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Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.

Note

Action

Decide which calibration routine to use for
calibrating the robot.

•

Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.

•

Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.

1

Follow the instructions given in the refer-
ence calibration routine on the FlexPendant
to create reference values.

If the robot is to be calibrated with refer-
ence calibration:

Find previous reference values for the axis
or create new reference values. These val-
ues are to be used after the repair proced-
ure is completed, for calibration of the ro-
bot.

Creating new values requires possibility to
move the robot.
Read more about reference calibration for
Axis Calibration in

Reference calibration

routine on page 358

.

If no previous reference values exist, and
no new reference values can be created,
then reference calibration is not possible.

Read more about reference calibration for
Pendulum Calibration in

Operating manu-

al - Calibration Pendulum

.

If the robot is to be calibrated with fine
calibration:

Remove all external cable packages
(DressPack) and tools from the robot.

Removal, gearbox axis 1

Use this procedure to remove gearbox, axis 1.

Note

Action

Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.

1

Move the robot to its most stable position,
shown in the figure to the right.

2

Jog the robot to this position:
Axis 2 = -40 degrees
Axis 3 = +65 degrees

DANGER

Turn off all:

•

electric power supply

•

hydraulic pressure supply

•

air pressure supply

to the robot, before entering the robot
working area.

3

See

Changing oil, axis-1 gearbox on

Drain the axis 1 gearbox.

4

Continues on next page

Product manual - IRB 460

315

3HAC039842-001 Revision: P

© Copyright 2012-2018 ABB. All rights reserved.

4 Repair

4.6.1 Replacing the axis 1 gearbox

Continued

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Summary of Contents for IRB 460 Series

Page 1: ...ROBOTICS Product manual IRB 460 ...

Page 2: ...Trace back information Workspace R18 2 version a18 Checked in 2018 11 20 Skribenta version 5 3 012 ...

Page 3: ...Product manual IRB 460 110 2 4 IRC5 Document ID 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved Specifications subject to change without notice ...

Page 4: ... persons or property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission Keep for future reference Additional copies of this manual may be obtained from ABB Original instructions ...

Page 5: ...ety signals in the manual 40 1 4 2 Safety symbols on product labels 47 2 Installation and commissioning 47 2 1 Introduction 48 2 2 Unpacking 48 2 2 1 Pre installation procedure 52 2 2 2 Working range and type of motion 54 2 2 3 Risk of tipping stability 55 2 3 On site installation 55 2 3 1 Lifting the robot with fork lift accessory 55 2 3 1 1 Fitting the fork lift accessory 58 2 3 1 2 Lifting the ...

Page 6: ... for bearings 143 4 2 3 Mounting instructions for seals 145 4 2 4 Cut the paint or surface on the robot before replacing parts 146 4 2 5 The brake release buttons may be jammed after service work 147 4 3 Complete robot 147 4 3 1 Replacing cable harness lower end axes 1 3 157 4 3 2 Replacing the cable harness upper end incl axis 6 164 4 3 3 Replacing the SMB unit 169 4 3 4 Replacing the brake relea...

Page 7: ...ons for the calibration tools 363 5 4 4 Axis Calibration Running the calibration procedure 367 5 5 Calibrating with Calibration Pendulum method 368 5 6 Verifying the calibration 369 5 7 Checking the synchronization position 371 6 Decommissioning 371 6 1 Environmental information 373 6 2 Scrapping of robot 375 7 Reference information 375 7 1 Introduction 376 7 2 Applicable standards 378 7 3 Unit co...

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Page 9: ...pair maintenance work Product manual scope The manual covers covers all variants and designs of the IRB 460 Some variants and designs may have been removed from the business offer and are no longer available for purchase Organization of chapters The manual is organized in the following chapters Contents Chapter Safety information that must be read through before performing any installation or serv...

Page 10: ...C050996 001 Application manual Electronic Position Switches 3HAC051016 001 Application manual Additional axes and stand alone con troller 3HAC042927 001 Technical reference manual Lubrication in gearboxes 3HAC050948 001 Technical reference manual System parameters i This manual contains all safety instructions from the product manuals for the manipulators and the controllers Revisions Description ...

Page 11: ...s changed see Securing the base plate on page 66 Reference to Hilti standard added to the foundation recommendation for the base plate and class designation for foundation is changed to european standard C25 C30 previously Swedish standard K25 K30 see Securing the base plate on page 66 All data about type of lubrication in gearboxes is moved from the manual to a separate lubrication manual see Typ...

Page 12: ...oor cables added Updated list of applicable standards Article number for the Calibration tool box Axis Calibration is changed Added text regarding overhaul in section specification of maintenance intervals Updated the section Start of robot in cold environments on page 93 Updated information regarding replacement of brake release board Lifting robot with roundslings updated Updated information reg...

Page 13: ...sioning Reference information safety standards unit conversions screw joints lists of tools Spare parts list with corresponding figures or references to separate spare parts lists References to circuit diagrams Technical reference manuals The technical reference manuals describe reference information for robotics products for example lubrication the RAPID language and system parameters Application...

Page 14: ...ts The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters 14 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved Product documentation Continued ...

Page 15: ...completed with a reference to the section where the equipment is listed with further information that is article number and dimensions The designation in the procedure for the component or attachment point corresponds to the designation in the referenced list The table below shows an example of a reference to a list of required equipment from a step in a procedure Note Illustration Action Art no i...

Page 16: ...This page is intentionally left blank ...

Page 17: ...arried out by in experienced or non qualified personnel Foreign objects Force majeure Nation region specific regulations To protect personnel the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed To be observed by the supplier of the complete system The integrator is respo...

Page 18: ...working in the work cell see the section Robot motion in the Product specification Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot Safe handling Users shall not be exposed to hazards including slipping tripping and falling hazards It must be possible to safely turn off tools such as milling cutters etc Make sure tha...

Page 19: ...view The protective stops and emergency stops are described in the product manual for the controller Product manual IRB 460 19 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 1 Safety 1 1 2 Protective stop and emergency stop ...

Page 20: ...guishing Note Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the manipulator or controller 20 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 1 Safety 1 2 1 Fire extinguishing ...

Page 21: ...s may require using an overhead crane or similar equipment Increased injury Before releasing the brakes make sure that the weight of the robot does not increase the pressure on the trapped person further increasing any injury DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unexpected ways Make sure no personnel is near or beneath the robot Product man...

Page 22: ... arrest burn injuries or other severe injuries To avoid these personal injuries switch off the main power on the controller before proceeding work Note Switch off all main power switches in a MultiMove system 22 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 1 Safety 1 2 3 Make sure that the main power has been switched off ...

Page 23: ...safety lock Make sure that no one else can turn on the power to the controller and robot while you are working with the system A good method is to remove the power cable to the controller If the robot is installed at a height hanging or other than standing directly on the floor there may be additional risks than those for a robot standing directly on the floor Energy stored in the robot for the pu...

Page 24: ...modifications to the robot Connection of external safety devices Apart from the built in safety functions the robot is also supplied with an interface for the connection of external safety devices An external safety function can interact with other machines and peripheral equipment via this interface This means that control signals can act on safety signals received from the peripheral equipment a...

Page 25: ...y stop equipment is cor rectly installed and connected 1 How to use the hold to run function is de scribed in section How to use the hold to run function in the Operating manual IRC5 with FlexPendant Usually the hold to run function is active only in manual full speed mode To in crease safety it is also possible to activate hold to run for manual reduced speed with a system parameter 2 The hold to...

Page 26: ...efore it is powered up 2 Verify that any safety equipment installed to secure the position or restrict the robot motion during service activity is removed 3 Verify that the fixture and work piece are well secured if applicable 4 Install all safety equipment properly 5 Make sure all personnel are standing at a safe distance from the robot and is out of its reach behind safety fences or similar 6 If...

Page 27: ... in USA or Canada Pay attention to the rotating axes of the robot Keep away from axes to not get entangled with hair or clothing Also be aware of any danger that may be caused by rotating tools or other devices mounted on the robot or inside the cell Keep clear of moving parts so that limbs hands or fingers do not get trapped or crushed by the robot To prevent anyone else from taking control of th...

Page 28: ...manipulator switches to the MOTORS OFF state To ensure safe use of the teach pendant the following must be implemented The enabling device must never be rendered inoperational in any way During programming and testing the enabling device must be released as soon as there is no need for the robot to move Anyone entering the working space of the robot must always hold the teach pendant This is to pr...

Page 29: ... risks IRC5 controller A danger of high voltage is associated with for example the following parts Be aware of stored electrical energy DC link Ultracapacitor bank unit in the controller Units such as I O modules can be supplied with power from an external source The main supply main switch The transformers The power unit The control power supply 230 VAC The rectifier unit 262 400 480 VAC and 400 ...

Page 30: ...be live even if the robot system is in the OFF position Power supply cables which are in motion during the working process may be damaged 30 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 1 Safety 1 3 6 Risks associated with live electric parts Continued ...

Page 31: ... straps must be tested frequently to ensure that they are not damaged and are operating cor rectly Product manual IRC5 Product manual IRC5 Compact Product manual IRC5 Panel Mounted Controller Use a wrist strap The wrist strap button is located inside the control ler 1 The mat must be grounded through a current limit ing resistor Use an ESD protective floor mat 2 The mat should provide a controlled...

Page 32: ... your hand at some distance to feel if heat is radiating from the potentially hot component before actually touching it Wait until the potentially hot component has cooled if it is to be removed or handled in any other way Do not put anything on hot metal surfaces e g paper or plastic 32 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 1 Safety 1 3 8 Hot...

Page 33: ...ure must be released in the complete pneumatic or hydraulic systems before starting to repair them Work on hydraulic equipment may only be performed by persons with special knowledge and experience of hydraulics All pipes hoses and connections have to be inspected regularly for leaks and damage Damage must be repaired immediately Splashed oil may cause injury or fire Safe design Gravity may cause ...

Page 34: ... as described below 1 Run each robot axis to a position where the combined weight of the robot arm and any load is maximized maximum static load 2 Switch the motor to the MOTORS OFF 3 Inspect and verify that the axis maintains its position If the robot does not change position as the motors are switched off then the brake function is adequate 34 Product manual IRB 460 3HAC039842 001 Revision P Cop...

Page 35: ...losion fire may follow depending upon the circumstances Note Appropriate disposal regulations must be observed Safe handling Use safety glasses when handling the batteries In the event of leakage wear rubber gloves and chemical apron In the event of fire use self contained breathing apparatus Do not short circuit recharge puncture incinerate crush immerse force discharge or expose to temperatures ...

Page 36: ...tion Action Description Warning Make sure that protective gear like goggles and gloves are al ways worn during this activity Changing and draining gearbox oil or grease may require hand ling hot lubricant heated up to 90 C Hot oil or grease Make sure that protective gear like goggles and gloves are al ways worn When working with gearbox lub ricant there is a risk of an allergic reaction Allergic r...

Page 37: ...a time to heat up the oil Warm oil drains quicker than cold oil Heat up the oil After filling verify that the level is correct The specified amount of oil or grease is based on the total volume of the gearbox When changing the lubricant the amount refilled may differ from the specified amount depending on how much has previously been drained from the gearbox Specified amount de pends on drained vo...

Page 38: ...he instructions are not followed that can lead to serious injury pos sibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc WARNING Warns for electrical hazards which could result in severe personal injury or dea...

Page 39: ...d conditions NOTE Describes where to find additional information or how to do an operation in an easier way TIP Product manual IRB 460 39 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 1 Safety 1 4 1 Safety signals in the manual Continued ...

Page 40: ...glish German and French Symbols on safety labels Description Symbol Warning xx0900000812 Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of ...

Page 41: ... Do not disassemble xx0900000815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the robot arm can fall down Continues on next page Product manual IRB 460 41 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights res...

Page 42: ...ip over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page 42 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 43: ...1 1 06 xx1300001087 Moving robot 1 2 3 4 5 6 xx0900000819 The robot can move unexpectedly xx1000001141 1 2 3 4 xx1500002616 Continues on next page Product manual IRB 460 43 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 44: ...0001242 Lifting of robot xx0900000822 Oil xx0900000823 Can be used in combination with prohibition if oil is not allowed Mechanical stop xx0900000824 Continues on next page 44 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 45: ...that this part is pressurized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller Do not step xx1400002648 Warns that stepping on these parts can cause damage to the parts Product manual IRB 460 45 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Contin...

Page 46: ...This page is intentionally left blank ...

Page 47: ...portant that all safety information is observed There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page17 before performing any installation work Note If the IRB 460 is connected to power always make sure that the robot is connected to protective ...

Page 48: ...specified in Weight robot on page 48 5 If the robot is not installed directly it must be stored as described in Storage condi tions robot on page 50 6 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 51 7 Before taking the robot to its installation site make sure that the site conforms to Loads on found...

Page 49: ...e shows the various forces and torques working on the robot during different kinds of operation Note These forces and torques are extreme values that are rarely encountered during operation The values also never reach their maximum at the same time WARNING The robot installation is restricted to the mounting options given in following load table s Floor mounted Max load emergency stop Endurance lo...

Page 50: ...interpreted as the frequency of the robot mass inertia robot assumed stiff when a foundation translational torsional elasticity is added i e the stiffness of the pedestal where the robot is mounted The minimum resonance frequency should not be interpreted as the resonance frequency of the building floor etc For example if the equivalent mass of the floor is very high it will not affect robot movem...

Page 51: ...d start 0 C 5 C see Start of robot in cold environments on page 93 Protection classes robot The table shows the available protection types of the robot with the corresponding protection class Protection class Protection type IP 67 Manipulator protection type Standard Product manual IRB 460 51 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 2 Installation and commissioning 2 2...

Page 52: ...al working range A Mechanical stop B Maximal working range C Tool flange center D Angles Position mm Position in figure Axis 3 Axis 2 Z X 0 0 1437 1505 1 20 40 1565 836 2 25 40 782 802 3 120 55 145 742 4 120 85 314 909 5 20 85 223 2385 6 20 45 1510 2111 7 Continues on next page 52 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 2 Installation and commis...

Page 53: ...o 165 Rotation motion 1 40 to 85 Arm motion 2 20 to 120 Arm motion 3 25 to 155 Arm motion 2 3 300 to 300 Turn motion 6 Turning radius xx1000001202 Motor axis 3 A Product manual IRB 460 53 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range and type of motion Continued ...

Page 54: ...position Do not change the robot position before securing it to the foundation Shipping and transportation position This figure shows the robot in its shipping position and transportation position 773 40 692 5 2 5 94 1707 m 380 627 907 xx1000001158 WARNING The robot is likely to be mechanically unstable if not secured to the foundation 54 Product manual IRB 460 3HAC039842 001 Revision P Copyright ...

Page 55: ...ift truck Preparations before fitting the fork lift pockets Note Action DressPack if used can stay fitted as long as the tool fitted on the turning disk is removed Remove any tools fitted on the axis 6 turning disk Note No tool is permitted to be fitted on the robot when lifting the robot with the fork lift accessory 1 773 40 692 5 2 5 94 1707 m 380 627 907 xx1000001158 Jog the robot to its shippi...

Page 56: ...ints on the robot The fork lift accessory is fitted on the robot as shown in the figure xx0600002910 Fork lift pocket A Attachment screw M20x60 quality 8 8 2 pcs x4 B Continues on next page 56 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 2 Installation and commissioning 2 3 1 1 Fitting the fork lift accessory Continued ...

Page 57: ... the ro bot with its attachment screws Note Before fitting any attachment screws make sure they are not damaged in any way Replace dam aged screws 1 Verify that all four fork lift pockets are properly secured before lifting 2 Product manual IRB 460 57 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 2 Installation and commissioning 2 3 1 1 Fitting the fork lift accessory Conti...

Page 58: ... truck Lifting the robot with fork lift truck Note Action Note No load is permitted on the robot Make sure that the robot is in shipping position 1 DANGER Make sure that all supplies for electrical power hydraulic pressure and air pres sure are turned off 2 Verify that all four fork lift pockets are properly secured before lifting 3 Continues on next page 58 Product manual IRB 460 3HAC039842 001 R...

Page 59: ...fitted If lifting with fewer than four fork lift pockets fitted there is a risk of accidents 4 IRB 6640 Ax2 A x3 Ax5 45 10 80 xx0600003401 IRB 460 xx1000001159 Continues on next page Product manual IRB 460 59 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 2 Installation and commissioning 2 3 1 2 Lifting the robot with fork lift truck Continued ...

Page 60: ...e present under the suspended load 7 Note Move the robot with low speed Move the robot slowly to its new position 8 Secure the robot to the foundation DANGER Do not power the robot up until it is se cured properly to the foundation 9 Remove the fork lift accessories 10 60 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 2 Installation and commissioning 2...

Page 61: ...e bolts in the rear M20 holes 2 Attach roundslings to robot according to fig ure Attachment points on page 62 3 Note Make sure that the roundslings do not lie against sensitive parts for example harness and customer equipment 4 CAUTION The IRB 460 robot weighs 925 kg All lifting accessories used must be sized accordingly 5 WARNING Personnel must not under any circum stances be present under the su...

Page 62: ...ckle 2 pcs Lifting capacity 2 000 kg B Roundsling 2 m 2 pcs Lifting capacity 2 000 kg C Roundsling 2 5 m 2 pcs Lifting capacity 2 000 kg Wrap once D Roundsling 2 m secures against rotation Lifting capacity 2 000 kg Wrap twice E 62 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 2 Installation and commissioning 2 3 2 Lifting robot with roundslings Contin...

Page 63: ...ke release unit Note Action Buttons are shown in figure Loca tion of brake release unit on page 63 The internal brake release unit is equipped with buttons for controlling the axes brakes The buttons are numbered according to the numbers of the axes Note Axes 4 and 5 do not exist 1 If the robot is not connected to the controller power must be supplied to the connector R1 MP according to the sectio...

Page 64: ... is released Supplying power to connector R1 MP If the robot is not connected to the controller power must be supplied to connector R1 MP on the robot in order to enable the brake release buttons Note Action DANGER Incorrect connections such as supplying power to the wrong pin may cause all brakes to be released simultaneously 1 xx0600002937 Supply 0V on pin 12 and 24V on pin 11 2 64 Product manua...

Page 65: ...kg All lifting accessories used must be sized accordingly 1 Shown in figure Hole configur ation on page 65 Fit lifting eyes in specified holes 2 Fit lifting slings to the eyes and to the lifting accessory CAUTION Lift and move the base plate very slowly If the base plate starts to swing it is a risk for injuries or damage 3 Product manual IRB 460 65 3HAC039842 001 Revision P Copyright 2012 2018 AB...

Page 66: ...3x45º 0 3 Ø 45P7 A A Ø1 5 4x 6 3 4 8 2 1 6 3x45º B B 2 1 3 3x R1 3 x 4 3x 90º C C 4 5 K 7 0 5 0 47 0 25 c 2x R22 5 1 6 D 2 c 5 2 5 º Common Zone E F G H xx1000001053 Common tolerance zone accuracy all over the base plate from one contact surface to the other E F G H Continues on next page 66 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 2 Installation...

Page 67: ...for alternative clamping 4x Ø18 A Continues on next page Product manual IRB 460 67 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 2 Installation and commissioning 2 3 5 Securing the base plate Continued ...

Page 68: ...for leveling bolts in the base plate A A A B B B B xx1500000312 Orienting grooves 3 pcs A Levelling bolts attachment holes 4 pcs B Continues on next page 68 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 2 Installation and commissioning 2 3 5 Securing the base plate Continued ...

Page 69: ...nt is defined in section Standard tools on page 383 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Base plate This section details how to secure the base plate to the foundation Note Action Make sure the foundation is levelled 1 Continues on next page Pro...

Page 70: ... orienting grooves and leveling bolts on page 68 Fit the base plate and use the levelling bolts to level the base plate 6 If required fit strips of sheet metal underneath the base plate to fill any gaps 7 Secure the base plate to the foundation with screws and sleeves 8 Maximum allowed deviation all over the base plate from one contact surface to the other 0 3 mm Recheck the four contact surfaces ...

Page 71: ...lling screws Note Remove before the robot base is fitted C Base plate attachment screws D Attachment screws The table below specifies the type of securing screws and washers to be used for securing the robot to the base plate foundation M24 x 100 Suitable screws lightly lubricated Quality 8 8 Quality Thickness 4 mm Suitable washer Outer diameter 44 mm Inner diameter 25 mm 725 Nm Tightening torque ...

Page 72: ...bot base is correctly fitted onto the guide sleeves Guide the robot gently using two M24 screws while lowering it into its mounting position 4 Specified in Attachment screws on page 71 Fit the bolts and washers in the base attach ment holes 5 Shown in figure Illustration robot fitted to base plate on page 71 Note Lightly lubricate screws before as sembly Tighten bolts in a criss cross pattern to e...

Page 73: ...ion used when securing the robot R400 4 x 15 4 x 3 7 5 xx0600002932 Continues on next page Product manual IRB 460 73 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 2 Installation and commissioning 2 3 6 Orienting and securing the robot Continued ...

Page 74: ...ation shows the cross section of the guide sleeve holes xx0600002934 74 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 2 Installation and commissioning 2 3 6 Orienting and securing the robot Continued ...

Page 75: ...pment on upper arm The illustration below shows the mounting holes available for fitting extra equipment on the upper arm For mounting of an external vacuum hose there are six holes on the upper arm The maximum weight for the vacuum hose and fastening device is 35 kg Continues on next page Product manual IRB 460 75 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 2 Installatio...

Page 76: ...315 5 90 M10 2x75 A M10 2x82 A M10 2x85 A D 6xM8 9 B 200 30 40 50 40 200 25 50 20 xx1000001041 M10 mounting holes on upper arm A Drill depth 15 mm B Continues on next page 76 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 2 Installation and commissioning 2 3 7 Fitting equipment on robot Continued ...

Page 77: ... on the turning disk xx1000001042 A B Y X xx1800001402 Tool flange in bottom view Locating hole A Tool coordinate system B Continues on next page Product manual IRB 460 77 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 2 Installation and commissioning 2 3 7 Fitting equipment on robot Continued ...

Page 78: ...to robot tool flange all bolt holes shall be used Only use screws with quality 12 9 78 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 2 Installation and commissioning 2 3 7 Fitting equipment on robot Continued ...

Page 79: ... robot References Load diagrams permitted extra loads equipment and their positions are specified in the product specification The loads must be defined in the software Operating manual IRC5 with FlexPendant 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 Prod...

Page 80: ...M6x8 2 pcs B Motor cover C Required equipment Note Article number Equipment etc Complete kit with signal lamp cables adapter gasket screws etc Spare parts on page 389 Signal lamp kit Fitted between motor and cable gland replace if damaged 3HAC033206 001 Gasket Content is defined in section Stand ard tools on page 383 Standard toolkit Continues on next page 80 Product manual IRB 460 3HAC039842 001 ...

Page 81: ...01064 Signal lamp bracket A Attachment screws for the bracket M8x12 2 pcs B Attachment screws for the signal lamp 2 pcs C Cable straps 2 pcs D Cable gland cover E Motor adapter including gasket F Attachment screw M6x40 1 pc G Continues on next page Product manual IRB 460 81 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 2 Installation and commissioning 2 3 9 Installation of ...

Page 82: ...n page 81 Arrange the signal cable in a loop at the signal cable bracket with two cable straps 4 Electrical installation signal lamp Use this procedure to connect the signal lamp to the axis 6 motor The instruction requires that the signal lamp is already mounted to the tilthouse Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before...

Page 83: ...ckage to the motor Secure with attachment screw M6x40 enclosed with the signal lamp kit 6 In addtion to the enclosed gasket that is fitted to the adapter there is also a gasket located on the motor Make sure it does not get damaged Re place if damaged Push the signal cable through the hole in the adapter and connect it to the connector inside the motor 7 Loosen the motor cables at the glands and a...

Page 84: ...ng fan option 87 1 can be installed on the axis 1 motor Location of cooling fan xx1300000168 Continues on next page 84 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 2 Installation and commissioning 2 4 1 Option 87 1 Installing the cooling fan for axis 1 motor ...

Page 85: ...anu al spare parts IRB 460 Cooling fan Choose this if equipping the robot with a cooling fan on the axis 1 motor Fan axis 1 cable harness Choose this if equipping the robot with a cooling fan on the axis 1 motor Motor cover Continues on next page Product manual IRB 460 85 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 2 Installation and commissioning 2 4 1 Option 87 1 Instal...

Page 86: ...g fan Note Action DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot air pressure supply to the robot Before entering the robot working area 1 xx1300000843 Disassemble the parts of the fan box by remov ing the attachment screws 2 xx1300000844 Loosen the three tightening screws to avoid damaging the surfaces of the motor when fit ting the fan box 3 Continu...

Page 87: ... it does not rest directly on the robot and secure the box with the three tightening screws using locking liquid Tighten them properly so that the box is firmly attached to the motor 7 Install the cabling and make adjustments in RobotWare as described in the following pro cedures 8 Continues on next page Product manual IRB 460 87 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserve...

Page 88: ...ion Move the robot to its calibration position 1 DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot air pressure supply to the robot Before entering the robot working area 2 xx1300000766 Insert the fan cable through the motor cover and tighten the screw 3 Continues on next page 88 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB Al...

Page 89: ...e to fit the motor cover at the correct direction see the figure 5 Connect the connector R3 FAN to the connector on the fan box 6 Strap the cable onto the axis 1 motor cables at position A 7 Product manual IRB 460 89 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 2 Installation and commissioning 2 4 1 Option 87 1 Installing the cooling fan for axis 1 motor Continued ...

Page 90: ...cted Axis 1 hardware mechanical stop and software EPS As standard configuration axis 1 is allowed to move 165º This section describes how to install hardware that restricts the working range Note Adjustments must also be made in the robot configuration software system parameters References to relevant manuals are included in the installation procedures 90 Product manual IRB 460 3HAC039842 001 Revi...

Page 91: ...s 1 The illustration shows the mounting position of the stop pin and one of the additional mechanical stops available for axis 1 The figure shows IRB 6640 but is also valid for IRB 460 xx0600002938 Movable mechanical stop A Attachment screw plus washer M12 x 40 quality 12 9 2 pcs B Fixed mechanical stop C Mechanical stop pin axis 1 D Continues on next page Product manual IRB 460 91 3HAC039842 001 ...

Page 92: ... to the robot Before entering the robot working area 1 Tightening torque 120 Nm Fit the additional mechanical stop to the frame according to the figure Mechanical stops axis 1 on page 91 2 The system parameters that must be changed Upper joint bound and Lower joint bound are described in Technical reference manual System parameters Adjust the software working range limitations system parameter con...

Page 93: ...he speed can be regulated with the RAPID instruction VelSet Start the robot with its normal program but with reduced speed 1 Adjusting the speed and acceleration during warm up Depending on how cold the environment is and what program is being used the speed might need to be ramped up until reached maximum The table shows examples of how to adjust the speed Speed velocity AccSet Work cycles v100 1...

Page 94: ...bot cables These cables are included in the standard delivery They are completely pre manufactured and ready to plug in Connection point robot Connection point cabinet Description Cable sub category R1 MP XS1 Transfers drive power from the drive units in the control cabinet to the robot motors Robot cable power R1 SMB XS2 Transfers resolver data from and power supply to the serial measurement boar...

Page 95: ... on manipulator There is a grounding bonding point on the manipulator base The grounding bonding point is used for potential equalizing between control cabinet manipulator and any peripheral devices xx1600001956 Product manual IRB 460 95 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 2 Installation and commissioning 2 7 1 Robot cabling and connection points Continued ...

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Page 97: ...t sections and divided according to the maintenance activity Safety information Observe all safety information before conducting any service work There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page 17 before performing any service work Note If...

Page 98: ...cal value is given for a typical work cycle but the value will differ depending on how hard each part is run The SIS used in M2004 is further described in the Operating manual Service Information System Overhaul Depending on application and operational environment a complete overhaul may be necessary in average around 40000 hours ABB Connected Services and its Assessment tools can help you to iden...

Page 99: ...ifies the required maintenance activities and intervals Interval Equipment Maintenance activity Robot Cleaning Every 6 months Axis 1 gearbox oil level Inspection Every 6 months Axes 2 and 3 gearboxes oil level Inspection Every 6 months Axis 6 gearbox oil level Inspection Every 12 monthsi Robot harness Inspection Every 12 months Information labels Inspection Every 12 months Mechanical stop axis 1 I...

Page 100: ...needs to be replaced The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned on until the battery is to be replaced See the replacement instruction for more details iv The battery low alert 38213 Battery charge low is displayed when remaining backup capacity robot powered off is less than 2 months The typical lifetime of a new battery is 36 months if the r...

Page 101: ...e Information System SIS that is integrated in the robot software can be used as guidance when planning gearbox service for the individual robot This applies to gearboxes on axes 1 2 3 and 6 In some applications such as Foundry or Washing the robot can be exposed to chemicals high temperature or humidity which can have an effect on the lifetime of the gearboxes Contact the local ABB Robotics Servi...

Page 102: ...her oils See Type and amount of oil in gearboxes on page 121 Lubricating oil Content is defined in section Standard tools on page 383 Standard toolkit These procedures include refer ences to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page 102 Product manual IRB 460 3HAC039842 001 Revision...

Page 103: ...ment Make sure that the oil temperature is 25 C 10 C 3 Shown in figure Location of gear box on page 102 Open the oil plug inspection 4 A B C xx1400002785 A Oil plug hole B Required oil level C Gearbox oil Measure the oil level Required oil level max 5 mm below the oil plug hole 5 Where to find type of oil and total amount is detailed in Type of lub rication in gearboxes on page121 Adjust the oil l...

Page 104: ...located in the lower arm rotational center underneath the motor attachment xx1000001295 Gearbox axis 2 A Oil plug filling B Continues on next page 104 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 3 Maintenance 3 3 2 Inspecting oil level gearbox axes 2 3 ...

Page 105: ...ee references to these procedures in the step by step instructions below Inspecting oil level gearbox 2 3 Use this procedure to inspect the oil level in gearbox axes 2 3 Note Action WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety inform ation in the section Safety risks during work with gearbox lubricants oil or grease on page 36 1 Continues on n...

Page 106: ... level at the oil plug filling 4 Required oil level max 5 mm below oil plug hole Art no is specified in Required equipment on page 105 Add oil if required 5 Filling of oil is detailed further in section Changing oil gearbox axes 2 and 3 on page 126 Tightening torque 25 Nm Refit oil plug filling 6 106 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 3 Mai...

Page 107: ...C032140 001 Lubricating oil Content is defined in section Standard tools on page 383 Standard toolkit These procedures include refer ences to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page Product manual IRB 460 107 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 3 ...

Page 108: ...supply to the robot before entering the robot working area 2 Shown in figure Location of gear box on page 107 Open oil plug filling 3 Required oil level 23 mm 2 mm below the motor mounting surface 4 Art no is specified in Required equipment on page 107 Add oil if required 5 Further information about how to fill the oil may be found in the section Changing oil gearbox axis 6 on page 130 Tightening ...

Page 109: ...able harness robot axes 1 6 A Connectors at base B Motor cables C Cable guide axis 2 D Metal clamps E Required equipment Visual inspection no tools are needed Continues on next page Product manual IRB 460 109 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 3 Maintenance 3 3 4 Inspecting cable harness ...

Page 110: ...e 109 Check the cable guide axis 2 Replace if damaged 5 Shown in figure Location of cable har ness axes 1 6 on page 109 Check the metal clamps on the lower arm 6 xx0500002498 Check the metal clamps holding the cable harness inside the upper arm as shown in figure to the right 7 A Metal clamp inside upper arm Shown in figure Location of cable har ness axes 1 6 on page 109 Check the metal clamp hold...

Page 111: ... A N A A B A H xx1000001292 Warning label Heat located on motor cover 3HAC4431 1 4 pcs A Warning label symbol of flash located on motor cover 3HAC1589 1 4 pcs B Combined warning label Moving robot Shut off with handle and Before dismantling see product manual 3HAC17804 1 C Continues on next page Product manual IRB 460 111 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 3 Main...

Page 112: ...l serial number L Label calibration M Label battery N Label stock robots P Required tools and equipment Visual inspection no tools are required Inspecting labels Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Inspect the labels located as shown in the figures 2 Article numbers for the labels ...

Page 113: ... in the figure xx1000001302 Mechanical stop pin axis 1 A Required equipment Visual inspection no tools are required Inspecting mechanical stop pin Use this procedure to inspect the axis 1 mechanical stop pin Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Continues on next page Product manual ...

Page 114: ...r damaged it must be replaced Note The expected life of gearboxes can be reduced after collision with the mechanical stop 114 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 3 Maintenance 3 3 6 Inspecting the axis 1 mechanical stop pin Continued ...

Page 115: ...d washers 2 pcs B Fixed stop C Mechanical stop pin axis 1 D Required equipment Note Article number Equipment etc See Spare parts on page 389 Mechanical stop Content is defined in section Standard tools on page 383 Standard toolkit Continues on next page Product manual IRB 460 115 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 3 Maintenance 3 3 7 Inspecting the additional mec...

Page 116: ...ke sure no additional stops are damaged 2 Make sure the stops are properly attached 3 Correct tightening torque additional mechanical stops Axis 1 120 Nm Article number is specified in Required equipment on page115 If any damage is detected the mechanical stops must be replaced Correct attachment screws Axis 1 M12 x 40 quality 12 9 4 116 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2...

Page 117: ...iew Required equipment Note Art no Equipment To be replaced if damaged See Spare parts on page 389 Damper lower arm upper To be replaced if damaged See Spare parts on page 389 Damper lower arm lower To be replaced if damaged See Spare parts on page 389 Damper axis 2 3 Continues on next page Product manual IRB 460 117 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 3 Maintenan...

Page 118: ...1 Shown in figure Location of dampers on page 117 Check all dampers for damage cracks or existing impressions larger than 1 mm 2 Check attachment screws for deformation 3 Art no is specified in Required equipment on page 117 If any damage is detected the damper must be replaced with a new one 4 118 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 3 Maint...

Page 119: ...pment Note Article number Equipment To be replaced if damage is detected See Spare parts on page 389 Signal lamp kit Content is defined in section Stand ard tools on page 383 Standard toolkit Inspecting signal lamp Use this procedure to inspect the function of the signal lamp Note Action Inspect that signal lamp is lit when motors are put in operation MOTORS ON 1 Continues on next page Product man...

Page 120: ...119 If the lamp is not lit trace the fault by inspecting whether the signal lamp is broken If so replace it inspecting cable connections measuring the voltage in the connectors of motor axis 6 24V inspecting the cabling Replace the cabling if a fault is detected 3 120 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 3 Maintenance 3 3 9 Inspecting the sig...

Page 121: ...nce or changing activities of lubrication always contact the local ABB Service organization for more information For ABB personnel Always check ABB Library for the latest revision of the manual Technical reference manual Lubrication in gearboxes in order to always get the latest information of updates about lubrication in gearboxes A new revision will be published on ABB Library immediately after ...

Page 122: ...n the following figure falseThe oil is drained through a hose which is located at the rear of the robot base xx1000001294 Oil plug inspection A Oil plug filling B Continues on next page 122 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 3 Maintenance 3 4 2 Changing oil axis 1 gearbox ...

Page 123: ...n page 121 Lubricating oil Capacity 8 000 ml Oil collecting vessel Content is defined in section Special tools on page 384 3HAC021745 001 Oil exchange equip ment Content is defined in section Standard tools on page 383 Standard toolkit Continues on next page Product manual IRB 460 123 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 3 Maintenance 3 4 2 Changing oil axis 1 gear...

Page 124: ... a nipple and an oil collecting vessel 4 Vessel capacity is specified in Required equipment on page123 Note Draining is time consuming Elapsed time depends on the temperature of the oil Tightening torque 25 Nm Refit oil plugs 5 Filling oil axis 1 gearbox Use this procedure to fill gearbox axis 1 with oil Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure s...

Page 125: ...earboxes on page 121 Refill the gearbox with clean lubricating oil The correct oil level is detailed in section Inspecting the oil level in axis 1 gearbox on page 102 4 Tightening torque 25 Nm Refit the oil plug filling 5 Product manual IRB 460 125 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 3 Maintenance 3 4 2 Changing oil axis 1 gearbox Continued ...

Page 126: ...neath motor attachment The figure shows the position of gearbox axis 2 xx1000001348 Ventilation hole plug gearbox axis 2 A Oil plug filling B Oil plug draining C Continues on next page 126 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 3 Maintenance 3 4 3 Changing oil gearbox axes 2 and 3 ...

Page 127: ...e and amount of oil in gearboxes on page 121 Lubricating oil Capacity 4 000 ml Oil collecting vessel Content is defined in section Special tools on page 384 3HAC021745 001 Oil exchange equip ment Content is defined in section Standard tools on page 383 Standard toolkit Continues on next page Product manual IRB 460 127 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 3 Maintena...

Page 128: ... on page 126 Remove the oil plug draining and drain gear box using a hose with a nipple and an oil col lecting vessel 4 Vessel capacity is specified in Re quired equipment on page 127 Draining is time consuming Elapsed time varies depending on the temperature of the oil Tightening torque 25 Nm Refit the oil plug draining 5 Filling axes 2 and 3 Use this procedure to fill gearboxes of axes 2 and 3 w...

Page 129: ...ld also be removed 3 Tightening torque 24 Nm Art no and total amount are specified in Required equipment on page 127 Refill gearbox with lubricating oil The amount of oil to be filled depends on the amount that was previously drained 4 Shown in Location of oil plugs on page 126 Refit oil plug filling and ventilation hole plug 5 Tightening torque 25 Nm Product manual IRB 460 129 3HAC039842 001 Revi...

Page 130: ...3HAC021745 001 Oil exchange equipment Vessel capacity 400 ml Oil collecting vessel Content is defined in section Standard tools on page 383 Standard toolkit Draining oil Use this procedure to drain oil from gearbox axis 6 When using oil change equipment follow the instructions enclosed with kit Note Action Put tilt house in a suitable position 1 Continues on next page 130 Product manual IRB 460 3H...

Page 131: ...tions enclosed with kit Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Shown in figure Location of oil plugs on page 130 Remove the oil plug filling 2 Art no and the total amount are specified in Required equipment on page 130 Refill the gearbox with lubricating oil Amount of oil to be refill...

Page 132: ... is powered off 2 days week or 18 months if the robot is powered off 16 h day The lifetime can be extended for longer production breaks with a battery shutdown service routine See Operating manual IRC5 with FlexPendant for instructions WARNING See instructions for batteries Safety risks during handling of batteries on page35 Location of SMB battery The SMB battery SMB serial measurement board is l...

Page 133: ...pare part no Equipment etc Battery includes protection circuits Only re place with a specified spare part or an ABB approved equivalent For spare part no see Spare parts on page 389 Battery unit Content is defined in section Standard tools on page 383 Standard toolkit See chapter Circuit diagrams on page 391 Circuit diagram Removing battery Use this procedure to remove the SMB battery Note Action ...

Page 134: ...ry on page 132 Pull out the battery and disconnect the battery cable 5 Shown in figure Location of SMB battery on page 132 Remove the SMB battery Battery includes protection circuits Only replace with a specified spare part or with an ABB ap proved equivalent 6 Refitting battery Use this procedure to refit the SMB battery Note Action DANGER Turn off all electric power supply hydraulic pressure sup...

Page 135: ...r C Battery cable Shown in figure Location of SMB battery on page 132 Secure the SMB battery cover with its attachment screws 4 Detailed in chapter Calibration section Updating revolution coun ters on page 353 Update the revolution counters 5 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...

Page 136: ...activities on page 102 2 Write down the oil level 3 Inspect the oil level again after for example 6 months 4 If the oil level is decreased then replace the gearbox Special cleaning considerations This section specifies some special considerations when cleaning the robot Always use cleaning equipment as specified Any other cleaning equipment may shorten the life of the robot Always check that all p...

Page 137: ...rime can be cleaned by rinsing with water water cleaner 1 The following list defines the prerequisites Maximum water pressure at the nozzle 700 kN m2 7 bar I Fan jet nozzle should be used min 45 spread Minimum distance from nozzle to encapsulation 0 4 meters Maximum flow 20 liters minI I Typical tap water pressure and flow Cables Movable cables need to be able to move freely Remove waste material ...

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Page 139: ... perform a specific repair activity are listed in the respective procedures The details of equipment are also available in different lists in the chapter Reference information on page 375 Safety information There are general safety information and specific safety information The specific safety information describes the danger and safety risks while performing specific steps in a procedure Make su...

Page 140: ...The pressure must under no circumstance be higher than 0 25 bar 20 25 kPa Also during the time when the pressure is raised 3 0 2 0 25 bar 20 25 kPa Disconnect the compressed air supply 4 If the compressed air is signific antly colder or warmer than the gearbox to be tested a slight pressure increase or decrease may occur This is quite normal Wait for approximately 8 10 minutes and make sure that n...

Page 141: ...o any stresses during the assembly work 3 Assembly of tapered bearings Follow the preceding instructions for the assembly of the bearings when mounting a tapered bearing on the robot In addition to those instructions the following procedure must be carried out to enable the roller elements to adjust to the correct position against the race flange Note Action Tension the bearing gradually until the...

Page 142: ...tarted During operation the bearing should be filled to 70 80 of the available volume Ensure that grease is handled and stored properly to avoid contamination Grease the different types of bearings as following description 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 142 Product manual IRB ...

Page 143: ...e correct type provided with cutting edge There is no damage to the sealing edge feel with a fingernail 1 Inspect the sealing surface before mounting If scratches or damage are found the seal must be replaced since it may result in future leakage 2 Article number is specified in Equipment on page143 Lubricate the seal with grease just before fitting Not too early there is a risk of dirt and foreig...

Page 144: ...enly when fastening the flange joint 4 O rings The following procedure describes how to fit o rings Note Action Ensure that the correct o ring size is used 1 Defective o rings including damaged or deformed o rings may not be used Check the o ring for surface defects burrs shape accuracy or deformation 2 Defective o rings may not be used Check the o ring grooves 3 The grooves must be geometrically ...

Page 145: ...052 001 Touch up paint Standard Foundry Plus ABB Orange Removing Description Action xx0900000121 Cut the paint with a knife in the joint between the part that will be removed and the struc ture to avoid that the paint cracks 1 Carefully grind the paint edge that is left on the structure to a smooth surface 2 Product manual IRB 460 145 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights re...

Page 146: ...ge to the robot Elimination To eliminate the danger after service work has been performed inside the SMB recess follow the procedure below Action Make sure the power is turned off 1 Remove the push button guard if necessary 2 Verify that the push buttons of the brake release unit are working by pressing them down one by one 3 Make sure none of the buttons are jammed in the tube If a button gets ja...

Page 147: ...3 and upper end axis 6 This procedure describes how to replace the lower end of the cable harness How to replace the upper end can be found in section Replacing the cable harness upper end incl axis 6 on page 157 Continues on next page Product manual IRB 460 147 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 3 1 Replacing cable harness lower end axes 1 3 ...

Page 148: ... 1 3 is located throughout the base frame and lower arm as shown in the figure xx1100000153 Continues on next page 148 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 3 1 Replacing cable harness lower end axes 1 3 Continued ...

Page 149: ...are part no see Spare parts on page 389 Cable harness 1 6 Motor axes 1 3 3HAC3438 1 Gasket Replace if damaged The content is defined in the sec tion Standard tools on page 383 Standard toolkit Continues on next page Product manual IRB 460 149 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 3 1 Replacing cable harness lower end axes 1 3 Continued ...

Page 150: ...axes 1 3 Note Action This is done in order to facilitate updat ing of the revolution counter Move the robot to the calibration position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 xx1100000155 Remove the rear cover plate from the robot by removing its attachment screws 3 Continues on next page 150 P...

Page 151: ... metal clamp that hold the cable harness inside the lower arm 7 Unscrew the screws of the motor covers for axes 1 2 and 3 and lift away the covers This is done in order to reach the motor connectors 8 See sections Replacing motor axis 1 on page 285 Replacing motors axes 2 and 3 on page 294 Disconnect all connectors at motors for axes 1 2 and 3 9 Continues on next page Product manual IRB 460 151 3H...

Page 152: ...MB6 from the SMB unit 12 Disconnect X8 X9 and X10 from the brake re lease unit 13 Remove the SMB cover and put somewhere safe 14 xx1000001330 Unscrew the screws for the cable gland SMB from inside the SMB recess and lift the cable gland out Perform this removal with care in order not to damage any of the components inside the SMB recess 15 Continues on next page 152 Product manual IRB 460 3HAC0398...

Page 153: ... axes 1 3 Use this procedure to refit the cable harness lower end axes 1 3 Note Action xx1000001331 Push the cable harness and connectors down through the cable guide axis 1 in the center of the frame CAUTION Make sure the cables are not twisted with each other or with customer harness if any 1 Continues on next page Product manual IRB 460 153 3HAC039842 001 Revision P Copyright 2012 2018 ABB All ...

Page 154: ...ents inside the SMB recess 2 Tightening torque for R1 SMB 10 Nm Reconnect connectors R1 MP and R1 SMB at the robot base 3 Attachment points are shown in the figure Location of cable harness lower end axes 1 3 on page 148 xx1100000156 Reconnect the earth cable 4 Continues on next page 154 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 3 1 Rep...

Page 155: ...ith its attachment screws 8 If cabling is used for 7th axis option refit the connector R2 FB7 to the SMB cover and tighten with 6 Nm WARNING Before continuing any service work please observe the safety information in section The brake release buttons may be jammed after service work on page 146 9 Push the cable harness up through the lower arm 10 Fasten the metal clamp that hold the cable harness ...

Page 156: ...revolution counters on page 353 Update the revolution counter 14 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 15 156 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 3 1 Replacing cable harness lower end axes 1 ...

Page 157: ... axis 6 The procedure for replacing the lower end axis 1 3 is detailed in section Replacing cable harness lower end axes 1 3 on page 147 Location of cable harness upper end The upper end of the cable harness is located as shown in the figure xx1100000158 Continues on next page Product manual IRB 460 157 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 3 2 Replacing ...

Page 158: ...quired equipment Note Art no Equipment etc For spare part no see Spare parts on page 389 Cable harness 1 6 Motor axis 6 Gasket Content is defined in section Standard tools on page 383 Standard toolkit Continues on next page 158 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 3 2 Replacing the cable harness upper end incl axis 6 Continued ...

Page 159: ... robot to the calibration position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Detailed in section Replacing cable har ness lower end axes 1 3 on page 147 If the complete cable harness is being re placed start removal by removing the cable harness lower end 3 xx1000001106 Remove the axis 6 motor cov...

Page 160: ...gland Disconnect connectors at axis 6 motor 5 xx1000001336 Remove the metal clamp that holds the cable at the tilt house by removing its nuts 6 Carefully pull the cable harness out of motor axis 6 7 Continues on next page 160 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 3 2 Replacing the cable harness upper end incl axis 6 Continued ...

Page 161: ...this procedure to refit the cable harness upper end Note Action Detailed in section Replacing cable har ness lower end axes 1 3 on page 147 Start by fitting the cable harness lower end if it has been removed 1 Push the cable harness through the upper arm tube 2 Continues on next page Product manual IRB 460 161 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 3 2 Rep...

Page 162: ...e tilthouse with its nuts 4 Push the axis 6 motor cables carefully through the cable gland Note Do not twist the cables 5 Reconnect all connectors in motor axis 6 6 Check the gasket If damaged replace it 7 Continues on next page 162 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 3 2 Replacing the cable harness upper end incl axis 6 Continued...

Page 163: ...and does not get jammed Note Make sure the cover is tightly sealed 9 Detailed in section Updating revolution counters on page 353 Update the revolution counter 10 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 page26 11 Product manual IRB 460 163 3HAC039842 001 Revision P Cop...

Page 164: ...e figure SMB board DSQC 633A with 2 pole contact xx1100000105 Battery pack 2 pole battery contact A Cover B BU button guard plate C Push button guard D Cover SMB E SMB unit F Brake release unit G Continues on next page 164 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 3 3 Replacing the SMB unit ...

Page 165: ...ts of SMB units and batteries The variant with the 3 pole battery contact has longer lifetime for the battery It is important that the SMB unit uses the correct battery Make sure to order the correct spare parts Do not replace the battery contact Note Article number Equipment etc For spare part number see Spare parts on page 389 SMB unit Continues on next page Product manual IRB 460 165 3HAC039842...

Page 166: ...t is sensitive to ESD on page 31 3 Shown in the figure Location of SMB unit on page 164 Remove the SMB cover by unscrewing its attachment screws CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures 4 Use caution and remove the connectors X8 X9 and X10 from the brake release board if need of more space 5 Shown ...

Page 167: ...nnect the battery cable to the SMB unit Make sure the lock on the battery cable connect or R2 G snaps into place during refitting 3 Art no is specified in Required equipment on page 165 Connect all connectors to the SMB board R1 SMB1 3 R1 SMB6 and R2 SMB 4 Shown in the figure Location of SMB unit on page 164 Fit the SMB unit onto the guide pins 5 Secure the SMB unit to the pins with the nuts and w...

Page 168: ...th 6 Nm 8 See Updating revolution counters on page 353 Update the revolution counter 9 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 10 168 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 3 3 Replacing the SMB u...

Page 169: ...ght next to the gearbox axis 2 as shown in figure below xx1100000105 Battery pack 2 pole battery contact A Cover B BU button guard plate C Push button guard D Cover SMB E SMB unit F Brake release unit G Continues on next page Product manual IRB 460 169 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 3 4 Replacing the brake release board ...

Page 170: ... Shown in the figure Location of brake release board on page 169 Remove the push button guard from the SMB cover 3 The guard must be removed to ensure a correct refitting of the brake release board Shown in the figure Location of brake release board on page 169 Open the SMB cover by unscrewing the attach ment screws Let the battery stay connected to avoid the need of synchronization of the robot C...

Page 171: ...aximum tightening torque 5 Nm Fasten the brake release board on the bracket with the attachment screws Make sure the board is positioned as straight as possible on the bracket The push buttons can otherwise get jammed when the SMB cover is refitted 3 Shown in the figure Location of brake release board on page 169 Art no is specified in Required equip ment on page 170 Refit the complete brake relea...

Page 172: ...to 6 one at a time to make sure that the buttons are moving freely and do not stay in a locked position 9 Detailed in the Calibration chapter section Updating revolution counters on page 353 If the battery has been disconnected the revolu tion counter must be updated 10 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section Fir...

Page 173: ...base gearbox axis 1 Location of the base The location of the base including gearbox axis 1 is shown in the figure It also shows the complete arm system as defined above xx1100000246 Continues on next page Product manual IRB 460 173 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 3 5 Replacing the base including axis 1 gearbox ...

Page 174: ...to the tools re quired Other tools and procedures may be required See refer ences to these procedures in the step by step instructions below See chapter Circuit diagrams on page 391 Circuit diagram Deciding calibration routine Decide which calibration routine to be used based on the information in the table Depending on which routine is chosen action might be required prior to beginning the repair...

Page 175: ...erence calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the complete arm system Use this procedure to remove the complete arm system Note Action Decide which calibration routine to use and take actions accordingly prior to beginning the...

Page 176: ...he complete arm sys tem on page 178 10 Adjust the length of each roundsling so that the lift is done completely level Stretch the roundslings so that they secure the weight of the arm system 11 xx1100000247 Unfasten the arm system from the base by unscrewing the attachment screws Note Use a bits holder with a thin head to remove the screws For example Stahlwille 736 40 D10 or similar The space is ...

Page 177: ...em 14 Note Continue lifting even if the arm system turns out to be unbalanced despite earlier adjust ments The risk of damaging the interface is bigger if the load is lowered unbalanced CAUTION Always move the robot at very low speed making sure it does not tip See Replacing the axis 1 gearbox on page 313 If needed continue to remove the axis 1 gearbox from the base 15 Continues on next page Produ...

Page 178: ... 174 Fit the adapter to the oil plug hole for filling oil into axis 1 gearbox 4 Art no is specified in Required equip ment on page 174 Fit a lifting eye and a shackle to the adapter 5 The roundsling will take the load of the frame during the lift of the arm system provided that the brake of axis 2 is re leased Fit a roundsling between the lower arm and the shackle 6 Continues on next page 178 Prod...

Page 179: ...78 4 Adjust the length of each roundsling so that the lift is done completely level Stretch the roundslings so that they secure the weight of the arm system 5 Note Make sure all hooks and attachments stay in the correct position while lifting the arm system and that the lifting accessory does not wear against sharp edges Lift the complete arm system and move it at very low speed to the mounting si...

Page 180: ...crank to turn the gearbox in order to find the right position for the holes Lower the complete arm system with guid ance from the guide pins previously fitted to the axis 1 gearbox Note The refitting must be made completely level Make sure the roundslings are adjusted prior to refitting the arm system 9 Reused screws can be used providing they are lubricated as described in Screw joints on page 37...

Page 181: ...e frame 17 A Mechanical stop pin See Performing a leak down test on page 140 Perform a leak down test of the axis 1 gear box 18 See Changing oil axis 1 gearbox on page 122 Refill the axis 1 gearbox with lubricating oil 19 Pendulum Calibration is described in Operating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 20 Axis Calibration is described in Calibrat ...

Page 182: ...ousing as shown in the figure below xx1100000132 Required equipment Note Art no Equipment etc O rings are not included For spare part no see Spare parts on page 389 Turning disk Continues on next page 182 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 1 Replacing the turning disk ...

Page 183: ... Use this procedure to remove the turning disk Note Action Run the robot to a position where the tilthouse is best positioned for the turning disk to be replaced 1 Note This is done in order to fascilitate fitting of the turning disk in the correct position Rotate axis 6 to its calibration position 2 xx1100000139 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supp...

Page 184: ...hown in the figure Location of turning disk on page 182 xx1100000076 Remove the turning disk 7 Foundry Plus 8 Remove old flange sealant residues and other con tamination from the contact surfaces Continues on next page 184 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 1 Replacing the turning disk Continued ...

Page 185: ...t on page 182 xx1100000140 Lubricate the o ring of the turning disk with grease and fit it to the turning disk 1 xx0200000218 A Sealing surface o ring Continues on next page Product manual IRB 460 185 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 1 Replacing the turning disk Continued ...

Page 186: ...ing disk allows the turning disk to be fitted in three different rotated positions Matching the calibration marks guarantees that the turning disk is fitted at the correct turn provided that the axis 6 was set in calibration position before the turning disk was removed 3 xx1400000995 Foundry Plus Apply Loctite 574 flange sealant on the contact surface 4 Continues on next page 186 Product manual IR...

Page 187: ...rform a leak down test of the gearbox axis 6 6 See section Changing oil gearbox axis 6 on page 130 Refill the axis 6 gearbox with oil 7 Refit any equipment removed during disas sembly to the turning disk 8 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 9 Product manua...

Page 188: ...ng outer race bearings on page 193 Press tool for removal of shaft on page 194 Removing the tilthouse unit on page 196 Premounting outer race of bearing and radial sealing axis 2 side on page202 Premounting outer race of bearing and radial sealing axis 3 side on page203 Refitting shafts on page 204 Refitting lock nuts and the remaining parts on page 206 Continues on next page 188 Product manual IR...

Page 189: ...ilthouse unit is located as shown in the figure xx1100000213 Continues on next page Product manual IRB 460 189 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 2 Replacing the tilthouse unit Continued ...

Page 190: ... arm axis 2 and the parallel arm axis 3 These two sides of the robot will be referred to in the replacing procedures xx1100000214 Axis 2 side See marking on lower arm Continues on next page 190 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 2 Replacing the tilthouse unit Continued ...

Page 191: ... Axis 3 side See marking on parallel arm Continues on next page Product manual IRB 460 191 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 2 Replacing the tilthouse unit Continued ...

Page 192: ... B Radial sealing C Bearing D Lock nut E VK cover 65x8 VK cover 19x6 Inside VK cover 65x8 not shown in this figure Required equipment Note Art no Equipment etc VK 19x6 2 pcs Spare parts on page 389 VK cover Continues on next page 192 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 2 Replacing the tilthouse unit Continued ...

Page 193: ... Standard tools on page 383 Standard toolkit These procedures include references to the tools re quired Other tools and procedures may be required See refer ences to these procedures in the step by step instructions below Press tool pre mounting outer race bearings The press tool used for pre mounting the outer bearing races in the tilthouse consists of the parts shown in the figure For art no see...

Page 194: ...s B Auxiliary shaft 3HAC040035 001 Only used on removal C Shaft axis 2 D Upper arm E Tilthouse F Support bushing 3HAC040029 002 G Hydraulic cylinder H Threaded bar M16 Press tool for fitting of shaft The press tool replacing shaft is used both for removal and refitting See figure how to use the tool depending on purpose For art no see Required equipment on page 192 The press tool replacing shaft a...

Page 195: ...n in the table Depending on which routine is chosen action might be required prior to beginning the repair work of the robot see the table Note Action Decide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from th...

Page 196: ...erence values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the tilthouse unit Use this procedure to remove the tilthouse unit Note Action Decide whi...

Page 197: ...pply air pressure supply to the robot before entering the robot working area 4 xx1100000227 Secure the tilthouse with a roundsling in an overhead crane or similar 5 See Replacing motor axis 6 on page 305 Disconnect motor cables from motor axis 6 Place the motor cables in a way that it will not be damaged 6 Continues on next page Product manual IRB 460 197 3HAC039842 001 Revision P Copyright 2012 2...

Page 198: ...house unit Note It is not needed to remove the upper link from the link 7 xx1100000230 Remove one of the M6 screws and washer for filling grease 8 Continues on next page 198 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 2 Replacing the tilthouse unit Continued ...

Page 199: ...1100000232 Use compressed air in the M6 hole for filling grease in order to remove the VK cover Put a hand with some paper over the VK cover in order to catch it CAUTION Only a very low air pressure is needed 11 Continues on next page Product manual IRB 460 199 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 2 Replacing the tilthouse unit Continued ...

Page 200: ...haft and auxiliary bushing used for removing the shaft as shown in the figure in Press tool for removal of shaft on page 194 Note A longer threaded bar M16 is needed when re moving the shaft than the one specified when fitting 14 The longer threaded bar M16 length 450 mm Continues on next page 200 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair...

Page 201: ...efore proceeding with the next shaft 17 Remove the shaft on the axis 3 side in the same way by following the steps above 18 CAUTION The robot tilt house weighs 50 kg All lifting accessories used must be sized ac cordingly 19 Continues on next page Product manual IRB 460 201 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 2 Replacing the tilthouse unit Continued ...

Page 202: ...ng axis 2 side Use this procedure to fit the outer race of the bearing and radial sealing in the tilthouse on the axis 2 side before fitting the tilthouse to the upper arm Note Action This work is best done on a workbench or sim ilar 1 Fit the radial sealing in the hole 2 Art no is specified in Required equip ment on page 192 Apply some grease in the hole for the bearings 3 Continues on next page ...

Page 203: ...he inner diameter of the radial sealing 5 Premounting outer race of bearing and radial sealing axis 3 side Use this procedure to fit the outer race of the bearing and radial sealing in the tilthouse on the axis 3 side before fitting the tilthouse to the upper arm Note Action This work is best done on a workbench or sim ilar 1 See X ray view of the assembly of the tilthouse unit on page 192 Fit the...

Page 204: ...ilthouse unit on page 192 Apply grease on the inner diameter of the radial sealing 5 Refitting shafts Before starting this procedure prepare the tilthouse as described in Premounting outer race of bearing and radial sealing axis 2 side on page202 Premounting outer race of bearing and radial sealing axis 3 side on page203 Use this procedure to refit the shafts of the tilthouse unit Note Action CAUT...

Page 205: ...the sur face where the tilthouse faces the upper arm 3 Parts A Dinitrol 490 B Tilthouse C Upper arm Art no is specified in Required equipment on page 192 Apply some grease in the hole for the shaft in the upper arm 4 See Location of axes 2 and 3 sides of the robot on page 190 Note Refit the axis 2 side first 5 Continues on next page Product manual IRB 460 205 3HAC039842 001 Revision P Copyright 20...

Page 206: ...ot be pressed in completely Press tool for fitting of shaft on page194 Press the parts together 9 Fit the axis 3 side in the same way by following the steps above 10 Refitting lock nuts and the remaining parts Before starting this procedure perform the procedure Refitting shafts on page 204 Use this procedure to refit the lock nuts and the other remaining parts of the tilthouse unit Note Action No...

Page 207: ...he lock nut on the axis 3 side Secure the axis 3 shaft with the lock nut Note Flat side of the lock nut facing inwards 7 Wipe clean the sufaces for the VK covers with Isopropanol 8 Fit the small VK covers on axes 2 and 3 using a plastic mallet 9 Fit the big VK covers on axes 2 and 3 using a plastic mallet 10 Fill bearings with grease by removing both M6 screws on either side One hole is used for f...

Page 208: ... on page 357 General calibration information is in cluded in section Calibration on page 347 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 16 208 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 2 Replacing the...

Page 209: ... sealing Robots delivered before October 2012 has a sealing structure that consists of a POM sealing if not updated with the new sealing structure according to above The removal and refitting procedures describe both versions of sealing structures The steps that differ are marked with information about which sealing structure the step is valid for Continues on next page Product manual IRB 460 209 ...

Page 210: ...th POM sealing A B C D E F G H J K xx1100000273 A Lock nut B Support ring C Sealing ring V ring D Lower arm E Bearing F T ring G Sealing ring V ring H Shaft J Bushing K Upper arm Continues on next page 210 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 3 Replacing the upper arm Continued ...

Page 211: ...haft J Bushing K Upper arm Press tool upper arm The press tool upper arm is used to assemble T ring and bearing in the upper arm For art no see Required equipment on page 213 Continues on next page Product manual IRB 460 211 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 3 Replacing the upper arm Continued ...

Page 212: ...her 3HAC040021 004 C Hydraulic cylinder 3HAC040021 005 D Press bushing 3HAC040026 003 Only used at assembly E Auxiliary shaft 3HAC040026 002 F Shaft G Bearing H Lower arm J Upper arm Continues on next page 212 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 3 Replacing the upper arm Continued ...

Page 213: ...3HAC040026 004 Only used at removal E Auxiliary shaft 3HAC040026 002 F Shaft G Bearing H Lower arm J Upper arm Required equipment Note Art no Equipment etc Includes 3HAC037314 001 bushing 2 pcs For spare part no see Spare parts on page389 Upper arm axis 4 2216264 16 V ring 3HAC022581 001 T ring The adapter consists of two parts the adapter and a pro tective cover Always use the protective cover to...

Page 214: ...e the table Note Action Decide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If ...

Page 215: ... to the robot before entering the robot work ing area 4 See section Replacing the cable harness upper end incl axis 6 on page 157 Remove the cable harness in the upper arm 5 CAUTION The robot upper arm weighs 120 kg All lifting accessories used must be sized accordingly 6 Secure the upper arm with a roundsling in an overhead crane or similar 7 Raise the lifting equipment to take the weight of the ...

Page 216: ...he shafts on axis 2 and axis 3 sides Note Remove lock nuts on axis 2 and 3 sides 1 xx1100000267 Remove the Radial seal sleeve and O ring from the shaft Note Remove Radial seal sleev and O ring on both axis 2 and 3 sides 2 Parts A Radial seal with dust lip B Sleeve C O ring Continues on next page 216 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repa...

Page 217: ... ad apter xx1100000264 A Protective cover B Adapter 4 Removing the upper arm part 2 Use this procedure to remove the upper arm part 2 Note Action Start the continued removal of shafts on the axis 3 side 1 NOTE 2 The axis 3 shaft must be removed in more than one step The reason is the fitting of the outer race of the bearing is very tight Continues on next page Product manual IRB 460 217 3HAC039842...

Page 218: ...appears again If the answer is No repeat the steps above to make sure the threads of the shaft and the upper arm are completely separated before continuing Check that the threads on the shaft and the upper arm are completely separated 8 If the answer is Yes pull the shaft out com pletely together with bearing and T ring using the pull tool shaft 9 Put the shaft in a clean and safe place 10 DANGER ...

Page 219: ...ith bearing grease 5 Apply lubricant paste Molycote 1000 on threads and cones of the shafts 6 Preparations before refitting the shafts of the upper arm Use this procedure to do the necessary preparations before refitting the shafts Note Action CAUTION The robot upper arm weighs 120 kg All lifting accessories used must be sized accordingly 1 Secure the upper arm with a roundsling in an overhead cra...

Page 220: ...sition Make sure that the upper arm is placed in a horizontal position 4 Refitting the upper arm shafts Use this procedure to refit the upper arm shafts Note Action NOTE 1 Refit the shaft on the axis 3 side first Carefully fit the shaft into the threads of the upper arm by hand only Note Do not use force since threads otherwise can be damaged 2 Continues on next page 220 Product manual IRB 460 3HA...

Page 221: ...e ad apter xx1100000264 A Protective cover B Adapter 3 A B C D xx1100000274 Place the T ring on the shaft by hand as close to its final position as possible 4 Parts A Lower arm B T ring C Surface on lower arm on which the T ring rests against D Shaft Continues on next page Product manual IRB 460 221 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 3 Replacing the ...

Page 222: ...e bearing is pressed in all the way and rests in the correct position on the shaft See figure Fill the inner race of the bearing with grease 7 xx1100000275 Fit the inner race of the bearing on the shaft and press it in using the press tool upper arm Note Make sure the bearing is pressed in all the way and rests in the correct position on the shaft See figure 8 Parts A Lower arm B Bearing inner rac...

Page 223: ... is important for a correct fit Secure the shaft with the lock nut on the axis 2 side by following this order 1 Tighten the lock nut with a tightening torque of 200 Nm Move the upper arm while applying the torque 2 Unscrew the lock nut 3 Apply locking liquid Loctite 243 on the threads of the lock nut 4 Tighten the lock nut with a tightening torque of 90 Nm Move the upper arm while applying the tor...

Page 224: ...lacing linkage upper link arm on page 225 Replacing linkage lower link arm on page 233 Replacing the linkage link on page 240 Refit the linkage system starting with the link 6 Pendulum Calibration is described in Operating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 7 Axis Calibration is described in Calibrat ing with Axis Calibration method on page 357 Ge...

Page 225: ...lower link arm and link see Replacing linkage lower link arm on page 233 Replacing the linkage link on page 240 Location of upper link arm The upper link arm is located as shown in the figure xx1100000167 A Upper link arm B Link C Lower link arm Continues on next page Product manual IRB 460 225 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 4 Replacing linkage u...

Page 226: ...by step instructions below Removing the upper link arm Use this procedure to remove the upper link arm Note Action Check especially that it is possible to re move the locking washer at the link Put the robot in a position where it is possible to reach all parts that shall be removed 1 xx1000001132 Let the tilthouse rest on a workbench on some pallets or similar This is done in order to prevent the...

Page 227: ... the link from moving if both the upper and lower link arms are removed 3 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 4 Continues on next page Product manual IRB 460 227 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 4 Replacing linkage upper link arm Continued ...

Page 228: ...ng washer 5 Parts A Lock screw B Locking washer xx1100000171 Remove the locking washer 6 Continues on next page 228 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 4 Replacing linkage upper link arm Continued ...

Page 229: ...ve it from the tilthouse a plastic mallet can be used 7 xx1100000172 Remove the radial sealing rings 8 Parts A Radial sealing ring B Bearing C Radial sealing ring Remove residual grease 9 Continues on next page Product manual IRB 460 229 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 4 Replacing linkage upper link arm Continued ...

Page 230: ...ey are not damaged 1 Lubricate the bearings properly with bearing grease 2 xx1100000172 Fit radial sealing rings in the upper link arm as shown in the figure 3 Parts A Radial sealing ring B Bearing C Radial sealing ring Continues on next page 230 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 4 Replacing linkage upper link arm Continued ...

Page 231: ...ler with three legs and press the upper link arm on to the shaft Note The press force shall be applied on the lock ing washer 5 Loctite 243 Apply locking liquid on the lock screw 6 Continues on next page Product manual IRB 460 231 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 4 Replacing linkage upper link arm Continued ...

Page 232: ...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 8 232 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 4 Replacing linkage upper link arm Continued ...

Page 233: ...lace the upper link arm arm and link see Replacing linkage upper link arm on page 225 Replacing the linkage link on page 240 Location of lower link arm The lower link arm is located as shown in the figure xx1100000167 A Upper link arm B Link Continues on next page Product manual IRB 460 233 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 5 Replacing linkage lower...

Page 234: ...tandard toolkit These procedures include references to the tools re quired Other tools and procedures may be required See refer ences to these procedures in the step by step instructions below Removing the lower link arm Use this procedure to remove the lower link arm Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering th...

Page 235: ...e in order to prevent the link from moving if both the upper and lower link arms are removed 2 xx1100000170 Remove the lock screw securing the locking washer 3 Parts A Lock screw B Locking washer Continues on next page Product manual IRB 460 235 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 5 Replacing linkage lower link arm Continued ...

Page 236: ...ll be needed to remove the link arm from the link To re move it from the frame a plastic mallet can be used Note If needed use a plastic mallet to remove the lower link arm 5 Continues on next page 236 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 5 Replacing linkage lower link arm Continued ...

Page 237: ...tion Spare part no is specified in Required equipment on page 234 If needed replace the bearings Note The bearings are sensitive for pushes Make sure they are not damaged 1 For art no see Required equipment on page 234 Lubricate the bearings properly with bearing grease 2 Continues on next page Product manual IRB 460 237 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repai...

Page 238: ...e lower link arm 4 Check that the lower link arm is pushed completely in position Apply a bearing puller with three legs and press the lower link arm on to the shaft Note The press force shall be applied on the lock ing washer 5 Continues on next page 238 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 5 Replacing linkage lower link arm Con...

Page 239: ...ck screw B Locking washer 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 8 Product manual IRB 460 239 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 5 Replacing linkage lower link arm Continued ...

Page 240: ...he upper and lower link arms see Replacing linkage upper link arm on page 225 Replacing linkage lower link arm on page 233 Location of link The link is located as shown in the figure xx1100000167 A Upper link arm B Link C Lower link arm Continues on next page 240 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 6 Replacing the linkage link ...

Page 241: ...bove The removal and refitting procedures describe both versions of sealing structures The steps that differ are marked with information about which sealing structure the step is valid for X ray view of the assembly of the link The figure shows an X ray view of the assembly of the link Design with POM sealing xx1100000212 A VK cover B Lock nut C Bearing D Bearing E POM Sealing Continues on next pa...

Page 242: ...pport ring i Replace if damaged O ring i Used for bearings 3HAC040022 002 Auxiliary shaft Used to press the outer races of bearings in link 3HAC040030 001 Press tool link bearing outer races 3HAC040031 001 Press tool support Used to fit the link 3HAC040022 001 Press tool link 3HAC040024 001 Socket KM 8 Used to remove the link Bearing puller Continues on next page 242 Product manual IRB 460 3HAC039...

Page 243: ...alibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration fo...

Page 244: ...s done to prevent the link from moving when the upper and lower link arms are re moved which can cause an accident 3 How to remove upper link arm see Replacing linkage upper link arm on page 225 How to remove lower link arm see Replacing linkage lower link arm on page 233 Remove upper and lower link arms 4 Continues on next page 244 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2...

Page 245: ...air pressure into the hole for filling grease Put one hand with some paper on top of the VK cover in order to catch it when it is re leased CAUTION Only a very low air pressure is needed 6 Continues on next page Product manual IRB 460 245 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 6 Replacing the linkage link Continued ...

Page 246: ...ide 9 If needed use a bearing puller to remove the link xx1100000198 Knock on the link as close as possible to its center Note Loosen the lifting force a little before start knocking If not the link can be locked by the lifting power Use a pair of levers or apply a bearing puller and bend the link loose 10 Remove the link 11 Continues on next page 246 Product manual IRB 460 3HAC039842 001 Revision...

Page 247: ...he radial sealing if damaged If needed replace bearings 15 Preparations fitting outer races of the bearings in link Use this procedure to fit the outer races of the bearings in the link Fit the outer races one at a time using the press tool as shown in the figures For art no see Required equipment on page 242 Continues on next page Product manual IRB 460 247 3HAC039842 001 Revision P Copyright 201...

Page 248: ...inner bearing in link E Press tool support F Hydralic cylinder G Stop nut Pressing the outer race of the outer bearing A B C D E F G xx1100000209 A Threaded bar M16 B Thread washer C Press tool link bearing outer races D Outer race of the outer bearing in link E Press tool support F Hydralic cylinder G Thread washer Continues on next page 248 Product manual IRB 460 3HAC039842 001 Revision P Copyri...

Page 249: ...osition See figure above 3 Check that the parts and the tool are ap plied correctly as shown in the figures above Press tool link The figure shows the press tool link fitted to a link with the POM sealing The press tool is fitted in the same way to a link that has a support ring instead of a POM sealing For art no see Required equipment on page 242 A B C D E F xx1100000211 A Threaded bar M16 B Thr...

Page 250: ...alid for design with support ring Place the o ring inside the groove of the support ring 2 Loctite 574 xx1300000008 Valid for design with support ring Apply locking liquid on the inner surface of the support ring 3 Continues on next page 250 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 6 Replacing the linkage link Continued ...

Page 251: ... 4 xx1100000200 Valid for design with POM sealing Place the POM sealing on the shaft 5 Secure the link with a roundsling in an over head crane and lift it to the mounting position 6 Art no is specified in Required equipment on page 242 Fit the auxiliary shaft on the shaft 7 Continues on next page Product manual IRB 460 251 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Rep...

Page 252: ...ace the inner race of the outer bearing and link in the following order on the shaft link bearing 9 Parts A Inner race of outer bearing B Link C Inner bearing complete Art no is specified in Required equipment on page 242 Press the parts together with the press tool link 10 Continues on next page 252 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Rep...

Page 253: ...h a torque of 300 Nm while rotating the link at the same time 2 Unscrew the lock nut 3 Tighten the lock nut finally with a tightening torque of 90 Nm 12 xx1100000204 Valid for design with POM sealing Use a screwdriver carefully to fit the POM sealing into its final position 13 Continues on next page Product manual IRB 460 253 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 ...

Page 254: ... specified in Required equipment on page 242 xx1100000206 Fill the link with grease 15 Continues on next page 254 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 6 Replacing the linkage link Continued ...

Page 255: ...h the calibration tools Recalibrate the robot 19 Axis Calibration is described in Calibrat ing with Axis Calibration method on page 357 General calibration information is included in section Calibration on page 347 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 20 Pro...

Page 256: ...ection as how to replace the link see Replacing the linkage link on page 240 X ray view of the assembly of the link The figure shows a X ray view of the assembly of the link xx1100000212 A VK cover B Lock nut C Bearing D Bearing E POM Sealing 256 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 7 Replacing the POM sealing for the link system...

Page 257: ... For spare part no see Spare parts on page389 Parallel rod 3HAC040021 001 Mounting Demounting tool Loctite 243 3HAB7116 1 Locking liquid Content is defined in section Standard tools on page 383 Standard toolkit Continues on next page Product manual IRB 460 257 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 8 Replacing parallel rod ...

Page 258: ...ad bush B Support bush C Hydraulic cylinder D Thread washer Removing the parallel rod Use this procedure to remove the parallel rod The procedure is the same in both ends Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 1 CAUTION In order to avoid accidents secure the upper arm with a roundsling...

Page 259: ...ck screw and washer securing the shaft of the parallel rod in position 3 Continues on next page Product manual IRB 460 259 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 8 Replacing parallel rod Continued ...

Page 260: ... A xx1100000030 4 A Thickness 8 mm For art no see Required equipment on page 257 Apply the mounting demounting tool to the shaft 5 Continues on next page 260 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 8 Replacing parallel rod Continued ...

Page 261: ...ove the parallel rod backwards from its up per connection point and let it rest against the base 7 Continues on next page Product manual IRB 460 261 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 8 Replacing parallel rod Continued ...

Page 262: ...me way as the upper end 10 Remove the parallel rod from the robot 11 Replace the bearings if necessary 12 How to apply the mounting demounting tool for refitting This figure shows how to apply the mounting demounting tool when refitting the parallel rod For art no see Required equipment xx1100000165 A Thread bush B Support bush C Hydraulic cylinder Continues on next page 262 Product manual IRB 460...

Page 263: ...rings are in the correct position in the parallel rod 2 xx1100000148 A Thrust washer B POM sealing Fit a POM sealing on the thrust washer 3 xx1100000149 Put the thrust washer with a POM sealing fitted on the axis 2 side of the parallel rod 4 Continues on next page Product manual IRB 460 263 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 8 Replacing parallel rod ...

Page 264: ...axis 3 side 5 xx1100000161 Place the parallel rod in its mounting posi tion in the lower end 6 Continues on next page 264 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 8 Replacing parallel rod Continued ...

Page 265: ...o not press the shims down too far A xx1100000030 7 A Thickness 8 mm xx1100000162 Refit the shaft using the mounting demount ing tool 8 Continues on next page Product manual IRB 460 265 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 8 Replacing parallel rod Continued ...

Page 266: ...sher 10 Plain washer 6 4x12x1 6 xx1100000163 Lift the parallel rod up into position for fitting of the upper end 11 Refit the upper end of the parallel rod in the same way 12 Continues on next page 266 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 8 Replacing parallel rod Continued ...

Page 267: ...rforming the first test run These are further detailed in the section First test run may cause injury or damage on page26 13 Product manual IRB 460 267 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 8 Replacing parallel rod Continued ...

Page 268: ...em is located as shown in the figure xx1100000175 A Lower arm B Parallel arm Required equipment Note Art no Equipment etc For art no see Spare parts on page389 Lower arm M16x90 Lock screw Continues on next page 268 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 9 Replacing the complete lower arm system ...

Page 269: ...nce values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on...

Page 270: ...ns Replacing cable harness lower end axes 1 3 on page 147 Replacing the cable harness upper end incl axis 6 on page 157 Remove the cable harness in upper and lower arms Secure the cable harness in a way that it is protected from getting damaged and from oil spill 6 See section Replacing the upper arm on page 209 Remove the complete upper arm 7 See section Replacing motors axes 2 and 3 on page 294 ...

Page 271: ...r similar 10 xx1000001179 Remove the lock screw securing the lower arm system 11 Connect to connector R2 MP2 or R2 MP3 depending on which side pin 2 pin 5 In order to release the brake connect the 24VDC power supply 12 Continues on next page Product manual IRB 460 271 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 9 Replacing the complete lower arm system Contin...

Page 272: ...x1100000181 Remove the two screws and remove the sealing cover 14 Note If the parts are not pushed together it will be difficult to remove the complete lower arm The space between gearboxes is cramp Therefore push the lower and parallel arms together with the help of an iron bar or similar before removing them 15 Continues on next page 272 Product manual IRB 460 3HAC039842 001 Revision P Copyright...

Page 273: ...an fall down and cause a serious accident 16 xx1100000178 Move the parallel arm and secure it to the lower arm as shown in the figure to prevent it from falling down 17 Continues on next page Product manual IRB 460 273 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 9 Replacing the complete lower arm system Continued ...

Page 274: ...o refit the lower arm system Note Action See section Replacing the parallel arm on page 278 Fit the parallel arm to the lower arm 1 CAUTION The robot lower arm weighs 110 kg All lifting accessories used must be sized accordingly 2 Continues on next page 274 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 9 Replacing the complete lower arm s...

Page 275: ...the brake connect the 24VDC power supply 4 For art no see Required equipment on page 268 xx1100000185 Place the lower arm system in its mounting position If the hole pattern need to be adjusted re lease the brake and use a rotation tool to find the correct hole pattern by moving the gears xx0200000165 A Rotation tool 5 Note Refit the axis 2 side first 6 Continues on next page Product manual IRB 46...

Page 276: ...Refit all M12 attachment screws with washers on the axis 3 side that are possible to fit See figure above 9 Change the position of the lower arm in order to reach the remaining attachment holes and fit the remaining screws 10 xx1000001179 Secure the lower arm by fitting a lock screw M16x90 11 Continues on next page 276 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All ri...

Page 277: ...g linkage lower link arm on page 233 Replacing linkage upper link arm on page 225 Refit the linkage starting with the link 17 Remove the lock screw 18 Pendulum Calibration is described in Operating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 19 Axis Calibration is described in Calibrat ing with Axis Calibration method on page 357 General calibration inform...

Page 278: ...76 A Lower arm B Parallel arm Required equipment Note Art no Equipment etc For spare part no see Spare parts on page389 Parallel arm 3HAB3537 1 Bearing grease Continues on next page 278 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 10 Replacing the parallel arm ...

Page 279: ...ious reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 358 If no previous reference values exist and no new reference values can b...

Page 280: ...o the lower arm be fore lifting the lower arm system If not se cured the parallel arm can fall down and cause a serious accident 4 CAUTION The robot lower arm weighs 110 kg All lifting accessories used must be sized accordingly 5 Continues on next page 280 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 10 Replacing the parallel arm Continu...

Page 281: ...el arm is best perfomed on a workbench 7 CAUTION The parallel arm system weighs 40 kg All lifting accessories used must be sized accordingly 8 Secure the parallel arm with a roundsling in an overhead crane 9 Continues on next page Product manual IRB 460 281 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 10 Replacing the parallel arm Continued ...

Page 282: ...gure 11 If needed replace bearings 12 Refitting the parallel arm Use this procedure to refit the parallel arm Note Action Refitting the parallel arm is best performed on a workbench 1 xx1100000218 Check that the assembly and the condition of the bearing is good If not replace dam aged parts 2 Continues on next page 282 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All ri...

Page 283: ...278 xx1100000192 Apply some grease in the hole for the bear ing 4 CAUTION The parallel arm system weighs 40 kg All lifting accessories used must be sized accordingly 5 Lift the parallel arm to where the lower arm is placed 6 Continues on next page Product manual IRB 460 283 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 4 10 Replacing the parallel arm Continued ...

Page 284: ... manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 10 Axis Calibration is described in Calibrat ing with Axis Calibration method on page 357 General calibration information is included in section Calibration on page 347 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...

Page 285: ...is 1 The motor axis 1 is located on the left hand side of the robot as shown in the figure xx1000001171 Continues on next page Product manual IRB 460 285 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing motor axis 1 ...

Page 286: ...cide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibra...

Page 287: ... actions accordingly prior to beginning the repair procedure 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 xx1000001165 Remove the motor cover to get access to the connectors on top of the motor 3 Continues on next page Product manual IRB 460 287 3HAC039842 001 Revision P Copyright 2012 2018 ABB All r...

Page 288: ...neath the motor cover 5 Connect to connector R2 MP1 pin 2 pin 5 In order to release the brake connect the 24 VDC power supply 6 xx1000001167 Remove the attachment screws of the motor Use the bits extension 7 Continues on next page 288 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing motor axis 1 Continued ...

Page 289: ...ed must be sized ac cordingly 9 xx1000001168 Remove the motor by carefully lifting it straight up to get the pinion away from gear CAUTION Be careful not to damage the pinion in the pro cess 10 Disconnect the brake release voltage 11 Check the pinion If there is any damage the pinion must be replaced 12 Continues on next page Product manual IRB 460 289 3HAC039842 001 Revision P Copyright 2012 2018...

Page 290: ...otor B O ring Note The o ring must be replaced when re placing the motor CAUTION The motor weighs 29 kg All lifting accessories used must be sized ac cordingly 2 Connect to connector R2 MP1 pin 2 pin 5 In order to release the brake connect the 24 VDC power supply 3 Continues on next page 290 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 5 1...

Page 291: ...ged 4 xx1000001167 Secure the motor with its four attachment screws and plain washers Use the bits exten sion 5 Attachment screws M10x40 quality 12 9 Gleitmo Tightening torque 50 Nm Disconnect the brake release voltage 6 Reconnect all connectors beneath the motor cover 7 Continues on next page Product manual IRB 460 291 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair...

Page 292: ... 9 Pendulum Calibration is described in Operating manual Calibration Pendu lum enclosed with the calibration tools Recalibrate the robot 10 Axis Calibration is described in Calib rating with Axis Calibration method on page 357 General calibration information is in cluded in section Calibration on page 347 Continues on next page 292 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 20...

Page 293: ...rforming 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 ...

Page 294: ...oth motors xx1000001174 Required equipment Note Art no Equipment etc Includes motor pinion o ring the o ring must be re placed when the motor is re placed For spare part no see Spare parts on page 389 chapter Motor axes 2 3 Continues on next page 294 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing motors axes 2 and 3 ...

Page 295: ...ork of the robot see the table Note Action Decide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create r...

Page 296: ... inserted into the hole for lock screw 2 See figure above Lock the lower arm by inserting the lock screw into the hole of the frame 3 This is done in order to secure axis 2 from col lapsing when the axis 2 motor is being removed CAUTION Tighten by hand Run axis 3 to the end position so that it rests against the mechanical stop Release the brake of axis 3 in order to set the weight of axis 3 agains...

Page 297: ...rain the oil from gearbox 6 xx1000001182 Remove the motor cover 7 xx1000001183 Remove the cable gland cover at the cable exit Note Make sure the gasket is not damaged Replace if damaged 8 Disconnect all connectors beneath the motor cover 9 Continues on next page Product manual IRB 460 297 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing motors axes 2 a...

Page 298: ...Use the bits extension 11 Art no is specified in Required equipment on page 294 Fit two guide pins in two of the motors attach ment holes 12 The figure shows IRB 760 but the principle is the same xx1000001131 Continues on next page 298 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing motors axes 2 and 3 Continued ...

Page 299: ...o the motor 14 CAUTION The motor weighs 29 kg All lifting accessories used must be sized ac cordingly 15 The figure shows IRB 760 but the principle is the same xx1000001105 Pull out the motor on the guide pins to get the pinion away from the gear Make sure the pinion does not get damaged 16 Remove the motor by gently lifting it straight out and place it on a secure surface 17 Continues on next pag...

Page 300: ...ce Make sure the o ring on the circumference of the motor is seated properly Lightly lubricate the o ring with grease 1 Connect to connector R2 MP1 pin 2 pin 5 In order to release the brake connect the 24 VDC power supply 2 Art no is specified in Required equipment on page 294 Fit the lifting tool motor axes 2 3 to the motor 3 Continues on next page 300 Product manual IRB 460 3HAC039842 001 Revisi...

Page 301: ...inciple is the same xx1000001185 Lift the motor and guide it on to the guide pins as close to the correct position as possible without pushing the motor pinion into the gear Note Make sure the motor is turned the right way that is connections for the cables facing down wards 6 Remove the lifting tool and allow the motor to rest on the guide pins 7 Continues on next page Product manual IRB 460 301 ...

Page 302: ...01181 Secure the motor with its four attachment screws and plain washers Use the bits exten sion Reused screws can be used providing they are lubricated as detailed in section Screw joints on page 379 before fitting 10 Attachment screws M10 x 40 quality 12 9 Gleitmo Tightening torque 50 Nm Disconnect the brake release voltage 11 Connect in accordance with markings on connectors Reconnect all conne...

Page 303: ... a new gasket 13 xx1000001182 Refit the motor cover with its attachment screws and washers Note Make sure the cover is tightly sealed 14 Continues on next page Product manual IRB 460 303 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing motors axes 2 and 3 Continued ...

Page 304: ...osed with the calibration tools Recalibrate the robot 18 Axis Calibration is described in Calib rating with Axis Calibration method on page 357 General calibration information is in cluded in section Calibration on page 347 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 ...

Page 305: ...pment etc Includes motor pinion o ring the o ring must be replaced when the motor is replaced For spare part no see Spare parts on page 389 Motor axis 6 Used to reach attachment screws for motor 3HAC023760 001 Bits extension Continues on next page Product manual IRB 460 305 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 5 3 Replacing motor axis 6 ...

Page 306: ...ven in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about r...

Page 307: ...lic pressure supply air pressure supply to the robot before entering the robot working area 3 xx1000001223 Remove motor cover 4 A xx0600002694 Remove the cable gland cover at the cable exit by unscrewing its attachment screw A on the inside Note Make sure the gasket is not damaged 5 Continues on next page Product manual IRB 460 307 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reser...

Page 308: ...n 5 In order to release the brake connect the 24 VDC power supply 7 xx1000001225 Remove attachment screws and washers Use the bits extension 8 Always use the screws for removal in pairs If required press the motor out of position by fitting two screws in the motor attach ment holes diagonal to each other 9 Continues on next page 308 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2...

Page 309: ...tting motor axis 6 Use this procedure to refit motor axis 6 Information Action xx1000001109 Make sure the o ring on the circumference of the motor is seated properly Lightly lubricate the o ring with grease Note The o ring must be replaced when the motor is replaced 1 Parts A Pinion B O ring C Circumference Continues on next page Product manual IRB 460 309 3HAC039842 001 Revision P Copyright 2012 ...

Page 310: ...rned the correct way See figure 4 Remove the guide pins 5 Apply locking liquid Loctite 243 on the attach ment screws 6 xx1000001225 Secure the motor with its four attachment screws and washers Reused screws may be used providing they are lubricated as detailed in section Screw joints on page 379 before fitting 7 Washers 8 4x16x1 6 quality Steel A2F Attachment screws M10 x 40 quality 8 8 A2F Tighte...

Page 311: ...0 Refit the connections to the UL lamp if the ro bot is equipped with one 11 xx1000001224 Check the gasket If damaged replace it 12 A xx0600002694 Refit the cable gland with its attachment screw 13 A Screw holding the cable gland Make sure the gasket is not damaged Replace if damaged Continues on next page Product manual IRB 460 311 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights rese...

Page 312: ... Calibration is described in Calib rating with Axis Calibration method on page 357 General calibration information is in cluded in section Calibration on page 347 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 16 312 Product manual IRB 460 3HAC039842 001 Revision P Co...

Page 313: ...0000122 Required equipment Note Art no Equipment etc Includes gearbox all o rings and seal ing rings For spare part no see Spare parts on page389 Gearbox Replace if damaged 3HAB3772 93 O ring Continues on next page Product manual IRB 460 313 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 6 1 Replacing the axis 1 gearbox ...

Page 314: ...manual 3HAC15716 1 Calibration Pendulum toolkit Required if Calibration Pendulum is the valid calib ration method for the robot Delivered as a set of calib ration tools 3HAC062326 001 Calibration tool box Axis Calibration Required if Axis Calibration is the valid calibration method for the robot Content is defined in sec tion Standard tools on page 383 Standard toolkit These procedures include ref...

Page 315: ...ration for Axis Calibration in Reference calibration routine on page 358 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be calibrated with fine calibration Remove all external cable packages DressPac...

Page 316: ...and a roundsling to the gearbox and base 7 Specified in Required equipment on page 313 CAUTION The base and axis 1 gearbox weighs 130 kg 108 kg All lifting accessories used must be sized accordingly 8 Art no is specified in Required equip ment on page 313 Lift the robot base including the axis 1 gearbox to allow the base and gear 1 sup port be fitted on each sides of the base 9 Continues on next p...

Page 317: ...g any work under neath the base 10 Remove the bottom plate from underneath the base in order to get access to the attach ment screws 11 xx1100000207 Attachment screws 12 pcs Washers 12 pcs Unscrew the attachment screws and re move the washers 12 Continues on next page Product manual IRB 460 317 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 6 1 Replacing the axis ...

Page 318: ...ngly 14 Lift the gearbox away with the already mounted lifting tools 15 xx1400000786 Turn the gearbox and remove the protec tion pipe by unscrewing two attachment screws Note Move the protective pipe over to the new gearbox 16 Continues on next page 318 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 6 1 Replacing the axis 1 gearbox Continued...

Page 319: ...ing is seated properly in its groove on the gearbox Lightly lubricate the o ring with grease 2 Specified in Required equipment on page 313 xx1000001395 Fit two lifting eyes on each side of the gear box Attach the lifting accessory base and gear 1 and a roundsling to the gearbox 3 Specified in Required equipment on page 313 Fit two guide pins in two of the attachment holes in the gearbox parallel t...

Page 320: ...y to its mounting position 7 12 pcs M16x60 quality 12 9 Gleitmo Secure the gearbox with its attachment screws and washers 8 Tightening torque 300 Nm Reused screws may be used providing they are lubricated as detailed in sec tion Screw joints on page379 before fit ting xx1100000207 Continues on next page 320 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserve...

Page 321: ...ION This is a complex task to be performed with utmost care in order to avoid injury or dam age 13 See section Performing a leak down test on page 140 Perform a leak down test 14 See Changing oil axis 1 gearbox on page 122 Refill the gearbox with oil 15 Pendulum Calibration is described in Operating manual Calibration Pendu lum enclosed with the calibration tools Recalibrate the robot 16 Axis Cali...

Page 322: ...rming the first test run These are further detailed in the section First test run may cause injury or damage on page 26 17 322 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 6 1 Replacing the axis 1 gearbox Continued ...

Page 323: ...re xx1100000123 Required equipment Note Art no Equipment etc For spare part no see Spare parts on page389 Gearbox axis 2 or axis 3 Lock screw M16x90 Fully threaded M12x60 Screw Bits extension Continues on next page Product manual IRB 460 323 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 6 2 Replacing the axis 2 gearbox ...

Page 324: ...ted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after ...

Page 325: ...xis 2 to 0 degrees and axis 3 to max degrees 3 Dimension of the lock screw is speficied in Required equipment on page 323 xx1000001179 Insert the lock screw in the lower arm in order to secure axis 2 NOTE Perform this by hand only 4 Release the brakes on axes 2 and 3 in order to let the parallel arm rest on the damper 5 Apply a roundsling or similar securing the parallel rod to the lower arm This ...

Page 326: ...nscrew the attachment screws of the motor flange and lift away the washers and the motor flange 2 xx1100000220 Apply two guide pins into two opposite holes in the gearbox 3 Note Always use guide pins in pairs CAUTION The gearbox weighs 51 kg All lifting accessories used must be sized accordingly 4 Art no is specified in Required equip ment on page 323 Fit the lifting tool to the gearbox 5 Continue...

Page 327: ... before refitting the axis 2 gearbox Use this procedure to do the necessary preparations before removing the axis 2 gearbox Note Action Clean all contact surfaces from residuals of paint and contamination 1 xx1100000223 Make sure that the o ring is fitted to the gearbox 2 Lightly lubricate the o ring with grease 3 Apply some grease on all contact surfaces 4 Continues on next page Product manual IR...

Page 328: ...d accordingly 1 Art no is specified in Required equip ment on page 323 Fit the lifting tool to the gearbox 2 Use an overhead crane or similar and lift the gearbox on to the guide pins 3 Slide the gearbox carefully on the guide pins to its mounting position 4 Use a crank to move the gearbox in order to find the holes for the attachment screws 5 xx1100000219 Secure the gearbox and the motor flange t...

Page 329: ...screws 10 Concluding refitting procedure of the axis 2 gearbox Use this procedure for the concluding refitting of the axis 2 gearbox Note Action Wipe the gearbox clean from residual grease 1 See Replacing motors axes 2 and 3 on page 294 Refit the motor 2 See Performing a leak down test on page 140 Perform a leakdown test 3 Draining axes 2 and 3 on page 128 Refill the gearbox with oil 4 Continues o...

Page 330: ...Axis Calibration method on page 357 General calibration information is included in section Calibration on page 347 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 7 330 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repai...

Page 331: ...re xx1100000123 Required equipment Note Art no Equipment etc For spare part no see Spare parts on page389 Gearbox axis 2 or axis 3 Lock screw M16x90 Fully threaded M12x60 Screw Bits extension Continues on next page Product manual IRB 460 331 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 6 3 Replacing the axis 3 gearbox ...

Page 332: ...ted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after ...

Page 333: ...d 5 This is done in order to be able to move the parallel arm in the continued removal pro cess Jog axis 3 the parallel arm to max degrees 6 Release the brakes on axis 3 in order to let the parallel arm rest on the damper 7 Jog axis 2 carefully to about 50 degrees 8 NOTE Check that the upper arm is moved forwards during jogging Let the tilthouse rest against something rigid that can take the weigh...

Page 334: ...guide pins in pairs CAUTION The gearbox weighs 51 kg All lifting accessories used must be sized accordingly 8 Fit the lifting tool to the gearbox 9 If required apply two fully threaded M12x60 screws to the holes in the gearbox in order to press it free 10 Lift out the gearbox from the frame using an overhead crane or similar with guidance from the fitted guide pins 11 Continues on next page 334 Pr...

Page 335: ...he gearbox in the frame 5 NOTE Apply two guide pins in opposite holes of the gearbox 6 The position of the guide pins must be in a way that they are possible to be re moved later One of the guide pins shorter than the other in order to fascilitate fitting into the lower arm CAUTION The gearbox weighs 51 kg All lifting accessories used must be sized accordingly 7 Art no is specified in Required equ...

Page 336: ...s axes 2 and 3 on page 294 Refit the axis 3 motor 6 Tightening torque 120 Nm Jog axes 2 and 3 to a position where the re maining attachment screws can be fitted and secured 7 Jog axis 3 the parallel arm very carefully to the position where the parallel rod can be refitted to the parallel arm 8 See Replacing parallel rod on page 257 Refit the parallel rod 9 See Performing a leak down test on page 1...

Page 337: ...rming the first test run These are further detailed in the section First test run may cause injury or damage on page 26 13 Product manual IRB 460 337 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 6 3 Replacing the axis 3 gearbox Continued ...

Page 338: ...0000124 Required equipment Note Art no Equipment Includes o ring For spare part no see Spare parts on page 389 Gearbox axis 6 For spare part no see Spare parts on page 389 Turning disk Continues on next page 338 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 6 4 Replacing gearbox axis 6 ...

Page 339: ...able packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new refere...

Page 340: ... all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 See section Changing oil gearbox axis 6 on page 130 Drain the oil from the gearbox 4 See section Replacing the turning disk on page 182 Remove the turning disk 5 xx1100000239 Remove the calibration plate axis 6 6 Continues on next page 340 Product manual IRB 460 3HAC039842...

Page 341: ...red apply two M8 screws in the holes shown in the figure and press out the gearbox 8 xx1000001412 Remove gearbox axis 6 carefully without damaging pinion or gear 9 Continues on next page Product manual IRB 460 341 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 6 4 Replacing gearbox axis 6 Continued ...

Page 342: ...robot working area 1 For art no see Required equipment on page 338 xx1100000241 Make sure the o ring is undamaged and fit ted to the gearbox If the o ring is damaged replace Lubricate the o ring with grease 2 See section Manually releasing the brakes on page 63 Release the brakes of the axis 6 motor manually 3 Continues on next page 342 Product manual IRB 460 3HAC039842 001 Revision P Copyright 20...

Page 343: ...to the tilthouse using guide pins Make sure the gears of the gearbox mate with the pinion of the axis 6 motor CAUTION Do not damage pinion or gears in the pro cess 5 Continues on next page Product manual IRB 460 343 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 6 4 Replacing gearbox axis 6 Continued ...

Page 344: ...leak down test 8 See section Changing oil gearbox axis 6 on page 130 Refill the gearbox with oil 9 xx1100000239 Refit the calibration plate 10 Pendulum Calibration is described in Op erating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 11 Axis Calibration is described in Calibrating with Axis Calibration method on page357 General calibration information is ...

Page 345: ...forming the first test run These are further detailed in the section First test run may cause injury or damage on page26 12 Product manual IRB 460 345 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 4 Repair 4 6 4 Replacing gearbox axis 6 Continued ...

Page 346: ...This page is intentionally left blank ...

Page 347: ...at is used for calibration of the robot Calibration position A generic term for all calibration methods that aim to move the robot to calibration position Standard calibration A calibration routine that generates a new zero posi tion of the robot Fine calibration A calibration routine that in the first step generates a reference to current zero position of the robot The same calibration routine ca...

Page 348: ...rdinate system for the robot Absolute accuracy calibration option al Absolute accuracy calibration data is found on the SMB serial measurement board in the robot For robots with RobotWare 5 05 or older the absolute accuracy calibration data is delivered in a file absacc cfg supplied with the robot at delivery The file replaces the calib cfg file and identifies motor positions as well as absolute a...

Page 349: ...of how to perform the calibration procedure and what to do at each step is given on the FlexPendant You will be guided through the calibration procedure step by step CalibWare Absolute Accuracy calibration To achieve a good positioning in the Cartesian coordinate system Absolute Accuracy calibration is used as a TCP calibration The CalibWare tool guides through the calibration process and calculat...

Page 350: ...unter memory is lost If the revolution counter memory is lost the counters must be updated See Updating revolution counters on page 353 This will occur when The battery is discharged A resolver error occurs The signal between a resolver and measurement board is interrupted A robot axis is moved with the control system disconnected The revolution counters must also be updated after the robot and co...

Page 351: ...marks and the synchronization position for each axis Synchronization marks IRB 460 xx1000001433 Calibration plate axis 1 A Calibration mark axis 2 B Calibration mark axis 3 C Calibration plate and marking axis 6 D Product manual IRB 460 351 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchronization position for axes ...

Page 352: ...n the graphic below Calibration service routines will handle the calibration movements automatically and these might be different from the positive directions shown below Manual movement directions 4 axes Note The graphic shows an IRB 260 The positive direction is the same for all 4 axis robots xx0500001927 352 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights res...

Page 353: ...resulting in an incorrect manipulator calibration Make sure the axes are positioned according to the correct calibration values not only according to the synchronization marks The correct values are found on a label located either on the lower arm underneath the flange plate on the base or on the frame At delivery the manipulator is in the correct position do NOT rotate axis 4 or 6 at power up bef...

Page 354: ... ABB menu tap Calibration xx1500000942 1 All mechanical units connected to the system are shown with their calibration status 2 Tap the mechanical unit in question xx1500000943 Continues on next page 354 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 5 Calibration 5 3 Updating revolution counters Continued ...

Page 355: ...s calibration method used during last field calibration Tap Manual Method Advanced xx1500000944 A screen is displayed tap Rev Counters en0400000771 4 Continues on next page Product manual IRB 460 355 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 5 Calibration 5 3 Updating revolution counters Continued ...

Page 356: ...he updating operation cannot be undone Tap Update to proceed with updating the revolution counters Tap Cancel to cancel updating the revolution counters Tapping Update updates the selected revolution counters and removes the tick from the list of axes 7 CAUTION If a revolution counter is incorrectly updated it will cause incorrect manipulator posi tioning which in turn may cause damage or injury C...

Page 357: ...vable calibration tool is inserted by the operator into a calibration bushing on the axis chosen for calibration according to instructions on the FlexPendant WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB Using other pins in the calibration bushings may cause severe damage to the robot and or personnel WARNING The calibration tool must be fully inse...

Page 358: ... the FlexPendant to create reference values When reference calibration is performed the robot is restored to the status given by the reference values Note When calibrating the robot with the reference calibration routine the robot must be dressed with the same tools process cabling and any other equipment as when the reference values were created Update revolution counters Choose this routine to m...

Page 359: ...ngs may cause severe damage to the robot and or personnel Note Article number Equipment etc Delivered as a set of calibration tools Required if Axis Calibration is the valid calib ration method for the robot 3HAC062326 001 Calibration tool box Axis Calibration Examining the calibration tool Check prior to usage Before using the calibration tool make sure that the tube insert the plastic protection...

Page 360: ...s should be checked Outer diameter within Ø12g4 mm Ø8g4 mm or Ø6g5 mm depending on calibration tool size Straightness within 0 005 mm xx1500000951 Outer diameter A 360 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 5 Calibration 5 4 2 Calibration tools for Axis Calibration Continued ...

Page 361: ...a bushing for the movable calibration tool are located on each axis as follows If there is not enough space on an axis to install a fixed calibration pin the axis is equipped with two bushings instead for installation of two calibration tools when calibration is carried out This is shown in the figure xx1700000437 xx1700000438 Continues on next page Product manual IRB 460 361 3HAC039842 001 Revisi...

Page 362: ... in the bushing Replace damaged parts with new if needed Note Article number Spare part Contains replacement calibration pin covers and protective plugs for the bushing 3HAC059487 001 Protection cover and plug set 362 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 5 Calibration 5 4 3 Installation locations for the calibration tools Continued ...

Page 363: ...ure 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 You will be guided through the calibration procedure step by step Use the following list to learn about the calibration procedure before running the RobotWare program on the FlexPendant It gives you a brief overview of the calibration procedure sequence...

Page 364: ...ant while conducting it Note Action DANGER While conducting the calibration the robot needs to be connected to power Make sure that the robots working area is empty as the robot can make unpredictable movements 1 Use a clean cloth Wipe the calibration tool clean Note The calibration method is exact Dust dirt or color flakes will affect the calibration value 2 Starting the calibration procedure Use...

Page 365: ...n the FlexPendant is given in Overview of the calibra tion procedure on the FlexPendant on page 363 Follow the instructions given on the FlexPendant 4 Restarting an interrupted calibration procedure If the Axis Calibration procedure is interrupted before the calibration is finished the RobotWare program needs to be started again Use this procedure to take required action Action Situation Press and...

Page 366: ...the o ring on the fixed calibration pin Replace if damaged or missing 1 Reinstall the protective cover on the fixed calibra tion pin on each axis directly after the axis has been calibrated Replace the cover with new spare part if missing or damaged 2 Protection cover and plug set 3HAC059487 001 xx1500000952 Reinstall the protective plug and sealing in the bushing on each axis directly after the a...

Page 367: ...ndulum Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools Product manual IRB 460 367 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 5 Calibration 5 5 Calibrating with Calibration Pendulum method ...

Page 368: ...change the position of the robot axes after running the program 1 This is detailed in section Synchronization marks and synchronization position for axes on page 351 Adjust the synchronization marks when the calibration is done if necessary 2 Write down the values on a new label and stick it on top of the calibration label 3 The label is located on the lower arm Remove any calibration equipment fr...

Page 369: ... page 351 and Updating revolution counters on page 353 Check that the synchronization marks for the axes align correctly If they do not update the revolu tion counters 6 Using the jogging window Use this procedure to jog the robot to the synchronization position of all axes Note Action On the ABB menu tap Jogging 1 Tap Motion mode to select group of axes to jog 2 Tap to select the axis to jog axis...

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Page 371: ...um Cables motors Copper Base lower arm upper arm Cast iron nodular iron Gears screws base frame and so on Steel Brakes motors Neodymium Cables connectors drive belts and so on Plastic rubber Gearboxes Oil grease Covers synchronization brackets Aluminium Oil and grease Where possible arrange for oil and grease to be recycled Dispose of via an authorized person contractor in accordance with local re...

Page 372: ...to organisms Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination 372 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 6 Decommissioning 6 1 Environmental information Continued ...

Page 373: ...attery is exposed to heat for example from a blow torch it will explode Always remove all oil grease in gearboxes If exposed to heat for example from a blow torch the oil grease will catch fire When motors are removed from the robot the robot will collapse if it is not properly supported before the motor is removed Product manual IRB 460 373 3HAC039842 001 Revision P Copyright 2012 2018 ABB All ri...

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Page 375: ...apter includes general information complementing the more specific information in the different procedures in the manual Product manual IRB 460 375 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 7 Reference information 7 1 Introduction ...

Page 376: ...015i Ergonomics of the thermal environment Part 1 EN ISO 13732 1 2008 EMC Generic emission EN 61000 6 4 2007 A1 2011 IEC 61000 6 4 2006 A1 2010 option 129 1 EMC Generic immunity EN 61000 6 2 2005 IEC 61000 6 2 2005 Arc welding equipment Part 1 Welding power sources EN IEC 60974 1 2012ii Arc welding equipment Part 10 EMC requirements EN IEC 60974 10 2014ii Safety of machinery Electrical equipment o...

Page 377: ... R15 06 Safety standard for robots and robotic equipment ANSI UL 1740 Industrial robots and robot Systems General safety require ments CAN CSA Z 434 14 Product manual IRB 460 377 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 7 Reference information 7 2 Applicable standards Continued ...

Page 378: ...39 37 in 3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume 378 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 7 Reference information 7 3 Unit conversion ...

Page 379: ...ld be used Screws lubricated in other ways Screws lubricated with Molycote 1000 should only be used when specified in the repair maintenance or installation procedure descriptions In such cases proceed as follows 1 Apply lubricant to the screw thread 2 Apply lubricant between the plain washer and screw head 3 Screw dimensions of M8 or larger must be tightened with a torque wrench Screw dimensions ...

Page 380: ...pair maintenance or installation procedure overrides the standard torque Tightening torque Nm Class 12 9 oil lubric ated Tightening torque Nm Class 10 9 oil lubric ated Tightening torque Nm Class 8 8 oil lubricated Dimension 6 M5 10 M6 40 34 24 M8 80 67 47 M10 140 115 82 M12 340 290 200 M16 670 560 400 M20 1150 960 680 M24 Lubricated screws Molycote Gleitmo or equivalent with allen head screws The...

Page 381: ...ening torque for water and air connectors when one or both connectors are made of brass Note A special torque specified in the repair maintenance or installation procedure overrides the standard torque Tightening torque Nm Max Tightening torque Nm Min Tightening torque Nm Nominal Dimension 15 8 12 1 8 20 10 15 1 4 25 15 20 3 8 50 30 40 1 2 90 55 70 3 4 Product manual IRB 460 381 3HAC039842 001 Rev...

Page 382: ...ssory when handling components with a weight exceeding 22 kg A wide range of lifting accessories and devices are available for each manipulator model Example Following is an example of a weight specification in a procedure Note Action CAUTION The robot weighs 925 kg All lifting accessories used must be sized accord ingly 382 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB ...

Page 383: ... Tool Qty Ring open end spanner 8 19 mm 1 Socket head cap 5 17 mm 1 Torx socket no 20 60 1 Box spanner set 1 Torque wrench 10 100 Nm 1 Torque wrench 75 400 Nm 1 Ratchet head for torque wrench 1 2 1 Hexagon headed screw M10x100 2 Hexagon headed screw M16x90 1 Hex bit socket head cap no 14 socket 40 mm L 100 mm 1 To be shortened to 12 mm Hex bit socket head cap no 14 socket 40 mm L 20 mm 1 Hex bit s...

Page 384: ... toolkit Calibration equipment Axis Calibration The following table specifies the calibration equipment needed when calibrating the robot with the Axis Calibration method The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory Always use the same calibration method as used at the factory Information about valid calibration method is found on the calibration label or i...

Page 385: ...r bearing 3HAC040021 004 Pressing tool 3HAC040021 005 Hollow cylinder RCH 123 3HAC040022 004 Threaded bar M16 3HAC040029 001 1 Press tool replacing shaft tilthouse The tool consists of 3HAC040029 002 Pressing tool bearing 3HAC040029 003 Pressing tool bearing 3HAC040021 004 Pressing tool 3HAC040021 005 Hollow cylinder RCH 123 3HAC040022 004 Threaded bar M16 length 450 mm removal For refitting lengt...

Page 386: ...ed bar M16 length 350 mm 3HAC040023 001 1 KM12 socket 3HAC040022 002 1 Auxiliary shaft 3HAC040030 001 1 Press tool link bearing outer races 3HAC040031 001 1 Lower part of pressing tool 3HAC040022 001 1 Press tool link The tool consists of 3HAC040022 002 Pressing tool 3HAC040022 003 Pressing tool 3HAC040021 004 Pressing tool 3HAC040021 005 Hollow cylinder RCH 123 3HAC040022 004 Threaded bar M16 len...

Page 387: ...1 1 Lifting accessory motor axes 2 3 3HAC15535 1 1 Support base and gear ax 1 3HAC15556 1 1 Lifting accessory base and gear ax 1 3HAC025214 001 1 Lifting accessory 1 Oil collecting vessel capacity 8 000 ml 3HAC021745 001 1 Oil exchange equipment Product manual IRB 460 387 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 7 Reference information 7 7 Special tools Continued ...

Page 388: ...ting accessories is not detailed in the activity procedure but in the instruction delivered with each piece of lifting accessories This implies that the instructions delivered with the lifting accessories should be stored for later reference 388 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 7 Reference information 7 8 Lifting accessories and lifting i...

Page 389: ...iews are not included in the manual but delivered as a separate document for registered users on myABB Business Portal www mypo rtal abb com Product manual IRB 460 389 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 8 Spare parts 8 1 Spare part lists and illustrations ...

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Page 391: ...B 140 type C 3HAC025611 001 Circuit diagram IRB 260 3HAC028647 009 Circuit diagram IRB 360 3HAC036446 005 Circuit diagram IRB 460 3HAC025691 001 Circuit diagram IRB 660 3HAC025691 001 Circuit diagram IRB 760 3HAC046307 003 Circuit diagram IRB 1200 3HAC2800 3 Circuit diagram IRB 1410 3HAC021351 003 Circuit diagram IRB 1600 1660 3HAC039498 007 Circuit diagram IRB 1520 3HAC6670 3 Circuit diagram IRB ...

Page 392: ...B 6650S 3HAC025744 001 3HAC025744 001 Circuit diagram IRB 6660 3HAC029940 001 3HAC043446 005 Circuit diagram IRB 6700 3HAC13347 1 Circuit diagram IRB 7600 3HAC025744 001 3HAC050778 003 Circuit diagram Product ProductName 3HAC056159 002 Circuit diagram IRB 910SC 392 Product manual IRB 460 3HAC039842 001 Revision P Copyright 2012 2018 ABB All rights reserved 9 Circuit diagrams 9 1 Circuit diagrams C...

Page 393: ...n position jogging to 369 scales 351 calibration scales 351 CalibWare 348 carbon dioxide extinguisher 20 cast iron disposal 371 changing oil axis 1 122 axis 2 126 axis 3 126 axis 6 130 cleaning 136 climbing on robot 23 Cold environments 93 connecting the robot and controller cabling 94 connection external safety devices 24 copper disposal 371 D damage to additional mechanical stop 115 damage to me...

Page 394: ...7 negative directions axes 352 neodymium disposal 371 NiCad disposal 371 nodular iron disposal 371 O oil amount in gearboxes 121 disposal 371 type of oil 121 oil change axis 1 122 axis 2 126 axis 3 126 axis 6 130 safety risks 36 oil level gearbox axes 2 3 104 gearbox axis 1 102 gearbox axis 6 107 operating conditions 51 option signal lamp 80 P pedestal installed on pedestal 23 plastic disposal 371...

Page 395: ...EN 376 EN IEC 376 EN ISO 376 start of robot in cold environments 93 steel disposal 371 storage conditions 50 symbols safety 38 synchronization position 353 sync marks 351 system integrator requirements 17 T temperatures operation 51 storage 50 testing brakes 34 three position enabling device 28 tools Axis Calibration 384 Calibration Pendulum 384 for service 384 torques on foundation 49 troubleshoo...

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Page 398: ...Telephone 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics and Motion No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics and Motion 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC039842 001 Rev P en Copyright 2012 2018 ABB All rights reserved Specifications subject to change without notice ...

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