ABB Robotics IRB 4600 Manual
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ABB Robotics IRB 4600 Manual

ABB Robotics IRB 4600 Manual

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ROBOTICS
Product manual
IRB 4600

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Summary of Contents for ABB Robotics IRB 4600

  • Page 1 ROBOTICS Product manual IRB 4600...
  • Page 2 Trace back information: Workspace 21A version a15 Checked in 2021-04-12 Skribenta version 5.4.005...
  • Page 3 Product manual IRB 4600 - 60/2.05 IRB 4600 - 45/2.05 IRB 4600 - 40/2.55 IRB 4600 - 20/2.50 IRC5 Document ID: 3HAC033453-001 Revision: Y © Copyright 2009-2021 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, damage to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    Start of robot in cold environments ............Electrical connections ..................2.8.1 Robot cabling and connection points ............2.8.2 Customer connection on robot ..............Maintenance Introduction ...................... Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 6 Changing the oil, axis-4 gearbox ..............3.4.7 Changing oil, axes-5 and -6 gearboxes ............3.4.8 Replacing SMB battery ................Cleaning activities ..................... 3.5.1 Cleaning the IRB 4600 ................Repair Introduction ...................... General procedures ................... 4.2.1 Performing a leak-down test ..............4.2.2 Mounting instructions for bearings .............
  • Page 7 Decommissioning Introduction ...................... Environmental information .................. Scrapping of robot ..................... Robot description Manipulator types and variants ................Type C of IRB 4600 .................... Type D of IRB 4600 .................... Reference information Introduction ...................... Applicable standards ..................Unit conversion ....................Screw joints ....................
  • Page 8 This page is intentionally left blank...

  • Page 9: Overview Of This Manual

    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 4600. Some variants and designs may have been removed from the business offer and are no longer available for purchase.
  • Page 10 Circuit diagram Reference to the circuit diagram for the robot.. References Reference Document ID Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Product specification - IRB 4600 3HAC032885-001 Product manual, spare parts - IRB 4600 3HAC049108-001 Circuit diagram - IRB 4600...
  • Page 11 45/60kg. • Motors in wrist as rebuilding parts added in section Rebuilding parts in Spare parts IRB 4600. • How to adjust the play on motors axes 4-6 and on wrist added in sec- tions Replacing motors, axes 4, 5 and 6 and...
  • Page 12 All information about Foundry Prime is removed from the manual. This manual now only contains information for a Standard IRB 4600. The instructions for a IRB 4600 Foundry prime can be found in a separate manual. For art. No. See...
  • Page 13 Changed type of oil in axes 1, 3 and 4 gearboxes. See Type of lubric- ation in gearboxes on page 144. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 14 The spare part number is added. • A new SMB unit and battery is introduced, with longer battery lifetime. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 15 Spare part numbers are corrected for the lower arm, see Lower arm type C and Rebuilding parts, and for motors, see Motors type C in Product manual, spare parts - IRB 4600. • Several more spare part numbers are corrected throughout the spare part chapter.
  • Page 16 Robot cabling and connection points on page • Levelmeter 2000 kit (6369901-347) no longer available. • Added spare parts for wrist and sealing for IRB 4600 -20/2.50. See Replacing wrist unit on page 263. • • Added a note regarding usage of an angled ethernet connection, see Customer connection on robot on page Published in release 19D.
  • Page 17 Note regarding maximum leakage current for attached equipment. Customer connection on robot on page • New Type D with alternative motor added to Type D of IRB 4600 on page 375. • "Type C" is now "Type C and Type D" through out the complete manual.

  • Page 18: 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 19 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 20: 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 21: Safety

    ABB is not liable for damages caused by the use of non-original spare parts and equipment. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 22: Requirements On Personnel

    The plant liable must make sure that the personnel is trained on the robot, and on responding to emergency or abnormal situations. Personal protective equipment Use personal protective equipment, as stated in the product manual. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 23: Safety Signals And Symbols

    NOTE Signal word used to indicate important facts and conditions. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 24 1.2.1 Safety signals in the manual Continued Symbol Designation Significance Signal word used to indicate where to find additional information or how to do an operation in an easier way. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 25: Safety Symbols On Manipulator Labels

    Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 26 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 27 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 28 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 29 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 30 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 31: Robot Stopping Functions

    The protective stops and emergency stops are described in the product manual for the controller. For more information see: • Product manual - IRC5 • Product manual - IRC5 Panel Mounted Controller Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 32: Installation And Commissioning

    When the robot is installed at a height, hanging, or other than mounted directly on the floor, there will be additional hazards. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 33 The risk assessment should also consider other hazards arising from the application, such as, but not limited to: • Water • Compressed air • Hydraulics Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 34 Before the robot system is put into operation, verify that the safety functions are working as intended and that any remaining hazards identified in the risk assessment are mitigated to an acceptable level. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 35: Operation

    Hazards due to the use of brake release devices and/or gravity beneath the manipulator shall be considered. A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 36: Maintenance And Repair

    90 °C. Hot oil or grease Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 37 Hazards related to batteries Under rated conditions, the electrode materials and liquid electrolyte in the batteries are sealed and not exposed to the outside. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 38 WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Related information See also the safety information related to installation and operation. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 39: 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 40: Brake Testing

    Note For robots with the option SafeMove, the Cyclic Brake Check routine is recommended. See the manual for SafeMove in References on page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 41: Troubleshooting

    Manipulator movements can cause serious injuries on users and may damage equipment. Related information See also the safety information related to installation, operation, maintenance, and repair. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 42: Decommissioning

    Hazards due to the use of brake release devices and/or gravity beneath the manipulator shall be considered. A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 43: Installation And Commissioning

    Note If the IRB 4600 is connected to power, always make sure that the robot is connected to protective earth and a residual current device (RCD) before starting any installation work. For more information see: •...

  • Page 44: Unpacking

    Installation of signal lamp (option) on page 77 Weight, robot The table shows the weight of the robot. Robot model Weight IRB 4600 440 kg Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 45 The robot installation is restricted to the mounting options given in following load table(s). Floor mounted Force Endurance load (in operation) Max. load (emergency stop) Force xy ±3940 N ±7790 N Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 46 This might be a problem, depending on the requirements from the applications. If this is a problem, the robot needs to be isolated from the environment. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 47 The table shows the available protection types of the robot, with the corresponding protection class. Protection type Protection class Manipulator, protection type Standard IP 67 Manipulator, protection type Foundry Plus IP 67 Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 48: Working Range And Type Of Motion

    680 mm 2202 mm 2552 mm IRB 4600 - 20/2.50 2833 mm 1696 mm 1361 mm 665 mm 2163 mm 2513 mm Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 49 680 mm 2202 mm 2552 mm IRB 4600 - 20/2.50 2833 mm 1696 mm 1361 mm 665 mm 2163 mm 2513 mm Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 50 IRB 4600 - 40/2.55 R2552 R680 IRB 4600 - 20/2.50 R2513 R665 Robot motion, IRB 4600-60/2.05, -45/2.05, -40/2.55 The table specifies the types and ranges of motion in every axes. Location of motion Type of motion Range of movement Axis 1 Rotation motion ±180°...
  • Page 51 +150° / -90° Axis 3 Arm motion +75° / -180° Axis 4 Wrist motion ±400° Axis 5 Bend motion ±120° Axis 6 Turn motion ±400° Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 52: Risk Of Tipping/Stability

    The position of the calibration mark (A) in the figure is approximate and is used as aiming aid. 0° xx0800000263 WARNING The robot will be mechanically unstable if not properly secured to the foundation. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 53: The Unit Is Sensitive To Esd

    The mat must be grounded through a current-limiting resistor. • Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 54: On-Site Installation

    Roundsling put folded in U-shape through the lifting lug Roundsling put folded in U-shape around gearbox axis 3 Lifting lug Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 55 Use this procedure to lift the robot in a safe way. Action Note CAUTION The IRB 4600 robot weighs 440 kg. All lifting accessories used must be sized ac- cordingly! CAUTION Attempting to lift the robot in any other posi-...
  • Page 56 A: Area where the connection box can be damaged while lifting. Lift the robot with an overhead crane. Lifting capacity: • Required equipment on page 54 Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 57: Lifting And Turning A Suspended Mounted Robot

    Contact ABB for more information. How to lift and turn the robot into position for tilted position: Contact ABB for more information. Illustration xx1500002116 Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 58: Manually Releasing The Brakes

    The brake will function again as soon as the button is released. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 59 See the previous figure. The brake will function again as soon as the button is released. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 60 If they are mixed up, damage can be caused to the intergrated quenching circuits. WARNING Incorrect connections can cause all brakes to be released simultaneously! xx1400001984 Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 61: Orienting And Securing The Robot

    Hole configuration, base The illustration shows the hole configuration used when securing the robot. xx0800000271 Hole for guide bushing Rear bolt holes Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 62 M16 x 70/80 (installation on foundation or base plate, us- ing guide bushings) Quality 8.8 Washers 17 x 30 x 3 6 pcs Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 63 • Hole configuration, base on page 61 CAUTION The IRB 4600 robot weighs 440 kg. All lifting accessories used must be sized accordingly! CAUTION When the robot is put down after being lifted or transported, there is a risk of it tipping, if not properly secured.
  • Page 64 When bolting a mounting plate or frame to a concrete floor, follow the general instructions for expansion-shell bolts. Screw joints must be able to withstand the stress loads defined in section Loads on foundation, robot on page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 65: Setting The System Parameters For A Suspended Or Tilted Robot

    The Gravity Beta is a positive rotation direction around the y-axis in the base coordinate system. The value is set in radians. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 66 Example of position Mounting angle (A°) Gravity Beta Floor mounted 0° 0.000000 (Default) Tilted mounting 15° 0.261799 Suspended mounting 180° 3.141593 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 67 Examples of mounting angles tilted around the Y axis (Gravity Beta) xx1700000267 Floor mounted Tilted mounting, mounting angle 15°. Suspended mounting, mounting angle 180°. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 68 Mounting angles and values on page The system parameters are described in Technical reference manual - System parameters. The system parameters are configured in RobotStudio or on the FlexPendant. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 69: Fitting Equipment On Robot

    15 kg 5 kg 15 kg 15 kg 35 kg IRB 4600-45/2.05 15 kg 5 kg 15 kg 15 kg 35 kg Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 70 The illustrations show the fitting holes available for fitting extra equipment on the base and frame of the robot. xx0800000276 Attachment holes on base Center axis 2 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 71 216 (2x M8 16) (3x M8 3x M8 2x M8 16 xx0800000280 Center axis 4 Center axis 3 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 72 1095 1496.5 1230.5 Position H and measurement C is only applicable to IRB 4600 - 40/2.55 and IRB 4600 - 20/2.50. Position H and measurement C is only applicable to IRB 4600 - 40/2.55 and IRB 4600 - 20/2.50. Variant Attachment screws 60/2.05...
  • Page 73 2.3.6 Fitting equipment on robot Continued Fitting equipment on wrist and mounting flange Extra equipment on wrist, robot versions IRB 4600 -60/2.05, -45/2.05 and -40/2.55 The illustration shows the fitting holes available for fitting extra equipment on the wrist of the robot.
  • Page 74 2.3.6 Fitting equipment on robot Continued Extra equipment on mounting flange, robot versions IRB 4600 -60/2.05, -45/2.05 and -40/2.55 The illustration shows the mechanical interface for the mounting flange. There are two versions of the mounting flange, differences are shown in the figures.
  • Page 75 2 Installation and commissioning 2.3.6 Fitting equipment on robot Continued Extra equipment on wrist and mounting flange, robot version IRB 4600 -20/2.50 The illustration shows the fitting holes available for fitting extra equipment on the wrist of the robot version IRB 4600 -20/2.50.

  • Page 76: 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 77: Installation Of Signal Lamp (Option)

    2 Installation and commissioning 2.3.8 Installation of signal lamp (option) 2.3.8 Installation of signal lamp (option) Signal lamp See the assembly instruction delivered with the signal lamp. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 78: Restricting The Working Range

    Remove the mechancial stop bracket if the robots full working range is from a mechanical stop to another mechanical stop. Otherwise the mechanical stop pin will be worn out. xx1500000253 Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 79: Mechanically Restricting The Working Range Of Axis 1

    These procedures include references to the may be required. See refer- tools required. ences to these procedures in the step-by-step instruc- tions below. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 80 Mounting instructions are also supplied with the kit. Action Note Determine the position of the stop lugs. See the figure Additional stops on page 80 for guidance. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 81 Remove the two screws holding the mechan- ical stop and the bracket. xx1100000091 A Attachment screw B Bracket, stop axis 1 Remove the bracket. Refit the attachment screws. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 82: Installing Options

    The fans are installed on the motors, axes 1 or 2, as shown in the figure below. xx0900000135 Fan, motor axis 2 Fan, motor axis 1 Protection cover Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 83 The details of the cooling fan are shown in the figure below. xx0500002158 Fanbox (motor axis 2) Attachment screws, fanbox plates (9 pcs) Groove in the connector Tightening screws, fanbox (3 pcs) Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 84 These procedures include references to may be required. See refer- the tools required. ences to these procedures in the step-by-step instruc- tions below. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 85 B: Position where the fan shall be aligned with connection box • C: Fan Fit the fanbox with two attachment screws M6x25. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 86 Parts: • A: Protection cover • B: Fan Secure the fan cable to the protection cover with a cable strap. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 87 B: Connector, power • C: Fan cable • D: Connector, fan • E: Cable gland • F: Motor cover, with fan cable Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 88 Modifying options dialogue, by using the Modify Controller System Wizard in the Sys- tem Builder of RobotStudio. Read more about modifying the system in Operating manual - RobotStudio. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 89: Installation Of Foundry Plus Cable Guard (Option No. 908-1)

    Separate instructions for IRB 2600, 4600, 6620, 6640, 6650S, 6660 and 7600 are available in English, German, French, Spanish and Italian and can be found on the DVD delivered with the Cable guard, article number 3HAC035933-001. xx1100000097 Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 90: Installing An Expansion Container

    Attachment screw M5x20, quality 8.8-A2F and washer (2+2 pcs) O-ring D1=9.5 D2=1.6 Oil plug (to be removed) Required equipment Equipment Note Expansion container Kit including oil. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 91 The screws must be replaced with longer screws. Remove the oil plug from the base. xx1900001818 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 92 Secure the expansion container with the at- tachment screws and washers. xx1500001959 Wipe off any oil residuals before continuing. Tightening torque 6 Nm. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 93 Turn the robot so it is not suspended. Turn the robot to suspended position. Inspect the oil level. See procedure for suspended robot, specting oil level, axis 1 gearbox on page 110. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 94: Robot In Hot Environments

    Let the overpressure leave the gearbox. Refit the oil plug. Continue releasing the overpressure on all gearboxes. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 95: 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 96: Electrical Connections

    Robot cable, power: 7 m 3HAC026787-001 Robot cable, power: 15 m 3HAC026787-002 Robot cable, power: 22 m 3HAC026787-003 Robot cable, power: 30 m 3HAC026787-004 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 97 There is a grounding/bonding point on the manipulator base. The grounding/bonding point is used for potential equalizing between control cabinet, manipulator and any peripheral devices. xx1600001004 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 98 Cabling to be installed on the robot is specified in section Installation of cooling fan for motors (option) on page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 99: Customer Connection On Robot

    R2.CS or R2.CP/CS Use a straight ethernet connector. Using an angled connector causes a collision risk with R2.CP, R2.CBUS or R2.CP/CS. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 100 R3.H1 +, R3.H2 - (inside the arm house, not shown in figure) Use a straight ethernet connector. Using an angled connector causes a collision risk with R2.CP, R2.CBUS, R2.CS or R2.CP/CS. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 101 R1.CP/CS R1.PROC1 (Air M16x1.5) R1.ETHERNET R1.SMB Customer connections base with 7th axis xx2000001637 R1.CP/CS R1.PROC1 (Air M16x1.5) R1.ETHERNET R1.SMB R2.FB7 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 102 Pins for cable area 0.21 - 0.93 Connector set R2.ETHER- 3HAC070439-001 upper arm • Bottle shaped shrinking hose • Angle shaped shrinking hose Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 103 XP5.3.1 R2.CS.R R1.CP/CS.b15 XP5.3.2 R2.CS.S R1.CP/CS.b16 XP5.3.3 R2.CS.T R1.CP/CS.b18 XP5.3.4 R2.CS.U R1.CP/CS.b19 XP5.3.5 R2.CS.V R1.CP/CS.b20 XP5.3.6 R2.CS.W R1.CP/CS.b21 XP5.2.9 R2.CS.X R1.CP/CS.b22 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 104 Customer Contact Customer Contact on robot base minal Controller on Upper arm, R2 (cable between robot and controller not supplied) XP5.2.10 R2.CS.Y R1.CP/CS.b23 XP5.2.11 R2.CS.Z R1.CP/CS.b24 Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 105: Maintenance

    Note If the IRB 4600 is connected to power, always make sure that the IRB 4600 is connected to protective earth and a residual current device (RCD) before starting any maintenance work. For more information see: •...

  • Page 106: Maintenance Schedule

    3.2.1 Specification of maintenance intervals Introduction The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the IRB 4600: • Calendar time: specified in months regardless of whether the system is running or not.

  • Page 107: Maintenance Schedule

    The following table specifies the required maintenance activities and intervals. Maintenance activity Equipment Interval Cleaning Robot Cleaning the IRB 4600 on page 184 Inspection Oil level in axis-1 gearbox Every 12 months. Inspection Oil level in axis-2 gearbox Every 12 months.
  • Page 108 1 12 months Inspection Motor fan Every 12 Inspect the fan for contam- months ination that could hinder the air supply. Clean if ne- cessary. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 109: Expected Component Life

    SIS (See the Operating manual - Service Infomation System) In applications such as Foundry or Washing the robot can be exposed to chemicals, high temperature or humidity which can have an effect on the lifetime of gearboxes. Contact the local ABB Robotics Service team for more information.

  • Page 110: Inspection Activities

    Other design than Type C and Type D. Read more about design Type C and Type D in section Type C of IRB 4600 on page 374 Type D of IRB 4600 on page 375. Required equipment Equipment...
  • Page 111 Oil plug, filling and inspection Oil plug, draining Other design (1) than Type C and Type D xx0800000304 Oil plug, inspection Oil plug, gearbox Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 112 Open the oil plug, inspection. Location of oil plugs (floor mounted) on page 111. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 113 Changing the oil, axis-1 gearbox on floor mounted robots on page 146 Refit the oil plug, inspection. Tightening torque: • 24 Nm Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 114 Other design (2) than Type C and Type D xx1000001436 Filling oil plug, on gearbox Draining oil plug, on surface for motor flange Surface for motor flange Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 115 Open the oil plug inspection on the axis 1 See the figure in: gearbox. • Location of oil plugs (floor moun- ted) on page 111 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 116 Before refitting the oil plug in the gearbox, always replace the oil plug sealing washer with a new one. If not there is a risk of leakage. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 117: Inspecting The Oil Level, Axis 2 Gearbox

    Other tools and procedures may be required. These procedures include references to the See references to these procedures in the tools required. step-by-step instructions below. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 118 Before refitting the oil plug in the gearbox, always replace the oil plug sealing washer with a new one. If not there is a risk of leakage. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 119: Inspecting The Oil Level, Axis 3 Gearbox

    The oil plug for inspection is shown in the figure. Type C and Type D xx1200000633 Oil plug, armhouse (Not visible in this figure. See enlarged figure!) Oil plug, armhouse Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 120 Gearbox lubricants (oil or grease) on page Move the robot to where the upper arm is placed in a +30° position. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 121 Type D, in armhouse: 10 Nm Other design than Type C and Type D, in gearbox: 3 Nm Type C and Type D, both plugs: 10 Nm Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 122: Inspecting The Oil Level, Axis 4 Gearbox

    Move the robot to where the upper arm points straight up and the oil plug hole is on top of the axis 4 gearbox. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 123 How to fill oil is described in section: • Changing the oil, axis-4 gearbox on page 169 Refit the oil plug, filling. Tightening torque: • 10 Nm Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 124: Inspecting Oil Level, Gearbox Axes

    3.3.5 Inspecting oil level, gearbox axes 5 - 6 Location of gearbox, axes 5-6 The gearbox axes 5-6 is located in the wrist unit. The oil plug is shown in the figure. The figure shows IRB 4600 -60/2.05, -45/2.05, -40/2.55 with wrist 60 kg xx0800000308 Oil plug, tilthouse Oil plug, wrist (also used as air inlet when draining from oil plug A) The figure shows IRB 4600 -20/2.50 with wrist 12/20 kg...
  • Page 125 This will level up oil in axes 5 and 6. See the figure in: • Inspecting oil level, gearbox axes 5 - 6 on page 124 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 126 Location of gearbox, axes 5-6 on page 124 Required oil level: • 63 ±3 mm below the edge of the oil plug hole. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 127 How to fill oil is described in section: • Changing oil, axes-5 and -6 gear- boxes on page 173 Refit the oil plug. Tightening torque: • 10 Nm Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 128: Inspecting The Cable Harness

    See references to these procedures in the tools required. step-by-step instructions below. Circuit diagram See chapter Circuit diagram on page 393. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 129 Replace the cable harness if wear, cracks or How to replace the cable harness is de- damage is detected. scribed in Repair on page 187. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 130: Inspecting Information Labels

    Warning - High temperature Label - Max. air pressure Warning - Brake release unit Label - Calibration AbsAcc Information Sign UL-Label Oil quality Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 131 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot work- ing area. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 132 3.3.7 Inspecting information labels Continued Action Note Check all labels. See the figure in Location of information labels on page 130. Replace any missing or damaged labels. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 133: Inspecting The Mechanical Stop Pin, Axis

    These procedures include may be required. See refer- references to the tools re- ences to these procedures in quired. the step-by-step instructions below. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 134 C O-ring (2 pcs) - Not used if bracket (D) is installed. D Bracket E Stop pin Check that the mechanical stop pin is prop- erly attached. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 135 Continued Action Note Check that the mechanical stop pin can move freely in both directions and the bracket works as it is supposed to. xx1000000222 Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 136: Inspecting Additional Mechanical Stops

    For spare part number see Spare part lists on page 391. Standard toolkit Content is defined in section Standard tools on page 385. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 137 If any damage on stops or attachment screws Attachment screws: etc. is detected, the mechanical stops must • M12x40, quality 8.8-A3F be replaced! • 2 pcs/stop lug Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 138: Inspecting Dampers

    • hydraulic pressure supply • air pressure supply to the robot, before entering the robot work- ing area. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 139 Check all dampers for existing impressions larger than 2-3 mm. Check attachment screws for deformation. If any damage is detected the damper must be replaced. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 140: Inspecting The Pressure Relief Valve

    If the air pressure is stopped up, too much pressure can be built up which can be hazardous. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 141 Action Note Check if the pressure relief valve is contam- inated or covered with litter. Clean if necessary. Note Use a cloth or a brush. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 142: Inspecting Signal Lamp (Option)

    If the signal lamp is damaged, it shall be replaced! Action Note Check that the signal lamp is lit when motors are put in operation ("MOTORS ON"). Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 143 Also repair possible damages of the special Foundry Prime paint coat of the robot. Cut the paint or surface on the robot be- fore replacing parts on page 194. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 144: Replacement Activities

    WebConfig. Location of gearboxes The figure shows the location of the gearboxes. xx0800000311 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 145 Not valid for type C and Type D: Used when the robot is fitted in a suspended position. Expansion container, gearbox axis 1 (valid for other design than Type C and Type Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 146: Changing The Oil, Axis-1 Gearbox On Floor Mounted Robots

    Oil plugs for filling and draining are not depending on in which position the robot is mounted: • Draining = Oil plug on base. • Filling = Oil plug on surface for motor flange. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 147 Filling = Oil plug on surface for motor flange. Mounted in suspended position: • Draining and filling = Oil plug on surface for motor flange. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 148 3.4.2 Changing the oil, axis-1 gearbox on floor mounted robots Continued xx0800000304 Oil plug, filling Oil plug, draining xx1000000669 Oil plug, draining Oil plug, filling Surface for motor flange Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 149 The gearbox can contain an excess of pressure that can be hazardous. Open the oil plug carefully in order to let out the ex- cess pressure. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 150 Before refitting the oil plug in the gearbox, always replace the oil plug sealing washer with a new one. If not there is a risk of leakage. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 151 Before refitting the oil plug in the gearbox, al- ways replace the oil plug sealing washer with a new one. If not there is a risk of leakage. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 152: Changing The Oil, Axis-1 Gearbox On Suspended Robots

    Mounted in suspended position: • Filling = Oil plug on surface for motor flange. • Draining = Oil plug on surface for motor flange. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 153 144 Oil collecting vessel The capacity of the vessel must be sufficient to take the complete amount of oil. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 154 The gearbox can contain an excess of pressure that can be hazardous. Open the oil plug carefully in order to let out the ex- cess pressure. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 155 The same amount shall later be refilled. after draining. Measure the volume of the drained oil in the vessel. Remove the hose and clean it. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 156 Verify that the hose of the oil change equipment is clean and then fit the quick connection to the oil plug for filling. xx1800001271 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 157 Expansion container axis-1 gearbox, suspended mounted robots Note Not valid for Type C and Type D! Expansion container is not needed on Type C and Type D. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 158 If a floor mounted robot shall be fitted in a suspended mounted position, an expansion container must be installed. See Installing an expansion container on page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 159: Changing The Oil, Axis-2 Gearbox

    Location of oil plugs on page 159. Standard toolkit Content is defined in section Standard tools on page 385. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 160 Used oil is hazardous material and must be disposed of in a safe way. See section commissioning on page 369 for more inform- ation. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 161 Type and amount of oil in gearboxes on page 144. Note The amount of oil to be filled depends on the amount previously being drained. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 162 Before refitting the oil plug in the gearbox, always replace the oil plug sealing washer with a new one. If not there is a risk of leakage. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 163: Changing The Oil, Axis-3 Gearbox

    Oil plugs are shown in the figure. Type C and Type D xx1200000633 Oil plug, armhouse (not visible in this figure) Oil plug, armhouse Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 164 Type of lubrication in gearboxes on page 144 Funnel xx1200000862 Standard toolkit Content is defined in section Standard tools on page 385. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 165 Location of oil plugs on page 163 Other design than Type C and Type D: Open the oil plug, gearbox and use it as a ventilation hole. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 166 Replace the oil plug, gearbox with a nipple See the figure in: where a draining hose is fitted. • Location of oil plugs on page 163 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 167 Move the upper arm to a position where the wrist is pointing towards the floor as shown in the figure. xx0800000329 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 168 D, in armhouse: 10 Nm Other design than Type C and Type D, in gearbox: 3 Nm Type C and Type D, both plugs: 10 Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 169: Changing The Oil, Axis-4 Gearbox

    A suitable hose would be a hose normally used for compressed air. Length: minimum 300 mm. Diameter: 5 mm. Funnel xx1200000862 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 170 Open oil plug, draining. See the figure in: • Location of oil plugs on page 169 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 171 • 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 172 Use a funnel. Note The amount of oil to be filled depends on the amount previously being drained. Refit the oil plug. Tightening torque: 10 Nm. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 173: Changing Oil, Axes-5 And -6 Gearboxes

    The figure shows wrist variant 60 kg xx0800000308 Oil plug, tilthouse Oil plug, wrist unit (also used as air inlet when draining from oil plug A) Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 174 Action Note Move the upper arm to a position where it points downwards. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 175 Action Note Move the upper arm to a horizontal position. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 176 • 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 177 • 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 178 Note If the robot is fitted in a suspended position, the wrist should be turned 180°. Refit the oil plugs. Tightening torque: • 10 Nm Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 179: Replacing Smb Battery

    See Operating manual - IRC5 with FlexPendant for instructions. WARNING Hazards related to batteries on page Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 180 DSQC 633A xx0800000322 SMB battery (2-pole battery contact) Battery cover Attachment screws SMB battery cable How to arrange the battery cable Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 181 Note Move the robot to its calibration position. This is done in order to facilitate the updating of the revolution counter. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 182 The unit is sensitive to ESD on page 53 Reconnect the battery cable to the SMB battery. See the figure in Location of SMB battery on page 180. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 183 Update the revolution counter. Detailed in Updating revolution counters on page 344. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 184: Cleaning Activities

    General To secure high uptime it is important that the IRB 4600 is cleaned regularly. The frequency of cleaning depends on the environment in which the product works. Different cleaning methods are allowed depending on the type of protection of the IRB 4600.
  • Page 185 3 Maintenance 3.5.1 Cleaning the IRB 4600 Continued Cleaning methods The following table defines what cleaning methods are allowed depending on the protection type. Protection Cleaning method type Vacuum Wipe with cloth Rinse with water High pressure water or cleaner...
  • Page 186 3 Maintenance 3.5.1 Cleaning the IRB 4600 Continued • Clean the cables if they have a crusty surface, for example from dry release agents. Cooling fans Inspect the air supply inlet of the the motor cooling fans. Clean to remove any contamination that could hinder the air supply.

  • Page 187: Repair

    Repair activities not described in this chapter must only be carried out by ABB. Report replaced units Note When replacing a part on the IRB 4600, report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit.

  • Page 188: 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 189: 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 190 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 191: Mounting Instructions For Sealings

    If the sealing is without dust lip, just lubricate the main lip with a thin layer of grease. xx2000000071 A Main lip B Grease C Dust lip Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 192 Check the o-ring for surface defects, burrs, Defective o-rings, including damaged shape accuracy, or deformation. or deformed o-rings, may not be used. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 193 Lubricate the o-ring with grease. Tighten the screws evenly while assembling. Check that the o-ring is not squashed outside the o-ring groove. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 194: 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 195: 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 196: Complete Robot

    Removing the SMB unit on page 226 • Brake release unit Removing the brake release board on page 232 • Motors Removing motors on page 287 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 197 Cable harness, base and frame. xx0900000009 Cover base Bracket Cable harness Axis-1 motor cable Axis-2 motor cable Axis-2 motor Axis-1 motor Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 198 Other tools and procedures may be re- These procedures include references to the quired. See references to these procedures tools required. in the step-by-step instructions below. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 199 • 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 200 Remove the cover base. xx0800000456 A Base B Cover base C Attachment screws Disconnect connectors on the brake release unit: • • • Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 201 A Thin nut, width 30 mm B R1.SMB C Bracket D Air connector Unscrew the nut for the air connection on the inside of the bracket. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 202 How to remove the SMB unit is described screws. in section: • Removing the SMB unit on page 226 Leave the screws in the base. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 203 Parts: • A: Screen connection (4 pcs) Disconnect the earth cables. xx0900000015 Parts: • A: Earth • B: Distance screws Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 204 How to remove the cable package from the frame. the frame is described in section • Removing cable harness in frame on page 205 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 205 B Connectors to SMB unit and Brake release unit C R1.CP/CS D Air hose E R1.MP F R1.SMB (Connector bent and taped upwards) Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 206 Cut the cable strap on the lower arm. See the figure in: • Location of the cable harness on page 197 (Cable harness, lower arm) Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 207 Remove the bracket on the armhouse. xx0800000335 Parts: • A: Tubular shaft unit • B: Attachment screws • C: Bracket, armhouse Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 208 • Removing motors on page 287 Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 209: Refitting The Complete Cable Harness

    Refitting the SMB unit on page 229 • Brake release unit Refitting the brake release board on page 233 • Motors Refitting motors on page 295 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 210 Cable harness, base and frame. xx0900000009 Cover base Bracket Cable harness Axis-1 motor cable Axis-2 motor cable Axis-2 motor Axis-1 motor Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 211 These procedures include references to the quired. See references to these procedures tools required. in the step-by-step instructions below. Cable grease 3HAC042536-001 (Shell Gadus S2) Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 212 B Connectors to SMB unit and Brake release unit C R1.CP/CS D Air hose E R1.MP F R1.SMB (Connector bent and taped upwards) Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 213 Note Use caution when performing this procedure in order not to damage cables or other components! Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 214 Connect the axis-1 and axis-2 motor cables. How to refit the motor cables is described in section: • Refitting motors on page 295 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 215 • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safe- guarded space. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 216 Attach the cable harness to the bracket. xx0900000098 Parts: • A: Attachment screw and nut • B: Bracket • C: Cable harness Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 217 Refit the SMB unit. How to refit the SMB unit is described in section: • Refitting the SMB unit on page 229 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 218 Before refitting the connectors on the bracket, arrange cables and connectors as shown in the figure. xx1200000857 A R1.CP/CS B R1.MP C Air hose Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 219 A Base B Distance screw C Attachment screw D Bracket Reconnect connectors on the brake release unit: • • • Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 220 Check that there is no leakage from the air hose. Reconnect the battery cable. Secure the battery cable with cable straps. xx0900000099 Parts: • A: Cable straps (2 pcs) Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 221 Before starting this procedure, first refit the cable harness in the frame and base. See: • Refitting the complete cable harness on page 209 • Refitting the complete cable harness on page 209 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 222 • Location of the cable harness on page 210 (Cable harness, lower arm) Push the cable harness carefully into the armhouse. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 223 Axis Calibration is described in Calibrating with Axis Calibration method on page 348. General calibration information is included in section Calibration on page 335. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 224 It is a vital part for the stability of the robot. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 225: Replacing Smb Unit

    Do not replace the battery contact! Equipment Note Standard toolkit Content is defined in section Standard tools on page 385. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 226 • 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 227 It is not needed to remove these three screws. xx0900000100 Parts: A Screw to be removed B Screws to be unscrewed a little (3 pcs) Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 228 See the figure in: the SMB unit: • Location of SMB unit on page 225 • R1.SMB1-2 • R1.SMB3-6 • R2.SMB Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 229 Location of SMB unit on page 225 Note Use caution when performing this procedure order not to damage cables or other com- ponents! Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 230 General calibration information is included in section Calibration on page 335. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 231: Replacing The Brake Release Board

    Connectors on push-button board The connectors X8, X9 and X10 are placed on the push-button board as shown in the figure below. xx1700000978 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 232 Remove the push button guard from the The guard must be removed to ensure a SMB cover. correct refitting of the brake release board. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 233 • 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 234 A Base B Base cover C Attachment screws M6x16 quality 8.8-A2F (6 pcs) Secure the base cover with its attachment screws. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 235 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 236: Replacing The Base

    Length: 2 m (2 pcs), 1.5 m (1 pcs) Lifting capacity: 1,000 kg. Support legs 3HAC15535-1 3 pcs Guide pin, M8x150 3HAC15520-2 Always use guide pins in pairs. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 237 Use this procedure to remove the complete arm system from the base. 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 238 Wrap up the cabling against the frame to • Removing cable harness in lower keep it undamaged during the remaining arm and armhouse on page 206 work. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 239 A Roundsling 1.5 m B Roundsling 2 m C Roundsling 2 m CAUTION The IRB 4600 robot weighs 440 kg. All lifting accessories used must be sized accordingly! Remove the bolts that secure the robot to the foundation. Lift the robot and fit three support legs to the robot base, using bolts, washers and nuts.
  • Page 240 Lower the robot and secure the support legs to the foundation, using bolts and washers. xx1800000875 Remove the cover plate at the bottom of the base. xx1800000879 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 241 Type C and Type • E: Cover plate • F: Attachment screws M6x16 qual- ity 8.8-A2F (5 pcs) Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 242 Fit three lifting eyes to the base and secure Lifting eye: M8 with roundslings in an overhead crane or similar. xx1800000931 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 243 Remove residues of old Loctite and other contaminations from surfaces before apply- ing new Loctite 574. Use Loctite 7063 (or similar) for cleaning. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 244 Fit two guide pins in opposite holes in the Guide pin, M8x150: 3HAC15520-2 axis-1 gearbox. Always use guide pins in pairs. xx1800000932 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 245 F: Attachment screws M6x16 qual- ity 8.8-A2F (5 pcs) Apply some grease to the o-ring and refit the o-ring between the cover and base. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 246 General calibration information is included in section Calibration on page 335. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 247: Upper Arm

    The upper complete arm is located as shown in the figure. xx1200000635 Upper arm Lower arm Washer (3 pcs) xx1200000520 Attachment screws M10x40 quality steel 12.9 Gleitmo (15 pcs) Axis-3 gearbox Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 248 Tubular shaft unit For spare parts no. see Spare parts - Upper arm (2.05/2.50/2.55) in Product manual, spare parts - IRB 2600. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 249 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 250 The weight of the complete upper arm (in- cluding the wrist) is 140 kg All lifting accessories used must be sized accordingly. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 251 A: Tubular shaft unit • B: Attachment screws M6x16 qual- ity 8.8-A2F (2 pcs) • C: Bracket Remove the signal lamp, if used. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 252 Dimension is specified in Required equipment on page 248. The purpose of these screws is to prevent the roundsling from sliding. xx1100000568 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 253 Attaching the roundslings to the upper sides of the screws and fasten the arm on page 254. free end of the roundsling to the lifting hook. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 254 • 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 255 Refit the cable bracket with its attachment screws. Reconnect all motor cables. How to connect motor cables is detailed in sections: • Refitting motors on page 295 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 256 General calibration information is included in section Calibration on page 335. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 257: Replacing Complete Tubular Shaft Unit

    These procedures include references to the tools quired. See references to these proced- required. ures in the step-by-step instructions be- low. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 258 • Changing the oil, axis-4 gearbox on page 169 Move the robot to the position shown in the figure. xx0800000336 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 259 CAUTION The robot arm tube weighs 65 kg. All lifting accessories used must be sized accordingly. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 260 Remove residues of old Loctite and other contaminations from the assembly surfaces. Remove any painting from the assembly surfaces, with a knife. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 261 There are two parallel pins guiding the tubular shaft unit into its place. Do not damage the gears when refitting the tubular shaft unit. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 262 General calibration information is included in section Calibration on page 335. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 263: Replacing Wrist Unit

    4 Repair 4.4.3 Replacing wrist unit 4.4.3 Replacing wrist unit Location of wrist unit The wrist unit is located in the upper arm as shown in the figures. IRB 4600 -60/2.05, -45/2.05, -40/2.55 xx0800000333 Upper arm Gear O-ring/sealing plate Wrist unit Spring washer, conical 8.4x18x2, quality steel-mZn12c (7 pcs)
  • Page 264 O-ring (Placed on the wrist, not visible) Sealing (lower image) Guide pin (only available for robots that are calibrated with Axis Calibration) Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 265 Use this procedure to remove the wrist unit. 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 266 • Changing oil, axes-5 and -6 gearboxes on page 173 CAUTION The robot wrist unit weighs 25 kg (IRB 4600 - 60/2.05, - 45/2.05, -40/2.55) and 15 kg (IRB 4600 - 20/2.50). All lifting accessories used must be sized ac-...
  • Page 267 Check if there is a parallel pin hole in the upper arm tube. The hole is available on robots that are calib- rated with the Axis Calibration method. xx1600000690 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 268 Axis Calibration, the calibration result will be affected negatively. xx1600000689 Verify that the parallel pin sticks out from the wrist according to the meas- urement given below. IRB 4600 -60/2.05, -45/2.05, -40/2.55 6 ±0,5 xx1600000702 IRB 4600 -20/2.50 xx1600000703 Clean all assembly surfaces.
  • Page 269 Prepare the refitting of the wrist by inserting the attachment screws and washers in the upper arm tube. CAUTION The robot wrist unit weighs 25 kg (IRB 4600 - 60/2.05, - 45/2.05, -40/2.55) and 15 kg (IRB 4600 - 20/2.50). All lifting accessories used must be sized ac- cordingly.
  • Page 270 General calibration information is in- cluded in section Calibration on page 335. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 271: Measuring The Play, Axis 5

    Content is defined in sec- tion Standard tools on page 385. Measuring tool, play 3HAB1611-6 (IRB 4600 -60/2.05, -45/2.05, -40/2.55) Measuring tool, play 3HAB6337-1 (IRB 4600 -20/2.50) Other tools and procedures may be required. These procedures include See references to these procedures in the references to the tools re- step-by-step instructions below.
  • Page 272 Apply load F in one direction, as shown in the figure to the right. Note Different load and distances for the differ- ent robot versions, as specified to the right! xx0300000186 Values for IRB 4600 - 60/2.05, -45/2.05, -40/2.55: • A: Measuring tool, play • B: 207.5 mm •...
  • Page 273 The maximum play allowed at the given reading the dial indicator. distance from the center of axis 5 is, for robot version: • IRB 4600 -60/2.05, -45/2.05, - 40/2.55: 0.10 mm • IRB 4600 -20/2.50: 0.08 mm Product manual - IRB 4600 3HAC033453-001 Revision: Y ©...

  • Page 274: Measuring The Play, Axis 6

    Content is defined in sec- tion Standard tools on page 385. Measuring tool, play 3HAB1611-6 (IRB 4600 -60/2.05, -45/2.05, -40/2.55) Measuring tool, play 3HAB6337-1 (IRB 4600 -20/2.50) Other tools and procedures may be required. These procedures include See references to these procedures in the references to the tools re- step-by-step instructions below.
  • Page 275 5. Note Different weight and distance for the dif- ferent robot versions, as specified to the right. xx0300000188 Values for robot versions IRB 4600 - 60/2.05, -45/2.05, -40/2.55: • A: Measuring tool, play • B: 207.5 mm •...
  • Page 276 4.4.5 Measuring the play, axis 6 Continued Action Information Apply load F in the opposite direction, as shown in the figure to the right. xx0300000190 Values for robot versions IRB 4600 - 60/2.05, -45/2.05, -40/2.55: • A: Measuring tool, play • B: 100 mm •...

  • Page 277: Lower Arm

    Location of lower arm Type C and Type D The lower arm is located as shown in the figure. xx1200000636 Upper arm Axis-3 gearbox Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 278 Other design than Type C and Type D The lower arm is located as shown in the figure. xx0800000360 Upper arm Axis-3 gearbox Lower arm Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 279 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 280 Removing the complete upper arm on page 250 CAUTION The robot lower arm weighs 65 kg. All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 281 • 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 282 Refit the complete upper arm. How to refit the complete upper arm is described in section: • Refitting the complete upper arm on page 254 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 283 General calibration information is included in section Calibration on page 335. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 284: Frame And Base

    Frame and base in Product manual, spare parts - IRB 2600. Standard toolkit Content is defined in section Standard tools on page 385. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 285 • Location of stop pin axis 1 on page 284 Note The o-rings are not used when bracket (D) is installed. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 286 See the figure in • Location of stop pin axis 1 on page 284 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 287: Motors

    Attachment screws, axis-2 motor (4 pcs) + washers. See Tightening torques and attachment screws on page 299 Connection box Axis-1 motor Axis-2 motor O-ring Hole Cable gland cover Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 288 Tightening torques and attachment screws on page 299 Axis-3 motor Axis-4 motor Axis-5 motor Axis-6 motor O-ring (axis-4, axis-5 and axis-6) Armhouse Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 289 13 kg Axis-2 motor 25 kg Axis-3 motor 13 kg Axis-4 motor 8 kg Axis-5 motor 8 kg Axis-6 motor 8 kg Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 290 This will make it possible to remove the motors without draining the oil from the gearbox. xx0800000388 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 291 Some steps are only applicable to a certain motor. Follow the steps carefully in order not to miss vital information! Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 292 Remove the connection box. motors on page 287 Note Only needed if the motor shall be replaced with a new one. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 293 Note Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 294 Location of axis-1 and axis-2 Check that the o-ring also is removed. It might motors on page 287 stay in the armhouse when the motor is re- moved. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 295: Refitting Motors

    Axis-2 motor: Attachment screw (4 pcs) + washers. See Tightening torques and attachment screws on page 299 Connection box Axis-1 motor Axis-2 motor O-ring Hole Cable gland cover Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 296 Tightening torques and attachment screws on page 299 Axis-3 motor Axis-4 motor Axis-5 motor Axis-6 motor O-ring (axis-4, axis-5 and axis-6) Armhouse Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 297 Weight in kg Axis-1 motor 13 kg Axis-2 motor 25 kg Axis-3 motor 13 kg Axis-4 motor 8 kg Axis-5 motor 8 kg Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 298 Use this procedure to fill oil in gearbox, if needed. Note Filling oil in the gearbox is only needed when refitting motors axes 2 and 3. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 299 Attachment screws Flange thickness Attachment screws 18.5 mm M10x40 15 mm M8x35 16 mm M10x35 13 mm M8x30 xx0900000443 Flange thickness Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 300 Parts: • A: Correct position of o-ring • B: Incorrect position of o-ring ! Replace with a new o-ring if damaged! Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 301 Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! Place the motor carefully in the gearbox. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 302 • Tightening torques and attach- ment screws on page 299 Note Apply the correct tightening torque! Disconnect the brake release voltage. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 303 If the gasket is damaged, it need to be replaced. Make sure that the gasket on the cover on the armhouse is intact. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 304 General calibration information is in- cluded in section Calibration on page 335. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 305: Adjusting The Play Of Axis 4, 5 And 6 Motors

    6 within this range. Push or tap the motor in radial direction so that the play becomes minimal within one motor turn, without the gear "chewing". Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 306: Gearboxes

    Frame Radial sealing Axis-1 gearbox with O-ring Harness pipe Washer (16 pcs) Attachment screws M10x100 quality Steel 12.9 Gleitmo (16 pcs) Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 307 Used to guide axis-1 gear and frame during refit- ting. Standard toolkit Content is defined in section Standard tools on page 385. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 308 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 309 Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 310 Secure the gearbox in an overhead crane or similar. Remove the attachment screws securing the See the figure in: gearbox. • Location of gearbox on page 306 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 311 There will be some excess oil running out of the gearbox when it is removed. Use some absorbent material to catch the oil. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 312 Check the radial sealing in the frame. Replace if damaged. xx1800000794 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 313 Location of gearbox on page 306 Replace o-ring if damaged. Clean all assembly surfaces. Remove any painting from the assembly surfaces, with a knife. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 314 It protects the radial sealing from being damaged during refitting. xx1800000795 CAUTION The gearbox weighs 27 kg. All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 315 Other design than Type C and Type D: 35 Nm • Type C and Type D: 68 Nm Remove the guide from the protection tube. xx1800000796 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 316 General calibration information is included in section Calibration on page 335. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 317 Gearbox axis 2 O-ring Frame Required equipment Equipment Article number Note Gearbox Spare part lists on page 391. Rotation tool 3HAB7887-1 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 318 Be careful not to damage the cables! Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 319 Drain the gearbox. How to drain the gearbox is described in sec- tion: • Changing the oil, axis-2 gearbox on page 159 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 320 • 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 321 See the figure in: washers that secure the gearbox to the • Location of gearbox axis 2 on page 317 frame. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 322 CAUTION The gearbox weighs 51 kg All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 323 Always use guide pins in pairs. Secure the gearbox with a roundsling in an overhead crane or similar. Release the brakes of the axis 2 motor. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 324 Attachment screws: M12x50 quality steel to secure the lower arm to the axis-2 gear- Gleitmo 12.9 (18 pcs) box. Tightening torque: 110 Nm. xx1800000935 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 325 General calibration information is included in section Calibration on page 335. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 326 Type C and Type D xx1200000638 Upper arm Axis-3 gearbox Washers (16 pcs) Attachment screws M10x50 quality Steel 12.9 Gleitmo (16 pcs) Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 327 Used to guide the gearbox and the upper arm during removal/refitting. Rotation tool 3HAB7887-1 Standard toolkit Content is defined in section Standard tools on page 385. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 328 Drain the gearbox. How to drain the gearbox is described in section: • Changing the oil, axis-3 gearbox on page 163 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 329 252 Connect the 24 VDC power supply to the axis-3 motor and release the brakes. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 330 CAUTION Remaining oil will drain out from the gear- box cavity when the gearbox is lifted out. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 331: Replacing Gearbox Axis

    Rotate the motor pinion and slide the gear- box into position. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 332: Replacing Gearbox Axis

    It is a vital part for the stability of the robot. xx0800000389 Parts: • A: Cover • B: Attachment screws M6x25, quality 8.8-A2F (10 pcs) Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 333 General calibration information is included in section Calibration on page 335. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 334 This page is intentionally left blank...

  • Page 335: Calibration

    A calibration routine to make a rough calibration of each manipulator axis. Synchronization mark Visual marks on the robot axes. When marks are aligned, the robot is in synchronization position. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 336: Calibration Methods

    To regain 100% Absolute accuracy perform- ance, the robot must be recalibrated for abso- lute accuracy after repair or maintenance that affects the mechanical structure. xx0400001197 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 337 Axis Calibration method Axis Calibration is a standard calibration method for calibration of IRB 4600 and is the most accurate method for the standard calibration. It is the recommended method in order to achieve proper performance.
  • Page 338 The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including the Operating manual - Calibration Pendulum, which describes the method and the different routines further. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 339: When To Calibrate

    If the robot is not floor mounted, then the robot accuracy could be affected. The robot needs to be calibrated after it is mounted. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 340: Synchronization Marks And Axis Movement Directions

    5.2.1 Synchronization marks and synchronization position for axes Introduction This section shows the position of the synchronization marks and the synchronization position for each axis. Synchronization marks, IRB 4600 IRB 4600-60/2.05, -45/2.05, -40/2.55, -20/2.50 xx0800000312 Synchronization mark, axis 1 Synchronization mark, axis 2 Synchronization mark, axis 3...
  • Page 341 5 Calibration 5.2.1 Synchronization marks and synchronization position for axes Continued IRB 4600 - 60/2.05, -45/2.05, 40/2.55 xx1700001814 Synchronization mark, axis 4 Synchronization mark, axis 5 Synchronization mark, axis 6 The two tips of the arrows should be inside the corresponding groove on the tilt housing when in synchronization position.
  • Page 342 5.2.1 Synchronization marks and synchronization position for axes Continued IRB 4600 -20/2.50 xx0800000320 Synchronization mark, axis 4 Synchronization mark, axis 5 IRB 4600 -20/2.50 xx0800000321 Synchronization mark, axis 6 Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 343: Calibration Movement Directions For All Axes

    Note! The graphic shows an IRB 7600. The positive direction is the same for all 6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in the opposite direction! xx0200000089 Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 344: Updating Revolution Counters

    At delivery the manipulator is in the correct position. Do NOT rotate axis 4 or 6 at power up before the revolution counters are updated. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 345 Step 2 - Updating the revolution counter with the FlexPendant Use this procedure to update the revolution counter with the FlexPendant (IRC5). Action On the ABB menu, tap Calibration. xx1500000942 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 346 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 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 347 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 367. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 348: Calibrating With Axis Calibration Method

    Keep a safe distance to the robot. 3 The axis position is stored in RobotWare with an active choice from the operator. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 349 SafeMove/EPS calibration has to be done. Make sure that the user rights admit to change the safety settings and to synchronize SafeMove/EPS. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 350 Axis must be put in position 0 degrees. How to calibrate a suspended robot The IRB 4600 is fine calibrated floor standing in factory, prior to shipping. To calibrate a suspended robot, reference calibration must be used. Reference values for a suspended robot must be created with the robot mounted at its working position, not standing on a floor.

  • Page 351: Calibration Tools For Axis Calibration

    If any part is missing or damaged, the tool must be replaced immediately. xx1500001914 Tube insert Plastic protection Steel spring ring Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 352 • 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 353: Installation Locations For The Calibration Tools

    This is shown in the figure. xx1600000641 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 354 5 Calibration 5.4.3 Installation locations for the calibration tools Continued xx1600000642 IRB 4600 - 20/2.50 xx1600000643 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 355 Standard) for the bushing. Protective plug on turning disc 3HAC057511-001 Only on IRB 4600 - 20/2.50. Replace if damaged or missing. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 356: Axis Calibration - Running The Calibration Procedure

    Protective plug on turning disc 3HAC057511-001 Only on IRB 4600 - 20/2.50. Replace if damaged or missing. Overview of the calibration procedure on the FlexPendant The actual instructions of how to perform the calibration procedure and what to do at each step is given on the FlexPendant.
  • Page 357 Wipe the calibration tool clean. Use a clean cloth. Note The calibration method is exact. Dust, dirt or color flakes will affect the calibration value. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 358 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 359 To be able to run Axis Calibration, SafeMove needs to be unsynchronized. The Axis Calibration routine recognizes if the robot is equipped with SafeMove and will force SafeMove to unsynchronize automatically. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 360 Refit the special protection plug to the turning IRB 4600 - 20/2.50 disc using the tool included in the calibration tool box. xx1700000905 Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 361 If the standard calibration data for axes 4, 5 or 6 Calibrating with Wrist Optimiz- should be updated with wrist optimization, run the ation method on page 365. calibration routine Wrist Optimization. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 362: Reference Calibration

    (step 5, see Brief introduction to Reference Calibration on page 362). Example "Adjust axis 4": 1 Create a backup. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 363 10 Check again against the verification position. 11 Repeat the manual tuning if needed. 12 Create a new reference if the intention is to use the reference in the future. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 364: 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 365: Calibrating With Wrist Optimization Method

    WARNING Robot moves automatically when pressing Calibrate. 6 Wrist optimization is finished. 7 Redefine / verify TCP for all tools. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 366: 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. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 367: Checking The Synchronization Position

    If they do not, up- ization position for axes on page 340 date the revolution counters. Updating revolution counters on page 344. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 368 This page is intentionally left blank...

  • Page 369: Decommissioning

    These parts must also be disposed of in accordance with the current legislation of the country in which the robot and control unit are installed. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 370: Environmental Information

    Incineration must be carried out under controlled conditions in accordance with local regulations. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 371 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 372: 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 373: Robot Description

    Axis 3 new gearbox Axis 3 new gearbox Axis 1 and 3 new Axis 4, 5, and 6 gearboxes new motors (Standard, Foundry Plus 2) Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 374: Type C Of Irb 4600

    7.2 Type C of IRB 4600 Type C - alternative gearboxes Type C of IRB 4600 have an alternative supplier of the axis-1 and axis-3 gearboxes. How to know which of the types is described, in the manual Throughout the manual the alternative gearboxes are described as "Type C". Other types of gearboxes are called "Other design than Type C".

  • Page 375: Type D Of Irb 4600

    7.3 Type D of IRB 4600 Type D - alternative motor Type D of IRB 4600 uses a Type C of IRB 4600 on page 374 with an alternative motor, and is only valid for the 20 kg/2.50 m variant.
  • Page 376 This page is intentionally left blank...

  • Page 377: Reference Information

    8.1 Introduction 8 Reference information 8.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 378: Applicable Standards

    – Immunity standard for industrial environments IEC 61000-6-4 Electromagnetic compatibility (EMC) – Part 6-4: Generic standards – Emission standard for industrial environments (option 129-1) Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 379 Degrees of protection provided by enclosures (IP code) Only valid for arc welding robots. Replaces IEC 61000-6-4 for arc welding robots. Only robots with protection Clean Room. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 380: 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 381: Screw Joints

    Any special torque specified overrides the standard torque! • Use the correct tightening torque for each type of screw joint. • Only use correctly calibrated torque keys. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 382 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 383 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 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 384: Weight Specifications

    Following is an example of a weight specification in a procedure: Action Note CAUTION The arm weighs 25 kg. All lifting accessories used must be sized accord- ingly. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 385: Standard Tools

    Socket head cap no: 6, socket 1/2" bit L 20 mm Socket head cap no: 8, socket 1/2" bit L 20 mm Small cutting plier T-handle with ball head Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 386: Special Tools

    The tools listed for measuring the play are used after service work on axes 5 and Description Robot variant Art. no. Measuring tool, play IRB 4600 - 60/2.05, -45/2.05, -40/2.55 3HAB1611-6 Measuring tool, play IRB 4600 - 20/2.50 3HAB6337-1 Special tools The following table specifies the special tools required during several of the service procedures.
  • Page 387 Description Art. no. Note Turning tool (includes lifting instruction) 3HAC034766-001 Valid for other designs than Type B, C and Type D. Continues on next page Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 388 The tools are specified directly in concerned instructions. Description Article no. Guide for reduction gear 3HACxxx Used to guide axis-1 gear and frame during refitting. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 389: Lifting Accessories And Lifting Instructions

    This implies that the instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 390 This page is intentionally left blank...

  • Page 391: Spare Part Lists

    Spare parts and exploded views are not included in the manual but delivered as a separate document for registered users on myABB Business Portal, www.abb.com/myABB. All documents can be found via myABB Business Portal, www.abb.com/myABB. Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 392 This page is intentionally left blank...

  • Page 393: Circuit Diagram

    Circuit diagram - IRB 2400 3HAC6670-3 Circuit diagram - IRB 2600 3HAC029570-007 Circuit diagram - IRB 4400/4450S 3HAC9821-1 Circuit diagram - IRB 4600 3HAC029038-003 Circuit diagram - IRB 6620 3HAC025090-001 Circuit diagram - IRB 6620 / IRB 6620LX 3HAC025090-001 Circuit diagram - IRB 6640...
  • Page 394 Circuit diagram - IRB 6700 / IRB 6790 3HAC043446-005 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 14000 3HAC050778-003 Circuit diagram - IRB 910SC 3HAC056159-002 Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.

  • Page 395: Index

    144 climbing on robot, 36 type of lubrication, 144 Cold environments, 95 connecting the robot and controller, cabling, 96 copper magnesium disposal, 370 disposal, 370 Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 396 47 turning protection types, 47 accessory, 57 symbols, 25 rubber disposal, 370 updating revolution counters, 344 users requirements, 22 safety brake testing, 40 Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 397 320, 324 adjusting, 95 upper arm, complete, 250, 255 verifying calibration, 366 Wrist Optimization overview of method, 365 weight, 44 base, 242–243 zero position checking, 367 Product manual - IRB 4600 3HAC033453-001 Revision: Y © Copyright 2009-2021 ABB. All rights reserved.
  • Page 400 ABB AB Robotics & Discrete Automation S-721 68 VÄSTERÅS, Sweden Telephone +46 (0) 21 344 400 ABB AS Robotics & Discrete Automation Nordlysvegen 7, N-4340 BRYNE, Norway Box 265, N-4349 BRYNE, Norway Telephone: +47 22 87 2000 ABB Engineering (Shanghai) Ltd. Robotics &...

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