Page 1 ROBOTICS Product manual IRB 7600...
Page 2 Trace back information: Workspace 23D version a13 Checked in 2023-12-07 Skribenta version 5.5.019...
Page 3 IRB 7600 - 500/2.3 IRB 7600 - 400/2.55 IRB 7600 - 340/2.8 IRB 7600 - 325/3.1 IRB 7600 - 150/3.5 IRC5, OmniCore Document ID: 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved. Specifications subject to change without notice.
Page 4 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.
Page 5: Table Of Contents
Working range, IRB 7600 - 150/3.5 .............. 2.4.4 Working range, IRB 7600 - 340/2.8 .............. 2.4.5 Working range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55 ........ 2.4.6 Working range, IRB 7600 - 500/2.3 .............. 2.4.7 Risk of tipping/stability ................
Page 6 4.3.1 Replacement of cable harness, axes 1-4 ............. 4.3.2 Replacement of cable harness, axes 5-6 ............4.3.3 Replacement of complete arm system ............Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 7 Introduction to decommissioning ................. Environmental information .................. Scrapping of robot ..................... Decommissioning of balancing device ..............Robot description Type A vs type B motors ..................Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 8 Spare part lists and illustrations ................10 Circuit diagram 10.1 Circuit diagrams ....................10.2 Validity of circuit diagram 3HAC025744-1 .............. 10.3 Validity of circuit diagram 3HAC13347-1 ..............Index Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 9: Overview Of This Manual
This manual describes the manipulator using either the IRC5 or the OmniCore controller. Product manual scope The manual covers all variants and designs of the IRB 7600. Some variants and designs may have been removed from the business offer and are no longer available for purchase.
Page 10 Replaces previous manuals: • Installation and Commissioning Manual • Maintenance Manual • Repair Manual, part 1 • Repair Manual, part 2. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 11 New lubricating oil in the gearboxes. Changes made in the chapter Mainten- ance on page 115 and Part list. • New variant of the robot (IRB 7600 - 500/2.55) implemented throughout the manual. • Wrist unit updated, new spare part number is specified in Replacement of complete wrist unit on page 237 and Spare part list.
Page 12 • Replacement of cable harness in Foundry Prime robots added to maintenance schedule, see Activities and intervals, Foundry Prime. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 13 247, the new section Replacement of lower arm shaft on page 257 and the exploded view Frame-Lower arm 2 in Product manual, spare parts - IRB 7600. • Some general tightening torques have been changed/added, see up- dated values in Screw joints on page 422.
Page 14 Caution about removing metal residues added in sections about SMB boards. • Information about minimum resonance frequency added. • Bending radius for static floor cables added. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 15 • Added information about Wrist Optimization in calibration chapter. • Replaced article number and name of grease, previously 3HAB3537-1. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 16 • Added illustrations to cleaning section. • Added information for the OmniCore robot controller. • Removed information about the M2000 and M2000A controllers. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 17: Product Documentation, Irc5, Omnicore
Product documentation, IRC5, OmniCore 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.
Page 18 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. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 19: How To Read The Product Manual
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. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
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Page 21: Safety
Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. The information does not cover how to design, install and operate a robot system, nor does it cover all peripheral equipment that can influence the safety of the robot system.
Page 22: Requirements On Personnel
The plant liable must make sure that the personnel is trained on the robot, and on responding to emergency or abnormal situations. Personal protective equipment Use personal protective equipment, as stated in the instructions. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 23: Safety Signals And Symbols
NOTE Signal word used to indicate important facts and conditions. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 24 Symbol Designation Significance Signal word used to indicate where to find additional information or how to do an operation in an easier way. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 25: Safety Symbols On Manipulator Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 26 Brake release Pressing this button will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 27 The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 28 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 xx1500002616 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 29 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 30 Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 31: Robot Stopping Functions
For more information see: • Product manual - OmniCore V400XT • Product manual - IRC5 • Product manual - IRC5 Panel Mounted Controller Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 32: Safety During Installation And Commissioning
When the robot is installed at a height, hanging, or other than mounted directly on the floor, there will be additional hazards. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 33 Compressed air • Hydraulics End-effector hazards require particular attention for applications which involve close human collaboration with the robot. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 34 Before the robot system is put into operation, verify that the safety functions are working as intended and that any remaining hazards identified in the risk assessment are mitigated to an acceptable level. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 35: Safety During Operation
A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 37 Specified amount de- on how much has previously pends on drained been drained from the gearbox. volume Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 38 Manipulator movements can cause serious injuries on users and may damage equipment. Related information See also the safety information related to installation and operation. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 39: Emergency Release Of The Robot Axes
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 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 40: Brake Testing
For robots with the option SafeMove, the Cyclic Brake Check routine is recommended. See the manual for SafeMove in References on page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 41: Safety During Troubleshooting
The manipulator can move unexpectedly at any time. DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers. A risk assessment must be done to address both robot and robot system specific hazards.
Page 42: Safety During Decommissioning
A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 43: Installation And Commissioning
Safety on page 21 before performing any installation work. Note Always connect the IRB 7600 and the robot to protective earth and residual current device (RCD) before connecting to power and starting any installation work. For more information see: •...
Page 44: Robot Transportation Precautions
Pre-installation procedure on page 50 Method 2 - transportation with a tool mounted to the robot Transportation according to method 2 is approved by ABB, only if use of method 1 is not possible. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH ©...
Page 45 Always read and follow the instructions in section Securing the robot with a transport support on page 48 • Always place the robot in the ABB recommended transport position for robot with tool, described in sub section Transport position with a transport support on page •...
Page 46 Transport position with a transport support All transportation of the robot with tool must follow these instructions. IRB 7600 xx0800000040 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 47 2.2 Robot transportation precautions Continued Recommended transport support Always use the recommended transport support when transporting a robot with tool. IRB 7600 xx0800000039 Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 48: Securing The Robot With A Transport Support
It must be done with great care and only when absolutely necessary. Fitting the transport support Illustration for fitting the transport support xx0800000062 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 49 Use the brake release for axis 5 and 6 to reach the final resting position for the tool, see the section Manually releasing the brakes on page 71 Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 50: Unpacking
It also contains information useful during later re-installation of the robot. Prerequisites for installation personnel Installation personnel working with an ABB product must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work • conform to all national and local codes.
Page 51: Technical Data
The actual mounting angle must always be configured in the system parameters, otherwise the performance and lifetime is affected. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 52 +39 ± 16 kN Torque xy ± 42 kNm ± 72 kNm Torque z ± 11 kNm ± 19.5 kNm Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 53 Value Minimum ambient temperature +5° C Maximum ambient temperature +50° C Maximum ambient humidity Max. 95% at constant temperat- Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 54 Protection type Protection class Manipulator, protection type Standard IP 67 Manipulator, protection type Foundry Plus IP 67 According to IEC 60529. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 55: Working Range, Irb 7600 - 150/3.5
2 Installation and commissioning 2.4.3 Working range, IRB 7600 - 150/3.5 2.4.3 Working range, IRB 7600 - 150/3.5 Illustration The illustration below shows the unrestricted working range of IRB 7600 - 150/3.5: xx0100000101 Product manual - IRB 7600 3HAC022033-001 Revision: AH...
Page 56: Working Range, Irb 7600 - 340/2.8
2 Installation and commissioning 2.4.4 Working range, IRB 7600 - 340/2.8 2.4.4 Working range, IRB 7600 - 340/2.8 Illustration The illustration below shows the unrestricted working range of IRB 7600 - 340/2.8: xx0300000296 Product manual - IRB 7600 3HAC022033-001 Revision: AH...
Page 57: Working Range, Irb 7600 - 400/2.55, Irb 7600
2.4.5 Working range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55 2.4.5 Working range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55 Illustration The illustration below shows the unrestricted working range of IRB 7600 - 400/2.55 and IRB 7600 - 500/2.55: xx0100000100...
Page 58: Working Range, Irb 7600 - 500/2.3
2 Installation and commissioning 2.4.6 Working range, IRB 7600 - 500/2.3 2.4.6 Working range, IRB 7600 - 500/2.3 Illustration The illustration below shows the unrestricted working range of IRB 7600 - 500/2.3: en0100000099 Product manual - IRB 7600 3HAC022033-001 Revision: AH...
Page 59: Risk Of Tipping/Stability
The robot might be positioned in a different position at delivery, due to actual configurations and options (for example DressPack). WARNING The robot will be mechanically unstable if not properly secured to the foundation. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 60: The Unit Is Sensitive To Esd
The mat must be grounded through a current-limiting resistor. • Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 61: On-Site Installation
Attachment points, spacer and horizontal attachment screws Attachment points, horizontal attachment screws Attachment points, vertical attachment screws Attachment points, horizontal attachment screws Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 62 Fork lift pocket (2 pcs, 3HAC15766-1 , 3HAC11264-1) Spacer (2 pcs) Horizontal attachment screws (4 pcs/ fork lift pocket) Vertical attachment screws (2 pcs) Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 63 Attachment points are shown in figure Attachment points on robot on page CAUTION The fork lift pocket weighs 60 kg! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 64 Make sure the securing screw is removed from the fork lift pocket! It is only used for robot model IRB 6650S. xx0700000655 A Securing screw Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 65 Insert fork lift forks into the pockets. xx0200000380 Reposition harness, if any, before using a fork lift! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 66 Refit the cooling fan to the motor, if any. Detailed in section Installation of cool- ing fan for motors (option) on page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 67: Lifting Robot With Lifting Accessory (Recommended Lifting Method)
Business Portal, www.abb.com/myABB. xx0200000153 Required equipment Equipment Article number Note Lifting accessory, robot 3HAC15607-1 Includes user instructions 3HAC15971-2 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 68 Make sure all hooks and attachments maintain their correct positions while lifting the robot! Always move the robot at very low speeds, making sure it does not tip. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 69: Lifting Robot With Roundslings
Chain sling with shortener, 4250 kg, 3 pcs (0.5 m, 0.5 m, 0.265 m) Roundsling, 1000 kg, 2 pcs Roundsling, 2000 kg, 3 pcs (4 m) Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 70 Make sure all hooks and attachments maintain correct position while lifting the robot! Always move the robot at very low speeds, making sure it does not tip. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 71: Manually Releasing The Brakes
The figure below shows the unit located at the frame. xx0200000376 Internal brake release unit with push buttons, located on the robot frame Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 73: Lifting The Base Plate
Lift and move the base plate very slowly. If the base plate starts to swing it is a risk for injuries or damage. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 74: Securing The Base Plate
E, F, G, H Common tolerance zone (accuracy all over the base plate from one contact surface to the other) Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 75 2 Installation and commissioning 2.5.6 Securing the base plate Continued xx0400000715 Four holes for alternative clamping, 4x Ø18 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 76 The illustration below shows the orienting grooves and attachment holes for leveling bolts in the base plate. xx1500000312 Orienting grooves (3 pcs) Levelling bolts, attachment holes (4 pcs) Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 77 This section details how to secure the base plate to the foundation. Action Note Make sure the foundation is levelled. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 78 0.3 mm. If it is not, use pieces of sheet metal or similar to bring the base plate to a levelled position. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 79: Orienting And Securing The Robot
Quality 8.8 Suitable washer: Thickness: 4 mm Outer diameter: 44 mm Inner diameter: 25 mm Tightening torque: 725 Nm Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 80 Lightly lubricate screws before as- sembly! Tighten bolts in a criss-cross pattern to ensure that the base is not distorted. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 81 This illustration shows the hole configuration used when securing the robot. xx0300000046 Cross section, guide sleeve hole This illustration shows the cross section of the guide sleeve holes. xx0100000109 Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 82: Fitting Equipment On Robot
2192 mm IRB 7600 - 400/2.55 2442 mm IRB 7600 - 340/2.8 2692 mm IRB 7600 - 325/3.1 2942 mm Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 83 Illustration, fitting of extra equipment on upper arm The illustration below shows the mounting holes available for fitting extra equipment on the upper arm. xx0100000116 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 84 Illustration, fitting of extra equipment on frame The mounting holes available for fitting extra equipment on the frame are shown below. xx0100000117 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 85 Tool flange, standard The illustration below shows the mounting holes available for fitting equipment on the turning disc. xx0100000119 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 86 When fitting tools on the tool flange, only use screws with quality 12.9. For other equipment use suitable screws and tightening torque for your application. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 87: Installation Of Base Spacers (Option)
Base plate 3HAC12937-7 Standard toolkit Content is defined in section Standard tools on page 426. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 88 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 114. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 89: Installation Of Cooling Fan For Motors (Option)
The fans are installed on the motors, axes 1 or 2, as shown in the figure below. xx1800000169 xx1800000170 Cooling fan, axis 1 Cooling fan, axis 2 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 90 1 & 2 cable harness • plate, customer • attachment screws and nuts. Cable harness inside control- 3HAC025488-001 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 91 Plate for customer connections, at base xx0500002301 Plate for customer connections Attachment screws, 3 pcs, M6x16 quality 8.8-A2F Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 92 Separate cabling for axis 1 or 2 The figure below shows the cabling used only for the fan on axis 1 or 2. xx0500002173 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 93 Run the cabling up through the base and frame, beneath the balancing device. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 94 Robot cabling and connection points on page 109. Also make adjustments in RobotWare, as de- scribed in the following procedure. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 95 RobotWare 6: modify the option information using theInstallation Manager function (Ro- botStudio). Read more about modifying the system in Operating manual - RobotStudio. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 96: Installation Of Foundry Plus Cable Guard (Option)
Separate instructions for IRB 2600, 4600, 6620, 6640, 6650S, 6660 and 7600 are available in English, German, French, Spanish, and Italian and can be found for registered users on myABB Business Portal (www.abb.com/myabb) and delivered with the Cable guard, article number 3HAC035933-001.
Page 97: Loads Fitted To The Robot, 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 listed in References on page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 98: Safety Lamp (Option For Irc5)
The lamp is active in MOTORS ON mode. Further information Further information about the MOTORS ON/MOTORS OFF mode may be found in the product manual for the controller. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 99: Extended Working Range, Axis 1 (Option)
220 degrees. Related information The system parameters are described in detail in the reference manual, see References on page Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 100 How to define the range of movement in M2000/M2000A is detailed in User’s guide - S4Cplus (BaseWare OS 4.0), chapter System Parameters - topic Manipulator. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 101: Restricting 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. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 102: Mechanically Restricting The Working Range Of Axis 1
Standard toolkit Technical reference manual - System Article number is specified in parameters section References on page Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 103 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 104: Mechanically Restricting The Working Range Of Axis 2
15°. Includes attachment screws. Standard toolkit Content is defined in section Standard tools on page 426. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 105 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 106: Mechanically Restricting The Working Range Of Axis 3
20 graduation in respective direction. Mechanical stops, axis 3 The illustration shows the mounting position of the mechanical stops on axis 3. The figure shows IRB 7600 but the principle is the same. xx0300000048 Additional mechanical stops Fixed mechanical stop Attachment screw M16x60 quality 12.9...
Page 107 Art. no. is specified in section Refer- Ware OS 4.0) (RobotWare 4.0) ences on page Technical reference manu- al - System parameters Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 108 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 109: Electrical Connections
See the Product manual - DressPack/SpotPack IRB 6650S/7600, see document number in References on page Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 110 Bending radius for static floor cables The minimum bending radius is 10 times the cable diameter for static floor cables. xx1600002016 Diameter Diameter x10 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 111 Inside cabinet: A43.X10 and A43.X11 Harness - cooling, 15 m 3HAC022723-004 Distributing cable: R1.FAN.SW2/3 Inside cabinet: A43.X10 and A43.X11 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 112 3HAC022723-005 Distributing cable: R1.FAN.SW2/3 Inside cabinet: A43.X10 and A43.X11 Harness - cooling, 30 m 3HAC022723-006 Distributing cable: R1.FAN.SW2/3 Inside cabinet: A43.X10 and A43.X11 Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 113: Start Of Robot In Cold Environments
If the program consists of large wrist movements, it is possible that the reorientation velocity, which is always high in predefined velocities, needs to be included in the ramping up. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 114: Test Run After Installation, Maintenance, Or Repair
Verify the application in the operating mode manual reduced speed. Collision risks CAUTION When programming the movements of the robot, always identify potential collision risks before initiating motion. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 115: Maintenance
Note If the IRB 7600 is connected to power, always make sure that the IRB 7600 is connected to protective earth and a residual current device (RCD) before starting any maintenance work.
Page 116: Maintenance Schedule And Expected Life
40000 hours. ABB Connected Services and its Assessment tools can help you to identify the real stress level of your robot, and define the optimal ABB support to maintain your robot working. Contact your local ABB Customer Service to get more information.
Page 117: Maintenance Schedule
Replace when damage or cracks is detected or life limit is approaching that specified in section Expected component life on page 121. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 118 174 6,000 hours Second change when DTC reads: 24,000 hours Following changes: Every 24,000 hours Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 119 24,000 hours Following changes: Every 24,000 hours DTC = Duty Time Counter. Shows the operational time of the robot. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 120 Inspection Motor fans, axes Every 12 Inspect the fans for 1-2-3 months contamination that could hinder the air supply. Clean if ne- cessary. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 121: Expected Component Life
5 is not calculated by SIS (See the Operating manual - Service Information System). In some applications, such as Foundry or Washing, the robot can be exposed to chemicals, high temperature or humidity, which can have an effect on the lifetime of the gearboxes. Contact the local ABB Robotics Service team for more information.
Page 122: Inspection Activities
Location of evacuation hole on motor The evacuation hole is located on each motor flange. The figure shows axis-1 motor as an example. xx2300001602 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 123 WARNING Handling gearbox oil involves several safety risks, Gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 125: Inspecting The Oil Level In Axis-1 Gearbox
162. Standard toolkit Content is defined in section Standard tools on page 426. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 126 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technic- al reference manual - Lubrication in gearboxes. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 127 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 128: Inspecting The Oil Level In Axis-2 Gearbox
Gearbox, axis 2 (behind the motor attachment, not shown in figure) Oil plug, filling (early design) Oil plug, draining Label, specifies the type of oil in the axis-2 gearbox Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 129 Use this procedure to inspect the oil level in the axis-2 gearbox. Action Note WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 130 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 131: Inspecting The Oil Level In Axis-3 Gearbox
162. Standard toolkit Content is defined in section Standard tools on page 426. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 132 Type and amount of oil in gearboxes on page 162. Detailed in section Changing oil, axis-3 gearbox on page 171. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 133 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 134: Inspecting The Oil Level In Axis-4 Gearbox
Required equipment Equipment, etc. Art. no. Note Lubricating oil Type and amount of oil in gearboxes on page 162. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 135 Type and amount of oil in gearboxes on page 162. Detailed in section Changing oil, axis-4 gearbox on page 174. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 136 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 137: Inspecting The Oil Level In Axis-5 Gearbox
Label, specifies the type of oil in the axis-5 secondary gearbox Oil plug, filling, secondary gearbox Cover, axis-5 gearbox Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 138 Required oil level to the upper edge of the filling and inspection oil plug hole (a): 80-96 mm xx0500002222 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 139 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 140: Inspecting The Oil Level In Axis-6 Gearbox
162. Standard toolkit Content is defined in section Standard tools on page 426. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 141 Turn axis 4 until the axis-4 angle reads: • -36° to -39° for oil plug position B1 • -80° to -83° for oil plug position B2 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 142 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 143: Inspecting The Balancing Device
Inspection points, balancing device on page 144. Balancing device, art. no. Action at detected faults 3HAC10538-1 Upgrade 3HAC14675-1 Maintenance Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 144 3HAC14962-1 Includes: bearings and seals • kit with bearings, o- rings and seals only • instructions for main- tenance. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 145 Required equipment on page 144. To decide whether to perform maintenance or upgrade, see section Action at detected faults on page 143. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 146 Leaks at the o-rings and/or sealings, are not acceptable and must be attended to immediately in order to avoid any damage to the bearing! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 147 Replacement of spherical roller bear- ing, balancing device on page 275. Incorrect leakage is shown in the previous figure. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 148 Inspection points, balancing device on page 144. Keep the areas around the balancing device clean and free from objects, such as service tools. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 149: Inspecting The Cable Harness
Circuit diagram See chapter Circuit diagram on page 435. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 150 Cable attachment, upper arm tube Cable attachment, rear of upper arm Connectors at cable harness division point, R2.M5/6 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 151 Replace the cable harness if wear, cracks or Described in section Replacement of damage is detected. cable harness, axes 5-6 on page 225 Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 152: Inspecting The Axis-1 Mechanical Stop Pin
• hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 153 The expected life of gearboxes can be reduced after collision with the mechanical stop. Make sure the mechanical stop pin can move in both directions. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 154: Inspecting The Mechanical Stops On Axes 1, 2, And 3
Mechanical stop ax 2 3HAC11077-1 Mechanical stop ax 3 3HAC13128-2 Standard toolkit Content is defined in section Standard tools on page 426. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 155 154! Correct attachment screws: • Axis 1: M16 x 35 • Axis 2: M16 x 50 • Axis 3: M16 x 80 Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 156: Inspecting The Damper On Axes 2 To 5
Required equipment Equipment Art. no. Note Damper axis 2 3HAC12990-1 Replace if damaged! Damper axis 3 3HAC11750-1 Replace if damaged! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 157 If any damage is detected, the damper must be re- Art. no. is specified in placed with a new one! quired equipment on page 156. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 158: Inspecting The Information Labels
Label, type of grease in ear Information labels at gearboxes and at robot base, specifying which oil is used in gearboxes Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 159 Replace any missing or damaged labels. Article numbers for the labels and plate set is specified in Spare part lists on page 433. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 160: Inspecting The Ul Lamp
These procedures include references be required. See references to to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 161 Check the cable connections. • Measure the voltage in connectors motor axis 3 (=24V). • Check the cabling. Replace cabling if a fault is detected. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 162: Changing/Replacement Activities
Axis 4 primary gearbox Axis 4 secondary gearbox Axis 5 primary gearbox Axis 5 secondary gearbox Axis 6 gearbox Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 163 Includes pump with outlet pipe. Use the suggested dispenser or a similar one: • Orion OriCan article number 22590 (pneumatic) Nipple for quick connect fitting, with o-ring Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 164: Changing Oil, Axis-1 Gearbox
Motor, axis 1 Oil plug, inspection (not in all designs) Label, specifies the type of oil in the gearbox Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 166 Close the oil drain hose, and put it back inside the base. Close the rear cover by securing it with its attach- ment screws. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 167 Technical reference manual - Lubrication in gearboxes. Refit the oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 168: Changing Oil, Axis-2 Gearbox
Content is defined in section ment Special tools on page 427. Standard toolkit Content is defined in section Standard tools on page 426. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 169 Before entering the robot working area. WARNING Handling gearbox oil involves several safety risks, Gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 170 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Refit the oil plug. Tightening torque: 24 Nm. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 171: Changing Oil, Axis-3 Gearbox
Note! Do not mix with other oil amount of oil in types! gearboxes on amount of page 162. oil in gear- boxes on page 162. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 172 Draining is time-consuming. Elapsed time varies depending on the temperature of the oil. Refit the oil plug. Tightening torque: 24 Nm. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 173 - Lubrication in gearboxes. Note Do not mix Kyodo Yushi TMO 150 with other oil types! Refit the oil plug. Tightening torque: 24 Nm. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 174: Changing Oil, Axis-4 Gearbox
Label, specifies the type of oil in the secondary gear Label, specifies the type of oil in the primary gear Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 175 Vessel capacity specified in draining, primary gearbox. quired equipment on page 175. CAUTION Drain as much oil as possible. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 176 - Lubrication in gearboxes. Refit the both oil plugs, filling. Shown in the figure Location of gearbox on page 174. Tightening torque: 24 Nm. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 177: Changing Oil, Axis-5 Gearbox
The oil plug for draining of the primary gearbox is on the opposite side of the wrist housing, not shown in the figure. Label, specifies the type of oil in the axis-5 primary gearbox Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 178 Drain the oil from the primary gearbox. Vessel capacity: 1 liter Run axis 4 to a position +90° from the calibration position. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 179 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 180 3.4.6 Changing oil, axis-5 gearbox Continued Action Note Refit the oil plugs. Shown in the figure Location of gearbox on page 177. Tightening torque: 24 Nm. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 181: Changing Oil, Axis-6 Gearbox
Vessel capacity: 1,000 ml. Oil exchange equip- 3HAC17313-1 Content is defined in section ment Special tools on page 427. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 182 The correct oil level is detailed in section Inspecting the oil level in axis-6 gearbox on page 140. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 183 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Refit both oil plugs. Tightening torque: 20 Nm. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 184: Replacing The Smb Battery
See the operating manual for the robot controller for instructions. WARNING Hazards related to batteries on page Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 185 Battery pack with a 2-pole battery contact (DSQC) xx0200000238 SMB battery cover SMB battery pack with 2-pole battery contact. Battery cable Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 186 Equipment, etc. Spare part no. Note Battery unit For spare part no. Battery includes protection circuits. Only re- see: place with a specified spare part or an ABB- • Spare part approved equivalent. lists on page 433 Standard toolkit Content is defined in section...
Page 187 Shown in figure Location of SMB Battery includes protection circuits. Only replace battery on page 185. with a specified spare part or with an ABB- ap- proved equivalent. Refitting, battery Use this procedure to refit the SMB battery. Action Note...
Page 188 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 114. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 189: Lubrication Activities
Hole through which the shaft is pressed Required equipment Equipment, etc. Art. no. Note Grease 3HAC042534-001 Tribol GR 100-0-PD, 150 ml Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 190 Inspection, balancing device - of the robot, in order to make sure there is Check for leakage on page 146. no incorrect leakage from the o-rings. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 191: Cleaning Activities
Axis 6 gearbox: open both oil plugs (filling and draining) and run axis 5 and 6 in different directions until the oil draining has stopped. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 192 Run the Service program at low speed (25%) during 10 minutes. Drain the gearbox properly. Repeat the steps above until the gearbox is flushed three times. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 193: Cleaning The Irb 7600
General To secure high uptime it is important that the IRB 7600 is cleaned regularly. The frequency of cleaning depends on the environment in which the product works. Different cleaning methods are allowed depending on the type of protection of the IRB 7600.
Page 194 Cleaning with water and steam 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), provided that the robot is not equipped with the option of motor cooling fans.
Page 195 3.6.2 Cleaning the IRB 7600 Continued Position Example of position Gaskets xx2300001627 Connectors xx2300001623 (The illustration shows IRB6700) Cable inlets xx2300001629 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 196 Typical tap water pressure and flow Instructions for steam or high pressure water cleaning ABB robots with protection types Foundry Plus, Wash, or Foundry Prime can be cleaned using a steam cleaner or high pressure water cleaner. The following list defines the prerequisites: •...
Page 197: Service Information System, M2000
204. parameters are to be entered from an extern- al PC, a set of software tools are available to build such an application. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 198: Description Of Service Information System (Sis)
Setting the SIS parameters on page 202. Remaining time Remaining time to next scheduled service date. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 199 The service interval for the axis in question has been reached. Joint x N/A No service time parameter calculation available. Applies to axes 4 and 5 (IRB 6600 and IRB 7600). The following information is available for the axis service status in the service routine.
Page 200 No data available When no data is available for the selection made, a message (No data available!) is displayed when trying to display the data. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 201: Sis System Parameters
The values can be defined by the operating organization as knowledge of the robot's working conditions are accumulated. Since the counters are to be used for purposes defined by the user, ABB cannot give any recommendations regarding their definitions. Operation time limit (service level) The number of operation hours selected as service interval.
Page 202: Setting The Sis Parameters
Select the required paramet- Available parameters are described in section SIS system ers by stepping up and parameters on page 201. down through the parameter list. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 203: Reading The Sis Output Logs
How to set the value determining when the mes- gearbox x! sage is to be shown, is detailed in section Setting the SIS parameters on page 202. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 204: Exporting The Sis Data
Operation time of gearbox axis 3 sisL10h_6 hours Gearbox time Estimated life of gearbox axis 6 sisL10h_Time_6 hours Gearbox time Operation time of gearbox axis 6 Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 205: Repair
Repair activities not described in this chapter must only be carried out by ABB. Report replaced units Note When replacing a part on the IRB 7600, report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit.
Page 206: General Procedures
Spray any suspected leak areas with the leak detec- tion spray. Bubbles indicate a leak. When the leak has been localized, take the necessary measures to correct the leak. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 207: Mounting Instructions For Bearings
Make sure the bearing is properly aligned as this will directly affect the durab- ility of the bearing. Greasing of bearings Note This instruction is not valid for solid oil bearings. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 208 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. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 209: Mounting Instructions For Sealings
A radial sealing consists of a flexible rubber lip bonded to a rigid metal case. Only one side of the sealing is static with a metal insert. xx2300000433 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 210 A Main lip B Grease C Dust lip Note Ensure that no grease is ap- plied to the red marked surface. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 211 If the flange surfaces are defective, the parts may not be used because leakage could occur. Clean the surfaces properly in accordance with the recommendations of ABB. Distribute the sealing compound evenly over the surface. Tighten the screws evenly when fastening the flange joint.
Page 212 Lubricate the o-ring with grease. Tighten the screws evenly while assembling. Check that the o-ring is not squashed outside the o-ring groove. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 213: Cut The Paint Or Surface On The Robot Before Replacing Parts
Carefully grind the paint edge that is left on the structure to a smooth surface. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 214: The Brake Release Buttons May Be Jammed After Service Work
If a button gets jammed in the depressed position, the alignment of the brake release unit must be adjusted so that the buttons can move freely in their tubes. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 215: Complete Robot
R2.FB7 and R2.SMB. Battery connector X3 R1.G and R2.G. If brake release located at the frame: also connectors X8, X9 and X10! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 216 Axis 3: 0 ° • Axis 4: 0 ° • Axis 5: +90 ° • Axis 6: no significance Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 217 R1.SMB4-6 from the SMB unit. Disconnect X8, X9 and X10 if the brake release board is located in frame. xx0200000118 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 218 • C: Attachment plate • D: Velcro strap Remove the cable gland securing the cables inside the lower arm. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 219 Axis 3: 0 degrees • Axis 4: 0 degrees • Axis 5: +90 degrees • Axis 6: no significance Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 220 Reconnect all connectors at motors 1 and 2. Specified and shown in the figure Location of cable harness on page 215! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 221 • A: Cable gland • B: Attachment screws, cable gland • C: Attachment plate • D: Velcro strap Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 222 Refit the cable gland securing the cables to the arm house. Make sure not to twist the harness! xx0100000143 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 223 215. Make an overall inspection of the installed cable Inspecting the cable harness harness. on page 149. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 224 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 114. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 225: Replacement Of Cable Harness, Axes 5-6
These procedures include references be required. See references to to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 226 Position the upper arm as follows: • Axis 4: 0 degrees • Axis 5: +90 degrees • Axis 6: no significance Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 227 Inspecting the cable harness harness. on page 149. Update the revolution counters. Detailed in section Updating re- volution counters on IRC5 robots on page 382. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 228: Replacement Of Complete Arm System
This is shown in the figure below. xx0100000150 Gearbox, axis 1 Motor, axis 1 Base attachment screws Upper arm Lower arm Frame Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 229 The procedure below details how to lift and remove the complete arm system. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 230 Remove the block for calibration from the bot- Shown in the figure Location of com- tom of the frame. plete arm system on page 228! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 231 A Attachment holes for the guide pins, M12. B Guiding hole for the spring pin loc- ated in the gearbox, axis 1. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 232 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 114. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 233: Upper And Lower Arm
Grease 3HAC042536- Used to lubricate the o-ring. Standard toolkit Content is defined in section Standard tools on page 426. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 234 Shown in the figure Location of turning securing the turning disk. disk on page 233. Remove the turning disk. xx1000001135 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 235 Screw joints on page 422 before fitting. Refill the gearbox, axis 6, with oil. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 236 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 114. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 237: Replacement Of Complete Wrist Unit
The wrist unit is located in the frontmost part of the upper arm as shown in the figure below. A more detailed view of the component and its position may be found in Exploded views in Product manual, spare parts - IRB 7600. xx0100000147 Wrist unit...
Page 238 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 240 Inspecting the oil level in axis-5 gearbox on page 137 • Inspecting the oil level in axis-6 gearbox on page 140 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 241 Make sure all safety requirements are met when performing the first test run. See Test run after in- stallation, maintenance, or repair on page 114. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 242: Replacement Of Complete Upper Arm
The upper arm is located on top of the robot as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views in Product manual, spare parts - IRB 7600. xx0100000148...
Page 243 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 244 30 pcs. upper arm! Lift the upper arm and place it on a secure surface. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 246 Make sure all safety requirements are met when performing the first test run. See Test run after in- stallation, maintenance, or repair on page 114. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 247: Replacement Of Complete Lower Arm
The figure (2) shows a cut view through the lower arm pivot point in axis 2 (item B in the figure above!), valid for robots with protection Standard. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 248 Shaft hole Sealing, axis 2/3 Attachment screw Washer Bearing Thrust washer Bushing Retaining ring Shaft Protection plug Protection washer Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 249 VK cover 3HAA2166-23 Replace if damaged. Only used on lower arms with a hole in the upper end (axis 3). Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 250 See to the tools required. references to these proced- ures in the step-by-step instructions below. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 251 249. Attachment is shown in the figure Loc- ation of lower arm on page 247. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 252 Apply the lifting tool to the lower arm. Article number is specified in Required equipment on page 249! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 253 • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 254 Article number is specified in quired equipment on page 249. Lift the lower arm and move it to its mounting position. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 255 Refit and reconnect all cables inside the lower Detailed in section Refitting, cable arm. harness, axes 1-4 on page 219. Refit removed cable attachments. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 256 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 114. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 257: Replacement Of Lower Arm Shaft
The figure shows components fitted to the lower arm shaft when the robot has protection Standard. xx0300000487 Protection plug Lower arm shaft (axis 2 shaft) Thrust washer Bearing Protection washer Retaining ring Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 258 433. Puller device, axis 2 shaft 3HAC075427-001 Hydraulic pressing accessory. User instructions are enclosed with the tool. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 259 Foundry Prime) Removal, lower arm shaft from robot with protection Standard Use this procedure to remove the lower arm shaft if the robot has protection Standard. If encountering any problems when removing the shaft, contact ABB Robotics! Action Note/Illustration WARNING...
Page 260 Removal, lower arm shaft on robot with protection Foundry Plus Use this procedure to remove the lower arm shaft if the robot has protection Foundry Plus. If encountering any problems when removing the shaft, contact ABB Robotics! Action Note WARNING...
Page 261 Apply mercas • A: Mercasol on marked areas. Push the shaft in by hand. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 262 Proceed with the refitting procedure of the lower arm, detailed in section Replacement of complete lower arm on page 247. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 263 Apply grease to the location of the shaft where the Art. no. is specified in Required bearing is to be mounted. equipment on page 258 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 264 Use locking liquid. Proceed with the refitting procedure of the lower arm, detailed in section Replacement of complete lower arm on page 247. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 265: Frame And Base
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! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 266 Use caution and disconnect the connectors from the Connectors R1.SMB1-3, SMB unit when pulling the board out. R1.SMB4-6 and R2.SMB Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 267 Be careful not to damage the sockets or pins. Make sure the connector and its locking arms are snapped down properly. xx1700000978 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 268 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 114. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 269: Replacement Of Brake Release Board
Brake release circuit (brake release unit inside) Attachment screws, brake release circuit, 4 pcs Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 270 Brake release unit at the frame, according harness, at frame to figure Location of brake release board, frame on page 270. DSQC1052 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 271 269. Disconnect the cable from the brake release circuit and remove the circuit from the base. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 272 Remove the brake release board from the Shown in the figure Location of brake re- plate. lease board, frame on page 270! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 273 Be careful not to damage the sockets or pins. Make sure the connector and its locking arms are snapped down properly. xx1700000978 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 274 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 114. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 275: Replacement Of Spherical Roller Bearing, Balancing Device
O-ring 3HAB3772-76 2 pcs required. Sealing ring 3HAC11581-6 2 pcs required. Grease 3HAC042536-001 For lubrication of the com- ponents. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 276 • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 277 Before entering the robot working area. Grease the inside walls of the front ear. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 278 Make sure no incorrect leakage occurs. It This is detailed in section Check for leak- could indicate damaged o-rings. age on page 146. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 279 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 114. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 280: Replacing The Balancing Device
Attachment screws, rear cover Balancing device shaft, including screw and washer Bearing attachment Parallel pin (inside bearing attachment) Attachment screws, bearing attachment Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 281 Hole in frame to access the balancing device front eye shaft with the puller/press tool Attachment hole for locking screw that secures the lower arm to the frame Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 282 Press equipment, bal- 3HAC076202-001 For replacing the balancing ancing device shaft device shaft. User instructions are en- closed with the tool. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 283 282! Attachments are shown in the figure Attachment points, balancing device on page 281. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 284 Remove the securing screw and washer from Shown in the figure Location of balan- the balancing device shaft. cing device on page 280! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 285 Lubricate and refit the o-ring on the support Make sure the o-ring is seated prop- shaft. erly! Replace if damaged. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 286 Make sure not to burden the guide pins with the weight of the balancing device! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 287 Make sure not to burden the guide pins with the weight of the balancing device! Remove the guide pins. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 288 DANGER Handling the tool incorrectly will cause serious injury. Read and follow enclosed user instructions for the tool. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 289 Lubrication is further detailed in section Lubrication of spherical roller bearing, balancing device on page 189. Clean the area from any excessive grease. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 290 Make sure the cover is properly secured before commissioning of the robot! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 291 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 114. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 292: Motors
The motor axis 1 is located on the left hand side of the robot as shown in the figure below. xx0100000123 Motor, axis 1 Cable gland cover, motor axis Cover for connector access Motor attachment screws Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 294 Before entering the robot working area. Remove the cover for connector access on top of the motor by unscrewing its four attachment screws. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 295 Art no. is specified in Required motor is seated properly. Lightly lubricate the o- equipment on page 293. ring with grease. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 296 Make sure all safety requirements are met when performing the first test run. See Test run after in- stallation, maintenance, or repair on page 114. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 297: Replacement Of Motor Axis 2
Guide pins M10 x 100 3HAC15521-1 For guiding the motor. Guides are to be used in pairs! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 298 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 299 Make sure the gasket is not damaged! tachment screws. Disconnect all connectors beneath the motor cover. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 300 • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 301 Remove the lifting tool and allow the motor to rest on the guide pins. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 302 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 114. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 303: Replacement Of Motor, Axis 3
Grease 3HAC042536-001 For lubricating the o-ring. Removal tool, mo- 3HAC14973-1 Always use the removal tools tor M12x in pairs! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 305 Fit the mechanical stop to the third and final attach- ment hole (A), below the fixed stop (B) in the upper arm. See the figure above! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 306 Remove the motor by gently lifting Make sure the motor pinion is not damaged! it straight out and disconnect the brake release voltage. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 307 In order to release the brake, connect the 24 VDC Connect to connector R2.MP3 power supply. • +: pin 2 • -: pin 5 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 308 Axis Calibration meth- od on page 389. General calibration information is included in section Calibration on page 375. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 309 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 114. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 310: Replacement Of Motor, Axis 4
Lifting tool, motor ax 2, 3, 4 3HAC15534-1 To be used if the upper arm is positioned horizontally. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 311 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 312 In horizontal position: drain the gearbox, Detailed in section Draining, oil, gearbox axis 4. axis 4 on page 175. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 313 • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 314 Make sure the motor pinion does not get making sure the motor pinion is properly damaged! mated to the gear of gearbox 4. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 315 Axis Calibration method on page 389. General calibration information is included in section Calibration on page 375. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 316 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 114. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 317: Replacement Of Motor, Axis 5
For releasing the brakes. Extension 300mm for bits 1/2" 3HAC12342-1 Removal tool, motor M12x 3HAC14973-1 Always use the removal tools in pairs! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 318 The procedure below details how to remove the motor, axis 5. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 319 Remove the motor by gently lifting it straight out. Make sure the motor pinion is not damaged! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 320 If required, use the extension 300 mm for bits 1/2". Art. no. is specified in Required equipment on page 317. Disconnect the brake release voltage. Reconnect all connectors beneath the motor cover. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 321 Make sure all safety requirements are met when performing the first test run. See Test run after in- stallation, maintenance, or repair on page 114. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 322: Replacement Of Motor, Axis 6
Removal tool, motor 3HAC14972-1 Always use the removal tools M10x in pairs! Extension 300mm for 3HAC12342-1 bits 1/2" Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 323 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 324 6 on page 182. Remove the rear motor cover by unscrewing the five attachment screws. Disconnect all connectors beneath the cover. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 325 Perform a leak-down test (if the gearbox has Detailed in section Performing a leak- been drained). down test on page 206. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 326 In horizontal position: drain the oil from the Detailed in section: Draining oil, gear- axis 6 gearbox. box axis 6 on page 182. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 327 6 and forwards in Removal, motor on page 324. Note Keep the old rear motor cover with the air nipple. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 328 Apply grease on the o-ring on the motor. Continue to refit the new motor according to section, Refitting, motor on page 325. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 329: Gearboxes
O-ring 3HAB3772-54 Replace if damaged! O-ring 3HAB3772-55 Replace if damaged! Sealing ring 3HAC11581-4 Replace if damaged! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 330 If no previous reference values exist, and routine on page 390. no new reference values can be created, then reference calibration is not possible. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 331 228. Unfasten the robot base from the foundation by removing the base attachment screws. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 332 Make sure the base remains in a stable position before performing any work under- neath the base! xx1000000364 A Support base (4 pcs) Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 333 • A: Oil drain hose • B: Attachment screws, gearbox axis 1, 18 pcs • C: Washers, 3 pcs Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 334 Turn the gearbox, and remove the protec- tion pipe by unscrewing two attachment screws. Note Move the protective pipe over to the new gearbox. xx1400000786 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 335 A: Guide pin • C: O-ring 3HAB 3772-54 • D: O-ring 3HAB 3772-55 • E: Sealing ring 3HAC 11581-4 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 336 329. CAUTION The gearbox weighs 200 Kg. All lifting accessories used must be sized ac- cordingly! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 337 Lift gearbox axis 1 onto the guide pins and Always use guide pins in pairs! lower it carefully to its mounting position. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 338 C: Washers, 3 pcs Refit the cable guide in the center of gearbox 1 with its attachment screws. xx1000001393 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 339 Axis Calibration method on page 389. General calibration information is in- cluded in section Calibration on page 375. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 340 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 114. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 341: Replacement Of Gearbox, Axis 2
A more detailed view of the component and its position may be found in chapter Exploded views in Product manual, spare parts - IRB 7600 . xx0100000135 Gearbox, axis 2 (behind motor attachment not shown in figure )
Page 342 See refer- references to the tools re- ences to these procedures quired. in the step-by-step instruc- tions below. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 343 The lowered position, as in figure A, is recommen- ded as it gives the least load on the tool. xx0200000260 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 344 Detailed in section Draining, oil on page 169. Remove the motor, axis 2. Detailed in section Removal, motor on page 299. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 345 A: M16 holes for pressing the gearbox out Remove the gearbox using an overhead crane or similar. Remove the friction washer and clean it. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 346 Fit the lifting tool, gearbox axis 2, to the gearbox. Article number is specified in quired equipment on page 342. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 347 Screw joints on page 422 before fitting. Remove the guide pins and tighten the remaining two screws as above. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 348 Calibrating with Axis Calibration method on page 389. General calibration information is included in section Calibration on page 375. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 349 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 114. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 350: Replacement Of Gearbox, Axis 3
The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views in Product manual, spare parts - IRB 7600. xx0100000137 Gearbox, axis 3...
Page 351 See refer- ences to the tools required. ences to these procedures in the step-by-step instructions below. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 352 Secure the upper arm in a horizont- Art. no. is specified in Required equipment on al position using round slings. page 351. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 353 (A) shown in the figure to the right to press the gearbox free. xx0200000033 • A: M16 holed for pressing the gearbox out Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 354 CAUTION The gearbox weighs 125 kg! All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 355 Remove the guide pins and lubricated as detailed in section Screw joints on tighten the remaining two page 422 before fitting. screws. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 356 Make sure all safety require- ments are met when performing the first test run. See Test run after installation, maintenance, or repair on page 114. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 357: Replacement Of Gearbox, Axis 4
The axis 4 gearbox is located at the rear of the upper arm as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views in Product manual, spare parts - IRB 7600. xx0100000144 Upper arm housing...
Page 358 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 359 15 gear attachment screws. gearbox on page 357. If required, insert screws into three holes in gear Z3 to press it out. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 360 Spare part no. is specified in Required equipment on page 358. Note Make sure the surface beneath the friction washers is clean and dry! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 361 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 114. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 362: Replacement Of Gearbox, Axis 5
The axis 5 gearbox is located in the wrist unit as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views in Product manual, spare parts - IRB 7600. xx0100000146...
Page 363 See references to these quired. procedures in the step- by-step instructions be- low. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 364 Remove the cover, axis 5 gearbox by unscrewing its Shown in the figure Location of attachment screws. gearbox on page 362! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 365 Turn the gear Z4 in order to reach all the srews. ure below! 7 pcs: M6 x 16. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 366 Shown in the figure Location of gently lowering it straight down, using the guide gearbox on page 362. pins. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 367 Make sure all safety requirements are met when performing the first test run. See Test run after in- stallation, maintenance, or repair on page 114. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 368 362. Proceed with step 11 in the refitting detailed in the previous procedure (procedure Refitting, gearbox axis 5 on page 366). Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 369: Replacement Of Gearbox, Axis 6
Includes o-ring 3HAB3772-49 Spare part lists on page 433. Washers 3HAC10122-13 Not included in the gearbox. Re- place if damaged. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 370 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 371 Foundry Plus: Remove old Loctite 574 flange sealant residues and other contamination from the contact sur- faces. xx1400001123 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 372 Detailed in the section Manually releasing the brakes on page Foundry Plus: Apply Loctite 574 flange sealant on the contact surface. xx1400001122 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 373 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or re- pair on page 114. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
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Page 375: Calibration
A calibration routine to make a rough calibration of each manipulator axis. Synchronization mark Visual marks on the robot axes. When marks are aligned, the robot is in synchronization position. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 377 Axis Calibration method Axis Calibration is a standard calibration method for calibration of IRB 7600. It is the recommended method in order to achieve proper performance. The following routines are available for the Axis Calibration method: •...
Page 378 Levelmeter calibration - alternative method Levelmeter calibration is referred to as the alternative method for calibration of ABB robots because of the less accurate values obtained during calibration. The method uses the same principles as Calibration Pendulum, but does not have as good of mechanical tolerances to the toolkit parts as the standard method with Calibration Pendulum.
Page 379: When To Calibrate
The resolver values are changed If resolver values are changed, the robot must be re-calibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration, according to information in this manual. If the robot has absolute accuracy calibration, it is also recommended, but not always necessary to calibrate for new absolute accuracy.
Page 380: Synchronization Marks And Axis Movement Directions
One of the marks is more narrow than the other and should be positioned within the limits of the wider mark. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 381: Calibration Movement Directions For All Axes
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...
Page 383 CANCEL returns to the Calibration window. Press OK again to confirm and start the update. CANCEL returns to the Revolution Counter Update window. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 384 Use this procedure to update the revolution counter with the FlexPendant (IRC5). Action On the ABB menu, tap Calibration. xx1500000942 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 385 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 Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 386 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 405. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 387: Updating Revolution Counters On Omnicore Robots
On the start screen, tap Calibrate. The calibration summary page for the mechanical unit is displayed. In the Calibration Methods menu, select Revolution Counters. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 388 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 405. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 389: Calibrating With Axis Calibration Method
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 into the calibration bushing, until the steel spring ring snaps into place.
Page 390 A benefit with reference calibration is that the current state of the robot is stored and not the state when the robot left the ABB factory. The reference value will be named according to tool name, date etc.
Page 391 Make sure that the user rights admit to change the safety settings and to synchronize SafeMove. For robots with EPS, the same applies as for SafeMove. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 392: Calibration Tools For Axis Calibration
There is no risk for bad calibrations as long as the calibration tool is in one piece. 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. Equipment, etc. Article number...
Page 393 It is possible to make the calibration tool identifiable with, for example, an RFID chip. The procedure of how to install an RFID chip is described below. Note The tool identifier is NOT delivered from ABB, it is a customized solution. Action Note It is possible to use any RFID solution, with the correct dimensions.
Page 394: Installation Locations For The Calibration Tools
Replace damaged parts with new. Spare part Article number Note Protection cover and plug set 3HAC056806-001 Contains replacement calibration pin covers and protective plugs for the bushing. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 395: Axis Calibration - Running The Calibration Procedure
WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration holes may cause severe damage to the robot and/or personnel. Equipment, etc.
Page 396 Axis used for the robot during last field calibration. Calibration. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 397 Axis Calibration procedure. CAUTION SafeMove must be synchronized after the calibration is completed. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 398 If the standard calibration data for axes 4, 5 or 6 Calibrating with Wrist Optimiz- should be updated with wrist optimization, run the ation method on page 402. calibration routine Wrist Optimization. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 399: Reference Calibration
(step 5, see Brief introduction to Reference Calibration on page 399). Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 400 11 Repeat the manual tuning if needed. 12 Create a new reference if the intention is to use the reference in the future. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 401: Calibrating With Calibration Pendulum Method
Where to find information for Calibration Pendulum Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 402: Calibrating With Wrist Optimization Method
3 Improved calibration data to the wrist axes is identified and presented. 4 Optimized positions for the wrist axes are presented. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 403 WARNING Robot moves automatically when pressing Calibrate. 6 Wrist optimization is finished. 7 Redefine / verify TCP for all tools. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 404: Verifying The Calibration
Write down the values on a new label and stick it on top of the calibration label. The label is located on the lower arm. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 405: Checking The Synchronization Position
If they do not, update the revolu- synchronization position for axes on tion counters. page 380 Updating revolution counters on page 382. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 406 Create a new program. Use MoveAbsJ in the Add Instruction menu. Create the following program: MoveAbsJ [[0,0,0,0,0,0], [9E9,9E9,9E9,9E9,9E9,9E9]] \NoEOffs, v1000, fine, tool0 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 407 If they do not, up- ization position for axes on page 380 date the revolution counters. Updating revolution counters on page 382. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 408 This page is intentionally left blank...
Page 409: Decommissioning
See also Environmental information on page 410. Transportation Prepare the robot or parts before transport, this to avoid hazards. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 410: Environmental Information
6.2 Environmental information 6.2 Environmental information Introduction ABB robots contain components in different materials. During decommissioning, all materials should be dismantled, recycled, or reused responsibly, according to the relevant laws and industrial standards. Robots or parts that can be reused or upcycled helps to reduce the usage of natural resources.
Page 411 Spills can form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. • Spillage can penetrate the soil causing ground water contamination. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 412: Scrapping Of Robot
A used robot does not have the same performance as on delivery. Springs, brakes, bearings, and other parts might be worn or broken. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 413: Decommissioning Of Balancing Device
The following procedure contains useful information about decommissioning. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 414 Cut a hole in the housing as shown in the Use a cutting torch with a long shaft. figure. The measurements shown below are maxim- um values! xx0200000082 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 415 Inner spring: cut at least four coils! Double-check the number of coils cut and make sure all the tension in the springs are removed. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 416 This page is intentionally left blank...
Page 417: Robot Description
Note The article numbers in the table can not be used for ordering spare parts. The numbers are only used for identification of installed motors. See Product manual, spare parts - IRB 7600 for spare part numbers. Robot Article number...
Page 418 B motor: 3HAC062450-005 (ABB Orange) / 3HAC062450- 004 (Graphite White). xx1800000129 Not interchangeable. The complete wrist unit must be replaced. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 419: Reference Information
8 Reference information 8.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 420: Applicable Standards
Industrial robots and robot Systems - General safety require- ments EN ISO 10218-1 Robots and robotic devices — Safety requirements for indus- trial robots — Part 1: Robots Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 421: Unit Conversion
2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 422: Screw Joints
8.4 Screw joints 8.4 Screw joints General This section describes how to tighten the various types of screw joints on ABB robots. The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials.
Page 423 Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm) Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric- ated ated Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 424 Nm - Max. Mixed The lower tightening torque of the two materials. Brass only Brass only Brass only Brass only Stainless steel only Brass only Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 425: Weight Specifications
All components exceeding 22 kg (50 lbs) are highlighted in this way. To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.
Page 426: Standard Tools
Hex bit socket head cap no. 6 socket 40 mm L=145 mm Hex bit socket head cap no. 6 socket 40mm bit L=220 mm Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 427: Special Tools
3HAC022637-001 Guide pins M16 x 150 3HAC13120-2 Guide pins M16 x 200 3HAC13120-3 Guide pins M16 x 250 3HAC13120-4 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 428 3HAC15943-1 Tools that may be rented The following table specifies the tools that may be rented from ABB in order to perform certain service procedures as described in the Product manual. The special tools are also listed directly in the instructions.
Page 429 Delivered as a set of calibration tools. ibration Required if Axis Calibration is the valid calibration method for the robot. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 430 • Couplings and adapters • Pump (manual) with hose and coupling • Graduated measuring glass • Oil gun • User instructions. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 431: Lifting Accessories And Lifting Instructions
The instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 432 This page is intentionally left blank...
Page 433: Spare Part Lists
Spare parts and exploded views are not included in the manual but delivered as a separate document for registered users on myABB Business Portal, www.abb.com/myABB. All documents can be found via myABB Business Portal, www.abb.com/myABB. Product manual - IRB 7600 3HAC022033-001 Revision: AH...
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Page 435: Circuit Diagram
Circuit diagram - IRB 6640 3HAC025744-001 Circuit diagram - IRB 6650S 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6660 3HAC025744-001 3HAC029940-001 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 436 Circuit diagram - IRB 6700 / IRB 6790 3HAC043446-005 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 14000 3HAC050778-003 Circuit diagram - IRB 910SC 3HAC056159-002 Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 437: Validity Of Circuit Diagram 3Hac025744-1
Label on the cable harness The label is located at the connectors in the base. Remove the rear cover plate to see the label. WebConfig Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 438: Validity Of Circuit Diagram 3Hac13347-1
3HAC 16331-1 IRB 7600 3HAC 14940-1 revision 0-2 For remaining cable harness assemblies, see section Validity of circuit diagram 3HAC025744-1 on page 437. Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 439: Index
378 calibration marks, 380 hanging Calibration Pendulum installed hanging, 32 overview of method, 401 hazard levels, 23 calibration position hazardous material, 410 Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 440 4, 310 motor axis 2, replacement, 297 motor axis 6, 322 motor axis 3, replacement, 303 replacements, report, 205 motor axis 4, replacement, 310 Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 441 427 upper arm, 244–245 speed wrist unit, 239–240 adjusting, 113 working range stability, 59 IRB 7600 - 150/3.5, 55 standards, 420 Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 442 IRB 7600 - 500/2.3, 58 overview of method, 402 IRB 7600 - 500/2.55, 57 restricting axis 1, 102 zero position restricting axis 2, 104 checking, 405 Product manual - IRB 7600 3HAC022033-001 Revision: AH © Copyright 2007 - 2023 ABB. All rights reserved.
Page 444 SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics & Discrete Automation 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2007 - 2023 ABB. All rights reserved. Specifications subject to change without notice.

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