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IRB 460 Series
ABB IRB 460 Series User Manual
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Note
Action
DANGER
Make
sure
all
safety
requirements
are
met
when
performing
the
first
test
run.
These
are
further
detailed
in
the
section
First
test
run
may
cause
injury
or
damage
on
page
26
.
11
Product
manual
-
IRB
460
293
3HAC039842-001
Revision:
P
©
Copyright
2012-2018
ABB.
All
rights
reserved.
4
Repair
4.5.1
Replacing
motor,
axis
1
Continued
292
294
Table of Contents
Default Chapter
5
Table of Contents
5
Overview of this Manual
9
Product Documentation
13
How to Read the Product Manual
15
1 Safety
17
General Safety Information
17
Limitation of Liability
17
Protective Stop and Emergency Stop
19
Safety Actions
20
Fire Extinguishing
20
Emergency Release of the Robot Axes
21
Make Sure that the Main Power Has Been Switched off
22
Safety Risks
23
Safety Risks During Installation and Service Work on Robots
23
Moving Robots Are Potentially Lethal
25
First Test Run May Cause Injury or Damage
26
Work Inside the Working Range of the Robot
27
Enabling Device and Hold-To-Run Functionality
28
Risks Associated with Live Electric Parts
29
The Unit Is Sensitive to ESD
31
Hot Parts May Cause Burns
32
Safety Risks Related to Pneumatic/Hydraulic Systems
33
Brake Testing
34
Safety Risks During Handling of Batteries
35
Safety Risks During Work with Gearbox Lubricants (Oil or Grease)
36
Safety Signals and Symbols
38
Safety Signals in the Manual
38
Safety Symbols on Product Labels
40
2 Installation and Commissioning
47
Introduction
47
Unpacking
48
Pre-Installation Procedure
48
Working Range and Type of Motion
52
Risk of Tipping/Stability
54
On-Site Installation
55
Lifting the Robot with Fork Lift Accessory
55
Fitting the Fork Lift Accessory
55
Lifting the Robot with Fork Lift Truck
58
Lifting Robot with Roundslings
61
Manually Releasing the Brakes
63
Lifting the Base Plate
65
Securing the Base Plate
66
Orienting and Securing the Robot
71
Fitting Equipment on Robot
75
Loads Fitted to the Robot, Stopping Time and Braking Distances
79
Installation of Signal Lamp, Upper Arm (Option)
80
Installation of Options
84
Option 87-1 - Installing the Cooling Fan for Axis-1 Motor
84
Restricting the Working Range
90
Introduction
90
Mechanically Restricting the Working Range of Axis 1
91
Robot in Cold Environments
93
Start of Robot in Cold Environments
93
Electrical Connections
94
Robot Cabling and Connection Points
94
3 Maintenance
97
Introduction
97
Maintenance Schedule and Expected Component Life
98
Specification of Maintenance Intervals
98
Maintenance Schedule
99
Expected Component Life
101
Inspection Activities
102
Inspecting the Oil Level in Axis-1 Gearbox
102
Inspecting, Oil Level Gearbox Axes 2 - 3
104
Inspecting, Oil Level Gearbox Axis 6
107
Inspecting, Cable Harness
109
Inspecting the Information Labels
111
Inspecting the Axis-1 Mechanical Stop Pin
113
Inspecting the Additional Mechanical Stops
115
Inspection, Dampers
117
Inspecting the Signal Lamp (Option)
119
Replacement/Changing Activities
121
Type of Lubrication in Gearboxes
121
Changing Oil, Axis-1 Gearbox
122
Changing Oil, Gearbox Axes 2 and 3
126
Changing Oil, Gearbox Axis 6
130
Replacing the SMB Battery
132
Cleaning Activities
136
Cleaning the IRB 460
136
4 Repair
139
Introduction
139
General Procedures
140
Performing a Leak-Down Test
140
Mounting Instructions for Bearings
141
Mounting Instructions for Seals
143
Cut the Paint or Surface on the Robot before Replacing Parts
145
The Brake Release Buttons May be Jammed after Service Work
146
Complete Robot
147
Replacing Cable Harness, Lower End (Axes 1-3)
148
Replacing the Cable Harness, Upper End (Incl. Axis 6)
157
Replacing the SMB Unit
164
Replacing the Brake Release Board
169
Replacing the Base, Including Axis 1 Gearbox
173
Upper and Lower Arm
182
Replacing the Turning Disk
182
Replacing the Tilthouse Unit
188
Continues on Next Page
189
Location of Tilthouse Unit
189
Location of Axes 2 and 3 Sides of the Robot
190
X-Ray View of the Assembly of the Tilthouse Unit
192
Press Tool for Removal of Shaft
194
Removing the Tilthouse Unit
196
Replacing the Upper Arm
209
Replacing Linkage - Upper Link Arm
225
Replacing Linkage - Lower Link Arm
233
Replacing the Linkage - Link
240
Replacing the POM Sealing for the Link System
256
Replacing Parallel Rod
257
Replacing the Complete Lower Arm System
268
Replacing the Parallel Arm
278
Motors
285
Replacing Motor, Axis 1
285
Replacing Motors, Axes 2 and 3
294
Replacing Motor, Axis 6
305
Gearboxes
313
Replacing the Axis 1 Gearbox
313
Replacing the Axis 2 Gearbox
323
Replacing the Axis 3 Gearbox
331
Product Manual - IRB
332
Replacing Gearbox Axis 6
338
5 Calibration
347
Calibration Methods
348
When to Calibrate
350
Synchronization Marks and Axis Movement Directions
351
Calibration Movement Directions for All Axes
352
Updating Revolution Counters
353
Calibrating with Axis Calibration Method
357
Calibration Tools for Axis Calibration
359
Installation Locations for the Calibration Tools
361
Axis Calibration - Running the Calibration Procedure
363
Calibrating with Calibration Pendulum Method
367
Verifying the Calibration
368
Checking the Synchronization Position
369
6 Decommissioning
371
Scrapping of Robot
373
7 Reference Information
375
Applicable Standards
376
Unit Conversion
378
Screw Joints
379
Weight Specifications
382
Standard Tools
383
Special Tools
384
Lifting Accessories and Lifting Instructions
388
8 Spare Parts
389
9 Circuit Diagrams
391
Index
393
4
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ABB IRB 460 Series Specifications
General
Brand
ABB
Model
IRB 460 Series
Category
Robotics
Language
English
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