ABB IRB 4600 - 60/2.05

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Table of Contents5
Overview of this Manual9
Product Documentation, IRC516
How to Read the Product Manual18
Safety19
Introduction to Safety Information19
General Safety Information20
Introduction to General Safety Information20
Safety in the Manipulator System21
Safety Risks22
Safety Risks During Installation and Service Work on Manipulators22
CAUTION - Hot Parts May Cause Burns25
Safety Risks Related to Tools/Work Pieces26
Safety Risks Related to Pneumatic/Hydraulic Systems27
Safety Risks with Pressure Relief Valve28
Safety Risks During Operational Disturbances29
Risks Associated with Live Electric Parts30
Safety Actions32
Safety Fence Dimensions32
Fire Extinguishing33
Emergency Release of the Manipulator's Arm34
Brake Testing35
Risk of Disabling Function "Reduced Speed 250 MM/S36
Safe Use of the Flexpendant37
Work Inside the Manipulator's Working Range38
Signal Lamp (Optional)39
Safety Stops40
What Is an Emergency Stop40
Safety Related Instructions42
Safety Signals in the Manual42
Safety Symbols on Manipulator Labels44
DANGER - Moving Manipulators Are Potentially Lethal49
DANGER - First Test Run May Cause Injury or Damage50
WARNING - the Brake Release Buttons May be Jammed after Service Work51
DANGER - Make Sure that the Main Power Has Been Switched off52
WARNING - the Unit Is Sensitive to ESD53
WARNING - Safety Risks During Handling of Batteries54
WARNING - Safety Risks During Work with Gearbox Lubricants (Oil or Grease)55
Installation and Commissioning57
Introduction57
Unpacking58
Pre-Installation Procedure58
Working Range and Type of Motion61
Risk of Tipping/Stability65
On-Site Installation66
Lifting Robot with Roundslings66
Lifting and Turning a Suspended Mounted Robot69
Manually Releasing the Brakes70
Orienting and Securing the Robot73
Setting the System Parameters for a Suspended Robot76
Fitting Equipment on Robot78
Loads84
Installation of Signal Lamp (Option)85
Restricting the Working Range86
Introduction86
Mechanically Restricting the Working Range of Axis 187
Installing Options90
Installation of Cooling Fan for Motors (Option)90
Installation of Foundry Plus Cable Guard (Option No. 908-1)97
Installing an Expansion Container98
Robot in Hot Environments100
Start of Robot in Hot Environments100
Robot in Cold Environments101
Start of Robot in Cold Environments101
Electrical Connections102
Robot Cabling and Connection Points102
Customer Connection on Robot104
Customer Connections on Upper Arm106
Maintenance109
Introduction109
Maintenance Schedule110
Specification of Maintenance Intervals110
Maintenance Schedule111
Expected Component Life113
Inspection Activities114
Inspecting Oil Level, Axis 1 Gearbox114
Inspecting the Oil Level, Axis 2 Gearbox121
Inspecting the Oil Level, Axis 3 Gearbox123
Inspecting the Oil Level, Axis 4 Gearbox126
Inspecting Oil Level, Gearbox Axes 5 - 6128
Inspecting the Cable Harness132
Inspecting Information Labels134
Inspecting the Mechanical Stop Pin, Axis 1137
Inspecting Additional Mechanical Stops140
Inspecting Dampers142
Inspecting the Pressure Relief Valve144
Inspecting Signal Lamp (Option)146
Replacement Activities148
Type of Lubrication in Gearboxes148
Changing the Oil, Axis-1 Gearbox on Floor Mounted Robots150
Changing the Oil, Axis-1 Gearbox on Suspended Robots156
Changing the Oil, Axis-2 Gearbox162
Changing the Oil, Axis-3 Gearbox166
Changing the Oil, Axis-4 Gearbox172
Changing Oil, Axes-5 and -6 Gearboxes176
Replacing SMB Battery182
Cleaning Activities187
Cleaning, Robot187
Repair189
Introduction189
General Procedures190
Performing a Leak-Down Test190
Mounting Instructions for Bearings191
Mounting Instructions for Seals193
Complete Robot195
Removing the Complete Cable Harness195
Refitting the Complete Cable Harness207
Replacing SMB Unit223
Replacing the Brake Release Unit228
Replacing the Base232
Upper Arm242
Replacing the Complete Upper Arm242
Replacing Complete Tubular Shaft Unit251
Replacing Wrist Unit257
Measuring the Play, Axis262
Measuring the Play, Axis 6265
Lower Arm268
Replacing the Lower Arm268
Frame and Base275
Replacing Stop Pin Axis 1275
Motors278
Removing Motors278
Refitting Motors286
Adjusting the Play of Axis 4, 5 and 6 Motors296
Gearboxes297
Replacing Gearbox Axis 1297
Replacing Gearbox Axis 2303
Replacing Gearbox Axis 3311
Calibration319
Introduction319
Calibration Methods320
Calibration Scale and Correct Axis Position322
Calibration Movement Directions for All Axes325
Updating Revolution Counters326
Checking the Calibration Position328
Decommissioning329
Introduction329
Environmental Information330
Robot Description331
Type C of IRB 4600331
Reference Information333
Introduction333
Applicable Safety Standards334
Unit Conversion336
Screw Joints337
Weight Specifications340
Standard Tools341
Special Tools342
Lifting Accessories and Lifting Instructions344
Spare Part List345
Rebuilding Parts345
Base Cover Assembly347
Base and Frame Unit348
Lower Arm and Frame350
Upper Arm IRB 4600-60/2.05, -40/2.05-40/2.50, -20/2.55352
Wrist Unit (60 Kg/45 Kg/20 Kg)358
Electrical Connections361
Gearboxes363
Motors365
Labels367
Options368
Circuit Diagram369
About Circuit Diagrams369

ABB IRB 4600 - 60/2.05 - Page 108

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