ABB IRB 4600 Foundry Prime Product Manual Download

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Note

Action

xx1700001178

Check if the pressure relief valves are con-
taminated or covered with litter.
Clean if necessary.

Note

Use a cloth or a brush.

Seal and paint the joints that have been
opened. Also repair possible damages of the
special Foundry Prime paint coat of the robot.
See

Cut the paint or surface on the robot be-

fore replacing parts on page 201

Product manual - IRB 4600 Foundry Prime

145

3HAC040585-001 Revision: M

3 Maintenance

3.4.11 Inspecting the leak proof o-ring and pressure relief valves

Continued

Summary of Contents for IRB 4600 Foundry Prime

Page 1: ...ROBOTICS Product manual IRB 4600 Foundry Prime ...

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

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: ... 39 1 4 Safety signals and symbols 39 1 4 1 Safety signals in the manual 41 1 4 2 Safety symbols on product labels 47 2 Installation and commissioning 47 2 1 Introduction 48 2 2 Installation and operational requirements for Foundry Prime robots 52 2 3 Unpacking 52 2 3 1 Pre installation procedure 56 2 3 2 Surface inspection before start up Foundry Prime 57 2 3 3 Working range and type of motion 60...

Page 6: ... valves 146 3 4 12 Inspecting Signal lamp option 148 3 4 13 Inspection of air hoses Foundry Prime 150 3 4 14 Inspection of surface treatment Foundry Prime 151 3 5 Replacement activities 151 3 5 1 Type of lubrication in gearboxes 153 3 5 2 Changing the oil axis 1 gearbox on floor mounted robots 160 3 5 3 Changing the oil axis 1 gearbox on suspended robots 167 3 5 4 Changing the oil axis 2 gearbox 1...

Page 7: ...zation marks and synchronization position for axes 359 5 2 2 Calibration movement directions for all axes 360 5 3 Updating revolution counters 364 5 4 Calibrating with Axis Calibration method 364 5 4 1 Description of Axis Calibration 367 5 4 2 Calibration tools for Axis Calibration 369 5 4 3 Installation locations for the calibration tools 371 5 4 4 Axis Calibration Running the calibration procedu...

Page 8: ...401 9 Circuit diagram 401 9 1 Circuit diagrams 403 Index 8 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved Table of contents ...

Page 9: ...ntenance work Product manual scope The manual covers covers all variants and designs of the IRB 4600 Foundry Prime 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 ...

Page 10: ...fety information i 3HAC021313 001 Product manual IRC5 IRC5 with main computer DSQC 639 3HAC047136 001 Product manual IRC5 IRC5 with main computer DSQC1000 3HAC027098 001 Operating manual Emergency safety information 3HAC050941 001 Operating manual IRC5 with FlexPendant 3HAC020738 001 Operating manual Troubleshooting IRC5 3HAC16578 1 Operating manual Calibration Pendulum 3HAC050944 001 Operating ma...

Page 11: ...with Sikaflex several updates E The following updates have been made in this revision Turning disc fixture is removed from special tools for Levelmeter cal ibration New illustrations for foundry prime air connections in manipulator base maintenance and repair chapter F Published in release R16 2 The following updates are made in this revision Corrections due to updates in terminology New dimension...

Page 12: ...re made in this revision Information added about fatigue to Axis Calibration tool see Calibration tools for Axis Calibration on page 367 Added sections in General procedures on page 196 Updated figure of axis 6 synchronization mark Updated Activities and intervals Foundry Prime on page 110 and Oil in axis 5 6 gearbox New spare parts numbers for brake release boards Note added to calibration chapte...

Page 13: ...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 manuals...

Page 14: ...anuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters 14 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved Product documentation Continued ...

Page 15: ...d 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 is specif...

Page 16: ...omponents Motors balancing device and the serial measurement board cavity shall be pressurized on Foundry Prime robots during operation and shut down The overpressure can be dropped when atmospheric humidity has reached the same level as the surrounding environment For more information see Pressurized components on page 48 Cleaning Special procedures are needed when cleaning the Foundry Prime robo...

Page 17: ...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 responsible ...

Page 18: ...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 that guards...

Page 19: ...e protective stops and emergency stops are described in the product manual for the controller Product manual IRB 4600 Foundry Prime 19 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 1 Safety 1 1 2 Protective stop and emergency stop ...

Page 20: ... Note Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the manipulator or controller 20 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 1 Safety 1 2 1 Fire extinguishing ...

Page 21: ...quire 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 manual IRB ...

Page 22: ... 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 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 1 Safety 1 2 3 Make sure that the main power has been switched off ...

Page 23: ...ock 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 purpose of...

Page 24: ...tions 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 as well a...

Page 25: ...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 run fu...

Page 26: ...y 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 maintenance or repair has been done pay speci...

Page 27: ...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 the robot ...

Page 28: ...ator 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 prevent a...

Page 29: ...RC5 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 400 700 VDC ...

Page 30: ...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 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 1 Safety 1 3 6 Risks associated with live electric parts Continued ...

Page 31: ...n Wrist straps must be tested frequently to ensure that they are not damaged and are operating cor rectly Product manual IRC5 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 discharge of static ...

Page 32: ...and 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 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 1 Safety 1...

Page 33: ... 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 any part...

Page 34: ... pressure relief valve is a vital part preventing too much air pressure being built up inside the robot If too much air pressure has been built up there is a risk of personal injury and mechanical damage 34 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 1 Safety 1 3 10 Safety risks with pressure relief valve ...

Page 35: ...ribed 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 Product manual IRB 4600 Foundry Prime 35 3HAC040585 001 Revisio...

Page 36: ...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 above t...

Page 37: ...ion 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 reaction ...

Page 38: ...o 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 volume Whe...

Page 39: ...uctions 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 death ELECT...

Page 40: ...tions NOTE Describes where to find additional information or how to do an operation in an easier way TIP 40 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 1 Safety 1 4 1 Safety signals in the manual Continued ...

Page 41: ...rman 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 crushing...

Page 42: ... 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 42 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All ri...

Page 43: ... if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page Product manual IRB 4600 Foundry Prime 43 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 44: ...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 44 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 45: ... 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 Product manual IRB 4600 Foundry Prime 45 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 46: ...s 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 46 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels...

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 4600 Foundry Prime is connected to power always make sure that the robot is connected...

Page 48: ...oxes Pressurized components The motors the balancing device and the serial measurement board cavity must be pressurized on Foundry Prime robots during operation and shut down The overpressure can be dropped when atmospheric humidity has reached the same level as the surrounding environment At the installation of the Foundry Prime robot a pressure sensor and pressure relief valve not included must ...

Page 49: ...Air flow Pressurizing equipment ABB recommends a safety valve if not included set at 0 4 bar pressure sensor set at 0 2 0 3 bar or regulator set for maximum 0 3 bar to be attached on the pressure side of the air system Example of products Description Equipment Festo SDE1 series Pressure sensor Festo LRP series Pressure regulator Connect air hose to over pressure limiter unit Note ABB recommends th...

Page 50: ...otect the wrist from direct or indirect high pressure water jet Note Make sure that the special Foundry Prime painting of the robot is not broken during testing installation or repair work Use the touch up kit available for Foundry Prime article number 3HAC035355 001 to repair any damages in the paint Continues on next page 50 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyrig...

Page 51: ...ment Will avoid that humid air is trapped into gearboxes or other cavities due to raised vacuum when cooling down Will give the robot a chance to dry as most rust preventive components in washing detergents have a decaying effect i e the rust preventive effect is reduced after a time Please refer to the Product Specification of the washing detergent in question for decaying effect Washing detergen...

Page 52: ...in Weight robot on page 52 5 If the robot is not installed directly it must be stored as described in Storage condi tions robot on page 55 6 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 55 7 Before taking the robot to its installation site make sure that the site conforms to Loads on foundation robo...

Page 53: ... 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 load in o...

Page 54: ...robot mass including equipment i For information about compensating for founda tion flexibility see Application manual Control ler software IRC5 section Motion Process Mode i The minimum resonance frequency given should be 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 ...

Page 55: ...ons for the robot Value Parameter 5 C Minimum ambient temperature 45 C Maximum ambient temperature 100 at constant temperature gaseous only Maximum ambient humidity 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 Foundry Prime Product manual IRB 4600 Found...

Page 56: ...01 to repair damages to paint surfaces Pre installation procedure Operation conditions robot Value Parameter 5 C Minimum ambient temperature 45 C Maximum ambient temperature 100 at constant temper ature gaseous only Maximum ambient humidity Protect attachment bolts and washers at the base Protect the attachment bolts and washers M24x100 at the base from physical obstructions and splashes with appr...

Page 57: ...king range floor mounted The illustration shows the unrestricted working range for a floor mounted robot xx0800000267 Pos F Pos E Pos D Pos C Pos B Pos A Variant 2051 mm 1701 mm 593 mm 1028 mm 1260 mm 2371 mm IRB 4600 60 2 05 Continues on next page Product manual IRB 4600 Foundry Prime 57 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 3 3 W...

Page 58: ...055 Pos F Pos E Pos D Pos C Pos B Pos A Variant 2051 mm 1701 mm 593 mm 1028 mm 1260 mm 2371 mm IRB 4600 60 2 05 Continues on next page 58 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 3 3 Working range and type of motion Continued ...

Page 59: ...ypes and ranges of motion in every axes Range of movement Type of motion Location of motion 180 Rotation motion Axis 1 150 90 Arm motion Axis 2 75 180 Arm motion Axis 3 400 Wrist motion Axis 4 120 125 Bend motion Axis 5 400 Turn motion Axis 6 Product manual IRB 4600 Foundry Prime 59 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 3 3 Working...

Page 60: ... before securing it to the foundation Shipping and transportation position This figure shows the robot in its shipping position and transportation position The position of the calibration mark A in the figure is approximate and is used as aiming aid 1 5 45 A 0 xx0800000263 WARNING The robot is likely to be mechanically unstable if not secured to the foundation 60 Product manual IRB 4600 Foundry Pr...

Page 61: ...ment Note Equipment Lifting capacity 1 000 kg Max load at 90 Overhead crane Lifting capacity roundsling 1 000 kg Length 2 m Roundslings 2 pcs Lifting Attach the roundslings as shown in the figure xx0800000262 Roundsling put folded in U shape through the lifting lug A Roundsling put folded in U shape around gearbox axis 3 B Lifting lug C Continues on next page Product manual IRB 4600 Foundry Prime ...

Page 62: ...ot to its most stable position 4 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 5 See the figure in Lifting on page 61 Attach roundsling A to the lifting lug on the frame and put folded in a U shape on either side of the upper arm 6 See the figure in Lifting on page 61 Attach roundsling B at axis 3 gearbox by run ning it fold...

Page 63: ...nec tion box at the base of the robot 9 A Area where the connection box can be damaged while lifting Lifting capacity See Required equipment on page 61 Lift the robot with an overhead crane 10 Product manual IRB 4600 Foundry Prime 63 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 4 1 Lifting robot with roundslings Continued ...

Page 64: ...numbers for the accessory and the instruction is specified in Special tools on page 394 Any additional equipment required is specified in the instruction for the lifting accessory Contact ABB for more information Illustration xx1500002116 64 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 4 2 Lifting and...

Page 65: ...eters Note The mounting angle must be configured correctly in the system parameters so that the robot system can control the movements in the best possible way An incorrect definition of the mounting angle will result in Overloading the mechanical structure Lower path performance and path accuracy Some functions will not work properly for example Load Identification and Collision detection Gravity...

Page 66: ...ystem parameter 7 axes high performance motion is set see Technical reference manual System parameters Gamma Rotation Gamma Rotation defines the orientation of the robot foot on the travel carriage track motion Mounting angles and values The parameter Gravity Beta or Gravity Alpha specifies the mounting angle of the robot in radians It is calculated in the following way Gravity Beta A x 3 141593 1...

Page 67: ...ing mounting angle 15 B Suspended mounting mounting angle 180 C Continues on next page Product manual IRB 4600 Foundry Prime 67 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 4 3 Setting the system parameters for a suspended or tilted robot Continued ...

Page 68: ...ngle of the robot The parameters belong to the type Robot in the topic Motion How to calculate a new value is detailed in Mounting angles and values on page66 The system parameters are described in Technical reference manual System parameters The system parameters are redefined in the Configuration Editor in RobotStudio or on the FlexPendant 68 Product manual IRB 4600 Foundry Prime 3HAC040585 001 ...

Page 69: ... the push button when the robot is connected to the controller This procedure details how to release the holding brakes with push buttons when the robot is connected to the controller Note Action xx0800000272 The internal brake release unit is located at the base of the robot 1 The brake release unit is equipped with six buttons for controlling the axes brakes The buttons are numbered according to...

Page 70: ... all brakes to be released simultaneously 1 Connect to connector R1 MP 0V to pin 12 24V to pin 11 The brake release unit is equipped with six buttons for controlling the axes brakes The buttons are numbered accord ing to the numbers of the axes Release the holding brake on a particular axis by pressing the corresponding button on the push button unit and keeping it de pressed 2 See the previous fi...

Page 71: ...ake cable the brake will be released imme diately when the power is switched on This may cause some unexpected robot movements 1 See chapter Circuit diagram on page401 Axes 1 2 and 3 Pos 2 24 V Pos 5 0 V xx1400001984 Connect an external 24 VDC power supply to the motor according to the figures Note Be careful not to interchange the 24V and 0V pins If they are mixed up damage can be caused to the i...

Page 72: ... Loads on foundation robot on page 53 and Requirements foundation on page 54 Hole configuration base The illustration shows the hole configuration used when securing the robot xx0800000271 Hole for guide bushing C Rear bolt holes D Continues on next page 72 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2...

Page 73: ... M16 3 pcs F Guide bushings 2 pcs G Specification attachment screws The table specifies the type of securing screws and washers to be used to secure the robot to the foundation or base plate Note Dimension Securing parts Facts 6 pcs M16 x 60 installation directly on foundation Securing screws oiled 200 Nm M16 x 70 80 installation on foundation or base plate us ing guide bushings Quality 8 8 6 pcs ...

Page 74: ... CAUTION The IRB 4600 Foundry Prime robot weighs 440 kg All lifting accessories used must be sized accordingly 3 CAUTION When the robot is put down after being lifted or transported there is a risk of it tipping if not properly secured 4 How to lift the robot is described in sec tion Lifting robot with roundslings on page 61 Lift the robot to its installation site 5 Fit two guide bushings to the r...

Page 75: ...olting a mounting plate or frame to a concrete floor follow the general instructions for expansion shell bolts Screw joints must be able to withstand the stress loads defined in section Loads on foundation robot on page 53 Product manual IRB 4600 Foundry Prime 75 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 4 5 Orienting and securing the ...

Page 76: ...robot and or its parts Note Never drill a hole in the robot without first consulting ABB Fitting equipment on robot Load areas The shaded area indicates the permitted positions center of gravity for any extra equipment fitted in the holes intended for this purpose xx0800000275 Max load D Max load A C Max load C Max load B Max load A Variant 35 kg 15 kg 15 kg 5 kg i 15 kg IRB 4600 60 2 05 i Payload...

Page 77: ... for fitting extra equipment on the base and frame of the robot xx0800000276 Attachment holes on base A Center axis 2 B Continues on next page Product manual IRB 4600 Foundry Prime 77 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 4 6 Fitting equipment on robot Continued ...

Page 78: ...f the robot 16 3x M8 90 216 2x M8 16 A C L 0 3 190 110 80 2x M8 16 0 3 16 65 130 3x M8 190 80 B xx0800000280 Center axis 4 A Center axis 3 B Continues on next page 78 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 4 6 Fitting equipment on robot Continued ...

Page 79: ...2 50 Attachment screws Variant 4x M8 through 60 2 05 Note On delivery all of the extra fitting holes are covered with coated set screws Remove these to fit extra equipment Seal with Mercasol Note If extra equipment is removed cover up equipment holes with coated set screws Seal with Mercasol Continues on next page Product manual IRB 4600 Foundry Prime 79 3HAC040585 001 Revision M Copyright 2013 20...

Page 80: ...000277 Note Do not remove screws indicated in the illustration below xx0800000281 Screws not to be removed Do not use these holes for fitting equipment on the wrist A Screw hole intended for swivel fitting B Continues on next page 80 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 4 6 Fitting equipment o...

Page 81: ...e way through xx0800000282 The mounting flange has through holes with a thread only part way through the hole R 50 8 H9 0 036 0 8 min 5 x 6 0 6x M10 17 1 30 F F 0 05 C D 0 3 C D E E 63 H8 9 min 10 SECTION F F xx1600000626 Note Use attachment screws M10 quality 12 9 and 15 mm used thread length Product manual IRB 4600 Foundry Prime 81 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights res...

Page 82: ...01 to repair damages to paint surfaces Pre installation procedure Operation conditions robot Value Parameter 5 C Minimum ambient temperature 45 C Maximum ambient temperature 100 at constant temper ature gaseous only Maximum ambient humidity Protect attachment bolts and washers at the base Protect the attachment bolts and washers M24x100 at the base from physical obstructions and splashes with appr...

Page 83: ...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 Product man...

Page 84: ...lamp See the assembly instruction delivered with the signal lamp 84 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 4 9 Installation of signal lamp option ...

Page 85: ...tion 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 WARNING Remove the mechancial stop bracket if the robots full working range is from a mechanical stop to another mechanical stop Otherwise the mechanical stop pin w...

Page 86: ...e changes in the mechanical limitations of the working range The system parameters that must be changed Upper joint bound and Lower joint bound are described in Technical reference manual System parameters Required equipment Note Art no Equipment etc Includes two additional stop lugs attachment screws washers and instruction See Spare part lists on page399 Mechanical stop axis 1 2 pcs stop lug See...

Page 87: ...ment screws D Washers E Fitting mechanical stop axis 1 How to fit the additional mechanical stop to the base is described in the procedure Mounting instructions are also supplied with the kit Note Action See the figure Additional stops on page 87 for guidance Determine the position of the stop lugs 1 Continues on next page Product manual IRB 4600 Foundry Prime 87 3HAC040585 001 Revision M Copyrigh...

Page 88: ...he robot work ing area 1 xx1100000091 A Attachment screw B Bracket stop axis 1 Remove the two screws holding the mechan ical stop and the bracket 2 Remove the bracket 3 Refit the attachment screws 4 Seal and paint the joints that have been opened Also repair possible damages of the special Foundry Prime paint coat of the robot See Cut the paint or surface on the robot be fore replacing parts on pa...

Page 89: ...obots ordered as suspended robots have the expansion container installed on delivery Expansion container xx1000000318 Cover A Attachment screw M6x16 quality 8 8 A2F 5 pcs B Oil expansion container with cover C Base D O ring D220x5 E Attachment screw M5x20 quality 8 8 A2F and washer 2 2 pcs F O ring D1 9 5 D2 1 6 G Oil plug to be removed H Continues on next page Product manual IRB 4600 Foundry Prim...

Page 90: ...ace it in suspended position with the base free for installation work 1 Remove the cover and the o ring from the base 2 xx1500001958 Remove the two existing attachment screws 3 The screws must be replaced with longer screws Remove the oil plug from the base 4 Apply some grease on the small o ring and place it in the recess on the expansion con tainer 5 xx1500001956 Fit a plastic plug in the oil dr...

Page 91: ...orque 6 Nm Check the o ring used on the cover Replace it if damaged 10 Refit the cover on the base with its attach ment screws 11 Turn the robot so it is not suspended 12 Turn the robot to suspended position 13 See procedure for suspended robot In specting oil level axis 1 gearbox on page 113 Inspect the oil level 14 Product manual IRB 4600 Foundry Prime 91 3HAC040585 001 Revision M Copyright 2013...

Page 92: ...draulic pressure supply to the robot before entering the robot work ing area 1 CAUTION Before approaching the potentially hot robot component observe the safety information in section Hot parts may cause burns on page 32 2 Note Before opening the oil plug make certain that the oil plug is above the oil level Place the robot accordingly 3 Tip Hold a cloth or some paper over the oil plug while openi...

Page 93: ...d 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 100 mm s...

Page 94: ... power supply to and control of the external axes motors as well as feedback from the servo system External axes cables option See the Application manual Additional axes and stand alone controller M2004 see document number in Refer ences on page 10 Robot cables These cables are included in the standard delivery They are completely pre manufactured and ready to plug in Connection point robot Connec...

Page 95: ...er for static floor cables A B xx1600002016 Diameter A Diameter x10 B Grounding and bonding point 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 xx1600001004 Product manual IRB 4600 Foundry Prime 95 3HAC040585 001 Revision M Copyright 2013 2018 ABB ...

Page 96: ...71626SH06 connector on the front part of the upper arm The customer connections are located on the robot as shown in the figure Customer connection xx1700002241 Air M16x1 5 24 cone sealing A R2 CP B R2 CS C R2 ETHERNET D Continues on next page 96 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 9 2 Custom...

Page 97: ...S One protective ground Number of signals customer connections R1 ETHERNET 4 EtherNet R1 ETHERNET Connection sets To connect power and signal conductors to the robot base upper arm connectors the following parts are recommended Content Art no Connector Connection set Sockets for cable area of 0 14 2 5 mm Hood foundry Hinged frame hood Multicontact module female 3HAC16667 1 R1 CP CS PROC1 on base H...

Page 98: ...e shaped shrinking hose Angle shaped shrinking hose 3HAC025396 001 R2 CP R2 CS R2 CP R2 CS 98 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 9 2 Customer connection on robot Continued ...

Page 99: ...le between robot and controller not supplied Customer Contact on Upper arm R2 Customer Ter minal Controller Signal name R1 CP CS d1 R2 CP A XP6 1 CPA R1 CP CS d6 R2 CP B XP6 2 CPB R1 CP CS d3 R2 CP C XP6 3 CPC R1 CP CS d4 R2 CP D XP6 4 CPD R1 CP CS d1 R2 CP E XP6 1 CPE R1 CP CS d6 R2 CP F XP6 2 CPF R2 CP G Earth CPG R1 CP CS d7 R2 CP H CPH Continues on next page Product manual IRB 4600 Foundry Pri...

Page 100: ... CS F XP5 2 4 CSF R1 CP CS b7 R2 CS G XP5 1 9 CSG R1 CP CS b8 R2 CS H XP5 1 10 CSH R1 CP CS b9 R2 CS J XP5 1 11 CSJ R1 CP CS b10 R2 CS K XP5 1 12 CSK R1 CP CS b11 R2 CS L XP5 1 3 CSL R1 CP CS b12 R2 CS M XP5 1 4 CSM R1 CP CS b13 R2 CS N XP5 1 5 CSN R1 CP CS b14 R2 CS P XP5 1 6 CSP R1 CP CS b15 R2 CS R XP5 3 1 CSR R1 CP CS b16 R2 CS S XP5 3 2 CSS R1 CP CS b18 R2 CS T XP5 3 3 CST R1 CP CS b19 R2 CS ...

Page 101: ... ventilated out to avoid that the humid air is sucked into e g gearboxes due to the raised vacuum when cooled down Environmental conditions 100 Humidity 9 0 Washing detergent with pH Washing detergent must contain rust inhibitor and be approved by ABB 60 C used in a typical waterjet clean ing application at suitable speed Cleaning bath temperature Air specification for pressurizing of robot The ai...

Page 102: ...se to air con nector on robot base see illustration 1 Do this when the controller cables are connected Protect the screws on the Harting connectors on the robot base from corrosion with Mer casol 2 See Air specification for pressurizing of robot on page 101 for correct pressure Pressurize the robot 3 See Inspection of air hoses Foundry Prime on page 148 Inspect the air system 4 Protecting from hig...

Page 103: ... on the wrist flange is protected with grease The joint between the wrist flange and the tool and the screw holes on the wrist flange must be protected Note Illustration Action A B xx0600003109 After mounting the tool clean the following surfaces from grease the visible surface not painted the rear end of the screw holes and end of screws 1 A screw holes and screws B unpainted surface Protect thes...

Page 104: ...r jet cleaning cell perform a inspection of the pressure in motors and SMB cavity 3 104 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 10 1 Installation of IRB 4600 Foundry Prime in a water jet application Continued ...

Page 105: ... in gearboxes it is required that the robot is running with high speed on each axes at least on one occasion each hour This is to lubricate the gearbox cavities Note When turning off a cleaning cell we recommend that the humid air is ventilated out from the cell to avoid that the humid air is sucked into gearboxes for example due to the raised vacuum when cooled down Product manual IRB 4600 Foundr...

Page 106: ...This page is intentionally left blank ...

Page 107: ...ivided 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 the IRB 4600 Fo...

Page 108: ... lubrication Conditional for example water content in gearbox control decide replacement intervals Preventive measures every 6 months secure the uptime of the robot Inspection of oil level in gearboxes Surface treatment Cable harness Activity to lubricate gearboxes cavities and gears Run each axis on high speed at least one occasion per hour This activity will lubricate the gearbox cavities and ge...

Page 109: ...ven 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 identify the real s...

Page 110: ... with protection type Foundry Prime Interval Equipment Maintenance activ ity Every 6 months Oil level in axis 1 gearbox Inspection Every 6 months Oil level in axis 2 gearbox Inspection Every 6 months Oil level in axis 3 gearbox Inspection Every 6 months Oil level in axis 4 gearbox Inspection Every 6 months Oil level in axis 5 gearbox Inspection Every 6 months Oil level in axis 6 gearbox Inspection...

Page 111: ...hours or 6 months iv Before changing oil always check the oil level Always analyze the water content in the exchanged oil according to Analyzing the water content in gearbox oil on page 190 to determine the condition of each gearbox If the water content in oil is more than 3 analyze the new oil within 2 months Repeatedly high water content in oil indicates wear of radial sealing in the gearbox v T...

Page 112: ... robot This applies to gearboxes on axes 1 2 and 3 The lifetime of gearbox axes 4 5 and 6 is not calculated by SIS See the Operating manual Service Infomation System In applications such as Foundry or Washing the robot can be exposed to chemicals high temperature or humidity which can have an effect on the lifetime of gearboxes Contact the local ABB Robotics Service team for more information The S...

Page 113: ... on page 151 Lubrication oil Content is defined in section Standard tools on page 393 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 Additional equipment Foundry Prime Note Art no Equipment Mercasol 3HAC034903 001 Rust preventive 3HAC026759 001 Sikaflex 5...

Page 114: ...igure Old design xx0800000304 Oil plug inspection A Oil plug gearbox B Current design A B C xx1000000669 Oil plug draining on gearbox A Oil plug filling on surface for motor flange B Surface for motor flange C Continues on next page 114 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 4 1 Inspecting oil level axis 1 gearbox...

Page 115: ...2 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 3 See Location of oil plugs floor mounted on page 114 Open the oil plug inspection 4 A B xx1200000859 Old design Measure the oil level by looking into the hole of the oil plug inspection Required oil level 0 5 mm up to the lower edge of the oil plug hol...

Page 116: ...d oil if required 7 Tightening torque 24 Nm Refit the oil plug inspection 8 Seal and paint the joints that have been opened Also repair possible damages of the special Foundry Prime paint coat of the robot See Cut the paint or surface on the robot before replacing parts on page 201 9 Inspecting the gearbox oil level in a suspended robot Location of oil plugs suspended Old design A B xx1200000883 O...

Page 117: ...verted position If the robot was taken down to stand on the floor the oil level would be above the oil plug hole which would result in oil leakage if the plug would be opened while robot stands on the floor Note Action WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section Safety risks during work with gearbox lubricants oil o...

Page 118: ...now on top 5 How to fill oil is described in section Changing the oil axis 1 gearbox on floor mounted robots on page 153 Add oil if required 6 Tightening torque 3 8 Nm Refit the oil plug Note Before refitting the oil plug in the gearbox always replace the oil plug sealing washer with a new one If not there is a risk of leakage 7 Seal and paint the joints that have been opened Also repair possible ...

Page 119: ...on oil For article number see Spare part lists on page 399 Oil plug Quick connect fitting Content is defined in section Standard tools on page 393 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 Additional equipment Foundry Prime Note Art no Equipment Merc...

Page 120: ...s of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 3 CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page 201 4 See the figure in Location of axis 2 gearbox on page 119 Open the oil plug inspection location de pends on how the robot i...

Page 121: ...washer with a new one If not there is a risk of leakage 8 Seal and paint the joints that have been opened Also repair possible damages of the special Foundry Prime paint coat of the robot See Cut the paint or surface on the robot before replacing parts on page 201 9 Product manual IRB 4600 Foundry Prime 121 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 4 2 I...

Page 122: ...d in section Standard tools on page 393 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 Additional equipment Foundry Prime Note Art no Equipment Mercasol 3HAC034903 001 Rust preventive 3HAC026759 001 Sikaflex 521FC 12340011 116 Loctite 574 Brush 3HAC035355...

Page 123: ...in order to let out the excess pres sure 4 CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot be fore replacing parts on page 201 5 See the figure in Location of axis 3 gearbox on page 122 Open the oil plug armhouse 6 Measure the oil level at the oil plug hole 7 Required oil level oil in the gearbox shall be just be...

Page 124: ...al Foundry Prime paint coat of the robot See Cut the paint or surface on the robot be fore replacing parts on page 201 10 124 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 4 3 Inspecting the oil level axis 3 gearbox Continued ...

Page 125: ...ard 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 Additional equipment Foundry Prime Note Art no Equipment Mercasol 3HAC034903 001 Rust preventive 3HAC026759 001 Sikaflex 521FC 12340011 116 Loctite 574 Brush 3HAC035355 001 Foundry Prime touch up kit Continues on ...

Page 126: ...e 4 CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot be fore replacing parts on page 201 5 See the figure in Location of axis 4 gearbox on page 125 Open the oil plug 6 Measure the oil level at the oil plug hole 7 Required oil level 35 5 mm below the oil plug flange How to fill oil is described in section Changing ...

Page 127: ...ed in section Standard tools on page 393 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 Additional equipment Foundry Prime Note Art no Equipment Mercasol 3HAC034903 001 Rust preventive 3HAC026759 001 Sikaflex 521FC 12340011 116 Loctite 574 Brush 3HAC03535...

Page 128: ...he excess pres sure 4 CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot be fore replacing parts on page 201 5 See the figure in Location of gearbox axes 5 6 on page 127 Open the oil plug wrist 6 Note Open the oil plug tilthouse when inspect ing This will level up oil in axes 5 and 6 See the figure in Inspecting oil...

Page 129: ...rist on top Move the upper arm axis 3 to a horizontal position then rotate axis 4 90 3 See the figure in Location of gearbox axes 5 6 on page 127 Note In this position it is not possible to open the oil plug tilthouse in order to level up oil in axes 5 and 6 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot work ing area 4 CAUTION The gearbo...

Page 130: ...oil if required 9 Tightening torque 10 Nm Refit oil plug wrist 10 Seal and paint the joints that have been opened Also repair possible damages of the special Foundry Prime paint coat of the robot See Cut the paint or surface on the robot be fore replacing parts on page 201 11 130 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 3 Maintenan...

Page 131: ...red equipment Note Equipment Content is defined in section Standard tools on page 393 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 See chapter Circuit diagram on page 401 Circuit diagram Continues on next page Product manual IRB 4600 Foundry Prime 131 3...

Page 132: ...nspection of the cable harness in order to detect wear or damage 2 Check the connectors at the base 3 Check the connectors at the armhouse 4 Check all brackets and straps are properly attached to the robot 5 How to replace the cable harness is de scribed in Repair on page 195 Replace the cable harness if wear cracks or damage is detected 6 Seal and paint the joints that have been opened Also repai...

Page 133: ...g instruction C Warning High temperature 2 pcs D Label Max air pressure E Warning Brake release unit F Label Calibration G Label Suspended robot H Required equipment Note Spare part number Equipment See Spare part lists on page 399 Labels Continues on next page Product manual IRB 4600 Foundry Prime 133 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 4 7 Inspec...

Page 134: ...ply to the robot before entering the robot work ing area 1 See the figure in Location of information labels on page 133 Check all labels 2 Replace any missing or damaged labels 3 134 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 4 7 Inspecting information labels Continued ...

Page 135: ...s on page 393 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 Additional equipment Foundry Prime Note Article number Equipment Mercasol 3HAC034903 001 Rust preventive 3HAC026759 001 Sikaflex 521FC 12340011 116 Loctite 574 Brush Continues on next page Pro...

Page 136: ...ic pressure supply to the robot before entering the robot work ing area 1 See the figure in Location of mechanical stop pin axis 1 on page 135 Regularly check that the mechanical stop pin is not bent or damaged in any other way 2 Continues on next page 136 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 4 8 Inspecting the ...

Page 137: ... ring 2 pcs Not used if bracket D is installed D Bracket E Stop pin 3 Check that the mechanical stop pin is prop erly attached 4 xx1000000222 Check that the mechanical stop pin can move freely in both directions and the bracket works as it is supposed to 5 Continues on next page Product manual IRB 4600 Foundry Prime 137 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 3 Mainte...

Page 138: ...l Foundry Prime paint coat of the robot See Cut the paint or surface on the robot be fore replacing parts on page 201 6 138 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 4 8 Inspecting the mechanical stop pin axis 1 Continued ...

Page 139: ...ed to 13 5 Type C 16 5 other design than Type C C Attachment screws D Washers E Required equipment Note Equipment etc Includes Stop Attachment screws plus washers Document for movable mechanical stop For spare part number see Spare part lists on page 399 Mechanical stop set axis 1 Content is defined in section Standard tools on page 393 Standard toolkit Continues on next page Product manual IRB 46...

Page 140: ... robot before entering the robot work ing area 1 See the figure in Location of additional mechanical stops on page 139 Check the additional mechanical stops on axis 1 for damage 2 Tightening torque 82 Nm Make sure the stops are properly attached 3 Attachment screws M12x40 quality 8 8 A3F 2 pcs stop lug If any damage on stops or attachment screws etc is detected the mechanical stops must be replace...

Page 141: ...amper Content is defined in section Standard tools on page 393 Standard toolkit Additional equipment Foundry Prime Note Art no Equipment Mercasol 3HAC034903 001 Rust preventive 3HAC026759 001 Sikaflex 521FC 12340011 116 Loctite 574 Brush 3HAC035355 001 Foundry Prime touch up kit Continues on next page Product manual IRB 4600 Foundry Prime 141 3HAC040585 001 Revision M Copyright 2013 2018 ABB All r...

Page 142: ...existing impressions larger than 2 3 mm 3 Check attachment screws for deformation 4 If any damage is detected the damper must be replaced 5 Seal and paint the joints that have been opened Also repair possible damages of the special Foundry Prime paint coat of the robot See Cut the paint or surface on the robot be fore replacing parts on page 201 6 142 Product manual IRB 4600 Foundry Prime 3HAC0405...

Page 143: ...nt is defined in section Standard tools on page 393 Standard toolkit Brush 3HAC035355 001 Foundry Prime touch up kit Leak spray Required consumables Note Article number Consumable Mercasol 3HAC034903 001 Rust preventive 3HAC026759 001 Sikaflex 521FC 12340011 116 Loctite 574 Continues on next page Product manual IRB 4600 Foundry Prime 143 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights...

Page 144: ...re can be built up which can be hazardous 2 Check if the leak proof o ring is contaminated or covered with litter 3 Clean if necessary Note Use a cloth or a brush xx1700001174 Screw Cover O ring 6 1 mm O ring 41 mm Spray the leak proof o ring valve with leak spray If leak is found change the 41 mm o ring according to figure Note Make sure not to lose the small o ring 4 Continues on next page 144 P...

Page 145: ... have been opened Also repair possible damages of the special Foundry Prime paint coat of the robot See Cut the paint or surface on the robot be fore replacing parts on page 201 6 Product manual IRB 4600 Foundry Prime 145 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 4 11 Inspecting the leak proof o ring and pressure relief valves Continued ...

Page 146: ...3 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 Additional equipment Foundry Prime Note Art no Equipment Mercasol 3HAC034903 001 Rust preventive 3HAC026759 001 Sikaflex 521FC 12340011 116 Loctite 574 Brush 3HAC035355 001 Foundry Prime touch up kit Contin...

Page 147: ...Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot work ing area 3 Check whether the signal lamp is broken If so replace 4 Check the cable connections 5 24V Measure the voltage in connectors motor axis 3 6 Check the cabling If a fault is detected re place 7 Seal and paint the joints that have been opened Also repair possible damages of the special F...

Page 148: ... the knob until the correct value is shown on the pressure gauge 1 0 2 0 3 bar D C B A xx1500002399 A Air connection robot B Pressure gauge C Cut off valve D Air connection It should take at least 5 seconds for the pressure to reach 0 bar Close the cut off valve 2 The time is 5 seconds If the answer is YES Localize the leakage by following the procedures below If the answer is NO The system is OK ...

Page 149: ...pray Note Bubbles indicate a leak 5 When the leak is localized correct the leak 6 Product manual IRB 4600 Foundry Prime 149 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 4 13 Inspection of air hoses Foundry Prime Continued ...

Page 150: ...d drying time is 24h 3HAC034903 001 Rust preventive 3HAC026759 001 Sikaflex 521FC 12340011 116 Loctite 574 Brush 3HAC035355 001 Foundry Prime touch up kit Inspection and repair of surface treatment Use this procedure to inspect the surface treatment on Foundry Prime robots Information Action Inspect all painted surfaces for damages 1 Repair damages as described in the instruc tion included in the ...

Page 151: ...al www mypo rtal abb com Before starting any inspection maintenance or changing activities of lubrication always contact the local ABB Service organization for more information For ABB personnel Always check ABB Library for the latest revision of the manual Technical reference manual Lubrication in gearboxes in order to always get the latest information of updates about lubrication in gearboxes A ...

Page 152: ...r one Orion OriCan article number 22590 pneumatic Used on the axis 2 gearbox Nipple for quick connect fitting with o ring Used when the robot is fitted in a suspended position Expansion container gearbox axis 1 152 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 5 1 Type of lubrication in gearboxes Continued ...

Page 153: ...s suspended see Changing the oil axis 1 gearbox on suspended robots on page 160 Location of oil plugs The axis 1 gearbox is located between the frame and base of the robot The oil plugs are shown in the figure Old design xx0800000304 Oil plug filling and venting A Oil plug draining B Continues on next page Product manual IRB 4600 Foundry Prime 153 3HAC040585 001 Revision M Copyright 2013 2018 ABB ...

Page 154: ... complete amount of oil Oil collecting vessel One example of oil dispenser can be found in section Type of lubrication in gearboxes on page 151 Oil dispenser Content is defined in section Standard tools on page 393 Standard toolkit Additional equipment Foundry Prime Note Art no Equipment Mercasol 3HAC034903 001 Rust preventive Continues on next page 154 Product manual IRB 4600 Foundry Prime 3HAC04...

Page 155: ...tion DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 1 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section Safety risks during work with gearbox lubricants oil or grease on page 37 2 CAUTION The gearbox can contain an excess of pressure that can be haza...

Page 156: ...an be found in section Type of lubrication in gearboxes on page 151 Different position due to design differ ences xx1800001137 Remove the plug from the vent hole WARNING If the oil plug for venting is not open when the oil dispenser is working there is a risk of damaging vital parts in the gearbox 5 xx1800001139 Suck out the oil with the oil dispenser Note There will be some oil left in the gear a...

Page 157: ...leakage 9 Other design than Type C 3 8 Nm Type C 24 Nm xx1800001138 Tightening torque 24 Nm Refit the oil plug venting 10 Different position due to design differ ences xx1800001137 xx1800001139 See Inspection and repair of surface treatment on page 150 If the robots paint coat is damaged during the procedure paint touchup is needed 11 Continues on next page Product manual IRB 4600 Foundry Prime 15...

Page 158: ...ety risks during work with gearbox lubricants oil or grease on page 37 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug care fully in order to let out the excess pressure 3 Different position due to design differ ences xx1800001137 Open the oil plug filling 4 xx1800001139 Continues on next page 158 Product manual IRB 4600 Foundry Prime 3HAC040585 001 ...

Page 159: ...nspect the oil level 6 Tightening torque 24 Nm Refit the oil plug 7 Different position due to design differ ences xx1800001137 xx1800001139 Seal and paint the joints that have been opened Also repair possible damages of the special Foundry Prime paint coat of the robot See Cut the paint or surface on the robot before repla cing parts on page 201 8 Product manual IRB 4600 Foundry Prime 159 3HAC0405...

Page 160: ...gearbox on floor mounted robots on page 153 Location of oil plugs The axis 1 gearbox is located between the frame and base of the robot The oil plugs are shown in the figures Other design than Type C A B xx1200000883 Oil plug venting A Oil plug draining and filling B Continues on next page 160 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserv...

Page 161: ...e capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel One example of oil dispenser can be found in section Type of lubrication in gearboxes on page 151 Oil dispenser Oil change equipment Continues on next page Product manual IRB 4600 Foundry Prime 161 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 5 3 Changing th...

Page 162: ...earbox Use this procedure to drain the gearbox of oil Tip In order to save time a pneumatic oil dispenser can be used to suck the oil out from the gearbox Note Action DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 1 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information...

Page 163: ...ing 7 Using a low air pressure start sucking the oil out from the gearbox with the oil change equipment 8 WARNING Used oil is hazardous material and must be disposed of in a safe way See section De commissioning on page381 for more inform ation 9 Tip Make a note how much oil was drained The same amount shall later be refilled Let the oil drain until the gearbox is empty Note There will be some oil...

Page 164: ...ng please read the safety information in the section Safety risks during work with gearbox lubricants oil or grease on page 37 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug care fully in order to let out the excess pressure 3 xx1800001271 Verify that the hose of the oil change equipment is clean and then fit the quick connection to the oil plug for...

Page 165: ...itting the oil plug in the gearbox al ways replace the oil plug sealing washer with a new one If not there is a risk of leakage 9 Seal and paint the joints that have been opened Also repair possible damages of the special Foundry Prime paint coat of the robot See Cut the paint or surface on the robot before repla cing parts on page 201 10 Expansion container axis 1 gearbox suspended mounted robots...

Page 166: ...obot shall be fitted in a suspended mounted position an expansion container must be installed See Installing an expansion container on page 89 166 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 5 3 Changing the oil axis 1 gearbox on suspended robots Continued ...

Page 167: ...und in Technical reference manual Lubrication in gearboxes Lubricating oil See Type and amount of oil in gearboxes on page 151 The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel To be fitted on a hose and then used for draining connected to the quick connect fit ting Nipple TEMA IF 3820 S06 See Location of oil plugs on page 167 Content is defined...

Page 168: ...ring the robot working area 1 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section Safety risks during work with gearbox lubricants oil or grease on page 37 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 3 See the figure in Lo...

Page 169: ...e There will be some oil left in the gearbox after draining 8 Tightening torque 24 Nm Refit oil plug Note Before refitting the oil plug in the gearbox always replace the oil plug sealing washer with a new one If not there is a risk of leakage 9 Filling oil axis 2 gearbox Use this procedure to fill the gearbox with oil Note Action DANGER Turn off all electric power supply hydraulic pressure supply ...

Page 170: ...il Note The amount of oil to be filled depends on the amount previously being drained 5 How to inspect the oil level is described in section Inspecting the oil level axis 2 gearbox on page 119 Inspect the oil level 6 Tightening torque 24 Nm Refit oil plug Note Before refitting the oil plug in the gearbox always replace the oil plug sealing washer with a new one If not there is a risk of leakage 7 ...

Page 171: ...ence manual Lubrication in gearboxes Lubricating oil See Type and amount of oil in gearboxes on page 151 The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel One example of oil dispenser can be found in section Type of lubrication in gearboxes on page 151 Oil dispenser xx1200000862 Funnel Continues on next page Product manual IRB 4600 Foundry Prime...

Page 172: ...ssembling parts See Cut the paint or surface on the robot before replacing parts on page201 Draining axis 3 gearbox Use this procedure to drain the gearbox of oil There is an alternative method to drain the gearbox See Draining alternative method on page 173 Note Action xx0800000327 Move the robot to an upright position as shown in the figure 1 A Oil collecting vessel Continues on next page 172 Pr...

Page 173: ...ing is time consuming Elapsed time varies depending on the temperature of the oil Drain the gearbox oil using an oil collecting vessel 7 WARNING Used oil is hazardous material and must be disposed of in a proper way See section De commissioning for more information 8 Tightening torque in armhouse 10 Nm in gearbox 3 Nm Refit oil plugs 9 Draining alternative method Use this procedure to drain the oi...

Page 174: ...tion in gear boxes on page 151 Connect the oil dispenser 6 See the figure in Location of oil plugs on page171 WARNING The oil plug gearbox must be open when the oil dispenser equipment is used Otherwise sealings and other parts will be damaged Open the oil plug armhouse now pointing up wards and use it as a ventilation hole 7 For capacity of the vessel see section Type of lubrication in gear boxes...

Page 175: ...bot working area 2 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section Safety risks during work with gearbox lubricants oil or grease on page 37 3 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug care fully in order to let out the excess pressure 4 See the figure in Location of o...

Page 176: ... oil level axis 3 gearbox on page 122 Inspect the oil level 7 Tightening torque in armhouse 10 Nm in gearbox 3 Nm Refit the oil plug 8 Seal and paint the joints that have been opened Also repair possible damages of the special Foundry Prime paint coat of the robot See Cut the paint or surface on the robot before repla cing parts on page 201 9 176 Product manual IRB 4600 Foundry Prime 3HAC040585 00...

Page 177: ... section Type of lubrication in gear boxes on page 151 Lubricating oil The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel Used for venting the gearbox during draining A suitable hose would be a hose normally used for compressed air Plastic hose Length minimum 300 mm Diameter 5 mm xx1200000862 Funnel Continues on next page Product manual IRB 4600 ...

Page 178: ...Use this procedure to drain oil from the gearbox Note Action xx0800000328 Move the robot to the position shown in the figure 1 A Oil collecting vessel DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 2 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section ...

Page 179: ...ximately 100 mm into the gearbox to vent the gear box This speeds up the draining significantly 6 WARNING Used oil is hazardous material and must be disposed of in a safe way See section De commissioning on page381 for more inform ation 7 Tightening torque 10 Nm Refit the oil plug 8 Filling oil Use this procedure to fill oil in the gearbox Note Action xx0800000330 Move the upper arm to the positio...

Page 180: ...lugs on page 177 Open the oil plug filling 5 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 151 Refill the gearbox with lubricating oil Tip Use a funnel 6 Note The amount of oil to be filled depends on the amount previously being drained Tightening torque 10 Nm Refit the oil plug 7 Seal and paint the joints that have been opened Also repair po...

Page 181: ...ype of oil article number and the amount in the gear box see section Type of lubrication in gear boxes on page 151 Lubrication oil The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel Content is defined in section Standard tools on page 393 Standard toolkit Additional equipment Foundry Prime Note Art no Equipment Mercasol 3HAC034903 001 Rust preven...

Page 182: ...l electric power supply hydraulic pressure supply to the robot before entering the robot working area 3 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section Safety risks during work with gearbox lubricants oil or grease on page 37 4 The capacity of the vessel must be suffi cient to take the complete amount of oil Put an oil ...

Page 183: ...st points upwards 1 See the figure in Location of oil plugs on page 181 Move axis 5 to a position where the oil plug tilthouse points upwards 2 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 3 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section Safety ...

Page 184: ...h lubrication oil Note The amount of oil to be filled depends on the amount previously being drained 8 How to inspect the oil level is described in section Inspecting oil level gearbox axes 5 6 on page 127 Inspect the oil level 9 Tightening torque 10 Nm Refit both oil plugs 10 Seal and paint the joints that have been opened Also repair possible damages of the special Foundry Prime paint coat of th...

Page 185: ...s For an SMB board with 2 pole battery contact the typical lifetime of a new battery is 36 months if the robot 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 du...

Page 186: ...0322 SMB battery 2 pole battery contact A Battery cover B Attachment screws C SMB battery cable D How to arrange the battery cable E Continues on next page 186 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 5 8 Replacing SMB battery Continued ...

Page 187: ...cludes protection circuits Replace it only with given spare part no or an ABB approved equivalent SMB battery pack See Spare part lists on page 399 Content is defined in section Standard tools on page 393 Standard toolkit See chapter Circuit diagram on page 401 Circuit diagram Additional equipment Foundry Prime Note Art no Equipment Mercasol 3HAC034903 001 Rust preventive 3HAC026759 001 Sikaflex 5...

Page 188: ...1 3 CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page 201 4 See the figure in Location of SMB battery on page 186 Remove the SMB battery cover CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures ...

Page 189: ... the SMB cables as shown in the figure 4 See the figure in Location of SMB battery on page 186 Secure the SMB cover with its attachment screws 5 Seal and paint the joints that have been opened Also repair possible damages of the special Foundry Prime paint coat of the robot See Cut the paint or surface on the robot before replacing parts on page 201 6 Detailed in Updating revolution counters on pa...

Page 190: ...0003155 More than 3 water in oil With more than 3 water content there is a risk for corrosion in the gearbox and reduced viscosity in the oil 1 A Water content in gearbox oil B Months or hours in operation C Replacement of gearbox Normal replacement interval is required for the gearbox A B 3 6 12 18 24 30 3000 6000 9000 12000 15000 xx0600003156 Less than 3 water in oil 2 A Water content in gearbox...

Page 191: ...vities on page 113 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 Oil spills discolors painted surfaces Oil spills on painted surfaces of the robot can result in discoloration Note After all repair and maintenance work involving oil always wipe the robot clean from all surplus oil Special cleaning conside...

Page 192: ...Instructions for rinsing with water ABB robots with protection types Standard Foundry Plus Wash or Foundry Prime can be cleaned by rinsing with water water cleaner 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 Typ...

Page 193: ...osive Approved cleaners and detergents All cleaners and detergents must be approved by ABB before use Contact ABB Robotics Sales Support to get the latest released list of approved cleaners and detergents Temperature of cleaning bath Maximum temperature 60ºC Ambient temperature must not be higher than 45 C Note Make sure that the special Foundry Prime painting of the robot is not broken during tes...

Page 194: ...This page is intentionally left blank ...

Page 195: ...ific 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 385 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 sure to read thro...

Page 196: ...sure 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 no pressu...

Page 197: ...tresses 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 recomm...

Page 198: ...uring 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 198 Product manual IRB 4600 Fou...

Page 199: ...t 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 page199 Lubricate the seal with grease just before fitting Not too early there is a risk of dirt and foreign partic...

Page 200: ...n 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 correct ...

Page 201: ... used on all Foundry Prime robots re gardless of the original color of the robot 3HAC035355 001 Touch up paint Foundry Prime Foundry Prime 2 Foundry Prime 3 Grey 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 s...

Page 202: ...001 Use Touch up paint Foundry Prime grey to paint the joint Note Always read the instruction in the product data sheet in the paint repair kit for Foundry Prime 6 Apply Mercasol on all screw heads and set screws after tightening 7 202 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 2 4 Cut the paint or surface on the robot bef...

Page 203: ...e 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 jammed in ...

Page 204: ... complete cable harness consists of the following parts presented in the order the work is recommended to be performed Removal in the base Removing cable harness in base on page 207 Removal in the frame Removing cable harness in frame on page 212 Removal in lower arm and armhouse Removing cable harness in lower arm and armhouse on page 214 How to replace the SMB unit brake release unit and motors ...

Page 205: ... base and frame xx0900000009 Cover base A Bracket B Cable harness C Axis 1 motor cable D Axis 2 motor cable E Axis 2 motor F Axis 1 motor G Continues on next page Product manual IRB 4600 Foundry Prime 205 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 1 Removing the complete cable harness Continued ...

Page 206: ...Deep well hexagon socket Content is defined in section Standard tools on page 393 Standard toolkit These procedures include references to the tools required Other tools and procedures may be re quired See references to these procedures in the step by step instructions below Continues on next page 206 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights...

Page 207: ...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 365 If no previous reference values exist and no new reference values can b...

Page 208: ...r base has been removed 3 Parts A R1 CP CS B R1 MP C Air hose connector D Position of R1 ETHERNET if used E R1 SMB CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page 201 4 A B C xx0800000456 A Base B Cover base C Attachment screws Remove the cover base 5 Continues on next page 208 Prod...

Page 209: ...onnector Unscrew the thin nut securing the R1 SMB connector on the outside of the bracket Tip Use a deep well hexagon socket width 30 mm like the ones used for spark plugs or similar xx1200000888 9 Unscrew the nut for the air connection on the inside of the bracket 10 Continues on next page Product manual IRB 4600 Foundry Prime 209 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reser...

Page 210: ...orming this procedure in order not to damage cables or other components 12 Parts A Bracket at a 90 angle B Base A B C D xx1200000890 A R1 CP CS B R1 MP C Air hose connector D R1 SMB Remove connectors and air hose connector completely from the bracket R1 CP CS R1 MP R1 SMB Air hose connector R1 ETHERNET if used 13 How to remove the SMB unit is described in section Removing the SMB unit on page247 R...

Page 211: ... of R1 SMB1 2 R1 SMB2 6 16 Parts A Screen connection 4 pcs xx0900000015 Disconnect the earth cables 17 Parts A Earth B Distance screws Continues on next page Product manual IRB 4600 Foundry Prime 211 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 1 Removing the complete cable harness Continued ...

Page 212: ...s in frame Use this procedure to remove the cable harness in the frame Tip Before starting this procedure first remove the cable harness in the base See Removing the complete cable harness on page 204 Note Action DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 1 How to remove the motor cables is de scribed in section Removing ...

Page 213: ...f the cable package in the base with tape as shown in the figure Tip In order to protect the connectors from getting residual grease on the cable har ness put some plastic over them prior to pushing it through the hole in the frame 6 Pull out the cable package through the hole in the frame Note Use caution when performing this proced ure in order not to damage cables or other components 7 How to r...

Page 214: ...ydraulic pressure supply to the robot before entering the robot working area 1 See the figure in Location of the cable harness on page205 Cable harness lower arm Cut the cable strap on the lower arm 2 CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page 201 3 Continues on next page 214 P...

Page 215: ...house D Cable bracket xx0800000335 Remove the bracket on the armhouse 5 Parts A Tubular shaft unit B Attachment screws C Bracket armhouse Continues on next page Product manual IRB 4600 Foundry Prime 215 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 1 Removing the complete cable harness Continued ...

Page 216: ...om the axis 3 axis 4 axis 5 and axis 6 motors see section Removing motors on page 305 Continue the removal of the cable package by disconnecting the motor cables of the axis 3 axis 4 axis 5 and axis 6 motors 8 216 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 1 Removing the complete cable harness Continued ...

Page 217: ...s of the following parts presented in the order the work is recommended to be performed Refitting in the frame Refitting the cable harness in the frame on page 220 Refitting in the base Refitting the cable harness in the base on page 224 Refitting in the lower arm and armhouse Refitting the cable harness in the lower arm and armhouse on page 230 How to refit the SMB unit brake release unit and mot...

Page 218: ...base and frame xx0900000009 Cover base A Bracket B Cable harness C Axis 1 motor cable D Axis 2 motor cable E Axis 2 motor F Axis 1 motor G Continues on next page 218 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 2 Refitting the complete cable harness Continued ...

Page 219: ...ools on page 393 Standard toolkit These procedures include references to the tools required Other tools and procedures may be re quired See references to these procedures in the step by step instructions below Shell Alvania WR2 Cable grease Additional equipment Foundry Prime Note Art no Equipment Mercasol 3HAC034903 001 Rust preventive Continues on next page Product manual IRB 4600 Foundry Prime 2...

Page 220: ...the robot before entering the robot working area 1 Clean the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 201 2 Cable grease is specified in Required equipment on page 219 Apply cable grease on these surfaces cable guide inside the hole the part of the cable harness that runs through the cable guide 3 Note Two alternative methods to insert t...

Page 221: ...esidual grease on the cable harness put some plastic over them prior to pushing it through the hole in the frame 5 Use this procedure when replacing the old cable harness 6 Method 1 step 2 Push the cable package carefully in through the base and up through the hole in the frame Note Use caution when performing this procedure in order not to damage cables or other components Continues on next page ...

Page 222: ...se on the cable harness put some plastic over them prior to pushing it through the hole in the frame Note Check that cables and air hose are placed as shown in the figure above Use this procedure when fitting a new cable harness Without removing the plastic around cables and hose push the cable harness through the hole in the frame Note Use caution when performing this procedure in order not to da...

Page 223: ...cure the cover to the frame with its attach ment screws 10 Parts A Frame B Hole in frame C Cover How to refit the motor cables is described in section Refitting motors on page 314 Connect the axis 1 and axis 2 motor cables 11 Continues on next page Product manual IRB 4600 Foundry Prime 223 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 2 Refitting the complete c...

Page 224: ...f the cable harness in the base 13 Refitting the cable harness in the base Use this procedure to refit the cable harness in the base Tip Before starting this procedure first refit the cable harness in the frame See Refitting the complete cable harness on page 217 Note Action DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 1 Co...

Page 225: ...ut the attachment screws in the holes but do not tighten them yet if they have been removed earlier Place the bracket on the attachment screws Secure the bracket with its attach ment screws 3 Parts A Base B Attachment screws 2 pcs C Bracket Continues on next page Product manual IRB 4600 Foundry Prime 225 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 2 Refitting...

Page 226: ...page 249 Refit the SMB unit 6 A xx0900000035 Refit the cables with the screen connec tions 7 Parts A Screen connections 4 pcs xx0900000013 Tip When refitting connectors on the bracket put it at a 90 angle 8 Parts A Bracket B Base Continues on next page 226 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 2 Refitting the comple...

Page 227: ...it the R1 SMB connector and air hose at this stage It will be easier to refit these two when the bracket has been fitted to the distance screws 10 Connectors A Earth cables B R1 SMB1 2 C R1 SMB3 6 D R2 SMB E R1 CP CS F R1 MP G Air hose H Position of R1 ETHERNET if used J R1 SMB Continues on next page Product manual IRB 4600 Foundry Prime 227 3HAC040585 001 Revision M Copyright 2013 2018 ABB All ri...

Page 228: ...t the R1 SMB connector on the bracket Tip Use a deep well hexagon socket width 30 mm like the ones used for spark plugs or similar xx1200000888 13 Refit the air hose connector on the bracket Note Check that there is no leakage from the air hose 14 Reconnect the battery cable 15 Continues on next page 228 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All ri...

Page 229: ...age 218 Refit the bracket on the frame 19 See the figure in Location of the cable harness on page 218 Refit the cable straps securing the cable harness to the frame 20 How to refit the cable harness on the lower arm and armhouse is described in section Refitting the cable harness in the lower arm and armhouse on page 230 Continue the refitting of the cable package on lower arm and armhouse 21 Cont...

Page 230: ...ply to the robot before entering the robot working area 1 A B C D xx0900000020 Secure the brackets on the lower arm 2 Parts A Bracket lower arm B Bracket lower arm C Bracket armhouse D Cable bracket See the figure in Location of the cable harness on page218 Cable harness lower arm Refit the cable straps securing the cable harness to the lower arm 3 Push the cable harness carefully into the armhous...

Page 231: ...ave been opened Also repair possible damages of the special Foundry Prime paint coat of the robot See Cut the paint or surface on the robot before replacing parts on page 201 8 Pendulum Calibration is described in Op erating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 9 Axis Calibration is described in Calibrating with Axis Calibration method on page364 Ge...

Page 232: ...Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 26 11 232 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 2 Refitting the complete cable harness Continued ...

Page 233: ...oolkit 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 12691907 1 Loctite 577 3HAC026621 001 Rust preventive Continues on next page Product manual IRB 4600 Foundry Prime 233 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 3 Replacement of...

Page 234: ...h up kit available for Foundry Prime art no 3HAC035355 001 to repair the damage paint coat see section Cut the paint or surface on the robot before replacing parts on page 201 CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page201 Continues on next page 234 Product manual IRB 4600 Found...

Page 235: ... pressure hoses on a IRB 4600 Foundry Prime robot xx1100000049 Continues on next page Product manual IRB 4600 Foundry Prime 235 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 3 Replacement of air nipples and hoses Foundry Prime Continued ...

Page 236: ...u lator Also read the safety sections Safety risks related to pneumat ic hydraulic systems on page 33 Risks associated with live electric parts on page 29 Safety risks during installation and service work on robots on page 23 1 xx1500002400 Remove hose and remove the straight fitting from the manipulator base 2 Continues on next page 236 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revisio...

Page 237: ... tools 3 xx1100000054 Remove the hoses from the elbow fit tings No tools needed 4 Continues on next page Product manual IRB 4600 Foundry Prime 237 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 3 Replacement of air nipples and hoses Foundry Prime Continued ...

Page 238: ...s on the cover at the frame No tools needed 6 Remove the straight fittings on the cover at the frame Use standard tools 7 Continues on next page 238 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 3 Replacement of air nipples and hoses Foundry Prime Continued ...

Page 239: ...m the upper elbow fitting 8 xx1100000060 Remove the upper elbow fitting 9 Continues on next page Product manual IRB 4600 Foundry Prime 239 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 3 Replacement of air nipples and hoses Foundry Prime Continued ...

Page 240: ...ap to secure the position of the rubber blocks 10 xx1100000057 Remove all hose clamps A from the lower arm 11 Remove the Pneumatic hose Foundry Prime 2500 mm from the upper arm 12 Continues on next page 240 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 3 Replacement of air nipples and hoses Foundry Prime Continued ...

Page 241: ...ers attachment plates and screws after refitting these components 2 xx1500002401 Refit the straight fitting on the manip ulator base Apply Loctite 577 on the thread Use standard tools 3 Continues on next page Product manual IRB 4600 Foundry Prime 241 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 3 Replacement of air nipples and hoses Foundry Prime Continued ...

Page 242: ...ead Use standard tools 4 xx1100000062 Refit the upper hose in the elbow fitting 5 Continues on next page 242 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 3 Replacement of air nipples and hoses Foundry Prime Continued ...

Page 243: ...hoses 6 xx1100000068 Refit the elbow fittings on the mo tors Apply Loctite 577 on the thread Use standard tools 7 Refit the hose on the elbow fitting 8 Continues on next page Product manual IRB 4600 Foundry Prime 243 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 3 Replacement of air nipples and hoses Foundry Prime Continued ...

Page 244: ...at the frame Apply Loctite 577 on the thread Use standard tools 10 xx1100000070 Refit the hoses on the straight fit tings on the cover at the frame 11 244 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 3 Replacement of air nipples and hoses Foundry Prime Continued ...

Page 245: ... are different variants of SMB units and batteries The variant with the 3 pole battery contact RMU 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 Equipment Content is defined in section Standard tools on page 393 Standard toolkit Continues on next page Product manual I...

Page 246: ...al 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 calib...

Page 247: ...g parts See Cut the paint or surface on the robot before replacing parts on page 201 3 A B C xx0900000103 Remove the base cover CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous fail ures 4 Parts A Attachment screws 6 pcs B Base cover C Cable straps securing the battery cable 2 pcs Cut the cable straps securing the ...

Page 248: ... 90 angle from the base Putting the bracket at a 90 angle facilitates the disconnecting of cables from the bracket Note Use caution when performing this procedure order not to damage cables or other com ponents 7 Parts A Bracket at a 90 angle B Base A xx0900000035 Disconnect cable clamps 8 Parts A Cable clamps See the figure in Location of SMB unit on page 245 Unscrew the attachment screws securin...

Page 249: ... the robot before entering the robot working area 1 Clean the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 201 2 xx1700000994 Reconnect contacts on the SMB unit R1 SMB1 2 R1 SMB3 6 R2 SMB Battery cable R1 G X3 Make sure the lock snaps into place during refit ting 3 See the figure in Location of SMB unit on page 245 Place the SMB unit on its ...

Page 250: ...ushing the base cover into position while at the same time check ing that no cables are damaged 9 Secure the base cover with the attachment screws 10 Parts A Attachment screws 6 pcs B Base cover C Base Seal and paint the joints that have been opened Also repair possible damages of the special Foundry Prime paint coat of the robot See Cut the paint or surface on the robot before replacing parts on ...

Page 251: ...n page364 General calibration information is included in section Calibration on page 353 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 13 Product manual IRB 4600 Foundry Prime 251 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 4 Rep...

Page 252: ... release board A Connectors on push button board The connectors X8 X9 and X10 are placed on the push button board as shown in the figure below X9 X8 X10 xx1700000978 Continues on next page 252 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 5 Replacing the brake release board ...

Page 253: ...ludes brake release board and harness Additional equipment Foundry Prime Note Art no Equipment Mercasol 3HAC034903 001 Rust preventive 3HAC026759 001 Sikaflex 521FC 12340011 116 Loctite 574 Brush 3HAC035355 001 Foundry Prime touch up kit Removing the brake release board Use this procedure to remove the brake release board Note Action DANGER Turn off all electric power supply hydraulic pressure sup...

Page 254: ...es can cause shortage on the boards which can result in hazardous fail ures 5 Parts A Base B Base cover C Attachment screws M6x16 quality 8 8 A2F 6 pcs Take a picture or make notes of how the robot cabling is positioned in regard to the brake release board 6 X9 X8 X10 xx1700000978 Disconnect connectors X8 X9 and X10 from the brake release board 7 Remove the nuts securing the brake release board 8 ...

Page 255: ...racket with its nuts with flange 4 See the figure in Location of brake release board on page 252 X9 X8 X10 xx1700000978 Reconnect connectors X8 X9 and X10 to the brake release board Be careful not to damage the sockets or pins Make sure the connector and its locking arms are snapped down properly 5 Verify that the robot cabling is positioned correctly according to previously taken pic ture notes W...

Page 256: ...ush buttons 1 to 6 one at a time to make sure that the buttons are moving freely and do not stay in any locked position 11 Seal and paint the joints that have been opened Also repair possible damages of the special Foundry Prime paint coat of the robot See Cut the paint or surface on the robot be fore replacing parts on page 201 12 DANGER Make sure all safety requirements are met when performing t...

Page 257: ...ower arm C Arm house part of complete upper arm D Tubular shaft unit part of complete upper arm E Wrist unit part of complete upper arm F Required equipment Note Article number Equipment Length 2 m 2 pcs 1 5 m 1 pcs Roundslings Lifting capacity 1 000 kg 3 pcs 3HAC15535 1 Support legs Always use guide pins in pairs 3HAC15520 2 Guide pin M8x150 Continues on next page Product manual IRB 4600 Foundry ...

Page 258: ...ference 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...

Page 259: ...surface on the robot before replacing parts on page 201 4 How to drain oil is detailed in section Changing the oil axis 1 gearbox on floor mounted robots on page 153 Drain the axis 1 gearbox Note Draining is time consuming Elapsed time varies depending on the tem perature of the oil 5 How to remove the cable harness in base and frame is detailed in sections Removing cable harness in base on page 2...

Page 260: ...o the foundation 9 xx1800000874 Lift the robot and fit three support legs to the robot base using bolts washers and nuts DANGER Working underneath the manipulator without safely securing the support legs between the robot base and the foundation will result in serious or fatal injury Make sure the robot is stable and safely secured to the foundation via the support legs before working underneath t...

Page 261: ...rind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page 201 12 xx1800000879 Remove the cover plate at the bottom of the base 13 Remove the base attachment screws and washers 14 Guide pin M8x150 3HAC15520 2 Fit two guide pins in opposite holes in the axis 1 gearbox 15 Always use guide pins in pairs xx1800000883 Continues on next page Pro...

Page 262: ...28 17 CAUTION The weight of the base is 49 kg All lifting accessories used must be sized accordingly 18 Lifting eye M8 xx1800000931 Fit three lifting eyes to the base and secure with roundslings in an overhead crane or similar 19 xx1800000885 Remove the support legs attachments screws and remove the base from the sup port legs 20 Continues on next page 262 Product manual IRB 4600 Foundry Prime 3HA...

Page 263: ...t the new base to the support legs and secure with the attachment screws 3 Clean the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 201 4 Tip Use Loctite 7063 or similar for cleaning Remove residues of old Loctite and other contaminations from surfaces before apply ing new Loctite 574 5 Continues on next page Product manual IRB 4600 Foundry Pr...

Page 264: ...ghs 380 kg together All lifting accessories must be sized accord ingly 7 Lift the arm system to the mounting site 8 Guide pin M8x150 3HAC15520 2 Fit two guide pins in opposite holes in the axis 1 gearbox 9 Always use guide pins in pairs xx1800000932 Continues on next page 264 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 6 ...

Page 265: ...he cover and base 11 Attachment screws M6x16 quality 8 8 A2F 5 pcs xx1800000879 Refit the cover plate at the bottom of the base with its attachment screws 12 xx1800000875 Remove the screws that secure the support legs to the foundation DANGER Stretch the roundslings to make sure that the robot weight is secured 13 Continues on next page Product manual IRB 4600 Foundry Prime 265 3HAC040585 001 Revi...

Page 266: ...tion is described in Op erating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 17 Axis Calibration is described in Calibrating with Axis Calibration method on page364 General calibration information is included in section Calibration on page 353 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in t...

Page 267: ...y steel 12 9 Gleitmo 19 pcs C Washers quality steel 8 4x13x1 5 19 pcs D Axis 2 gearbox E Required equipment Note Equipment For spare parts no see Spare parts Upper arm 2 05 2 50 2 55 in Product manual spare parts IRB 2600 Armhouse Continues on next page Product manual IRB 4600 Foundry Prime 267 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 1 Replacing the compl...

Page 268: ...ng Screws Dimension M8 Length 70 mm Quality 8 8 IRB 4600 60 2 05 M8 2 pcs Guide pins Content is defined in section Standard tools on page 393 Standard toolkit These procedures include references to the tools required Other tools and procedures may be re quired See references to these proced ures in the step by step instructions be low Additional equipment Foundry Prime Note Art no Equipment Mercas...

Page 269: ...in Reference calibration routine on page 365 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 C...

Page 270: ...the brakes of axis 3 to rest the weight onto the roundslings 6 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 7 CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page 201 8 How to disconnect cables from motors is deta...

Page 271: ...rmhouse 12 Parts A Signal lamp B Bracket C Cable bracket Using caution pull the cable package out of the hole where the cable bracket was fit ted 13 Stop the air from the Foundry Prime air hose Insert a screw in the hose and a lock it with a hose clamp 14 Continues on next page Product manual IRB 4600 Foundry Prime 271 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair ...

Page 272: ...ews in the wrist unit The purpose of these screws is to prevent the roundsling from sliding 1 Dimension is specified in Required equipment on page 267 xx1100000565 Fit two rotating lifting points to the attachment holes in the arm house see the figure Secure the lifting point tightly against the arm house but at the same time mak ing sure that the screw does not bottom Use an extra washer if the s...

Page 273: ...ides of the screws and fasten the free end of the roundsling to the lifting hook 4 See figure Attaching the roundslings to the upper arm on page 273 Attaching the roundslings to the upper arm A C B D xx1100000567 Screws to prevent the roundsling from sliding 2 pcs A Rotating lifting point 2 pcs B Roundsling around wrist unit Length 1 5 m C Roundsling attached to arm house 2 pcs Length 1 5 m D Cont...

Page 274: ...ee Attaching the lifting accessories to the upper arm on page 272 Attach the lifting accessories to the upper arm 6 Specified in Required equipment on page 267 Fit guide pins to the upper arm 7 Lift the upper arm to the robot using an overhead crane 8 Release the brakes of the axis 3 motor 9 See the figure in Location of the complete upper arm on page 267 Tightening torque 35 Nm Refit the upper ar...

Page 275: ...0800000335 Refit the bracket on the tubular shaft unit 15 Parts A Tubular shaft unit B Attachment screws M6x16 qual ity 8 8 A2F 2 pcs C Bracket Refit the signal lamp if used 16 Seal and paint the joints that have been opened Also repair possible damages of the special Foundry Prime paint coat of the robot See Cut the paint or surface on the robot before replacing parts on page 201 17 Continues on ...

Page 276: ...64 General calibration information is included in section Calibration on page 353 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 19 276 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 1 Replacing ...

Page 277: ...55 in Product manual spare parts IRB 2600 Tubular shaft unit 2 pcs Dimension M8 Guide pins Isopropanol Cleaning agent Loctite 574 Sealing liquid Content is defined in section Standard tools on page 393 Standard toolkit These procedures include references to the tools required Other tools and procedures may be re quired See references to these proced ures in the step by step instructions be low Con...

Page 278: ...l 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 365 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about refer...

Page 279: ...ve the bracket securing the cable package to the tubular shaft unit by remov ing its attachment screws 6 Parts A Tubular shaft unit B Attachment screws M6x16 qual ity 8 8 A2F 2 pcs C Bracket Place the cable package in a way that it will not be damaged in the continued removal procedure 7 How to remove motors is described in section Removing motors on page 305 Remove motors axes 4 5 and 6 8 Continu...

Page 280: ...dsling At the other end of the tubular shaft unit a shackle can be fitted if the wrist unit is re moved 11 See the figure in Location of tubular shaft unit on page 277 Remove the attachment screws that secure the tubular shaft unit 12 Note There are two parallel pins guiding the tubular shaft unit into its place See figure in Replacing complete tubular shaft unit on page 277 Remove the tubular sha...

Page 281: ... from the assembly surfaces with a knife A B C D xx0800000457 Apply sealing liquid Loctite 574 on the surface between the tubular shaft unit and the armhouse Make sure to apply the sealing liquid in circles around each of the attachment holes 4 Parts A Armhouse B Surface where Loctite 574 shall be applied C Tubular shaft unit D Cylindrical pin 2 pcs CAUTION The robot arm tube weighs 65 kg All lift...

Page 282: ...ular shaft unit using caution CAUTION Do not damage the gears when refitting the tubular shaft unit 8 See the figure in Location of tubular shaft unit on page 277 Tightening torque 22 Nm Secure the tubular shaft unit with its attach ment screws 9 How to refit motors is described in sec tion Refitting motors on page 314 Refit motors axes 4 5 and 6 10 See Performing a leak down test on page 196 Perf...

Page 283: ...ing with Axis Calibration method on page364 General calibration information is included in section Calibration on page 353 Seal and paint the joints that have been opened Also repair possible damages of the special Foundry Prime paint coat of the robot See Cut the paint or surface on the robot before replacing parts on page 201 16 DANGER Make sure all safety requirements are met when performing th...

Page 284: ...that are calibrated with Axis Calibration Required equipment Note Equipment For spare parts no see Spare parts Upper arm 2 05 2 50 2 55 in Product manual spare parts IRB 2600 Wrist unit For spare parts no see Spare parts Upper arm 2 05 2 50 2 55 in Product manual spare parts IRB 2600 O ring For adjusting the play Measuring tool Content is defined in section Standard tools on page 393 Standard tool...

Page 285: ...n 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 i...

Page 286: ... the paint edge when disassembling parts See Cut the paint or surface on the robot before repla cing parts on page 201 6 See the figure in Location of wrist unit on page 284 Remove the attachment screws and carefully remove the wrist unit CAUTION Do not damage gears 7 Refitting of wrist unit Use this procedure to refit the wrist unit Note Action DANGER Turn off all electric power supply hydraulic ...

Page 287: ...el pin is not installed on a robot cal ibrated with Axis Calibration the calibration result will be affected negatively 4 Verify that the parallel pin sticks out from the wrist according to the meas urement given below IRB 4600 60 2 05 6 0 5 xx1600000702 Clean all assembly surfaces 5 Remove any painting from the assembly sur faces with a knife Continues on next page Product manual IRB 4600 Foundry...

Page 288: ... of the motor Push the wrist as shown in the figure to locate the smallest play in the same way as for adjustment of motors for axes 4 5 and 6 See Refitting motors on page314 10 Parts A Gears on drive shaft unit axes 5 6 B Gears on the wrist See the figure in Location of wrist unit on page 284 Tightening torque 35 Nm Secure the wrist unit with its attachment screws and washers 11 How to measure th...

Page 289: ...perating manual Calibration Pendu lum enclosed with the calibration tools Recalibrate the robot 16 Axis Calibration is described in Calib rating with Axis Calibration method on page 364 General calibration information is in cluded in section Calibration on page 353 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First te...

Page 290: ... Note Article number Equipment Mercasol 3HAC034903 001 Rust preventive 3HAC026759 001 Sikaflex 521FC 12340011 116 Loctite 574 Brush 3HAC035355 001 Foundry Prime touch up kit Measurement axis 5 The procedure below details how to measure the play of axis 5 Note The measuring tool and measuring values differ depending on robot version Information Action DANGER Turn off all electric power supply hydra...

Page 291: ... zero 5 xx0300000187 Apply load F in the opposite direction as shown in the figure to the right 6 Values for IRB 4600 60 2 05 A Measuring tool play B 207 5 mm C 135 mm F 90N The maximum play allowed at the given distance from the center of axis 5 is for robot version IRB 4600 60 2 05 Remove the load and measure the play by reading the dial indicator 7 Product manual IRB 4600 Foundry Prime 291 3HAC...

Page 292: ...tional equipment Foundry Prime Note Article number Equipment Mercasol 3HAC034903 001 Rust preventive 3HAC026759 001 Sikaflex 521FC 12340011 116 Loctite 574 Brush 3HAC035355 001 Foundry Prime touch up kit Measurement axis 6 The procedure below details how to measure the play in axis 6 Note The measuring tool and measuring values differ depending on robot version Information Action DANGER Turn off a...

Page 293: ...and distances for the differ ent robot versions as specified to the right 4 Values for robot versions IRB 4600 60 2 05 A Measuring tool play B 100 mm C 100 mm F 50N Remove the load and set the dial indicat or to zero 5 xx0300000190 Apply load F in the opposite direction as shown in the figure to the right 6 Values for robot versions IRB 4600 60 2 05 A Measuring tool play B 100 mm C 100 mm F 50N Co...

Page 294: ...er of axis 6 is for robot version IRB 4600 60 2 05 Remove the load and measure the play by reading the dial indicator 7 294 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 5 Measuring the play axis 6 Continued ...

Page 295: ...box B Lower arm C Washer 19 pcs D Attachment screws M8x40 quality Steel 12 9 Gleitmo 19 pcs E Frame F Axis 2 gearbox G Washer 18 pcs H Attachment screws M12x50 quality Steel 12 9 Gleitmo 18 pcs J Continues on next page Product manual IRB 4600 Foundry Prime 295 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the lower arm ...

Page 296: ...e 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...

Page 297: ...move the cable package in frame lower arm and armhouse is de scribed in sections Removing cable harness in frame on page 212 Removing cable harness in lower arm and armhouse on page 214 Replacement of air nipples and hoses Foundry Prime on page233 Remove the cable package from all axes except in the base 4 Secure the upper arm with a roundsling in an overhead crane 5 CAUTION Always cut the paint w...

Page 298: ...e sized accordingly 8 xx0800000379 Fit a lifting lug in one of the upper holes in the lower arm for the attachment screws 9 Parts A Lifting lug xx1800000935 Remove the attachment screws and wash ers that secure the lower arm to the axis 2 gearbox 10 Remove the lower arm 11 Continues on next page 298 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights ...

Page 299: ... on page 201 2 CAUTION The robot lower arm weighs 65 kg All lifting accessories used must be sized accordingly 3 xx0800000379 Fit a lifting lug in one of the upper holes in the lower arm for the attachment screws 4 Parts A Lifting lug Secure the lower arm with a roundsling in an overhead crane and lift it to the robot 5 Continues on next page Product manual IRB 4600 Foundry Prime 299 3HAC040585 00...

Page 300: ... on page233 Refit the cable package 9 Seal and paint the joints that have been opened Also repair possible damages of the special Foundry Prime paint coat of the robot See Cut the paint or surface on the robot before replacing parts on page 201 10 Pendulum Calibration is described in Op erating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 11 Axis Calibratio...

Page 301: ...bracket D is installed C Bracket D Stop pin E Required equipment Note Equipment For spare parts number see Spare parts Frame and base in Product manual spare parts IRB 2600 Stop pin Content is defined in section Standard tools on page 393 Standard toolkit Continues on next page Product manual IRB 4600 Foundry Prime 301 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair ...

Page 302: ...R Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 1 CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page 201 2 See the figure in Location of stop pin axis 1 on page 301 Remove the attachment screws securing the bracket and ...

Page 303: ...The small spike on the bracket shall be pointing downwards for correct fitting of the stop pin 4 Parts A Bracket B Stop pin C Small spike 3HAB7116 1 Loctite 243 Secure the stop pin together with bracket D on the frame with its attachment screws Use Locking liquid 5 Tightening torque 10 Nm See the figure in Location of stop pin axis 1 on page 301 Seal and paint the joints that have been opened Also...

Page 304: ... the first test run These are further detailed in the section First test run may cause injury or damage on page26 7 304 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 6 1 Replacing stop pin axis 1 Continued ...

Page 305: ...dry Prime xx1100000083 Attachment screws M5x16 quality Steel 8 A2F 7 pcs A Motor cover B Attachment screws motor axis 1 4 pcs washers Tightening torques and at tachment screws on page 318 C Connection box D Axis 1 motor E O ring F Cable gland cover G Continues on next page Product manual IRB 4600 Foundry Prime 305 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 7 1...

Page 306: ...achment screws axis 3 motor 4 pcs washers See Tightening torques and attachment screws on page 318 B Attachment screws axis 4 axis 5 and axis 6 motors 3x4 pcs washers Tightening torques and attachment screws on page 318 B Axis 3 motor C Axis 4 motor D Axis 5 motor E Axis 6 motor F O ring axis 4 axis 5 and axis 6 G Armhouse H Continues on next page 306 Product manual IRB 4600 Foundry Prime 3HAC0405...

Page 307: ... the step by step instructions below Additional equipment Foundry Prime Note Art no Equipment Mercasol 3HAC034903 001 Rust preventive 3HAC026759 001 Sikaflex 521FC 12340011 116 Loctite 574 Brush 3HAC035355 001 Foundry Prime touch up kit CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on pag...

Page 308: ...efer 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 cal...

Page 309: ...arm rests in the end position Axis 3 motor Move axis 2 to 0 and axis 3 to maximal Release the brake of axis 3 to be sure that the upper arm is completely vertical and rests against the damper of axis 2 and axis 3 Draining gearbox Use this procedure to drain gearboxes if needed Note Draining of gearbox is only needed when removing the axes 2 and 3 motors Note Action Axis 1 motor Draining of gearbox...

Page 310: ... calibration routine to use and take actions accordingly prior to beginning the repair procedure 1 See Removing motors on page 305 Position of robot on page 309 Move the robot to the recommended position for the motor that shall be removed 2 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 3 See Removing motors on page 305 Drai...

Page 311: ...ry Prime on page 305 Only applicable to axis 1 and axis 2 motors Remove the cable gland cover 8 See the figure in Location of axis 1 and axis 2 motors Foundry Prime on page 305 Only applicable to axis 1 and axis 2 motors Remove the connection box Note Only needed if the motor shall be replaced with a new one 9 Note When removing the axis 3 motor the cables of the axis 4 axis 5 and axis 6 motors mu...

Page 312: ...r Only applicable to motors axes 2 and 3 Release the brake of axis 2 untill the lower arm firmly rests on the damper 12 Note Whenever parting mating motor and gearbox the gears may be damaged if excessive force is used 13 See the figure in Location of axis 1 and axis 2 motors Foundry Prime on page 305 Remove the attachment screws securing the motor If needed use a 300 mm extension for bits 1 2 Mot...

Page 313: ...t of motor axis 1 is not immediate in order to avoid contamina tion 17 See the figure in Location of axis 1 and axis 2 motors Foundry Prime on page 305 Only applicable to motors axes 4 5 and 6 Check that the o ring also is removed It might stay in the armhouse when the motor is re moved 18 Product manual IRB 4600 Foundry Prime 313 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserv...

Page 314: ...ww myportal abb com Location of axis 1 and axis 2 motors Foundry Prime The figure shows motor axis1 on IRB 4600 Foundry Prime xx1100000083 Attachment screws M5x16 quality Steel 8 A2F 7 pcs A Motor cover B Attachment screws motor axis 1 4 pcs washers Tightening torques and at tachment screws on page 318 C Connection box D Continues on next page 314 Product manual IRB 4600 Foundry Prime 3HAC040585 0...

Page 315: ... of each motor A Attachment screws axis 3 motor 4 pcs washers See Tightening torques and attachment screws on page 318 B Attachment screws axis 4 axis 5 and axis 6 motors 3x4 pcs washers See Tightening torques and attachment screws on page 318 B Axis 3 motor C Axis 4 motor D Axis 5 motor E Axis 6 motor F O ring axis 4 axis 5 and axis 6 G Armhouse H Continues on next page Product manual IRB 4600 Fo...

Page 316: ...s in the step by step instructions below For art no see Reference information Lifting tool axis 2 For art no see Reference information Lifting tool axis 3 For spare part no see Spare part lists on page 399 Motors Additional equipment Foundry Prime Note Art no Equipment Mercasol 3HAC034903 001 Rust preventive 3HAC026759 001 Sikaflex 521FC 12340011 116 Loctite 574 Brush 3HAC035355 001 Foundry Prime ...

Page 317: ...e position recommended in order to facilitate replacement of motors Information Action xx0800000388 Axis 1 axis 4 axis 5 and axis 6 motors Move the robot to a position where the wrist is pointing to the floor as shown in the figure This will make it possible to remove the motors without draining the oil from the gearbox xx1100000548 Axis 2 motor Move the robot to a position where the lower arm res...

Page 318: ...g torques and attachment screws The table shows the tightening torques for all motors Tightening torque Quality Attachment screw Motor 22 Nm 8 8 A2F M8x25 Motor axis 1 35 Nm 8 8 A2F Screwlengths depending on flange thickness on page 318 Motor axis 2 22 Nm 8 8 A2F Screwlengths depending on flange thickness on page 318 Motor axis 3 22 Nm 8 8 A2F M8x25 Motor axis 4 22 Nm 8 8 A2F M8x25 Motor axis 5 22...

Page 319: ... 2 Clean the surface from contamination such as oil and dirt 3 Remove any painting from the assembly sur faces with a knife Make sure that the motor and the pinion are not damaged or scratched 4 Lightly lubricate the o ring with grease 5 xx0900000082 Make sure the o ring on the flange of the motor is seated properly 6 Parts A Correct position of o ring B Incorrect position of o ring Replace with a...

Page 320: ...ors on all axes of the robot Some steps are only applicable to a certain motor Follow the steps carefully in order not to miss vital information Information Action See Refitting motors on page 314 Preparations before the refitting of motors on page 319 Note Before starting the refitting of the motor first make the necessary preparations 1 Note Whenever parting mating motor and gearbox the gears ma...

Page 321: ...it the motor making sure the motor pinion is properly mated to the gear in the gearbox 6 A xx0900000300 Applicable to motor axis 3 Make sure that the wire exit holes of motor axis 3 are in the correct position See illustration 7 Parts A Wire exit holes motor axis 3 Continues on next page Product manual IRB 4600 Foundry Prime 321 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved...

Page 322: ...e to motors axes 4 5 and 6 Adjust the play of the motor 10 Tightening torque and attachment screws are specified in the table Tightening torques and attach ment screws on page 318 Secure the motor with its attachment screws and washers Note Apply the correct tightening torque 11 Disconnect the brake release voltage 12 See the figure in Location of axis 1 and axis 2 motors Foundry Prime on page 314...

Page 323: ...e sure that the o ring is in place 16 How to fill oil in the gearbox is de scribed in sections Changing the oil axis 2 gearbox on page 167 Changing the oil axis 3 gearbox on page 171 Applicable to motors axis 2 Refill gearbox oil 17 If the gasket is damaged it need to be replaced Applicable to motors axes 3 4 5 and 6 Make sure that the gasket on the cover on the armhouse is intact 18 Continues on ...

Page 324: ...o repair possible damages of the special Foundry Prime paint coat of the robot See Cut the paint or surface on the robot before replacing parts on page 201 21 Pendulum Calibration is described in Operating manual Calibration Pendu lum enclosed with the calibration tools Recalibrate the robot 22 Axis Calibration is described in Calib rating with Axis Calibration method on page 364 General calibrati...

Page 325: ...lay within this range Axis 5 motor 1 Turn the outgoing shaft for axis 4 in intervals of 90 for one full turn and find the smallest play for the axis 5 motor within this range 2 Turn the axis 5 motor one full turn at a time for a total of five turns and find the smallest play within this range Axis 6 motor 1 Turn the outgoing shaft for axis 4 in intervals of 90 for one full turn and find the smalle...

Page 326: ...mmended to be done with the robot resting on its side xx1100000007 Frame A Radial sealing B O ring C Gearbox axis 1 D Washer 21 pcs E Attachment screws M8x80 quality Steel 12 9 Gleitmo 21 pcs F Radial sealing G Sealing ring H Continues on next page 326 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 1 Replacing gearbox axis 1...

Page 327: ...no Equipment Mercasol 3HAC034903 001 Rust preventive 3HAC026759 001 Sikaflex 521FC 12340011 116 Loctite 574 Brush 3HAC035355 001 Foundry Prime touch up kit 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 Acti...

Page 328: ...fine calibration Remove all external cable packages DressPack and tools from the robot Illustration of robot put down on its side The robot is put down on its side for a safe removal of the axis 1 gearbox Prepare an area on the floor with cardboard plastic foam or similar and prepare higher support for the wrist Make sure the cabling brackets on the lower arm are unfastened and moved out of the wa...

Page 329: ... when disassembling parts See Cut the paint or surface on the robot before replacing parts on page 201 5 See Removing motors on page 305 Remove the axis 1 motor 6 See Removing the base on page 259 xx1800000593 Remove the complete arm system from the base and lay down the robot on its side 7 Continues on next page Product manual IRB 4600 Foundry Prime 329 3HAC040585 001 Revision M Copyright 2013 20...

Page 330: ... overhead crane or similar 10 See the figure in Location of gearbox on page 326 Remove the attachment screws securing the gearbox 11 xx1800000789 Remove two gearbox attachment screws opposite to each other and fit two guide pins into the holes 12 Guide pin M8x150 3HAC15520 2 Always use guide pins in pairs Continues on next page 330 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Co...

Page 331: ...x when it is removed Use some absorbent material to catch the oil 15 Note Always use removal tools in pairs diagon al to each other Slide the gearbox out onto the guide pins and lift it away If necessary use removal tools to remove the gearbox 16 xx1800000791 Continues on next page Product manual IRB 4600 Foundry Prime 331 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Rep...

Page 332: ... paint or surface on the robot before replacing parts on page 201 2 xx1800000794 Check the radial sealing in the frame Replace if damaged 3 xx0800000440 Fit a lifting lug in the uppermost hole for the base attachment screws 4 A Roundsling B Lifting lug C Uppermost base attachment hole D Axis 1 gearbox Continues on next page 332 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyri...

Page 333: ...e on the o ring 6 Clean all assembly surfaces 7 Remove any painting from the assembly surfaces with a knife xx1800000793 Fit two guide pins to the frame 8 Guide pin M8x150 3HAC15520 2 Always use guide pins in pairs Guide for reduction gear 3HACxxx xx1800000795 Fit the guide for the gear on top of the pro tection tube It protects the radial sealing from being damaged during refitting 9 Continues on...

Page 334: ... Double check that the oil plugs are in the correct position A B xx0800000441 11 A Opening for oil plug in frame B Oil plug xx1800000790 Secure the gearbox with its attachment screws and washers 12 Remove the guide pins from the frame and secure the remaining two screws 13 35 Nm Continues on next page 334 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All r...

Page 335: ...nd paint the joints that have been opened Also repair possible damages of the special Foundry Prime paint coat of the robot See Cut the paint or surface on the robot before replacing parts on page 201 5 Pendulum Calibration is described in Op erating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 6 Axis Calibration is described in Calibrating with Axis Calibr...

Page 336: ...Attachment screws M12x50 quality Steel 12 9 Gleitmo 15 pcs A Washers 15 pcs B Sleeve delivered with gearbox D Gearbox axis 2 E O ring F Frame G Continues on next page 336 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing gearbox axis 2 ...

Page 337: ... 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 ...

Page 338: ... frame but still be connected to the frame through the cabling Be careful not to damage the cables Note Action Decide which calibration routine to use and take actions accordingly prior to beginning the repair procedure 1 The figure shows IRB 2600 but the position of the robot is correct xx1200000068 Move the robot to the position shown in the figure Upper arm should rest on the axis 3 damper 2 Co...

Page 339: ...e on the robot before replacing parts on page 201 5 A B C xx1100000946 A Cable bracket B Cable bracket C Cable strap Loosen the cabling from the lower arm by removing two cable brackets and a cable strap 6 CAUTION The weight of the complete upper and lower arm together is 205 kg All lifting accessories used must be sized accordingly 7 Attach a roundsling around the upper arm house 8 Continues on n...

Page 340: ...0935 Remove the attachment screws and washers that secure the lower arm to the axis 2 gearbox 11 Remove the lower and upper arm package from the frame WARNING The cable harness is still installed on the robot Make sure not to damage the cables or the cable brackets on the robot 12 CAUTION The gearbox weighs 51 kg All lifting accessories used must be sized accordingly 13 Continues on next page 340 ...

Page 341: ...C13056 2 Fit guide pins to help guiding the gearbox out from the frame 17 Always use guide pins in pairs Note Always use removal tools in pairs diagonal to each other If necessary use removal tools to re move the gearbox 18 Remove the gearbox CAUTION Use caution in order not to damage gearbox or pinion 19 Refitting gearbox axis 2 Use this procedure to refit the gearbox Note Action DANGER Turn off ...

Page 342: ...gearbox axis 2 Clean all assembly surfaces 5 Remove any painting from the assembly surfaces with a knife O ring nitrile rubber 3HAB3772 120 Apply some grease on the o ring before fit ting 6 See the figure in Location of gearbox axis 2 on page 336 Valid for Type C Replace if damaged Guide pin M12x150 3HAC13056 2 Fit two guide pins in opposite holes in the frame 7 Always use guide pins in pairs Secu...

Page 343: ...m a leak down test 12 Fit the guide pins to the gearbox 13 CAUTION The weight of the complete upper and lower arm together is 205 kg All lifting accessories used must be sized accordingly 14 Lift the upper and lower arms into mounting position and guide them in place with the guide pins 15 It might be necessary to rotate the motor pinion with the rotating tool to find the mat ing position Attachme...

Page 344: ...cing parts on page 201 19 Pendulum Calibration is described in Op erating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 20 Axis Calibration is described in Calibrating with Axis Calibration method on page364 General calibration information is included in section Calibration on page 353 DANGER Make sure all safety requirements are met when performing the firs...

Page 345: ... quality Steel 12 9 Gleitmo 18 pcs E Required equipment Note Art no Equipment See Spare part lists on page 399 Gearbox M8 2 pcs Guide pins Used to guide the gearbox and the upper arm during removal refitting 3HAB7887 1 Rotation tool Continues on next page Product manual IRB 4600 Foundry Prime 345 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 3 Replacing gearbox...

Page 346: ...le 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...

Page 347: ... the gearbox is described in section Changing the oil axis 3 gearbox on page 171 Drain the gearbox 2 xx0800000336 Move the robot to the position shown in the figure 3 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 4 CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint o...

Page 348: ...cessories to the upper arm 8 Connect the 24 VDC power supply to the axis 3 motor and release the brakes 9 Releasing the brakes of the axis 3 motor unloads the weight of the upper arm by stretching the roundslings 10 See the figure in Location of the complete upper arm on page 267 Remove the attachment screws that secure the upper arm to the lower arm Note Do not remove the attachment screws se cur...

Page 349: ...cation of gearbox axis 3 on page 345 Remove the remaining attachment screws that secures the gearbox 16 Note There will be some surplus oil in the gear box Place some absorbant cloth or similar under the gearbox 17 Note Always use removal tools in pairs diagon al to each other Slide the gearbox carefully out onto the guide pins and lift it away If necessary use a pair of screws to push out the gea...

Page 350: ...10 Note Whenever parting mating motor and gear box the gears may be damaged if excessive force is used 11 Article number for the rotation tool is specified in Required equipment on page 345 Slide the gearbox into position while rotating the motor pinion to find the mating position Use a rotation tool Tip Two persons are required for this step since the upper arm is hanging freely in the air One pe...

Page 351: ...Remove the 24 VDC power supply 21 Tightening torque 14 Nm Refit the upper armhouse cover with its at tachment screws and washers WARNING The cover on the armhouse must be fitted when the robot is running It is a vital part for the stability of the robot 22 Make sure that the cover is tightly sealed A B xx0800000389 Parts A Cover B Attachment screws M6x25 quality 8 8 A2F 10 pcs Make sure that the a...

Page 352: ...placing parts on page 201 26 Pendulum Calibration is described in Op erating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 27 Axis Calibration is described in Calibrating with Axis Calibration method on page364 General calibration information is included in section Calibration on page 353 DANGER Make sure all safety requirements are met when performing the f...

Page 353: ...sed 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 can later...

Page 354: ... 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 accuracy...

Page 355: ...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 356: ...emory is lost If the revolution counter memory is lost the counters must be updated See Updating revolution counters on page 360 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 controlle...

Page 357: ...synchronization position for each axis Synchronization marks IRB 4600 IRB 4600 60 2 05 xx0800000312 Synchronization mark axis 1 A Synchronization mark axis 2 B Synchronization mark axis 3 C Continues on next page Product manual IRB 4600 Foundry Prime 357 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchronization position for ...

Page 358: ... two tips of the arrows should be inside the corresponding groove on the tilt housing when in synchronization position F 358 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchronization position for axes Continued ...

Page 359: ...l handle the calibration movements automatically and these might be different from the positive directions shown below Manual movement directions 6 axes Note The graphic shows an IRB 7600 The positive direction is the same for all 6 axis robots except the positive direction of axis 3 for IRB 6400R which is in the opposite direction xx0200000089 Product manual IRB 4600 Foundry Prime 359 3HAC040585 ...

Page 360: ...mode 1 See Synchronization marks and synchron ization position for axes on page 357 Jog the manipulator to align the synchron ization marks 2 Step 2 Updating the revolution counter with the FlexPendant on page 361 When all axes are positioned update the revolution counter 3 Correct calibration position of axis 4 and 6 When jogging the manipulator to synchronization position it is extremely importa...

Page 361: ...f the motor calibration data is correct try to rotate the axis one turn update the revolution counter and check the synchronization marks again try both directions if needed Step 2 Updating the revolution counter with the FlexPendant Use this procedure to update the revolution counter with the FlexPendant IRC5 Action On the ABB menu tap Calibration xx1500000942 1 Continues on next page Product man...

Page 362: ...re 6 02 and later 3 Calibration method used at factory for each axis is shown as well as calibration method used during last field calibration Tap Manual Method Advanced xx1500000944 Continues on next page 362 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 5 Calibration 5 3 Updating revolution counters Continued ...

Page 363: ...ayed warning that the 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...

Page 364: ...alibration 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 inserted in...

Page 365: ...rence 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 make a rough calibration of each manipulator axis by u...

Page 366: ...rking position not standing on a floor To calibrate a suspended robot with the fine calibration routine the robot must first be taken down and then be mounted standing on the floor 366 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 5 Calibration 5 4 1 Description of Axis Calibration Continued ...

Page 367: ...ersonnel 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 Contains a removal tool for removing special protection plugs on the turning disk 3HAC062326 001 Calibration tool box Axis Calibration Examining the calibration tool Check prior to usage Before using the calibration tool make sure that the t...

Page 368: ... 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 368 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 5 Calibration 5 4 2 Calibration tools for Axis Calibration Continued ...

Page 369: ... 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 xx1600000641 Continues on next page Product manual IRB 4600 Foundry Prime 369 3HAC040585 001 Revis...

Page 370: ...le number Spare part Contains replacement calibration pin covers and protective plugs for the bushing 3HAC060730 001 protection type Foundry Prime Protection cover and plug set Only on IRB 4600 20 2 50 3HAC057511 001 Protective plug on turning disc Replace if damaged or missing 370 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 5 Calibra...

Page 371: ...type Foundry Prime Protection cover and plug set Only on IRB 4600 20 2 50 3HAC057511 001 Protective plug on turning disc Replace if damaged or missing Overview of the calibration procedure on the FlexPendant The actual instructions of how to perform the calibration procedure and what to do at each step is given on the FlexPendant You will be guided through the calibration procedure step by step Us...

Page 372: ...ng snaps into place 9 The robot moves to verify that the calibration tool is removed 10 Choose whether to save the calibration data or not Calibration of the robot is not finished until the calibration data is saved as last step of the calibration procedure Preparation prior to calibration The calibration procedure is described in the FlexPendant while conducting it Note Action DANGER While conduc...

Page 373: ...00000942 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 Product manual IRB 4600 Foundry Prime 373 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 5 Calibration 5 4 4 Axis Calibration Running the calibration procedure Continued ...

Page 374: ... press Play The three position enabling device on the FlexPendant has been released during robot movement Remove the calibration tool if it is installed and restart the calibration procedure from the beginning See Starting the calibration procedure on page 373 The RobotWare program is terminated with PP to Main If the calibration tool is in contact the robot axis needs to be jogged in order to rel...

Page 375: ...Calibration procedure by pressing Play 3 Unsynchronized speed exceeded SafeMove message while saving robot data Note Action SafeMove generates the message Unsynchron ized speed exceeded while saving robot data xx1500002481 1 Press Acknowledge to continue Axis Calibration procedure 2 Restart Axis Calibration procedure by pressing Play 3 Continues on next page Product manual IRB 4600 Foundry Prime 3...

Page 376: ...k 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 3HAC060730 001 protection type Foundry Prime Continues on next page 376 Product manual IRB 4600 Foundry Prime 3HAC04...

Page 377: ... the sealing with new spare part if missing or damaged 3 Protection cover and plug set 3HAC060730 001 protection type Foundry Prime IRB 4600 20 2 50 xx1700000905 Refit the special protection plug to the turning disc using the tool included in the calibration tool box 4 IRB 4600 20 2 50 xx1700000906 Remove the tool from the protection plug 5 Product manual IRB 4600 Foundry Prime 377 3HAC040585 001 ...

Page 378: ...Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools 378 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 5 Calibration 5 5 Calibrating with Calibration Pendulum method ...

Page 379: ...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 357 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 from the ...

Page 380: ...57 and Updating revolution counters on page 360 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 1 2 or...

Page 381: ...untry in which the robot and the control unit are installed If the robot or the control unit is partially or completely disposed of the various parts must be grouped together according to their nature which is all iron together and all plastic together and disposed of accordingly These parts must also be disposed of in accordance with the current legislation of the country in which the robot and c...

Page 382: ...wer 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 Turning disc foundry Nickel Oil and grease Where possible arrange for oil and grease to be recycled Dispose of via an authorized person contractor in accordance with local regul...

Page 383: ...isms Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination Product manual IRB 4600 Foundry Prime 383 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 6 Decommissioning 6 2 Environmental information Continued ...

Page 384: ...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 384 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 AB...

Page 385: ...cludes general information complementing the more specific information in the different procedures in the manual Product manual IRB 4600 Foundry Prime 385 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 7 Reference information 7 1 Introduction ...

Page 386: ...gonomics 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 of machi...

Page 387: ...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 4600 Foundry Prime 387 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 7 Reference information 7 2 Applicable standards Continued ...

Page 388: ...n 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 388 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 7 Reference information 7 3 Unit conversion ...

Page 389: ...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 390: ...intenance 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 follow...

Page 391: ...rque 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 4600 Foundry Prime 391 3HAC040585 ...

Page 392: ...en 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 440 kg All lifting accessories used must be sized accord ingly 392 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 20...

Page 393: ...kit and any tools listed in the instruction Contents standard toolkit Tool Qty Ring open end spanner 8 19 mm 1 Socket head cap 2 5 17 mm 1 Torx socket no 20 60 1 Torque wrench 10 100 Nm 1 Small screwdriver 1 Plastic mallet 1 Ratchet head for torque wrench 1 2 1 Socket head cap no 5 socket 1 2 bit L 20 mm 1 Socket head cap no 6 socket 1 2 bit L 20 mm 1 Socket head cap no 8 socket 1 2 bit L 20 mm 1 ...

Page 394: ...uct manual Art no Qty Description 2 pcs Guide pins removal refitting of axis 1 gearbox 2 pcs Guide pins removal refitting of axis 3 gearbox Oil change equipment The following table specifies the oil change equipment The tool is specified directly in concerned instructions in the product manual Art no Included parts Description 3HAC021745 001 vacuum pump with regulator hose and coupling couplings a...

Page 395: ...ent 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 in the calibration menu on the FlexPendant If no data is found related to standard calibration Calibr...

Page 396: ...sory axis 2 Lifting accessory axis 3 For lifting of upper arm 2 pcs Rotating lifting point Dimension M8 Example Gunnebo RLP GrabiQ M8 10 xx1100000564 Special tools This table specifies the special tools required during several of the service procedures The tools are specified directly in concerned instructions Article no Qty Description 3HACxxx 1 Guide for reduction gear Used to guide axis 1 gear ...

Page 397: ...cessories 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 Product manual IRB 4600 Foundry Prime 397 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 7 Reference information 7 8 Lifting accessories and l...

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Page 399: ... 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 4600 Foundry Prime 399 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 8 Spare part lists 8 1 Spare part lists and illustrations ...

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Page 401: ...ype 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 2400 3H...

Page 402: ... 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 402 Product manual IRB 4600 Foundry Prime 3HAC040585 001 Revision M Copyright 2013 2018 ABB All rights reserved 9 Circuit diagram 9 1 Circuit dia...

Page 403: ... approved 193 requirements 193 cleaning 191 climbing on robot 23 Cold environments 93 connecting the robot and controller cabling 94 connection external safety devices 24 copper disposal 382 D danger levels 39 detergents approved 193 requirements 193 direction of axes 359 E enabling device 28 environmental information 382 ESD damage elimination 31 sensitive equipment 31 expansion container install...

Page 404: ...exPendant 361 updating 360 risk of tipping 60 robot labels 41 protection class 55 protection types 55 symbols 41 rubber disposal 382 S safety brake testing 35 ESD 31 fire extinguishing 20 moving robots 25 release robot axes 21 signals 39 signals in manual 39 symbols 39 symbols on robot 41 test run 26 working range 27 safety fence 18 safety risk electric parts 29 hot parts 32 hydraulic system 33 in...

Page 405: ...1 turning accessory 64 U updating revolution counters 360 V validity and responsibility 17 velocity adjusting 93 verifying calibration 379 W weight 52 base 262 263 robot 62 74 260 280 281 286 288 298 299 330 334 340 342 348 350 392 upper and lower arm 339 343 upper arm complete 270 274 X xx replacing 143 Z zero position checking 380 Product manual IRB 4600 Foundry Prime 405 3HAC040585 001 Revision...

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Page 408: ...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 3HAC040585 001 Rev M en Copyright 2013 2018 ABB All rights reserved Specifications subject to change without notice ...

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