ABB Robotics IRB 4600 User manual

ROBOTICS
Product manual
IRB 4600

Trace back information:
Workspace 21A version a15
Checked in 2021-04-12
Skribenta version 5.4.005

Product manual
IRB 4600 - 60/2.05
IRB 4600 - 45/2.05
IRB 4600 - 40/2.55
IRB 4600 - 20/2.50
IRC5
Document ID: 3HAC033453-001
Revision: Y
© Copyright 2009-2021 ABB. All rights reserved.
Specifications subject to change without notice.

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damage to 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.
© Copyright 2009-2021 ABB. All rights reserved.
Specifications subject to change without notice.

Table of contents
9Overview of this manual ...................................................................................................................
18Product documentation ....................................................................................................................
20How to read the product manual ......................................................................................................
211 Safety
211.1 Safety information .............................................................................................
211.1.1 Limitation of liability .................................................................................
221.1.2 Requirements on personnel ......................................................................
231.2 Safety signals and symbols .................................................................................
231.2.1 Safety signals in the manual ......................................................................
251.2.2 Safety symbols on manipulator labels .........................................................
311.3 Robot stopping functions ....................................................................................
321.4 Installation and commissioning ............................................................................
351.5 Operation ........................................................................................................
351.5.1 Unexpected movement of robot arm ...........................................................
361.6 Maintenance and repair ......................................................................................
361.6.1 Maintenance and repair ............................................................................
391.6.2 Emergency release of the robot axes ..........................................................
401.6.3 Brake testing ..........................................................................................
411.7 Troubleshooting ................................................................................................
421.8 Decommissioning ..............................................................................................
432 Installation and commissioning
432.1 Introduction to installation and commissioning .......................................................
442.2 Unpacking .......................................................................................................
442.2.1 Pre-installation procedure .........................................................................
482.2.2 Working range and type of motion ..............................................................
522.2.3 Risk of tipping/stability .............................................................................
532.2.4 The unit is sensitive to ESD .......................................................................
542.3 On-site installation ............................................................................................
542.3.1 Lifting robot with roundslings ....................................................................
572.3.2 Lifting and turning a suspended mounted robot ............................................
582.3.3 Manually releasing the brakes ...................................................................
612.3.4 Orienting and securing the robot ................................................................
652.3.5 Setting the system parameters for a suspended or tilted robot .........................
692.3.6 Fitting equipment on robot ........................................................................
762.3.7 Loads fitted to the robot, stopping time and braking distances .........................
772.3.8 Installation of signal lamp (option) ..............................................................
782.4 Restricting the working range ..............................................................................
782.4.1 Axes with restricted working range .............................................................
792.4.2 Mechanically restricting the working range of axis 1 ......................................
822.5 Installing options ...............................................................................................
822.5.1 Installation of cooling fan for motors (option) ................................................
892.5.2 Installation of Foundry Plus Cable guard (option no. 908-1) .............................
902.5.3 Installing an expansion container ...............................................................
942.6 Robot in hot environments ..................................................................................
942.6.1 Start of robot in hot environments ..............................................................
952.7 Robot in cold environments .................................................................................
952.7.1 Start of robot in cold environments ............................................................
962.8 Electrical connections ........................................................................................
962.8.1 Robot cabling and connection points ..........................................................
992.8.2 Customer connection on robot ...................................................................
1053 Maintenance
1053.1 Introduction ......................................................................................................
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1063.2 Maintenance schedule .......................................................................................
1063.2.1 Specification of maintenance intervals ........................................................
1073.2.2 Maintenance schedule .............................................................................
1093.2.3 Expected component life .........................................................................
1103.3 Inspection activities ...........................................................................................
1103.3.1 Inspecting oil level, axis 1 gearbox .............................................................
1173.3.2 Inspecting the oil level, axis 2 gearbox ........................................................
1193.3.3 Inspecting the oil level, axis 3 gearbox ........................................................
1223.3.4 Inspecting the oil level, axis 4 gearbox ........................................................
1243.3.5 Inspecting oil level, gearbox axes 5 - 6 ........................................................
1283.3.6 Inspecting the cable harness .....................................................................
1303.3.7 Inspecting information labels .....................................................................
1333.3.8 Inspecting the mechanical stop pin, axis 1 ...................................................
1363.3.9 Inspecting additional mechanical stops .......................................................
1383.3.10 Inspecting dampers .................................................................................
1403.3.11 Inspecting the pressure relief valve ............................................................
1423.3.12 Inspecting Signal lamp (option) ..................................................................
1443.4 Replacement activities .......................................................................................
1443.4.1 Type of lubrication in gearboxes ................................................................
1463.4.2 Changing the oil, axis-1 gearbox on floor mounted robots ...............................
1523.4.3 Changing the oil, axis-1 gearbox on suspended robots ...................................
1593.4.4 Changing the oil, axis-2 gearbox ................................................................
1633.4.5 Changing the oil, axis-3 gearbox ................................................................
1693.4.6 Changing the oil, axis-4 gearbox ................................................................
1733.4.7 Changing oil, axes-5 and -6 gearboxes ........................................................
1793.4.8 Replacing SMB battery .............................................................................
1843.5 Cleaning activities .............................................................................................
1843.5.1 Cleaning the IRB 4600 ..............................................................................
1874 Repair
1874.1 Introduction ......................................................................................................
1884.2 General procedures ...........................................................................................
1884.2.1 Performing a leak-down test ......................................................................
1894.2.2 Mounting instructions for bearings .............................................................
1914.2.3 Mounting instructions for sealings ..............................................................
1944.2.4 Cut the paint or surface on the robot before replacing parts ............................
1954.2.5 The brake release buttons may be jammed after service work .........................
1964.3 Complete robot .................................................................................................
1964.3.1 Removing the complete cable harness ........................................................
2094.3.2 Refitting the complete cable harness ..........................................................
2254.3.3 Replacing SMB unit .................................................................................
2314.3.4 Replacing the brake release board .............................................................
2364.3.5 Replacing the base ..................................................................................
2474.4 Upper arm .......................................................................................................
2474.4.1 Replacing the complete upper arm .............................................................
2574.4.2 Replacing complete tubular shaft unit .........................................................
2634.4.3 Replacing wrist unit .................................................................................
2714.4.4 Measuring the play, axis 5 .........................................................................
2744.4.5 Measuring the play, axis 6 .........................................................................
2774.5 Lower arm .......................................................................................................
2774.5.1 Replacing the lower arm ...........................................................................
2844.6 Frame and base ................................................................................................
2844.6.1 Replacing stop pin axis 1 ..........................................................................
2874.7 Motors ............................................................................................................
2874.7.1 Removing motors ....................................................................................
2954.7.2 Refitting motors ......................................................................................
3054.7.3 Adjusting the play of axis 4, 5 and 6 motors .................................................
3064.8 Gearboxes .......................................................................................................
3064.8.1 Replacing gearbox axis 1 ..........................................................................
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3174.8.2 Replacing gearbox axis 2 ..........................................................................
3264.8.3 Replacing gearbox axis 3 ..........................................................................
3355 Calibration
3355.1 Introduction to calibration ...................................................................................
3355.1.1 Introduction and calibration terminology ......................................................
3365.1.2 Calibration methods .................................................................................
3395.1.3 When to calibrate ...................................................................................
3405.2 Synchronization marks and axis movement directions .............................................
3405.2.1 Synchronization marks and synchronization position for axes .........................
3435.2.2 Calibration movement directions for all axes ................................................
3445.3 Updating revolution counters ...............................................................................
3485.4 Calibrating with Axis Calibration method ...............................................................
3485.4.1 Description of Axis Calibration ..................................................................
3515.4.2 Calibration tools for Axis Calibration ...........................................................
3535.4.3 Installation locations for the calibration tools ...............................................
3565.4.4 Axis Calibration - Running the calibration procedure ......................................
3625.4.5 Reference calibration ...............................................................................
3645.5 Calibrating with Calibration Pendulum method .......................................................
3655.6 Calibrating with Wrist Optimization method ...........................................................
3665.7 Verifying the calibration ......................................................................................
3675.8 Checking the synchronization position ..................................................................
3696 Decommissioning
3696.1 Introduction ......................................................................................................
3706.2 Environmental information ..................................................................................
3726.3 Scrapping of robot .............................................................................................
3737 Robot description
3737.1 Manipulator types and variants ............................................................................
3747.2 Type C of IRB 4600 ............................................................................................
3757.3 Type D of IRB 4600 ............................................................................................
3778 Reference information
3778.1 Introduction ......................................................................................................
3788.2 Applicable standards .........................................................................................
3808.3 Unit conversion .................................................................................................
3818.4 Screw joints ....................................................................................................
3848.5 Weight specifications .........................................................................................
3858.6 Standard tools ..................................................................................................
3868.7 Special tools ....................................................................................................
3898.8 Lifting accessories and lifting instructions ..............................................................
3919 Spare part lists
3919.1 Spare part lists and illustrations ...........................................................................
39310 Circuit diagram
39310.1 Circuit diagrams ................................................................................................
395Index
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Overview of this manual
About this manual
This manual contains instructions for:
• mechanical and electrical installation of the robot
• maintenance of the robot
• mechanical and electrical repair of the robot.
The robot described in this manual has the protection type Standard and Foundry
Plus.
Usage
This manual should be used during:
• installation, from lifting the robot to its work site and securing it to the
foundation, to making it ready for operation
• maintenance work
• repair work and calibration.
Who should read this manual?
This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
Maintenance/repair/installation personnel working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
Product manual scope
The manual covers covers all variants and designs of the IRB 4600. 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:
ContentsChapter
Safety information that must be read through before performing
any installation or service work on the robot. Contains general
safety aspects as well as more specific information on how to
avoid personal injuries and damage to the product.
Safety
Required information about lifting and installation of the robot.Installation and commis-
sioning
Step-by-step procedures that describe how to perform mainten-
ance of the robot. Based on a maintenance schedule that may
be used to plan periodical maintenance.
Maintenance
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Overview of this manual

ContentsChapter
Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.
Repair
Calibration procedures and general information about calibration.Calibration
Environmental information about the robot and its components.Decommissioning
Useful information when performing installation, maintenance
or repair work. Includes lists of necessary tools, additional doc-
uments, safety standards etc.
Reference information
Complete spare part list and complete list of robot components,
shown in exploded views.
Spare part / part list
Detailed illustrations of the robot with reference numbers to the
part list.
Exploded views
Reference to the circuit diagram for the robot..Circuit diagram
References
Document IDReference
3HAC040585-001Product manual - IRB 4600 Foundry Prime
3HAC032885-001Product specification - IRB 4600
3HAC049108-001Product manual, spare parts - IRB 4600
3HAC029038-003Circuit diagram - IRB 4600
3HAC031045-001Safety manual for robot - Manipulator and IRC5 or OmniCore
controller i
3HAC021313-001Product manual - IRC5
IRC5 with main computer DSQC 639.
3HAC047136-001Product manual - IRC5
IRC5 with main computer DSQC1000.
3HAC027098-001Operating manual - Emergency safety information
3HAC050941-001Operating manual - IRC5 with FlexPendant
3HAC020738-001Operating manual - Troubleshooting IRC5
3HAC16578-1Operating manual - Calibration Pendulum
3HAC050944-001Operating manual - Service Information System
3HAC042927-001Technical reference manual - Lubrication in gearboxes
3HAC050948-001Technical reference manual - System parameters
3HAC051016-001Application manual - Additional axes and stand alone controller
3HAC050996-001Application manual - Electronic Position Switches
3HAC030421-001Application manual - CalibWare Field
iThis manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Revisions
DescriptionRevision
First edition-
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Continued

DescriptionRevision
The following updates have been made in this revision:
• Added more information about working in the safeguarded space.
• Added more information about hazards with oil.
• Information about the quality and used threadlength for attachment
screws on mounting flange, added in Installation chapter section Fitting
equipment on wrist and mounting flange on page 73.
• The text in the introduction to chapters Installation,Maintenance and
Repair has been updated concerning the robot being connected to
earth when power connected.
•Levelmeter calibration added in sections Brief description of calibration
methods on page 337 and Calibration equipment, Levelmeter (alternative
method) on page 386.
• Section Upper arm (2.05/2.50/2.55) in Spare parts updated with Type
A spare parts.
• Section Lifting and turning a suspended mounted robot on page 57
added in Installation chapter.
• Section Installation of Foundry Plus Cable guard (option no. 908-1)
on page 89 added in Installation chapter.
• New DANGER! added in section Manually releasing the brakes on
page 58.
•Restricting working range with software added in section Mechanically
restricting the working range of axis 1 on page 79.
• The sections describing Replacing motors axes 1 through 6 has been
updated. Two new sections Removing motors on page 287 and Refitting
motors on page 295 replaces the older ones.
A
The following updates have been made in this revision:
• Missing text "type A" for armhousing 3HAC034549-005 added in
chapter Spare parts section Upper arm (2.05/2.50/2.55).
• Wrist Foundry added in chapter Spare parts, section Wrist unit (20 kg
and 45/60kg.
• Motors in wrist as rebuilding parts added in section Rebuilding parts
in Spare parts IRB 4600.
• How to adjust the play on motors axes 4-6 and on wrist added in sec-
tions Replacing motors, axes 4, 5 and 6 and Replacing wrist unit on
page 263.
•Correction of required oil level, see Inspecting oil level, axis 1 gearbox
on page 110.
In chapter Safety :
• Updated safety signal graphics for levels Danger and Warning, see
Safety signals in the manual on page 23.
• New safety labels on the manipulators, see Safety symbols on manip-
ulator labels on page 25.
• Revised teminology: robot replaced with manipulator.
B
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Continued

DescriptionRevision
The following updates have been made in this revision:
• Added Installing an expansion container on page 90.
• A figure showing IRB 2600 removed in section Orienting and securing
the robot on page 61.
• Section Installation of Foundry Plus Cable guard (option no. 908-1)
on page 89 added.
• Updated the section Start of robot in cold environments on page 95.
• Interval for inspection of signal lamp added in section Maintenance
schedule on page 107.
• New design of frame added in sections Inspecting oil level, axis 1
gearbox on page 110 and Changing the oil, axis-1 gearbox on floor
mounted robots on page 146.
• Figure showing required oil level added in section Inspecting oil level,
axis 1 gearbox on page 110.
• Inspection of oil level on suspended robot updated in section Inspect-
ing oil level, axis 1 gearbox on page 110.
C
The following updates have been made in this revision:
• Added information about the bracket on the mechanical stop pin axis
1 has been updated in section Mechanically restricting the working
range of axis 1 on page 79,Inspecting the mechanical stop pin, axis
1 on page 133 and Replacing stop pin axis 1 on page 284
•All information about Foundry Prime is removed from the manual. This
manual now only contains information for a Standard IRB 4600. The
instructions for a IRB 4600 Foundry prime can be found in a separate
manual. For art. No. See References on page 10.
D
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Continued

DescriptionRevision
The following updates have been made in this revision:
• A new block, about general illustrations, added in section How to read
the product manual on page 20.
•Figure and describing text edited for the stress forces. Also, the actual
values of the stress forces are updated. See Loads on foundation,
robot on page 45.
• The difference in weight between the different robot variants is minor,
therefor the weight specification for the robot is simplified. See Weight,
robot on page 44.
• Removed Foundry from table with protection classes. See Protection
classes, robot on page 47.
• Additional information about software adjustments when suspending
robot, new section Setting the system parameters for a suspended or
tilted robot on page 65.
• Note about fan cabling added in the cable list. See Robot cabling and
connection points on page 96.
• Note about ambient temperature deleted from the maintenance
schedule. See Maintenance schedule on page 107.
• Changed information about the robot position when removing motor.
See Removing motors on page 287.
• Additional instructions for how to adjust the play of axes 4, 5 and 6
motors. See Adjusting the play of axis 4, 5 and 6 motors on page 305.
• Added step about removing/refitting axis 1 motor when replacing the
axis 1 gearbox. Also added information about guide pins. See Repla-
cing gearbox axis 1 on page 306. Also minor additions concerning the
mating of gearbox and motor, in all such instructions.
• New section about calibration movement directions for axes is added,
see Calibration movement directions for all axes on page 343.
• New section about how to perform a rough calibration of each robot
axis is added, see Updating revolution counters on page 344.
• New section about how to check the calibration position is added, see
Checking the synchronization position on page 367.
• Spare part number for tubular shaft unit is corrected, see Spare parts
- Upper arm.
• Additional information about lifting accessories and how to attach
them to the upper arm of the robot, see Attaching the lifting accessories
to the upper arm on page 252.
• Additional information in the procedure for replacing the base with
improved lifting instruction etc., see Replacing the base on page 236.
• Changed type of oil in axes 1, 3 and 4 gearboxes. See Type of lubric-
ation in gearboxes on page 144.
E
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Continued

DescriptionRevision
The following updates have been made in this revision:
• Corrected measurement that belong to figure xx0300000187, when
fitting tools for measuring the play of axis 5, see Measuring the play,
axis 5 on page 271.
• Deleted the spare part number for harnesses in Spare parts - lower
arm and instead inserted a reference to the Electrical connections.
• Corrected the spare part numbers for cable harnesses, see Electrical
connections.
• Added information about releasing the motor brakes in order to set
the weight of different axes onto lifting accessories, see Replacing
the complete upper arm on page 247,Replacing gearbox axis 3 on
page 326 and Replacing gearbox axis 2 on page 317.
•Changed the instruction for how to replace the axes 2 and 3 gearboxes
without having to remove the cable harness, see Replacing gearbox
axis 3 on page 326 and Replacing gearbox axis 2 on page 317.
• Added safety information about preventing roundslings from sliding
when lifting the upper arm tube, see Replacing complete tubular shaft
unit on page 257.
• Added information about removing painting, if any, from assembly
surfaces when replacing gearboxes and motors.
• Added tip to speed up the draining of axis 4 gearbox, see Changing
the oil, axis-4 gearbox on page 169.
• Added information about o-ring and made other minor approvements
to the instruction for replacing wrist unit, see Replacing wrist unit on
page 263.
•Added information about disconnecting the battery cable when remov-
ing the cable harness, see Removing the complete cable harness on
page 196.
• Added a funnel to equipment list, see Changing the oil, axis-3 gearbox
on page 163.
• Added Profibus to the section about connections to extra equipment,
see Customer connection on robot on page 99.
• Some general tightening torques have been changed/added, see up-
dated values in Screw joints on page 381.
• The method of changing the axis-1 gearbox oil in suspended robots
is improved, see the new section Changing the oil, axis-1 gearbox on
suspended robots on page 152.
• Added spare part number for type B gearbox (axis 3), see Spare parts,
upper arm.
• Added information about batteries.
F
The following updates have been made in this revision:
•Cable harness for Profibus is added to the spare part list, see Electrical
connections.
• Article number for guide sleeves is added.
• Information about the type and amount of oil has been removed from
the manual and can now be found in the Technical reference manu-
al - Lubrication in gearboxes, see References on page 10.
• Type C is added throughout the manual.
• Valid for other designs than type C: Information about oil plug sealing
washer on the axis-1 and axis-2 gearbox is changed. The spare part
number is added.
• A new SMB unit and battery is introduced, with longer battery lifetime.
G
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Continued

DescriptionRevision
The following updates have been made in this revision:
• Spare part numbers are corrected for the lower arm, see Lower arm
type C and Rebuilding parts, and for motors, see Motors type C in
Product manual, spare parts - IRB 4600.
• Several more spare part numbers are corrected throughout the spare
part chapter.
•Section describing inspection of oil level in axis-1 gearbox for suspen-
ded robots is clarified, see Inspecting oil level, axis 1 gearbox on
page 110.
H
The following updates have been made in this revision:
• New article number for working range limit, axis 1 (Type C), is added
in spare parts.
• New article number for turning tool (Type C) is added in spare parts.
• Spare parts for electrical connections, cable harness, is updated.
• Instructions on how to fill oil in suspended robot is corrected, and
article number for oil change equipment is added to special tools.
• Amount of oil in axis-3 gearbox (Type C) is changed.
• Added information about risks when scrapping a decommissioned
robot, see Scrapping of robot on page 372.
•Spare parts and exploded views are not included in this document but
delivered as a separate document. See Product manual, spare
parts - IRB 4600.
J
The following updates have been made in this revision:
•Illustration changes in Dimension, mounting surface and guide bushing
on page 62.
• Term "Guide sleeves" changed to "Guide bushings", see Dimension,
mounting surface and guide bushing on page 62.
• A new WARNING! is added in the section about motor replacement,
informing not to mix different motor types.
• Minor corrections.
K
The following updates have been made in this revision:
•Added values for restricted working range if the robot is equipped with
a gearbox Type C, see Mechanically restricting the working range of
axis 1 on page 79.
• Information about removing the mech stop bracket added in section
Axes with restricted working range on page 78.
L
The following updates have been made in this revision:
• Turning disk fixture is removed from special tools for Levelmeter cal-
ibration.
• Oil levels adjusted.
• Information about grounding and bonding point added, see Robot
cabling and connection points on page 96.
M
Published in release R16.2. The following updates are done in this revision:
• Corrections due to updates in terminology.
• New dimensional drawing of the turning disk added to Fitting equip-
ment on wrist and mounting flange on page 73.
• New standard calibration method is introduced (Axis Calibration). See
Calibration on page 335.
• Information about grounding point added. See Robot cabling and
connection points on page 96.
N
Published in release R17.1. The following updates are done in this revision:
•Changed the tightening torque of the oil plug located on axis-1 gearbox.
P
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Continued

DescriptionRevision
Published in release R17.2. The following updates are done in this revision:
• Information about coupled axes in Updating revolution counters on
page 344.
• Caution about removing metal residues added in sections about SMB
boards.
• Information added into calibration procedure regarding installation of
calibration tool on turning disc, see Overview of the calibration proced-
ure on the FlexPendant on page 356.
• Information about minimum resonance frequency added.
• Bending radius for static floor cables added.
• Updated list of applicable standards.
•Article number for the Calibration tool box, Axis Calibration is changed.
• Updated the section Start of robot in cold environments on page 95.
• Updated information regarding replacement of brake release board.
•Updated information regarding disconnecting and reconnecting battery
cable to serial measurement board.
• Definition of reference calibration clarified.
Q
Published in release R18.1. The following updates are done in this revision:
•Information added about fatigue to Axis Calibration tool, see Calibration
tools for Axis Calibration on page 351.
• Added sections in General procedures on page 188.
• Updated figure of axis-6 synchronization mark.
• Safety restructured.
• Added information about harness customer ethernet connection.
• New spare part numbers for Brake release board.
• Note added to calibration chapter to emphasize the requirement of
equally dressed robot when using previously created reference calib-
ration values.
• Information about myABB Business Portal added.
• Information about measuring the play in axis 5 and 6 updated.
• Added Nickel in Environmental information.
R
Published in release R18.2. The following updates are done in this revision:
• Updates related to mechanical stop pin.
• Changed the method for replacing the axis-1 gearbox and the base.
S
Published in release R18.2. The following updates are done in this revision:
• Updated references.
T
Published in release 19B. The following updates are made in this revision:
• New touch up color Graphite White available. See Cut the paint or
surface on the robot before replacing parts on page 194.
• New article numbers for manipulator cables in section Robot cabling
and connection points on page 96.
• Levelmeter 2000 kit (6369901-347) no longer available.
• Added spare parts for wrist and sealing for IRB 4600 -20/2.50. See
Replacing wrist unit on page 263.
•
• Added a note regarding usage of an angled ethernet connection, see
Customer connection on robot on page 99.
U
Published in release 19D. The following updates are made in this revision:
• Note added about the need to calibrate if the robot is other than floor
mounted. See When to calibrate on page 339.
V
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Continued

DescriptionRevision
Published in release 20B. The following updates are made in this revision:
• Clarified and added information in mounting instructions for rotating
sealings, see Mounting instructions for sealings on page 191.
• Clarified text about position of robot and added table with dependen-
cies between axes during Axis Calibration.
• Article number of Calibration tool box, Axis Calibration is changed
from 3HAC062326-001 to 3HAC074119-001.
• Replaced article number and name of grease, previously 3HAB3537-
1.
• Added information about Wrist Optimization in calibration chapter.
W
Published in release 20C. The following updates are made in this revision:
• Added note about differences in type of oil pre-filled in axis-4 gear
compared to recommended oil for field maintenance.
• Updated section about customer connections in regard to Ethernet
etc. See Customer connection on robot on page 99.
X
Published in release 21A. The following updates are made in this revision:
• Note regarding maximum leakage current for attached equipment.
See Customer connection on robot on page 99.
• New Type D with alternative motor added to Type D of IRB 4600 on
page 375.
• "Type C" is now "Type C and Type D" through out the complete
manual.
Y
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Overview of this manual
Continued

Product documentation
Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories.
This listing is based on the type of information in the documents, regardless of
whether the products are standard or optional.
Tip
All documents can be found via myABB Business Portal, www.abb.com/myABB.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
•Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
•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
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
•What is included (for example cables, I/O boards, RAPID instructions, system
parameters, software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
Continues on next page
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Product documentation

Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.
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Product documentation
Continued

How to read the product manual
Reading the procedures
The procedures contain references to figures, tools, material, and so on. The
references are read as described below.
References to figures
The procedures often include references to components or attachment points
located on the manipulator/controller. The components or attachment points are
marked with italic text in the procedures and completed with a reference to the
figure where the current component or attachment point is shown.
The denomination in the procedure for the component or attachment point
corresponds to the denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a
procedure.
Note/IllustrationAction
Shown in the figure Location of
gearbox on page xx.
Remove the rear attachment screws, gearbox.8.
References to required equipment
The procedures often include references to equipment (spare parts, tools, etc.)
required for the different actions in the procedure. The equipment is marked with
italic text in the procedures and completed with a reference to the section where
the equipment is listed with further information, that is article number and
dimensions.
The designation in the procedure for the component or attachment point
corresponds to the designation in the referenced list.
The table below shows an example of a reference to a list of required equipment
from a step in a procedure.
Note/IllustrationAction
Art. no. is specified in Required
equipment on page xx.
Fit a new sealing, axis 2 to the gearbox.3.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 21.
Illustrations
The robot is illustrated with general figures that does not take painting or protection
type in consideration.
Likewise, certain work methods or general information that is valid for several robot
models, can be illustrated with illustrations that show a different robot model than
the one that is described in the current manual.
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How to read the product manual