Contents - Table Of Contents
- Table Of Contents
- Table Of Contents
- Overview of this manual
- Product documentation, IRC5
- How to read the product manual
- Safety
- General safety information
- Safety in the manipulator system
- Safety risks
- CAUTION - Hot parts may cause burns
- Safety risks related to tools/work pieces
- Safety risks related to pneumatic/hydraulic systems
- Safety risks with pressure relief valve
- Safety risks during operational disturbances
- Risks associated with live electric parts
- Safety actions
- Fire extinguishing
- Emergency release of the manipulator's arm
- Brake testing
- Risk of disabling function "Reduced speed 250 mm/s
- Safe use of the FlexPendant
- Work inside the manipulator's working range
- Signal lamp (optional)
- Safety stops
- Safety related instructions
- Safety symbols on manipulator labels
- DANGER - Moving manipulators are potentially lethal
- DANGER - First test run may cause injury or damage
- WARNING - The brake release buttons may be jammed after service work
- DANGER - Make sure that the main power has been switched off
- WARNING - The unit is sensitive to ESD
- WARNING - Safety risks during handling of batteries
- WARNING - Safety risks during work with gearbox lubricants (oil or grease)
- Installation and commissioning
- Unpacking
- Working range and type of motion
- Risk of tipping/stability
- On-site installation
- Lifting and turning a suspended mounted robot
- Manually releasing the brakes
- Orienting and securing the robot
- Setting the system parameters for a suspended robot
- Fitting equipment on robot
- Loads
- Installation of signal lamp (option)
- Restricting the working range
- Mechanically restricting the working range of axis 1
- Installing options
- Installation of Foundry Plus Cable guard (option no. 908-1)
- Installing an expansion container
- Robot in hot environments
- Robot in cold environments
- Electrical connections
- Customer connection on robot
- Customer connections on upper arm
- Maintenance
- Maintenance schedule
- Expected component life
- Inspection activities
- Inspecting the oil level, axis 2 gearbox
- Inspecting the oil level, axis 3 gearbox
- Inspecting the oil level, axis 4 gearbox
- Inspecting oil level, gearbox axes 5 - 6
- Inspecting the cable harness
- Inspecting information labels
- Inspecting the mechanical stop pin, axis 1
- Inspecting additional mechanical stops
- Inspecting dampers
- Inspecting the pressure relief valve
- Inspecting Signal lamp (option)
- Replacement activities
- Changing the oil, axis-1 gearbox on floor mounted robots
- Changing the oil, axis-1 gearbox on suspended robots
- Changing the oil, axis-2 gearbox
- Changing the oil, axis-3 gearbox
- Changing the oil, axis-4 gearbox
- Changing oil, axes-5 and -6 gearboxes
- Replacing SMB battery
- Cleaning activities
- Repair
- General procedures
- Mounting instructions for bearings
- Mounting instructions for seals
- Complete robot
- Refitting the complete cable harness
- Replacing SMB unit
- Replacing the brake release unit
- Replacing the base
- Upper arm
- Replacing complete tubular shaft unit
- Replacing wrist unit
- Measuring the play, axis 5
- Measuring the play, axis 6
- Lower arm
- Frame and base
- Motors
- Refitting motors
- Adjusting the play of axis 4, 5 and 6 motors
- Gearboxes
- Replacing gearbox axis 2
- Replacing gearbox axis 3
- Calibration
- Calibration methods
- Calibration scale and correct axis position
- Calibration movement directions for all axes
- Updating revolution counters
- Checking the calibration position
- Decommissioning
- Environmental information
- Robot description
- Reference information
- Applicable safety standards
- Unit conversion
- Screw joints
- Weight specifications
- Standard tools
- Special tools
- Lifting accessories and lifting instructions
- Spare part list
- Base cover assembly
- Base and frame unit
- Lower arm and frame
- Upper arm IRB 4600-60/2.05, -40/2.05-40/2.50, -20/2.55
- Wrist unit (60 kg/45 kg/20 kg)
- Labels
- Options
- Circuit diagram
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2514.4.2 Replacing complete tubular shaft unit .........................................................2574.4.3 Replacing wrist unit .................................................................................2624.4.4 Measuring the play, axis 5 ........................................................................2654.4.5 Measuring the play, axis 6 .........................................................................2684.5 Lower arm .......................................................................................................2684.5.1 Replacing the lower arm ...........................................................................2754.6 Frame and base ................................................................................................2754.6.1 Replacing stop pin axis 1 ..........................................................................2784.7 Motors ............................................................................................................2784.7.1 Removing motors ....................................................................................2864.7.2 Refitting motors ......................................................................................2964.7.3 Adjusting the play of axis 4, 5 and 6 motors .................................................2974.8 Gearboxes .......................................................................................................2974.8.1 Replacing gearbox axis 1 ..........................................................................3034.8.2 Replacing gearbox axis 2 ..........................................................................3114.8.3 Replacing gearbox axis 3 ..........................................................................3195 Calibration3195.1 Introduction .....................................................................................................3205.2 Calibration methods ...........................................................................................3225.3 Calibration scale and correct axis position .............................................................3255.4 Calibration movement directions for all axes ..........................................................3265.5 Updating revolution counters ...............................................................................3285.6 Checking the calibration position ..........................................................................3296 Decommissioning3296.1 Introduction ......................................................................................................3306.2 Environmental information ..................................................................................3317 Robot description3317.1 Type C of IRB 4600 ............................................................................................3338 Reference information3338.1 Introduction ......................................................................................................3348.2 Applicable safety standards ................................................................................3368.3 Unit conversion .................................................................................................3378.4 Screw joints ....................................................................................................3408.5 Weight specifications .........................................................................................3418.6 Standard tools ..................................................................................................3428.7 Special tools ....................................................................................................3448.8 Lifting accessories and lifting instructions ..............................................................3459 Spare part list3459.1 Rebuilding parts ................................................................................................3479.2 Base cover assembly .........................................................................................3489.3 Base and frame unit ...........................................................................................3509.4 Lower arm and frame .........................................................................................3529.5 Upper arm IRB 4600-60/2.05, -40/2.05-40/2.50, -20/2.55 ............................................3589.6 Wrist unit (60 kg/45 kg/20 kg) ..............................................................................3619.7 Electrical connections ........................................................................................3639.8 Gearboxes .......................................................................................................3659.9 Motors ............................................................................................................3679.10 Labels .............................................................................................................3689.11 Options ...........................................................................................................36910 Circuit diagram36910.1 About circuit diagrams .......................................................................................3HAC033453-001 Revision: H 7© Copyright 2009-2013 ABB. 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