20: Safety Actions

    1.2 Safety actions 1.2.1 Fire extinguishing Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the manipulator or controller. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 21: Emergency Release Of The Robot Axes

    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. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 22: Make Sure That The Main Power Has Been Switched Off

    To avoid these personal injuries, switch off the main power on the controller before proceeding work. Note Switch off all main power switches in a MultiMove system. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 23: Safety Risks

    Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 24 ABB is not liable for damages caused by the use of non-original spare parts and special equipment. ABB is not liable for damages or injuries caused by unauthorized modifications to the robot.

  • Page 25: Moving Robots Are Potentially Lethal

    The hold-to-run function is used in manual mode, not in automatic mode. Make sure no personnel are present within the working range of the robot before pressing the start button. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 26: First Test Run May Cause Injury Or Damage

    If maintenance or repair has been done, pay special attention to the function of the part that was serviced. Collision risks CAUTION When programming the movements of the robot, always identify potential collision risks before the first test run. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 27: Work Inside The Working Range Of The Robot

    Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 28: Enabling Device And Hold-To-Run Functionality

    How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 29: Risks Associated With Live Electric Parts

    The power supply for the motors (up to 800 VDC). • The user connections for tools or other parts of the installation (max. 230 VAC). Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 30 Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 31: The Unit Is Sensitive To Esd

    The mat must be grounded through a current-limit- ing resistor. Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 32: Hot Parts May Cause Burns

    Wait until the potentially hot component has cooled if it is to be removed or handled in any other way. Do not put anything on hot metal surfaces, e.g. paper or plastic. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 33: Safety Risks Related To Pneumatic/Hydraulic Systems

    Gravity may cause any parts or objects held by these systems to drop. Dump valves should be used in case of emergency. Shot bolts should be used to prevent tools, etc., from falling due to gravity. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 34: Brake Testing

    3 Inspect and verify that the axis maintains its position. If the robot does not change position as the motors are switched off, then the brake function is adequate. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 35: Safety Risks During Handling Of Batteries

    Risk of fire or explosion. Operating temperatures are listed in Pre-installation procedure on page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 36: Safety Risks During Work With Gearbox Lubricants (Oil Or Grease)

    Possible pressure build-up in gearbox Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 37 The magnetic oil plugs will take Contaminated oil in care of any remaining metal gear boxes chips. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 38: Safety Signals And Symbols

    ELECTROSTATIC Warns for electrostatic hazards which could result DISCHARGE (ESD) in severe damage to the product. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 39 Symbol Designation Significance NOTE Describes important facts and conditions. Describes where to find additional information or how to do an operation in an easier way. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 40: Safety Symbols On Product Labels

    Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 41 Brake release Pressing this button will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 42 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 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 43 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 xx1500002616 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 44 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 45 Shut off with handle Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 46 This page is intentionally left blank...

  • Page 47: Installation And Commissioning

    If the IRB 460 is connected to power, always make sure that the robot is connected to protective earth before starting any installation work. For more information see: • Product manual - IRC5 Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 48: Unpacking

    It also contains information useful during later re-installation of the robot. Prerequisites for installation personnel Installation personnel working with an ABB product must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work • conform to all national and local codes.
  • Page 49 The robot installation is restricted to the mounting options given in following load table(s). Floor mounted Force Endurance load (in operation) Max. load (emergency stop) Force xy ± 6.2 kN ± 10.6 kN Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 50 Maximum ambient temperature +55° C Maximum ambient temperature (less than 24 hrs) +70°C Maximum ambient humidity 95% at constant temperature (gaseous only) Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 51 The table shows the available protection types of the robot, with the corresponding protection class. Protection type Protection class Manipulator, protection type Standard IP 67 Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 52: Working Range And Type Of Motion

    Tool flange center Position in figure Position (mm) Angles (°) Axis 2 Axis 3 1505 1437 1565 -314 2385 2111 1510 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 53 Arm motion -40° to +85° Arm motion -20° to +120° Arm motion 25° to 155° Turn motion -300° to +300° Turning radius xx1000001202 Motor, axis 3 Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 54: Risk Of Tipping/Stability

    This figure shows the robot in its shipping position and transportation position. xx1000001158 WARNING The robot is likely to be mechanically unstable if not secured to the foundation. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 55: On-Site Installation

    If the robot is dressed, this must be taken into consideration when the robot is be- ing lifted. xx1000001158 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 56 The fork lift accessory is fitted on the robot as shown in the figure. xx0600002910 Fork lift pocket Attachment screw M20x60 quality 8.8 (2 pcs x4) Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 57 A Fork lift pocket (4 pcs) B Attachment screw M20x60 quality 8.8 (2 pcs x4) Verify that all four fork lift pockets are properly secured before lifting. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 58: Lifting The Robot With Fork Lift Truck

    Verify that all four fork lift pockets are properly secured before lifting. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 59 If lifting with fewer than four fork lift pockets fitted, there is a risk of accidents! xx0600002911 IRB 6640 xx0600003401 IRB 460 xx1000001159 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 60 Secure the robot to the foundation DANGER Do not power the robot up until it is se- cured properly to the foundation. Remove the fork lift accessories. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 61: Lifting Robot With Roundslings

    All lifting accessories used must be sized accordingly! WARNING Personnel must not, under any circum- stances, be present under the suspended load! Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 62 Roundsling, 2 m (2 pcs). Lifting capacity: 2,000 kg. Roundsling, 2.5 m (2 pcs). Lifting capacity: 2,000 kg. Wrap once! Roundsling, 2 m, secures against rotation. Lifting capacity: 2,000 kg. Wrap twice! Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 63: Manually Releasing The Brakes

    If the robot is not connected to the controller, power must be supplied to the connector R1.MP according to the section Supplying power to connector R1.MP on page Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 64 Incorrect connections, such as supplying power to the wrong pin, may cause all brakes to be released simultaneously! Supply 0V on pin 12 and 24V on pin 11. xx0600002937 Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 65: Lifting The Base Plate

    Fit lifting slings to the eyes and to the lifting accessory. CAUTION Lift and move the base plate very slowly. If the base plate starts to swing it is a risk for injuries or damage. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 66: Securing The Base Plate

    E, F, G, H Common tolerance zone (accuracy all over the base plate from one contact surface to the other) Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 67 2 Installation and commissioning 2.3.5 Securing the base plate Continued xx0400000715 Four holes for alternative clamping, 4x Ø18 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 68 The illustration below shows the orienting grooves and attachment holes for leveling bolts in the base plate. xx1500000312 Orienting grooves (3 pcs) Levelling bolts, attachment holes (4 pcs) Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 69 Base plate This section details how to secure the base plate to the foundation. Action Note Make sure the foundation is levelled. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 70 0.3 mm. If it is not, use pieces of sheet metal or similar to bring the base plate to a levelled position. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 71: Orienting And Securing The Robot

    M24 x 100 Quality: Quality 8.8 Suitable washer: Thickness: 4 mm Outer diameter: 44 mm Inner diameter: 25 mm Tightening torque: 725 Nm Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 72 Note Lightly lubricate screws before as- sembly! Tighten bolts in a criss-cross pattern to ensure that the base is not distorted. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 73 2.3.6 Orienting and securing the robot Continued Hole configuration, base This illustration shows the hole configuration used when securing the robot. R400 xx0600002932 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 74 2 Installation and commissioning 2.3.6 Orienting and securing the robot Continued Cross section, guide sleeve hole This illustration shows the cross section of the guide sleeve holes. xx0600002934 Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 75: Fitting Equipment On Robot

    For mounting of an external vacuum hose there are six holes on the upper arm. The maximum weight for the vacuum hose and fastening device is 35 kg. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 76 Note! The weight of the extra equipment on the upper arm must be deducted from the maximal handling capacity. 6xM10 315.5 6xM8 9 (B) xx1000001041 M10 mounting holes on upper arm Drill depth 15 mm Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 77 The illustration below shows the mounting holes available for fitting equipment on the turning disk. xx1000001042 xx1800001402 Tool flange in bottom view Locating hole Tool coordinate system Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 78 Continued Fastener quality For fastening of gripper tool flange to robot tool flange all bolt holes shall be used. Only use screws with quality 12.9. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 79: Loads Fitted To The Robot, Stopping Time And Braking Distances

    The performance of the motor brake depends on if there are any loads attached to the robot. For more information, see product specification for the robot. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 80: Installation Of Signal Lamp, Upper Arm (Option)

    Fitted between motor and cable gland, replace if damaged. Standard toolkit Content is defined in section Stand- ard tools on page 383. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 81 Attachment screws for the signal lamp (2 pcs) Cable straps (2 pcs) Cable gland cover Motor adapter including gasket Attachment screw, M6x40 (1 pc) Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 82 Remove the motor cover by unscrewing the four See figure Location of signal lamp, attachment screws. upper arm on page Disconnect the motor connectors. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 83 Secure motor cables at cable gland again. Fit the motor cover with the attachment screws. Make sure the cabling is placed correctly when refitting the cover and does not get jammed. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 84: Installation Of Options

    2.4.1 Option 87-1 - Installing the cooling fan for axis-1 motor General A cooling fan (option 87-1) can be installed on the axis-1 motor. Location of cooling fan xx1300000168 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 85 Motor cover Choose this if equipping the robot with a cooling fan on the axis-1 motor. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 86 Loosen the three tightening screws, to avoid damaging the surfaces of the motor when fit- ting the fan box. xx1300000844 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 87 Install the cabling and make adjustments in RobotWare, as described in the following pro- cedures. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 88 Before entering the robot working area. Insert the fan cable through the motor cover and tighten the screw. xx1300000766 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 89 Connect the connector R3.FAN to the connector on the fan box. Strap the cable onto the axis-1 motor cables (at position A). xx1300000768 Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 90: Restricting The Working Range

    This section describes how to install hardware that restricts the working range. Note! Adjustments must also be made in the robot configuration software (system parameters). References to relevant manuals are included in the installation procedures. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 91: Mechanically Restricting The Working Range Of Axis 1

    Movable mechanical stop Attachment screw plus washer, M12 x 40 quality 12.9 (2 pcs) Fixed mechanical stop Mechanical stop pin axis 1 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 92 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 93: Robot In Cold Environments

    If the program consists of large wrist movements, it is possible that the reorientation velocity, which is always high in predefined velocities, needs to be included in the ramping up. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 94: Electrical Connections

    Robot cable signal, shielded: 15 m 3HAC2530-1 Robot cable signal, shielded: 22 m 3HAC2540-1 Robot cable signal, shielded: 30 m 3HAC2566-1 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 95 There is a grounding/bonding point on the manipulator base. The grounding/bonding point is used for potential equalizing between control cabinet, manipulator and any peripheral devices. xx1600001956 Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 96 This page is intentionally left blank...

  • Page 97: Maintenance

    If the IRB 460 is connected to power, always make sure that the IRB 460 is connected to protective earth before starting any maintenance work. For more information see: • Product manual - IRC5 Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 98: Maintenance Schedule And Expected Component Life

    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.

  • Page 99: Maintenance Schedule

    First change when DTC reads: • 6,000 hours Second change when DTC reads: • 20,000 hours Following changes: • Every 20,000 hours Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 100 The maintenance of other external equipment for the robot is detailed in separate documentation. Maintenance activity Equipment Interval Inspection Signal lamp Every: 12 months Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 101: Expected Component Life

    This applies to gearboxes on axes 1, 2, 3 and 6. In some applications, such as Foundry or Washing, the robot can be exposed to chemicals, high temperature or humidity, which can have an effect on the lifetime of the gearboxes. Contact the local ABB Robotics Service team for more information.

  • Page 102: Inspection Activities

    These procedures include refer- be required. See references to ences to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 103 Further information about how to fill with oil is found in section Changing oil, axis-1 gearbox on page 122. Refit the oil plug. Tightening torque:25 Nm Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 104: Inspecting, Oil Level Gearbox Axes 2 - 3

    The gearboxes axes 2-3 are located in the lower arm rotational center, underneath the motor attachment. xx1000001295 Gearbox, axis 2 Oil plug, filling Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 105 Before proceeding, please read the safety inform- ation in the section Safety risks during work with gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 106 Filling of oil is detailed further in section Changing oil, gearbox axes 2 and 3 on page 126. Refit oil plug, filling. Tightening torque: 25 Nm. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 107: Inspecting, Oil Level Gearbox Axis 6

    These procedures include refer- be required. See references to ences to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 108 Changing oil, gearbox axis 6 on page 130. Refit oil plug, filling. Tightening torque: 25 Nm. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 109: Inspecting, Cable Harness

    Cable harness robot, axes 1-6 Connectors at base Motor cables Cable guide, axis 2 Metal clamps Required equipment Visual inspection, no tools are needed. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 110 Detailed in section: is detected! Replacing cable harness, lower end (axes 1-3) on page 147. Replacing the cable harness, upper end (incl. axis 6) on page 157. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 111: Inspecting The Information Labels

    Warning label, symbol of flash (located on motor cover), 3HAC1589-1 (4 pcs) Combined warning label "Moving robot", "Shut off with handle" and "Before dismantling see product manual", 3HAC17804-1 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 112 Inspect the labels, located as shown in the figures. Replace any missing or damaged labels. Article numbers for the labels and plate set is specified in Spare parts on page 389. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 113: Inspecting The Axis-1 Mechanical Stop Pin

    • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 114 If the mechanical stop pin is bent or damaged, it must be replaced. Note The expected life of gearboxes can be reduced after collision with the mechanical stop. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 115: Inspecting The Additional Mechanical Stops

    Article number Note Mechanical stop Spare parts on page 389. Standard toolkit Content is defined in section Standard tools on page 383. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 116 If any damage is detected, the mechanical stops must Article number is specified in be replaced. Required equipment on page 115. Correct attachment screws: • Axis 1: M12 x 40, quality 12.9. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 117: Inspection, Dampers

    To be replaced if damaged. page 389. Damper axis 2, 3 Spare parts on To be replaced if damaged. page 389. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 118 Check attachment screws for deformation. If any damage is detected, the damper must be Art.no. is specified in Required replaced with a new one. equipment on page 117. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 119: Inspecting The Signal Lamp (Option)

    Use this procedure to inspect the function of the signal lamp. Action Note Inspect that signal lamp is lit when motors are put in operation ("MOTORS ON"). Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 120 • measuring the voltage in the connectors of motor axis 6 (=24V). • inspecting the cabling. Replace the cabling if a fault is detected. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 121: Replacement/Changing Activities

    Before starting any inspection, maintenance, or changing activities of lubrication, always contact the local ABB Service organization for more information. For ABB personnel: Always check ABB Library for the latest revision of the manual Technical reference manual - Lubrication in gearboxes, in order to always get the latest information of updates about lubrication in gearboxes.

  • Page 122: Changing Oil, Axis-1 Gearbox

    Oil plug, inspection Oil plug, filling Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 123 Content is defined in section ment Special tools on page 384. Standard toolkit Content is defined in section Standard tools on page 383. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 124 Before proceeding, please read the safety information in the section Safety risks during work with gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 125 102. on page 121. Refit the oil plug, filling. Tightening torque: 25 Nm. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 126: Changing Oil, Gearbox Axes 2 And 3

    The figure shows the position of gearbox, axis 2. xx1000001348 Ventilation hole plug, gearbox axis 2 Oil plug, filling Oil plug, draining Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 127 Content is defined in section ment Special tools on page 384. Standard toolkit Content is defined in section Standard tools on page 383. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 128 • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 129 Refit oil plug,filling and ventilation hole plug. Shown in Location of oil plugs on page 126. Tightening torque: 25 Nm. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 130: Changing Oil, Gearbox Axis 6

    Use this procedure to drain oil from gearbox axis 6. When using oil change equipment, follow the instructions enclosed with kit. Action Note Put tilt house in a suitable position. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 131 Correct oil level is detailed in section Inspection, oil level axis-6 gearbox on page 108. Refit the oil plug. Tightening torque: 25 Nm. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 132: Replacing The Smb Battery

    Battery pack with a 2-pole battery contact (DSQC) xx1000001360 SMB battery pack SMB battery cover Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 133 Spare part no. Note Battery unit For spare part no. Battery includes protection circuits. Only re- see: place with a specified spare part or an ABB- • Spare parts approved equivalent. on page 389 Standard toolkit Content is defined in section...
  • Page 134 Shown in figure Location of SMB Battery includes protection circuits. Only replace battery on page 132. with a specified spare part or with an ABB- ap- proved equivalent. Refitting, battery Use this procedure to refit the SMB battery. Action Note...
  • Page 135 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 136: Cleaning Activities

    Never point the water jet at connectors, joints, sealings, or gaskets. • Do not use compressed air to clean the robot. • Never use solvents that are not approved by ABB to clean the robot. • Do not spray from a distance closer than 0.4 m. •...
  • Page 137 Cleaning with water and steam Instructions for rinsing with water ABB robots with protection types Standard, Foundry Plus, Wash, or Foundry Prime can be cleaned by rinsing with water (water cleaner). The following list defines the prerequisites: •...
  • Page 138 This page is intentionally left blank...

  • Page 139: Repair

    Each procedure contains all the information required to perform the activity, for example spare parts numbers, required special tools, and materials. WARNING Repair activities not described in this chapter must only be carried out by ABB. Otherwise damage to the mechanics and electronics may occur. Required equipment The details of the equipment required to perform a specific repair activity are listed in the respective procedures.

  • Page 140: General Procedures

    Spray any suspected leak areas with the leak detec- tion spray. Bubbles indicate a leak. When the leak has been localized, take the necessary measures to correct the leak. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 141: Mounting Instructions For Bearings

    Make sure the bearing is properly aligned as this will directly affect the durab- ility of the bearing. Greasing of bearings Note This instruction is not valid for solid oil bearings. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 142 Grooved ball bearings must be filled with grease from both sides. • Tapered roller bearings and axial needle bearings must be greased in the split condition. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 143: Mounting Instructions For Seals

    Never hammer directly on the seal as this may result in leakage. Make sure no grease left on the robot surface. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 144 If the flange surfaces are defective, the parts may not be used because leakage could occur. Clean the surfaces properly in accordance with the recommendations of ABB. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.

  • Page 145: Cut The Paint Or Surface On The Robot Before Replacing Parts

    Carefully grind the paint edge that is left on the structure to a smooth surface. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 146: The Brake Release Buttons May Be Jammed After Service Work

    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. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 147: Complete Robot

    How to replace the upper end can be found in section Replacing the cable harness, upper end (incl. axis 6) on page 157. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 148: Replacing Cable Harness, Lower End (Axes 1-3)

    The cable harness, lower end (axes 1-3) is located throughout the base, frame and lower arm as shown in the figure. xx1100000153 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 149 Motor, axes 1-3 Replace if damaged. Standard toolkit The content is defined in the sec- tion Standard tools on page 383. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 150 Remove the rear cover plate from the robot by removing its attachment screws. xx1100000155 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 151 1, 2 and 3. • Replacing motor, axis 1 on page 285 • Replacing motors, axes 2 and 3 on page 294 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 152 Perform this removal with care, in order not to damage any of the components inside the SMB recess. xx1000001330 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 153 1 in the center of the frame. CAUTION Make sure the cables are not twisted with each other or with customer harness (if any)! xx1000001331 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 154 Attachment points are shown in the figure Location of cable harness - lower end (axes 1-3) on page 148. Reconnect the earth cable. xx1100000156 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 155 Push the cable harness up through the lower arm. Fasten the metal clamp that hold the cable harness in the lower arm with the nuts. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 156 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 157: Replacing The Cable Harness, Upper End (Incl. Axis 6)

    Location of cable harness, upper end The upper end of the cable harness is located as shown in the figure. xx1100000158 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 158 Spare parts on page 389 Gasket Motor, axis 6 Standard toolkit Content is defined in section Standard tools on page 383. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 159 Remove the axis 6 motor cover by removing its attachment screws, in order to reach the connectors. xx1000001106 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 160 Remove the metal clamp that holds the cable at the tilt house, by removing its nuts. xx1000001336 Carefully pull the cable harness out of motor axis 6. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 161 (axes 1-3) on page 147 Push the cable harness through the upper arm tube. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 162 Note Do not twist the cables! Reconnect all connectors in motor axis 6. Check the gasket. If damaged, replace it. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 163 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 164: Replacing The Smb Unit

    Battery pack (2-pole battery contact) Cover BU button guard plate Push button guard Cover SMB SMB unit Brake release unit Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 165 Do not replace the battery contact! Equipment, etc. Article number Note SMB unit For spare part number, see: Spare parts on page 389. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 166 164. Use caution and disconnect the connectors from the Connectors R1.SMB1-3, SMB unit when pulling the board out. R1.SMB4-6 and R2.SMB Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 167 Be careful not to damage the sockets or pins. Make sure the connector and its locking arms are snapped down properly. xx1700000978 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 168 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 169: Replacing The Brake Release Board

    Battery pack (2-pole battery contact) Cover BU button guard plate Push button guard Cover SMB SMB unit Brake release unit Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 170 Remove the complete brake release board (including brake release board and bracket) from the SMB recess, by removing its two at- tachment screws. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 171 Screened cables must not get in contact with the brake release board after installation. Eliminate all risks of contact between screened cables and the brake release board. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 172 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 173: Replacing The Base, Including Axis 1 Gearbox

    The location of the base, including gearbox axis 1, is shown in the figure. It also shows the complete arm system as defined above. xx1100000246 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 174 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 175 Run an overhead crane to a position above the robot. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 176 Article number is specified in Required itate the removal of the complete arm system equipment on page 174. and prevent damage on the gearbox. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 177 If needed, continue to remove the axis 1 Replacing the axis 1 gearbox on gearbox from the base. page 313. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 178 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. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 179 The refitting must be made completely level! Make sure the roundslings are adjusted prior to refitting the arm system. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 180 Parts: A Serrated lock washer (24 pcs) B Axis 1 gearbox C Attachment screws M12x110 qual- ity 12.9 gleitmo (24 pcs) Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 181 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 182: Upper And Lower Arm

    Equipment, etc. Art. no. Note Turning disk For spare part no. O-rings are not included! see: Spare parts on page 389. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 183 • air pressure supply to the robot, before entering the robot working area. Remove any equipment fitted to the turning disk. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 184 182. Remove the turning disk. xx1100000076 Foundry Plus: Remove old flange sealant residues and other con- tamination from the contact surfaces. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 185 Required equip- grease and fit it to the turning disk. ment on page 182. xx1100000140 xx0200000218 • A: Sealing surface, o-ring Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 186 Foundry Plus: Apply Loctite 574 flange sealant on the contact surface. xx1400000995 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 187 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 188: Replacing The Tilthouse Unit

    Premounting outer race of bearing and radial sealing, axis 3 side on page 203 • Refitting shafts on page 204 • Refitting lock nuts and the remaining parts on page 206 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 189: Continues On Next Page

    4.4.2 Replacing the tilthouse unit Continued Location of tilthouse unit The tilthouse unit is located as shown in the figure. xx1100000213 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 190: Location Of Axes 2 And 3 Sides Of The Robot

    (axis 2) and the parallel arm (axis 3). These two sides of the robot will be referred to in the replacing procedures. xx1100000214 Axis 2 side (See marking on lower arm) Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 191 4 Repair 4.4.2 Replacing the tilthouse unit Continued xx1100000215 Axis 3 side (See marking on parallel arm) Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 192: X-Ray View Of The Assembly Of The Tilthouse Unit

    VK cover 19x6 (Inside VK cover 65x8), not shown in this figure Required equipment Equipment, etc. Art.no. Note VK cover Spare parts on page 389 VK 19x6 (2 pcs) Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 193 Required equipment on page 192. A B C xx1100000250 Thread washer (2 pcs) Support washer (3HAC040029-001) Upper arm Outer race bearing Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 194: Press Tool For Removal Of Shaft

    The press tool replacing shaft applied as shown in the figure is used to fit the shaft. The press tool consists of the parts shown in the figure. NOTE! The thread washer Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 195 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 196: Removing The Tilthouse Unit

    Move the robot to a position where the tilthouse rests on a workbench, pallets or similar. xx1100000225 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 197 Disconnect motor cables from motor axis 6. Replacing motor, axis 6 on page 305 Place the motor cables in a way that it will not be damaged. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 198 It is not needed to remove the upper link from the link. xx1100000228 Remove one of the M6 screws and washer for filling grease. xx1100000230 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 199 Put a hand with some paper over the VK cover in order to catch it. CAUTION Only a very low air pressure is needed! xx1100000232 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 200 194 Note A longer threaded bar M16 is needed when re- moving the shaft than the one specified when fitting. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 201 CAUTION The robot tilt house weighs 50 kg. All lifting accessories used must be sized ac- cordingly! Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 202 Fit the radial sealing in the hole. Apply some grease in the hole for the bearings. Art.no. is specified in Required equip- ment on page 192. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 203 192. Apply some grease in the hole for the bearings. Art.no. is specified in Required equipment on page 192. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 204 Use this procedure to refit the shafts of the tilthouse unit. Action Note CAUTION The robot tilt house weighs 50 kg. All lifting accessories used must be sized ac- cordingly! Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 205 192. Location of axes 2 and 3 sides of the robot on page 190. Note Refit the axis 2 side first! Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 206 Use this procedure to refit the lock nuts and the other remaining parts of the tilthouse unit. Action Note Note Start the assembly on the axis 2 side! Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 207 Replacing linkage - upper link arm on page 225 Refit the motor cable, axis 6. Replacing motor, axis 6 on page 305 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 208 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 209: Replacing The Upper Arm

    The removal and refitting procedures describe both versions of sealing structures. The steps that differ are marked with information about which sealing structure the step is valid for. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 210 A B C xx1100000273 Lock nut Support ring Sealing ring (V-ring) Lower arm Bearing T-ring Sealing ring (V-ring) Shaft Bushing Upper arm Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 211 The press tool upper arm is used to assemble T-ring and bearing in the upper arm. For art. no. see Required equipment on page 213. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 212 Thread washer (3HAC040021-004) Hydraulic cylinder (3HAC040021-005) Press bushing (3HAC040026-003). Only used at assembly. Auxiliary shaft (3HAC040026-002) Shaft Bearing Lower arm Upper arm Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 213 The adapter consists of two parts: the adapter and a pro- tective cover. Always use the protective cover together with the adapter! Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 214 Read more about reference calibration for then reference calibration is not possible. Pendulum Calibration in Operating manu- al - Calibration Pendulum. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 215 Replacing the linkage - link on page 240 Remove the tilthouse unit. See section • Replacing the tilthouse unit on page 188 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 216 Remove Radial seal, sleev and O-ring on both axis 2 and 3 sides! xx1100000267 Parts: • A: Radial seal with dust lip • B: Sleeve • C: O-ring Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 217 The axis 3 shaft must be removed in more than one step. The reason is the fitting of the outer race of the bearing is very tight. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 218 Action Note This procedure is best performed on a work- bench or similar. Place the shafts on the workbench. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 219 All lifting accessories used must be sized accordingly! Secure the upper arm with a roundsling in an overhead crane or similar. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 220 Carefully fit the shaft into the threads of the upper arm, by hand only. Note Do not use force since threads otherwise can be damaged! Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 221 A: Lower arm • B: T-ring • C: Surface on lower arm on which the T-ring rests against • D: Shaft Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 222 B: Bearing inner race • C: Surface on shaft on which the inner race of bearing rests against • D: T-ring • E: Shaft Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 223 Notice the different procedures for axis 3 and axis 2 sides! Refit the shaft on the axis 2 side, by following the steps in this procedure. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 224 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 225: Replacing Linkage - Upper Link Arm

    Location of upper link arm The upper link arm is located as shown in the figure. xx1100000167 Upper link arm Link Lower link arm Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 226 CAUTION In order to avoid accidents, also secure the upper arm in an overhead crane. xx1000001132 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 227 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot work- ing area. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 228 Remove the lock screw securing the locking washer. xx1100000170 Parts: A Lock screw B Locking washer Remove the locking washer. xx1100000171 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 229 Remove the radial sealing rings. xx1100000172 Parts: A Radial sealing ring B Bearing C Radial sealing ring Remove residual grease. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 230 Fit radial sealing rings in the upper link arm as shown in the figure. xx1100000172 Parts: A Radial sealing ring B Bearing C Radial sealing ring Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 231 Note The press force shall be applied on the lock- ing washer. Apply locking liquid on the lock screw. Loctite 243. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 232 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 233: Replacing Linkage - Lower Link Arm

    Location of lower link arm The lower link arm is located as shown in the figure. xx1100000167 Upper link arm Link Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 234 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot work- ing area. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 235 Remove the lock screw securing the locking washer. xx1100000170 Parts: A Lock screw B Locking washer Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 236 Note If needed use a plastic mallet to remove the lower link arm. xx1100000174 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 237 Lubricate the bearings properly with bearing For art. no. see Required equipment on grease. page 234. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 238 Note The press force shall be applied on the lock- ing washer. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 239 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 240: Replacing The Linkage - Link

    Replacing linkage - lower link arm on page 233 Location of link The link is located as shown in the figure. xx1100000167 Upper link arm Link Lower link arm Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 241 The figure shows an X-ray view of the assembly of the link. Design with POM sealing xx1100000212 VK cover Lock nut Bearing Bearing POM Sealing Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 242 3HAC040031-001 Press tool, link 3HAC040022-001 Used to fit the link. Socket KM 8 3HAC040024-001 Bearing puller Used to remove the link. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 243 Use this procedure to remove the link. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 244 Replacing linkage - upper link arm on page 225 How to remove lower link arm see: • Replacing linkage - lower link arm on page 233 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 245 VK cover in order to catch it when it is re- leased. CAUTION Only a very low air pressure is needed! xx1100000195 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 246 Use a pair of levers or apply a bearing puller and bend the link loose. Remove the link. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 247 For art. no. see Required equipment on page 242. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 248 Press tool link (bearing outer races) Outer race of the outer bearing in link Press tool support Hydralic cylinder Thread washer Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 249 For art. no. see Required equipment on page 242. xx1100000211 Threaded bar M16 Thread washer Hydralic cylinder Press bush Auxiliary shaft Shaft Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 250 Valid for design with support ring. Loctite 574 Apply locking liquid on the inner surface of the support ring. xx1300000008 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 251 Fit the auxiliary shaft on the shaft. Art.no. is specified in Required equipment on page 242 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 252 C: Inner bearing complete Press the parts together with the press tool, Art.no. is specified in Required equipment link. on page 242. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 253 90 Nm. Valid for design with POM sealing. Use a screwdriver carefully to fit the POM sealing into its final position. xx1100000204 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 254 Note Refit the VK cover. xx1100000205 Fill the link with grease. Art.no. is specified in Required equipment on page 242 xx1100000206 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 255 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 256: Replacing The Pom Sealing For The Link System

    X-ray view of the assembly of the link The figure shows a X-ray view of the assembly of the link. xx1100000212 VK cover Lock nut Bearing Bearing POM Sealing Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 257: Replacing Parallel Rod

    Spare parts on page389 Mounting/Demounting tool 3HAC040021-001 Locking liquid 3HAB7116-1 Loctite 243 Standard toolkit Content is defined in section Standard tools on page 383. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 258 CAUTION In order to avoid accidents secure the upper arm with a roundsling in an overhead crane or similar. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 259 4.4.8 Replacing parallel rod Continued Action Note Remove the lock screw and washer, securing the shaft of the parallel rod in position. xx1100000141 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 260 A: Thickness = 8 mm. Apply the mounting/demounting tool to the For art. no. see: shaft. • Required equipment on page 257 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 261 Remove the upper shaft. xx1100000144 Move the parallel rod backwards from its up- per connection point and let it rest against the base. xx1100000146 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 262 This figure shows how to apply the mounting/demounting tool when refitting the parallel rod. For art. no. see Required equipment. xx1100000165 Thread bush Support bush Hydraulic cylinder Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 263 B: POM sealing Put the thrust washer (with a POM sealing fitted) on the axis 2 side of the parallel rod. xx1100000149 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 264 Place the other POM sealing on the axis 3 side. xx1100000151 Place the parallel rod in its mounting posi- tion in the lower end. xx1100000161 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 265 Do not press the shims down too far. xx1100000142 xx1100000030 A = Thickness 8 mm Refit the shaft using the mounting/demount- ing tool. xx1100000162 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 266 Lift the parallel rod up into position for fitting of the upper end. xx1100000163 Refit the upper end of the parallel rod in the same way. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 267 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 268: Replacing The Complete Lower Arm System

    Parallel arm Required equipment Equipment, etc. Art.no. Note Lower arm For art. no. see: • Spare parts on page389 Lock screw M16x90 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 269 Use this procedure to remove the lower arm system. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 270 3 on page 294. Motors are removed in order to be able to rotate lower and parallel arms. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 271 Connect to connector R2.MP2 or R2.MP3 24VDC power supply. depending on which side: • + : pin 2 • -: pin 5 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 272 If the parts are not pushed together, it will be difficult to remove the complete lower arm. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 273 Move the parallel arm and secure it to the lower arm as shown in the figure, to prevent it from falling down. xx1100000178 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 274 Replacing the parallel arm on page 278 CAUTION The robot lower arm weighs 110 kg. All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 275 A: Rotation tool xx1100000185 Note Refit the axis 2 side first! Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 276 Secure the lower arm by fitting a lock screw M16x90. xx1000001179 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 277 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 278: Replacing The Parallel Arm

    Required equipment Equipment, etc. Art.no. Note Parallel arm For spare part no. see: • Spare parts on page389 Bearing grease 3HAB3537-1 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 279 Remove the complete lower arm system from See section Replacing the complete lower the robot. arm system on page 268. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 280 CAUTION The robot lower arm weighs 110 kg. All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 281 The parallel arm system weighs 40 kg. All lifting accessories used must be sized accordingly! Secure the parallel arm with a roundsling in an overhead crane. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 282 Check that the assembly and the condition of the bearing is good. If not, replace dam- aged parts. xx1100000218 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 283 The parallel arm system weighs 40 kg. All lifting accessories used must be sized accordingly! Lift the parallel arm to where the lower arm is placed. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 284 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 285: Motors

    Location of motor axis 1 The motor axis 1 is located on the left hand side of the robot as shown in the figure. xx1000001171 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 286 Read more about reference calibration for then reference calibration is not possible. Pendulum Calibration in Operating manu- al - Calibration Pendulum. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 287 Remove the motor cover to get access to the connectors on top of the motor. xx1000001165 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 288 • + : pin 2 • -: pin 5 Remove the attachment screws of the motor. Use the bits extension. xx1000001167 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 289 Be careful not to damage the pinion in the pro- cess! xx1000001168 Disconnect the brake release voltage. Check the pinion. If there is any damage, the pinion must be replaced. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 290 In order to release the brake, connect the 24 Connect to connector R2.MP1 VDC power supply. • + : pin 2 • -: pin 5 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 291 M10x40 quality 12.9 Gleitmo Tightening torque: • 50 Nm Disconnect the brake release voltage. Reconnect all connectors beneath the motor cover. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 292 Calib- rating with Axis Calibration method on page 357. General calibration information is in- cluded in section Calibration on page 347. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 293 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 294: Replacing Motors, Axes 2 And 3

    • motor page 389 chapter • pinion • o-ring (the o-ring must be re- placed when the motor is re- placed) Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 295 Read more about reference calibration for then reference calibration is not possible. Pendulum Calibration in Operating manu- al - Calibration Pendulum. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 296 This is done in order to secure axis 3 from col- lapsing when the axis 3 motor is being removed. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 297 Remove the cable gland cover at the cable exit Note Make sure the gasket is not damaged! Replace if damaged. xx1000001183 Disconnect all connectors beneath the motor cover. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 298 Art. no. is specified in Required ment holes. equipment on page 294. The figure shows IRB 760 but the principle is the same. xx1000001131 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 299 Make sure the pinion does not get damaged! xx1000001105 Remove the motor by gently lifting it straight out and place it on a secure surface. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 300 -: pin 5 Fit the lifting tool, motor axes 2-3 to the motor. Art. no. is specified in Required equipment on page 294. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 301 Remove the lifting tool and allow the motor to rest on the guide pins. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 302 50 Nm Disconnect the brake release voltage. Reconnect all connectors beneath the motor Connect in accordance with markings cover. on connectors. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 303 Use a new gasket! xx1000001183 Refit the motor cover with its attachment screws and washers. Note Make sure the cover is tightly sealed! xx1000001182 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 304 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 305: Replacing Motor, Axis 6

    (the o-ring must be replaced when the motor is replaced) Bits extension 3HAC023760-001 Used to reach attachment screws for motor. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 306 Use this procedure to remove motor, axis 6. Action Information Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 307 Remove the cable gland cover at the cable exit by unscrewing its attachment screw (A) on the inside. Note Make sure the gasket is not damaged! xx0600002694 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 308 Always use the screws for removal in by fitting two screws in the motor attach- pairs! ment holes diagonal to each other Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 309 The o-ring must be replaced when the motor is replaced. xx1000001109 Parts: • A: Pinion • B: O-ring • C: Circumference Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 310 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 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 311 Refit the cable gland with its attachment screw. xx0600002694 • A: Screw holding the cable gland Make sure the gasket is not damaged! Replace if damaged. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 312 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 313: Gearboxes

    • gearbox • Spare parts • all o-rings and seal- on page 389. ing rings O-ring 3HAB3772-93 Replace if damaged! Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 314 See refer- quired. ences to these pro- cedures in the step- by-step instructions below. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 315 Drain the axis 1 gearbox. Changing oil, axis-1 gearbox on page 122. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 316 1 sup- ment on page 313. port be fitted on each sides of the base. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 317 Unscrew the attachment screws and re- move the washers. xx1100000207 Attachment screws: 12 pcs. Washers: 12 pcs. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 318 Turn the gearbox, and remove the protec- tion pipe by unscrewing two attachment screws. Note Move the protective pipe over to the new gearbox. xx1400000786 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 319 Fit two guide pins in two of the attachment Specified in Required equipment on holes in the gearbox, parallel to each other. page 313. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 320 Reused screws may be used, providing they are lubricated as detailed in sec- tion Screw joints on page 379 before fit- ting. xx1100000207 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 321 Calibrat- ing with Axis Calibration method on page 357. General calibration information is in- cluded in section Calibration on page 347. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 322 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 323: Replacing The Axis 2 Gearbox

    Gearbox, axis 2 or axis 3 For spare part no. see: • Spare parts on page389 Lock screw M16x90 Screw M12x60 Fully threaded Bits extension Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 324 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 325 Apply a roundsling (or similar) securing the parallel rod to the lower arm. This is done in order to lock the parallel arm in position. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 326 All lifting accessories used must be sized accordingly! Fit the lifting tool to the gearbox. Art. no. is specified in Required equip- ment on page 323. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 327 Make sure that the o-ring is fitted to the gearbox. xx1100000223 Lightly lubricate the o-ring with grease. Apply some grease on all contact surfaces. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 328 Attachment screws: M12x60 quality 12.9 gleitmo (16 pcs) Tightening torque: 120 Nm Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 329 Perform a leakdown test. Performing a leak-down test on page 140. Refill the gearbox with oil. Draining, axes 2 and 3 on page 128 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 330 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 331: Replacing The Axis 3 Gearbox

    Gearbox, axis 2 or axis 3 For spare part no. see: • Spare parts on page389 Lock screw M16x90 Screw M12x60 Fully threaded. Bits extension Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 332: Product Manual - Irb

    If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 333 Jog axis 3 (the parallel arm) to max + de- grees. DANGER Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 334 Lift out the gearbox from the frame using an overhead crane or similar, with guidance from the fitted guide pins. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 335 All lifting accessories used must be sized accordingly! Fit the lifting tool to the gearbox. Art. no. is specified in Required equip- ment on page 323. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 336 Axis Calibration is described in Calibrat- ing with Axis Calibration method on page 357. General calibration information is included in section Calibration on page 347. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 337 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 338: Replacing Gearbox Axis 6

    Includes o-ring • Spare parts on page 389. Turning disk For spare part no. see: • Spare parts on page 389. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 339 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 340 Remove the turning disk. See section • Replacing the turning disk on page 182 Remove the calibration plate axis 6. xx1100000239 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 341 Remove gearbox axis 6 carefully without damaging pinion or gear. xx1000001412 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 342 Lubricate the o-ring with grease. xx1100000241 Release the brakes of the axis 6 motor See section manually. • Manually releasing the brakes on page 63 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 343 Make sure the gears of the gearbox mate with the pinion of the axis 6 motor. CAUTION Do not damage pinion or gears in the pro- cess! xx1100000242 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 344 Axis Calibration is described in Calibrating with Axis Calibration method on page 357. General calibration information is included in section Calibration on page 347. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 345 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 346 This page is intentionally left blank...

  • Page 347: Calibration

    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.

  • Page 348: Calibration Methods

    Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant. If no data is found related to standard calibration, Calibration Pendulum is used as default. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 349 Brief description of calibration methods Calibration Pendulum method Calibration Pendulum is a standard calibration method for calibration of all ABB robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S). Two different routines are available for the Calibration Pendulum method: •...

  • Page 350: When To Calibrate

    The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration, according to information in this manual. If the robot has absolute accuracy calibration, it is also recommended, but not always necessary to calibrate for new absolute accuracy.

  • Page 351: Synchronization Marks And Axis Movement Directions

    Synchronization marks, IRB 460 xx1000001433 Calibration plate, axis 1 Calibration mark, axis 2 Calibration mark, axis 3 Calibration plate and marking, axis 6 Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 352: Calibration Movement Directions For All Axes

    Manual movement directions, 4 axes Note! The graphic shows an IRB 260. The positive direction is the same for all 4-axis robots xx0500001927 Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 353: Updating Revolution Counters

    (try both directions, if needed). Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 354 All mechanical units connected to the system are shown with their calibration status. Tap the mechanical unit in question. xx1500000943 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 355 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 A screen is displayed, tap Rev. Counters. en0400000771 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 356 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 369. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 357: Calibrating With Axis Calibration Method

    FlexPendant. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. WARNING The calibration tool must be fully inserted into the calibration bushing, until the steel spring ring snaps into place.
  • Page 358 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.

  • Page 359: Calibration Tools For Axis Calibration

    There is no risk for bad calibrations as long as the calibration tool is in one piece. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. Equipment, etc. Article number...
  • Page 360 • Outer diameter within Ø12g4 mm, Ø8g4 mm or Ø6g5 mm (depending on calibration tool size). • Straightness within 0.005 mm. xx1500000951 Outer diameter Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 361: Installation Locations For The Calibration Tools

    This is shown in the figure. xx1700000437 xx1700000438 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 362 Replace damaged parts with new, if needed. Spare part Article number Note Protection cover and plug set 3HAC059487-001 Contains replacement calibration pin covers and protective plugs for the bushing. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 363: Axis Calibration - Running The Calibration Procedure

    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. Equipment, etc.
  • Page 364 Use this procedure to call for the Axis Calibration method on the FlexPendant. Action Note On the ABB menu, tap Calibration. xx1500000942 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 365 The three-position enabling device on the Press and hold the three-position enabling FlexPendant has been released during robot device and press Play. movement. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 366 Ensure that the sealing is not damaged. Replace the plug and the sealing with new spare part, if missing or damaged. xx1500000952 Protection cover and plug set: 3HAC059487-001. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 367: Calibrating With Calibration Pendulum Method

    Where to find information for Calibration Pendulum Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 368: Verifying The Calibration

    Write down the values on a new label and stick it on top of the calibration label. The label is located on the lower arm. Remove any calibration equipment from the robot. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 369: Checking The Synchronization Position

    If they do not, up- ization position for axes on page 351 date the revolution counters. Updating revolution counters on page 353. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 370 This page is intentionally left blank...

  • Page 371: Decommissioning

    Incineration must be carried out under controlled conditions in accordance with local regulations. Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 372 Spills can form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. • Spillage can penetrate the soil causing ground water contamination. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 373: Scrapping Of Robot

    • When motors are removed from the robot, the robot will collapse if it is not properly supported before the motor is removed. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 374 This page is intentionally left blank...

  • Page 375: Reference Information

    7.1 Introduction 7 Reference information 7.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 376: Applicable Standards

    Terminology and general principles EN 574:1996 + A1:2008 Safety of machinery - Two-hand control devices - Functional aspects - Principles for design Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 377 Safety requirements for industrial robots and robot systems ANSI/UL 1740 Safety standard for robots and robotic equipment CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require- ments Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 378: Unit Conversion

    1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 379: Screw Joints

    UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below) and is extremely resistant to fatigue.
  • Page 380 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 381 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm - Nominal Min. Max. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 382: Weight Specifications

    All components exceeding 22 kg (50 lbs) are highlighted in this way. To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.

  • Page 383: Standard Tools

    Hex bit socket head cap no. 6 socket 40 mm L=145 mm Hex bit socket head cap no. 6 socket 40mm bit L=220 mm Multigrip plier Plastic mallet Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 384: Special Tools

    This table specifies the special tools required during several of the service procedures. The tools are specied directly in concerned instructions. Description Article no. Guide pins M12x130 3HAC022637-001 Guide pins M10x150 3HAC13120-2 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 385 350 mm. Auxiliary shaft 3HAC040035-001 Used together with press tool 3HAC040029-001 (only when removing). KM7 socket 3HAC040025-001 Adapter 3HAC040027-001 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 386 3HAC040021-003 Pressing tool • 3HAC040021-005 Hollow cylinder RCH 123 • 3HAC040021-006 Threaded bar M16 length 530 mm. Shims thickness 8 mm Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 387 Support, base and gear ax 1 3HAC15535-1 Lifting accessory, base and gear ax 1 3HAC15556-1 Lifting accessory 3HAC025214-001 Oil collecting vessel capacity 8,000 ml Oil exchange equipment 3HAC021745-001 Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 388: Lifting Accessories And Lifting Instructions

    This implies that the instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 389: Spare Parts

    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.mypo- rtal.abb.com. Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 390 This page is intentionally left blank...

  • Page 391: Circuit Diagrams

    Circuit diagram - IRB 6400RF 3HAC8935-1 Circuit diagram - IRB 6600 type A 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6600 type B 3HAC13347-1 3HAC025744-001 Continues on next page Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 392 3HAC029940-001 Circuit diagram - IRB 6700 3HAC043446-005 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 Circuit diagram - Product.ProductName 3HAC050778-003 Circuit diagram - IRB 910SC 3HAC056159-002 Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.

  • Page 393: Index

    351 gearboxes calibration position location of, 121 jogging to, 369 grease scales, 351 disposal, 371 calibration scales, 351 guide pins, base plate, 66 CalibWare, 348 Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 394 34 neodymium ESD, 31 disposal, 371 fire extinguishing, 20 NiCad moving robots, 25 disposal, 371 release robot axes, 21 nodular iron signals, 38 Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 395 CAN, 377 restricting axis 1, 91 EN, 376 EN IEC, 376 EN ISO, 376 zero position start of robot in cold environments, 93 checking, 369 Product manual - IRB 460 3HAC039842-001 Revision: P © Copyright 2012-2018 ABB. All rights reserved.
  • Page 398 PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics and Motion 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2012-2018 ABB. All rights reserved. Specifications subject to change without notice.

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Irb 460-110/2.4

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