Page 1 ABB Robotics Product manual IRB 7600...
Page 2 Trace back information: Workspace R13-1 version a6 Checked in 2013-03-31 Skribenta version 1184...
Page 3 Product manual IRB 7600 - 500/2.55 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 M2000, M2000A, M2004 Document ID: 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 4 The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.
Page 5: Table Of Contents
Working range, IRB 7600 - 150/3.5 .............. 2.4.3 Working range, IRB 7600 - 340/2.8 .............. 2.4.4 Working range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55 ........ 2.4.5 Working range, IRB 7600 - 500/2.3 .............. 2.4.6 Risk of tipping/stability ................
Page 6 Lubrication of spherical roller bearing, balancing device ......... Service Information System, M2000 ..............3.6.1 Using the SIS system ................3.6.2 Description of Service Information System (SIS) ........... 3.6.3 SIS system parameters ................3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 7 Calibration movement directions for all axes ............Updating revolution counters ................Checking the calibration position ................Decommissioning Environmental information .................. Decommissioning of balancing device ..............Reference information Introduction ...................... Applicable safety standards ................Unit conversion ....................3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 8 Frame-Lower arm 2 ................... Upper arm ....................... Wrist complete ....................10 Circuit diagram 10.1 About circuit diagrams ..................10.2 Validity of circuit diagram 3HAC025744-1 .............. 10.3 Validity of circuit diagram 3HAC13347-1 ..............Index 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 9: Overview Of This Manual
Prerequisites A maintenance/repair/installation craftsman working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Organization of chapters The manual is organized in the following chapters: Chapter...
Page 10 Application manual - Additional axes and stand 3HAC021395-001 M2004 alone controller Application manual - External axes 3HAC9299-1 M2000 Additional document references Document name Document ID Application manual - CalibWare Field 5.0 3HAC030421-001 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 11 Mainten- ance on page 145 Spare part / part list on page 417. • 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 262 Spare part list on page 419.
Page 12 Safety signals in the manual on page • New safety labels on the manipulators, see Safety symbols on manipu- lator labels on page • Revised terminology: robot replaced with manipulator. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 13 6 on page 383. • Corrected article number for axis-2-3 sealing, see Replacement of complete lower arm on page 271 Replacement of complete upper arm on page 266. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 14 Overview of this manual Continued Revision Description This revision includes the following updates: • A new SMB unit and battery is introduced, with longer battery lifetime. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 15: Product Documentation, M2000/M2000A
A complete listing of all available software manuals is available from ABB. Controller hardware option manual Each hardware option for the controller is supplied with its own documentation.
Page 16: Product Documentation, M2004
All documents listed can be ordered from ABB on a DVD. The documents listed are valid for M2004 manipulator systems. Product manuals...
Page 17 Operating manual - Introduction to RAPID • Operating manual - IRC5 with FlexPendant • Operating manual - RobotStudio • Operating manual - Trouble shooting IRC5, for the controller and manipulator. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 18: How To Read The Product Manual
Likewise certain work methods or general information, that is valid for several robot models, can be illustrated with pictures that show a different robot model that the one described in the current manual. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 19: Safety
Specific safety information, pointed out in the procedures. How to avoid and eliminate the danger is either described directly in the procedure, or in specific instructions in the section Safety related instructions on page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 20: General Safety Information
• stopping functions Safety stops describes different types of • description of emergency stop stops. • description of safety stop • description of safeguarding 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 21: Safety In The Manipulator System
Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial manipulator will not cause injury or damage even if all safety instructions are complied with. Related information...
Page 22: Safety Risks
ABB is not liable for damages caused by the use of non-original spare parts and special equipment. ABB is not liable for damages or injuries caused by unauthorized modifications to the manipulator system.
Page 23 Removed cables to the measurement sys- WARNING If the internal cables for the measurement system have been disconnected during repair or maintenance, then the revolution counters must be updated. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 24 Do not under any circumstances, deal with the balancing device in any other way than that detailed in the product documentation! For example, attempting to open the balan- cing device is potentially lethal! 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 25: Caution - Hot Parts May Cause Burns
Wait until the potentially hot component has cooled if it is to be removed or handled in any other way. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 26: Safety Risks Related To Tools/Work Pieces
Unauthorized modifications of the originally delivered manipulator are prohibited. Without the consent of ABB it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength could be affected.
Page 27: Safety Risks Related To Pneumatic/Hydraulic Systems
Gravity may cause any parts or objects held by these systems to drop. • Dump valves should be used in case of emergency. • Shot bolts should be used to prevent tools, etc., from falling due to gravity. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 28: Safety Risks During Operational Disturbances
If the working process is interrupted, extra care must be taken due to risks other than those associated with regular operation. Such an interruption may have to be rectified manually. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 29: Risks Associated With Live Electric Parts
The power supply unit for additional tools, or special power supply units for the machining process. • The external voltage connected to the controller remains live even when the robot is disconnected from the mains. • Additional connections. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 30 Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 31: Safety Actions
(see the section Robot motion in the Product specification). Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the manipulator. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 32: Fire Extinguishing
1 Safety 1.2.4.2 Fire extinguishing 1.2.4.2 Fire extinguishing Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the manipulator system (manipulator or controller)! 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 33: Emergency Release Of The Manipulator's Arm
Increased injury Before releasing the brakes, make sure that the weight of the arms does not increase the pressure on the trapped person, further increasing any injury! 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 34: Brake Testing
3 Check that the axis maintains its position. If the manipulator does not change position as the motors are switched off, then the brake function is adequate. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 35: Risk Of Disabling Function "Reduced Speed 250 Mm/S
1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" Note Do not change Transm gear ratio or other kinematic system parameters from the FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s". 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 36: Safe Use Of The Flexpendant
The hold-to-run function can only be used in manual mode. How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 37: Work Inside The Manipulator's Working Range
NEVER, under any circumstances, stay beneath any of the manipulator’s axes! There is always a risk that the manipulator will move unexpectedly when manipulator axes are moved using the enabling device or during other work inside the manipulator’s working range. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 38: Signal Lamp (Optional)
Function 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. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 39: Safety Stops
Emergency stop should not be used for normal program stops as this causes extra, unnecessary wear on the manipulator. For how to perform normal program stops, see section Stopping programs in Operating manual - IRC5 with FlexPendant. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 40 Dual Cabinet Controller). There can also be other types of emergency stops on your manipulator. Consult your plant or cell documentation to see how your manipulator system is configured. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 41: Safety Related Instructions
ELECTROSTATIC Warns for electrostatic hazards which could result DISCHARGE (ESD) in severe damage to the product. xx0200000023 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 42 1.3.1 Safety signals in the manual Continued Symbol Designation Significance NOTE Describes important facts and conditions. xx0100000004 Describes where to find additional information or how to do an operation in an easier way. xx0100000098 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 43: Safety Symbols On Manipulator Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 44 Pressing this button will release the brakes. This means that the manipulator arm can fall down. xx0900000808 Tip risk when loosening bolts The manipulator can tip over if the bolts are not securely fastened. xx0900000810 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 45 Risk of crush injuries. xx0900000817 Heat Risk of heat that can cause burns. xx0900000818 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 Brake release buttons xx0900000820 xx1000001140 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 46 Mechanical stop xx0900000824 No mechanical stop xx1000001144 Stored energy Warns that this part contains stored energy. Used in combination with Do not dismantle symbol. xx0900000825 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 47 Symbol Description Pressure Warns that this part is pressurized. Usually contains additional text with the pressure level. xx0900000826 Shut off with handle Use the power switch on the controller. xx0900000827 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 48: Danger - Moving Manipulators Are Potentially Lethal
The hold-to-run function is used in manual mode, not in automatic mode. Make sure no personnel are present within the working range of the manipulator be- fore pressing the start button. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 49: Danger - First Test Run May Cause Injury Or Damage
Pay special attention to the function of the part previously serviced Collision risks CAUTION When programming the movements of the manipulator always check potential collision risks before the first test run. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 50: Warning - The Brake Release Buttons May Be Jammed After Service Work
Make sure none of the buttons are jammed in the tube. 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! 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 51: Danger - Make Sure That The Main Power Has Been Switched Off
Note/illustration Switch off the main switch on the Drive Module. xx0600002783 K: Main switch, Drive Module Switch off the main switch on the Control A: Main switch, Control Module Module. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 52: Warning - The Unit Is Sensitive To Esd
Location of wrist strap button The location of the wrist strap button is shown in the following illustration. IRC5 The wrist strap button is located in the top right corner. xx0500002171 Wrist strap button 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 53: Warning - Safety Risks During Handling Of Batteries
Risk of fire or explosion. page Use safety glasses when handling the batteries. In the event of leakage, wear gloves and chemical apron. In the event of fire, use self-contained breathing apparatus. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 54: Warning - Safety Risks During Work With Gearbox Lubricants (Oil Or Grease)
Do not present in the gearbox, causing overfill the gearbox when filling. lubricant to spray from the xx0100000002 opening. Possible pressure build-up in gearbox Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
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Page 57: Installation And Commissioning
If the IRB 7600 is connected to power, always make sure that the robot is connected to protective earth before starting any installation work! For more information see: • Product manual - IRC5 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 58: Robot Transportation Precautions
Transportation in any other way than method 1 or 2 can seriously damage the robot.If the robot is incorrectly transported and the instructions are not followed, the robot is not covered by the warranty and ABB will not accept any compensation claim.
Page 59 Always read and follow the instructions in section Pre-installation procedure on page 65 Method 2 Transportation according to method 2 is approved by ABB, if use of method 1 is not possible. Always follow these instructions when transporting an ABB robot according to method 2: •...
Page 60 2 Installation and commissioning 2.2 Robot transportation precautions Continued IRB 7600 xx0800000037 Transport Support Hexagon socket head cap screw M16x140 Threaded bar M10x200 Nut M10 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 61 2 Installation and commissioning 2.2 Robot transportation precautions Continued Transport position with a transport support All transportation of the robot with tool must follow these instructions. IRB 7600 xx0800000040 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 62 2 Installation and commissioning 2.2 Robot transportation precautions Continued Recommended transport support Always use the recommended transport support when transporting a robot with tool. IRB 7600 xx0800000039 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 63: Securing The Robot
Releasing the brakes is a hazardous action that may cause injury and damage property. It must be done with great care and only when absolutely necessary. Securing the robot xx0800000062 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 64 This can seriously damage the robot. 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 85 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 65: Unpacking
It also contains information useful during later re-installation of the robot. Checking the pre-requisites for installation Installation craftsmen working with an ABB robot 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 67 Maximum tilt 5° The limit for the maximum payload on the robot is reduced if the robot is tilted from 0°. Contact ABB for further information about accept- able loads. Minimum resonance 22 Hz frequency Storage conditions, robot...
Page 68: Working Range, Irb 7600 - 150/3.5
2 Installation and commissioning 2.4.2 Working range, IRB 7600 - 150/3.5 2.4.2 Working range, IRB 7600 - 150/3.5 Illustration The illustration below shows the unrestricted working range of IRB 7600 - 150/3.5: xx0100000101 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 69: Working Range, Irb 7600 - 340/2.8
2 Installation and commissioning 2.4.3 Working range, IRB 7600 - 340/2.8 2.4.3 Working range, IRB 7600 - 340/2.8 Illustration The illustration below shows the unrestricted working range of IRB 7600 - 340/2.8: xx0300000296 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 70: Working Range, Irb 7600 - 400/2.55, Irb 7600
2 Installation and commissioning 2.4.4 Working range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55 2.4.4 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:...
Page 71: Working Range, Irb 7600 - 500/2.3
2 Installation and commissioning 2.4.5 Working range, IRB 7600 - 500/2.3 2.4.5 Working range, IRB 7600 - 500/2.3 Illustration The illustration below shows the unrestricted working range of IRB 7600 - 500/2.3: en0100000099 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 72: Risk Of Tipping/Stability
This figure shows the robot in its shipping position, which also is a recommended transport position. xx0100000103 WARNING The robot is likely to be mechanically unstable if not secured to the foundation! 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 73: On-Site Installation
Frame version without an oil plug, use the fork lift set: 3HAC0604-2 Frame version with an oil plug (C), use the fork lift set: 3HAC0604-1 Attachment holes, fork lift 3HAC0604-2 Attachment holes, fork lift 3HAC0604-1 Oil plug Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 74 Fork lift set, incl. all required 3HAC0604-2 See figure Fork lift set, 3HAC0604-2 on hardware page Standard toolkit Content is defined in section Standard tools on page 411. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 75 The fork lift set, 3HAC0604-2, is fitted to the robot as shown in the figure below. xx0100000102 Vertical attachment screws (4 pcs / fork lift pocket) Fork lift pockets (2 pcs) Spacer (2 pcs) Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 76 ONLY! Action Note If a cooling fan for the axis 1 motor is used, it must be removed in order to use the fork lift device! Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 77 Fit the two spacers to the robot and secure. Attachment points are shown in figure Attachment points on robot on page CAUTION The fork lift pocket weighs 60 kg! Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 78 B Spacers, 2 pcs. 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 79 Reposition harness, if any, before using a fork lift! CAUTION The IRB 7600 robot weighs 2500 kg. All lifting accessories used must be sized ac- cordingly! Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 80 Refit the cooling fan to the motor, if any. Detailed in section Installation of cool- ing fan for motors, axes 1-3 (option) on page 108. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 81: Lifting Robot With Lifting Slings
Illustration, lifting slings The figure below shows how to lift the complete robot with lifting slings. xx0200000153 Load hook Swivelling lifting eyes, 4 pcs Shortening hook Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 82 Raise overhead crane to lift the robot. 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. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 83: 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 84 Raise the overhead crane to lift the robot. 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. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 85: Manually Releasing The Brakes
Brake release at base The figure below shows the unit located at the base. xx0200000375 Internal brake release unit with push buttons, located on the robot base Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 86 Release the holding brake on a particular robot axis by pressing the corresponding button on the internal brake release unit. The brake will function again as soon as the button is released. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 87 DANGER Incorrect connections, such as supplying power to the wrong pin, may cause all brakes to be released simultaneously! Supply 0V on pin 12 and 24V on pin 11. xx0600002937 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 88: Manually Releasing The Brakes, External Brake Release Unit
How to use the internal brake release unit, if available, is detailed in section Manually releasing the brakes on page Required equipment Equipment Art. no. External brake release unit 3HAC12987-1 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 89 The illustration below shows where to connect the external brake release unit in order to release the holding brakes of the robot. xx0100000104 Connector R1.BU Rear connector plate Rear cover plate External brake release unit Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 90 Locate the free connector, connected to the rear of Shown in the figure Connectors, connector R1.MP, behind the rear connector plate. external brake release unit on page Make sure it is designated R1.BU. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 91 Release the holding brake of each robot axis by pressing the respective button on the external brake release unit. Disconnect the external brake release unit. Refit the rear cover plate with its attachment screws. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 92: Lifting The Base Plate
Fit lifting eyes in specified holes. Shown in figure Hole configur- ation on page Fit lifting slings to the eyes and to the lifting device. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 93: Securing The Base Plate
0,25 c (2x R22,5) 3x 90º xx1000001053 E, F, G, H Common tolerance zone (accuracy all over the base plate from one contact surface to the other) Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 94 2 Installation and commissioning 2.5.7 Securing the base plate Continued xx0400000715 Four holes for alternative clamping, 4x Ø18 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 95 Other tools and procedures may 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 96 2 Installation and commissioning 2.5.7 Securing the base plate Continued Recommendations, quality The table specifies any recommendations made by ABB: Variable Recommendation Recommended bolt quality and dimen- Hilti HDA-P, M20 x 250/50 (maximum thickness of sion base plate = 50 mm)
Page 97: Orienting And Securing The Robot
Suitable screws, lightly lubricated: M24 x 140 Quality: Quality 8.8 Suitable washer: Thickness: 4 mm Outer diameter: 44 mm Inner diameter: 25 mm Tightening torque: 725 Nm Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 98 Note 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 99 Hole configuration, base 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 100: 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 IRB 7600 - 130/3.5 3398 mm Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 101 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 102 IRB 7600 - 150/3.5 2012 mm 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 103 2.5.9 Fitting equipment on robot Continued xx0100000118 Illustration, fitting on turning disk The illustration below shows the mounting holes available for fitting equipment on the turning disk. xx0100000119 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 104 When fitting tools on the turning disk (see the figures above), only use screws with quality 12.9. Standard screws with quality 8.8 may be used when fitting other equipment to the mounting holes. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 105: Installation Of Base Spacers (Option)
Includes mounting set with at- tachment screws and mount- ing instruction. Base plate 3HAC12937-7 Standard toolkit Content is defined in section Standard tools on page 411. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 106 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 107: Extended Working Range, Axis 1 (Option 561-1)
3.84 radians The system parameters that must be = 220 degrees. changed (Upper joint bound and Lower joint bound) are described in Technical reference manual - System parameters. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 108: Installation Of Cooling Fan For Motors, Axes 1-3 (Option)
If both cooling fans and position switches are installed on the robot, the complete cabling must be used! It can not be combined with the separate cabling. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 109 The fans are installed on the motors, axes 1-3, as shown in the figure below. xx0500002157 Cooling fan, axis 1 Cooling fan, axis 2 Cooling fan, axis 3 Rear cover plate Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 110 Cooling fan, axis 1 Rear cover plate Cooling fan The details of the cooling fan are shown in the figure below. xx0500002158 Fanbox Attachment screws, fanbox plates (9 pcs) Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 111 Material set fan axes 1 and 3HAC023999-001 The set includes: • fan axes 1 & 2 cable harness • plate, customer • attachment screws and nuts. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 112 Other tools and procedures These procedures include references to may be required. See refer- the tools required. ences to these procedures in the step-by-step instruc- tions below. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 113 2.5.12 Installation of cooling fan for motors, axes 1-3 (option) Continued Plate for customer connections, at base xx0500002301 Plate for customer connections Attachment screws, 3 pcs, M6x16 quality 8.8-A2F Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 114 Separate cabling for axis 1 or 2 The figure below shows the cabling used only for the fan on axis 1 or 2. xx0500002173 Cable bracket Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 115 113. Art. no. is specified in Required equipment on page 111. Run the cabling up through the base and frame, beneath the balancing device. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 116 RobotWare 5.0: change the settings in the Modifying options dialogue, by using the Modify Controller System Wizard in the Sys- tem Builder of RobotStudio. Read more about modifying the system in Operating manual - RobotStudio. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 117: Installation Of Foundry Plus Cable Guard (Option No. 908-1)
Separate instructions for IRB 140, 4600, 1600, 6620, 6640, 6650S, 6660 and 7600 are available in English, German, French, Spanish and Italian and can be found on the DVD delivered with the Cable guard, article number 3HAC035933-001. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 118: Loads
Operating manual - IRC5 with FlexPendant (M2004) Stop time and braking distances Robot motor brake performance depends on any loads attached. For information about brake performance, read the product specification for the robot. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 119: Installation Of Signal Lamp (Option)
2 Installation and commissioning 2.5.15 Installation of signal lamp (option) 2.5.15 Installation of signal lamp (option) Signal lamp See the assembly instruction delivered with the signal lamp. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 120: Restricting The Working Range
This section describes how to install hardware that restricts the working range. Note Adjustments must also be made in the robot configuration software (system parameters). References to relevant manuals are included in the installation procedures. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 121: Mechanically Restricting The Working Range Of Axis 1
Mechanical stop for axis 1, 15° 3HAC11076-2 Includes attachment screws and an assembly drawing. Standard toolkit Content is defined in section Standard tools on page 411. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 122 If the mechanical stop pin is deformed after a hard collision, it must be replaced! Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 123: Mechanically Restricting The Working Range Of Axis 2
Includes six stops, 3HAC11407-1, each one restricting the working range by 15°. Includes attachment screws. Standard toolkit Content is defined in section Standard tools on page 411. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 124 If the mechanical stop pin is deformed after a hard collision, it must be replaced! Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 125: Mechanically Restricting The Working Range Of 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 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 126 User’s guide - S4Cplus (Base- 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 127 If the mechanical stop pin is deformed after a hard collision, it must be replaced! Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 128: Installation Of Position Switches (Option)
The position switch kits may be delivered in one of two ways: • Fitted by ABB Robotics on delivery. In this case, the cams must still be fitted and locked by the user. For axis 1, the cover for the cams must also be fitted.
Page 129 2 and 3. Instead the switch is connected directly to the connector in the base, R1.SW1. xx0100000158 Position switch, axis 1 Set screw, cam (cam stop) Protection sheet Rail Rail attachment Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 131 Position switch, axis 3 Set screw, cam (cam stop) Rail Rail attachment Specifications Maximum voltage/current for the position switches: Parameter Value Voltage Max. 50 VDC Current Max. 1 A Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 132 133. Install the cabling for axes 2 and/or 3. Detailed in section Installation of cable harness for position switches and fans on page 136. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 133 Cam stop, M5 nut and M5 x 6 set screw Adjustable cam Profile Illustration, cutting the cam The illustration below show how to cut the position switch cam. xx0100000114 Remove the gray section Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 134 2 Installation and commissioning 2.6.5 Installation of position switches (option) Continued Illustration, attachment plate for axis-2 switch xx1200000523 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 135 2 Installation and commissioning 2.6.5 Installation of position switches (option) Continued Plate for customer connections, at base xx0500002301 Plate for customer connections Attachment screws, 3 pcs, M6x16 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 136 • hydraulic pressure supply to the ro- • air pressure supply to the robot Before entering the robot working area. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 137 A Cable bracket, frame. Also shown in the figure Cable harness for pos- ition switches and fans, axes 1-3 on page 136. B Velcro strap C Connector R2.SW2 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 138 Secure the axis 3 fan cable with the bracket, Shown in the figure Cable harness for upper arm. position switches and fans, axes 1-3 on page 136. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 139 Refit the rear cover to the robot base. Install additional cabling to and inside the Cabling is specified in section: control cabinet. • Position switch cables, robot base to controller (option) on page 141 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 140: Electrical Connections
Robot cable, signals Transfers resolver data from R1.SMB and power supply to the serial measurement board. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 141 R1.SW2/3 XS58 Position switch cable, axes 2 and 3, 22 m 3HAC13176-3 R1.SW2/3 XS58 Position switch cable, axes 2 and 3, 30 m 3HAC13176-4 R1.SW2/3 XS58 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 142 Harness - cooling, 15 m 3HAC022723-004 Distributing cable: R1.FAN.SW2/3 Inside cabinet: A43.X10 and A43.X11 Harness - cooling, 22 m 3HAC022723-005 Distributing cable: R1.FAN.SW2/3 Inside cabinet: A43.X10 and A43.X11 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 143 2 Installation and commissioning 2.7.1 Robot cabling and connection points Continued Cable Art. no. Connection point Harness - cooling, 30 m 3HAC022723-006 Distributing cable: R1.FAN.SW2/3 Inside cabinet: A43.X10 and A43.X11 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 144 This page is intentionally left blank...
Page 145: Maintenance
If the IRB 7600 is connected to power, always make sure that the IRB 7600 is connected to protective earth before starting any maintenance work! For more information see: • Product manual - IRC5 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 146: Maintenance Schedule And Expected Life
The SIS used in M2000 and M2000A is further described in the section Service Information System, M2000 on page 225. The SIS used in M2004 is further described in the Operating manual - Service Information System. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 147: Maintenance Schedule
1, 2 and 3 on page 180 • Oil change, gearbox axis Changing Axis 1 gearbox oil Every: 1 on page 195 • 12,000 hours Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 148 • Oil change, gearbox, ax- is 4 on page 205 6,000 hours Second change when DTC reads: 24,000 hours Following changes: Every 24,000 hours Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 149 See Operating manual - IRC5 with FlexPendant for instructions. Always lubricate the front eye bearing after refitting the shaft of the balancing device. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 150 1, 2 and 12 months 3 on page 184 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. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 151: 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 152: Inspection Activities
Art. no. Note Lubricating oil Type and amount of oil in gearboxes on page 194. Standard toolkit Content is defined in section Standard tools on page 411. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 153 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 154 Tightening torque: 24 Nm. WARNING Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 155: Inspection, Oil Level Gearbox Axis 2
Gearbox, axis 2 (behind motor attachment not shown in figure ) Oil plug, filling (early design) Oil plug, draining Label, specifies the type of oil in axis 2 gearbox Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 156 Other tools and procedures may These procedures include refer- be required. See references to ences to the tools required. these procedures in the step-by- step instructions below. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 157 Tightening torque: 24 Nm. WARNING Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 158: Inspection, Oil Level Gearbox Axis 3
Note Lubricating oil Type and amount of oil in gear- boxes on page 194. Standard toolkit Content is defined in section Standard tools on page 411. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 159 Tightening torque: 24 Nm. WARNING Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 160: Inspection, Oil Level Gearbox Axis 4
Label, specifies the type of oil in the primary gear of axis 4 Required equipment Equipment, etc. Art. no. Note Lubricating oil Type and amount of oil in gearboxes on page 194. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 161 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 194. Detailed in section Oil change, gearbox, axis 4 on page 205. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 162 Tightening torque: 24 Nm. WARNING Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 163: Inspection, Oil Level, Gearbox Axis 5
Oil plug, filling, primary gearbox (draining on opposite side of wrist housing, not shown in figure) Label, specifies the type of oil in primary gear axis 5 Label, specifies the type of oil in secondary gear axis 5 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 164 Open the oil plug, filling, in the secondary gear Shown in the figure Location of gearbox on page 163. Measure the oil level. Required oil level: max. 10 mm to the oil plug hole. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 165 Tightening torque: 24 Nm. WARNING Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 166: Inspection, Oil Level Gearbox Axis 6
Art. no. Note Lubricating oil Type and amount of oil in gearboxes on page 194. Standard toolkit Content is defined in section Standard tools on page 411. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 167 • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Open the oil plug, filling. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 168 Tightening torque: 24 Nm. WARNING Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 169: Inspection, Balancing Device
The article number of the balancing device is located on a label at the rear cover, shown in the figure Inspection points, balancing device on page 170. Balancing device, art. no. Action at detected faults 3HAC10538-1 Upgrade 3HAC14675-1 Maintenance Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 170 The figure also shows the inspection points, further described in the instructions. xx0300000580 Balancing device Piston rod (inside) Shaft, including securing screw Ear, bearing and o-rings Label with article number Inspect the surroundings Bearing, balancing device attachments Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 171 Other tools and These procedures include procedures may be references to the tools re- required. See refer- quired. ences to these procedures in the step-by-step in- structions below. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 172 Action at detected faults on page 169. • balancing device (a ...replace the balancing device or consult ABB Robotics. tapping sound, How to replace the device is detailed in section Repla- caused by the springs cing the balancing device on page 298.
Page 173 Action Note Clean the area at the front ear from old grease. Run the robot for some minutes, in order to move the balancing device piston. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 174 See the figure Inspection points, balancing device on page 170. Keep the areas around the balancing device clean and free from objects, such as service tools. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 175: Inspection, Cable Harness
See refer- to the tools required. ences to these procedures in the step-by-step instructions below. Circuit diagram See chapter Circuit diagram on page 457. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 176 The robot cable harness, axes 5-6, is located as shown in the figure below. xx0200000155 Cable attachment, upper arm tube Cable attachment, rear of upper arm Connectors at cable harness division point, R2.M5/6 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 177 Replace the cable harness if wear, cracks or Described in section Replacement of damage is detected. cable harness, axes 5-6 on page 250 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 178: Inspecting, Mechanical Stop Pin, Axis
Inspect the mechanical stop pin, axis 1. Shown in figure Location of mechan- ical stop pin on page 178. Make sure mechanical stop pin can move in both directions. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 179 Art. no. is specified in Required must be replaced! equipment on page 178. Note The expected life of gearboxes can be reduced as a result of collisions with the mechanical stop. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 180: Inspection, Mechanical Stop, Axes 1, 2 And
Limits the robot working range to 15°. Mechanical stop ax 2 3HAC11077-1 Mechanical stop ax 3 3HAC13128-2 Standard toolkit Content is defined in section Standard tools on page 411. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 181 Art. no. is specified in Required must be replaced! equipment on page 180! Correct attachment screws: • Axis 1: M16 x 35 • Axis 2: M16 x 50 • Axis 3: M16 x 80 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 182: Inspection, Damper Axes 2-5
Damper, axis 4 (2 pcs) Damper, axis 5 (2 pcs) 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 183 Check attachment screws for deformation. If any damage is detected, the damper must be re- Art. no. is specified in placed with a new one! quired equipment on page 182. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 184: Inspection, Position Switch Axes 1, 2 And 3
The position switches, axes 1, 2 and 3, are located as shown in the figures below. xx0100000158 Position switch, axis 1 Set screw, cam Protection sheet Rail Rail attachment Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 185 3.3.12 Inspection, position switch axes 1, 2 and 3 Continued The illustration below shows the position switch for axis 2. xx0100000159 Position switch, axis 2 Set screw, cam Rail Rail attachment Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 186 Position switch, axis 2 3HAC15715-2 To be replaced in case of detected damage. Position switch, axis 3 3HAC15715-2 To be replaced in case of detected damage. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 187 Check that the space inside the sheets is clean enough not to disturb the function of the position switch. If any damage is detected, the position switch must be replaced. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 188: Inspection, Information Labels
Label, type of oil in gearbox 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 189 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Check the labels, located as shown in the figures. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 190 3 Maintenance 3.3.13 Inspection, information labels Continued Action Note Replace any missing or damaged labels. Art. no. is specified in Required equipment on page 189. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 191: Inspection, Ul-Lamp
Other tools and procedures may 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 192 191! • Check the cable connections. • Measure the voltage in connectors motor axis 3 (=24V). • Check the cabling. Replace cabling if a fault is detected. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 193: Changing/Replacement Activities
Axis 1 gearbox Axis 2 gearbox Axis 3 gearbox Axis 4 primary gearbox Axis 4 secondary gearbox Axis 5 primary gearbox Axis 5 secondary gearbox Axis 6 gearbox Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 194 10. In order to always get the latest information of updates about lubrication in gearboxes, always check on ABB Library for the latest revision of the manual. A new revision will be published on ABB Library immediatly after any updates.
Page 195: Oil Change, Gearbox Axis 1
Gearbox, axis 1 Oil plug, filling Motor, axis 1 Oil plug, inspection (not in all designs) Label, specifies the type of oil in the gearbox Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 197 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 198 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, filling. Tightening torque: 24 Nm. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 199: Changing Oil, Axis-2 Gearbox
Oil exchange equip- 3HAC021745-001 Content is defined in section ment Special tools on page 412. Standard toolkit Content is defined in section Standard tools on page 411. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 200 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 201 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. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 202: Changing Oil, Axis-3 Gearbox
Type Note! Do not mix with other oil amount of oil in types! gearboxes on amount of page 194. oil in gear- boxes on page 194. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 203 202. the oil quicker! Note 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 204 Technical reference manual - Lubrication in gearboxes. Note Do not mix Kyodo Yushi TMO 150 with other oil types! Refit the oil plug. Tightening torque: 24 Nm. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 205: Oil Change, Gearbox, Axis 4
Oil plug, filling, primary gearbox (draining not shown in figure, located further down on the motor flange) Label, specifies the type of oil in the secondary gear Label, specifies the type of oil in the primary gear Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 206 Drain the primary gear by opening the oil plug, Vessel capacity specified in draining, primary gearbox. quired equipment on page 206. Refit the both oil plugs, draining. Tightening torque: 24 Nm. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 207 Technical reference manual - Lubrication in gearboxes. Refit the both oil plugs, filling. Shown in the figure Location of gearbox on page 205. Tightening torque: 24 Nm. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 208: Oil Change, Gearbox, Axis 5
Oil plug, filling primary gearbox (draining on opposite side of wrist housing, not shown in figure) Label, specifies the type of oil in primary gear Label, specifies the type of oil in secondary gear Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 209 Open the oil plug, draining, secondary gearbox. Shown in the figure Location of gearbox on page 208. Drain the oil from the secondary gear. Vessel capacity: 4,000 ml. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 210 Technical reference manual - Lubrication in gearboxes. Refit the both oil plugs, filling. Shown in the figure Location of gearbox on page 208. Tightening torque: 24 Nm. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 211: Oil Change, Gearbox Axis 6
194. page 194. Oil collecting vessel Vessel capacity: 1,000 ml. Oil exchange equip- 3HAC17313-1 Content is defined in section ment Special tools on page 412. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 212 Drain the oil from gearbox 6 by removing the oil Vessel capacity: 1000 ml. plug. Collect the oil with a suitable vessel. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 213 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 both oil plugs. Tightening torque: 24 Nm. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 214: Replacing The Smb Battery
See Operating manual - IRC5 with FlexPendant for instructions. WARNING See instructions for batteries, WARNING - Safety risks during handling of batteries on page Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 215 Battery pack with a 2-pole battery contact xx0200000238 SMB battery cover SMB battery pack with 2-pole battery contact. Battery cable Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 216 Equipment, etc. Spare part no. Note Battery pack For spare part no. Battery includes protection circuits. Only re- see: place with a specified spare part or an ABB- • Spare part / approved equivalent. part list on page 417 Standard toolkit...
Page 217 Shown in figure Location of SMB Battery includes protection circuits. Only replace battery on page 215. 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 218 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 219: Lubrication 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 220 Tightening torque: 24 Nm. 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. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 221: Cleaning, Robot
Perform according to section Cleaning with water and steam on page 221. Cleaning with water and steam Cleaning methods that can be used for ABB robots with protection Standard, Foundry Plus, Wash and Foundry Prime. Equipment, etc. Note Vacuum cleaner Cloth with mild detergent •...
Page 222 Never point the water jet at connectors, joints, sealings, or gaskets! • Never use compressed air to clean the robot! • Never use solvents that are not approved by ABB to clean the robot! • Never spray from a distance closer than 0.4 meters! •...
Page 223: Lubrication Of Spherical Roller Bearing, Balancing Device
Sealing spacer Hole through which the shaft is pressed Required equipment Equipment, etc. Art. no. Note Grease 3HAA1001-294 Optimol PDO, 150 ml Lubrication nipple Grease pump Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 224 Inspection, balancing device - of the robot, in order to make sure there is Check for leakage on page 172. no incorrect leakage from the o-rings. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 225: Service Information System, M2000
PC, or if the SIS data on page 234. parameters are to be entered from an extern- al PC, a set of software tools are available to build such an application. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 226: Description Of Service Information System (Sis)
Date when next scheduled service is planned. This date is calcu- lated using system parameters, as detailed in section Setting the SIS parameters on page 231. Remaining time Remaining time to next scheduled service date. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 227 Exporting the SIS data on page 234! Service interval exceeded When the service time has been exceeded for the selection made, an error message (Service interval exceeded!) is displayed. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 228 3.6.2 Description of Service Information System (SIS) Continued 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. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 229: 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. The figures below shows the options of parameters to be set.
Page 230 (estimated remaining lifetime) of each gearbox. This is done by extrapolating data from earlier operation into a function of time, using a formula including: • input and output torque • gearbox spindle speed • other variables 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 231: Setting The Sis Parameters
This is an instruction of how to enter SIS parameters to the M2000 robot system. Action Note Open "System parameters" Detailed in the User's Guide. using the TPU. Go to "System paramet- ers/Manipulator/types 2". xx0200000045 en0200000046 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 232 The parameter list is dis- played. en0200000048 en0200000049 Select the required paramet- Available parameters are described in section SIS system ers by stepping up and parameters on page 229. down through the parameter list. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 233: 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 231. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 234: Exporting The Sis Data
Estimated life of gearbox axis 3 sisL10h_Time_3 Gearbox time Operation time of gearbox axis 3 sisL10h_6 Gearbox time Estimated life of gearbox axis 6 sisL10h_Time_6 Gearbox time Operation time of gearbox axis 6 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 235: Repair
If the IRB 7600 is connected to power, always make sure that the IRB 7600 is connected to earth before starting any repair work. For more information see: • Product manual - IRC5 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 236: General Procedures
The test is complete. Spray suspected leak areas with leak detection spray. Bubbles indicate a leak. When the leak has been localized, take the necessary measures to correct the leak. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 237: Mounting Instructions For Bearings
• During operation, the bearing should be filled to 70-80% of the available volume. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 238 Grease the different types of bearings as following description: • Grooved ball bearings must be filled with grease from both sides. • Tapered roller bearings and axial needle bearings must be greased in the split condition. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 239: Mounting Instructions For Seals
Mount the seal correctly with a mounting tool. Never hammer directly on the seal as this may result in leakage. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 240 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, preferably with a brush. Tighten the screws evenly when fastening the flange joint.
Page 241: Complete Robot
Connectors at serial measurement board; R1.SMB1-3, R1.SMB4-6, R1.SMB1.7, 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 242 Axis 1: 0 ° • Axis 2: 0 ° • Axis 3: 0 ° • Axis 4: 0 ° • Axis 5: +90 ° • Axis 6: no significance Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 243 Disconnect connectors R2.SMB, R1.SMB1-3, 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 244 A: Cable gland • B: Attachment screws, cable gland • C: Attachment plate • D: Velcro strap Remove the cable gland securing the cables inside the lower arm. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 245 Axis 1: 0 degrees • Axis 2: 0 degrees • Axis 3: 0 degrees • Axis 4: 0 degrees • Axis 5: +90 degrees • Axis 6: no significance Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 246 241. Reconnect all connectors at motors 1 and 2. Specified and shown in the figure Location of cable harness on page 241! Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 248 Make sure not to twist the harness! xx0100000143 Reconnect all connectors at motor 3 and motor Specified and shown in the figure Location of cable harness on page 241! Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 249 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 250: Replacement Of Cable Harness, Axes
Other tools and procedures may 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 251 The procedure below details how to refit the upper cable harness. Action Note Position the upper arm as follows: • Axis 4: 0 degrees • Axis 5: +90 degrees • Axis 6: no significance Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 252 M6, 2 pcs. fastening the screws! Refit the plastic cover on the rear of the upper arm. Update the revolution counters. Detailed in section Updating re- volution counters on page 392. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 253: Replacement Of Complete Arm System
1, that is the upper and lower arms, balancing device and frame. 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 254 Oil change, gearbox axis 1 on page 195. Disconnect the cabling in the rear of the robot base and remove the cable support plate inside of the base. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 255 All lifting equipment used must be sized accordingly! Fit and adjust the lifting device as detailed Art. no. is specified in Required equip- in enclosed instruction. ment on page 254. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 256 Performing a leak- down test on page 236. Refill the gearbox axis 1 with lubricating oil. Detailed in section Filling, oil, gearbox axis 1 on page 198. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 257 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 258: Upper And Lower Arm
Must be replaced when repla- cing the turning disk! Grease 3HAB3537-1 Used to lubricate the o-ring. Standard toolkit Content is defined in section Standard tools on page 411. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 259 Remove the attachment screws (33 pcs) Shown in the figure Location of turning securing the turning disk. disk on page 258. Remove the turning disk. xx1000001135 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 260 Reused screws may be used, providing they are lubricated as detailed in section Screw joints on page 407 before fitting. Refill the gearbox, axis 6, with oil. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 261 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 262: Replacement Of Complete Wrist Unit
View with cable harness mounted on robot Required equipment Equipment, etc. Art. no. Note Wrist For spare part num- ber, see Spare part / part list on page 417. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 263 Slightly raise the wrist unit to unload the screw joint, facilitating removal of the attachment screws. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 264 Refit any cable ties that were previously cut during disassembly. Reconnect connector R2.M5/6 at the rear cable di- Shown in the figure Location of vision point. wrist unit on page 262. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 265 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 266: Replacement Of Complete Upper Arm
Oil plug, draining Oil plug, filling Attachment hole, M12 Sealing between lower arm and gearbox 3 Attachment holes for lifting device, upper arm Attachment holes for lifting eye Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 267 266. upper arm using the included attachment screws. Art. no. is specified in Required equipment on page 267. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 268 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 269 If both washer sides are damaged, re- place the washer. Art. no. is spe- cified in Required equipment on page 267. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 270 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 271: 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 272 Lower arm Balancing device piston rod ear Frame Shaft hole Sealing, axis 2/3 Attachment screw Washer Bearing Thrust washer Bushing Retaining ring Shaft Protection plug Protection washer Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 273 Equipment, etc. Spare part no. Art. no. Note Bearing 3HAC4310-1 Always use a new bearing! Sealing, axis 2/3 3HAC17213-1 Always use a new sealing! VK cover 3HAA2166-23 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 274 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 275 The lower arm weighs 225 kg! All lifting equipment used must be sized accordingly! Apply the lifting tool to the lower arm. Art. no. is specified in Required equip- ment on page 273! Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 276 Included in the lifting tool, lower arm, the lower arm. art. no. is specified in Required equipment on page 273. xx0200000262 Attachment holes for the two guidings. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 277 200. Refit and reconnect all cables inside the lower Detailed in section Refitting, cable arm. harness, axes 1-4 on page 245. Refit removed cable attachments. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 278 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 279: 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 280 Always use a new bearing see: when reassembling! • Spare part / part list on page 417. Puller device, axis 2 shaft 3HAC021563-001 Press device, axis 2 shaft 3HAC021600-001 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 281 The illustration below shows the puller tool used to remove the lower arm shaft (axis 2 shaft). xx0400001029 Nipple for the hydraulic pump Nipple for the glycerin pump Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 282 Indicator 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 This procedure is a step in the complete...
Page 284 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 285 Apply the press device, axis 2 shaft against the Art. no. is specified in Required shaft. equipment on page 280! Tighten the M16 nut. Tightening torque: 20 Nm. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 286 Use this procedure to refit the lower arm shaft if the robot has protection Foundry Plus. Action Note/Illustration Clean the shaft with isopropanol and lubricate it Art. no. is specified in Required with grease. equipment on page 280! Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 287 Remove the press device, axis 2 shaft. Apply grease to the location of the shaft where the Art. no. is specified in Required bearing is to be mounted. equipment on page 280 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 288 Use locking liquid. Proceed with the refitting procedure of the lower arm, detailed in section Replacement of complete lower arm on page 271. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 289: Frame And Base
SMB unit For spare part number, see: Spare part / part list on page 417. Standard toolkit Content is defined in section Standard tools on page 411. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 290 Note DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 291 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 292: Replacement Of Brake Release Unit
The early design includes a brake release unit with or without push buttons, located at the base as shown in the figure below. xx0200000127 Brake release circuit (brake release unit inside) Attachment screws, brake release circuit, 4 pcs Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 293 3HAC16036-1 Brake release unit at the frame, according buttons, at frame to figure Location of brake release unit, frame on page 293. Push button guard 3HAC2744-1 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 294 Note DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 295 The unit is sensitive to ESD. Before handling the unit please read the safety information in the section WARNING - The unit is sensitive to ESD! on page 52 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 296 C Connector X10 D Push buttons Refit the SMB cover with its attachment screws. Shown in the figure Location of brake release unit, frame on page 293. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 297 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 298: Replacing The Balancing Device
Support shaft inside (included in balancing device 3HAC14675-1) 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 299 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 300 Hydraulic pump, 80 3HAC13086-1 To be used with the hydraul- ic cylinder. Standard toolkit Content is defined in sec- tion Standard tools on page 411. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 301 311. Remove the securing screw and washer from Shown in the figure Location of balan- the balancing device shaft. cing device on page 298! Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 302 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 303 Raise the balancing device to a position where the balancing device shaft may be inserted through the piston shaft front eye. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 304 The rear cover of the balancing device is a safety device for the piston rod during opera- tion! Make sure the cover is properly secured before commissioning of the robot! Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 305 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 306: Replacement Of Spherical Roller Bearing, Balancing Device
3HAA2167-17 Sealing spacer 3HAC12988-1 2 pcs required. O-ring 3HAB3772-76 2 pcs required. Sealing ring 3HAC11581-6 2 pcs required. Grease 3HAB3537-1 For lubrication of the com- ponents. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 307 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 308 • air pressure supply to the robot Before entering the robot working area. Grease the inside walls of the front ear. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 309 Make sure no incorrect leakage occurs. It Further information is available in section could indicate damaged o-rings. Check for leakage on page 172. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 310 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 311: Unloading The Balancing Device Using Hydraulic Press Tool
The figure below shows the hydraulic cylinder mounted on the press tool. The press tool includes two press devices that are used to different models of the balancing device. xx0200000174 Press block Hydraulic cylinder Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 312 Press device Art. no: 3HAC14675-2 Art. no: 3HAC15767-2 (for balancing device 3HAC14675-1) xx0300000600 xx0300000605 Art. no: 3HAC18100-1 (for balancing Art. no: 3HAC023018-001 device 3HAC023018-001) xx0300000599 xx0700000423 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 313 Turn the fix plate to position "Closed" in order See the figure Press tool and hydraulic to lock the tool in loaded condition. cylinder on page 311. Unload the hydraulic cylinder. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 314 4 Repair 4.5.5 Unloading the balancing device using hydraulic press tool Continued Action Note The hydraulic cylinder may now be removed from the tool, when necessary. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 315: Restoring The Balancing Device Using A Hydraulic Press Tool
The press tool includes two press devices that are used to different models of the balancing device. xx0200000174 Press block Hydraulic cylinder Press device Bolt, press device Moving pin with marking Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 316 Refit the support shaft to the balancing device. 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 317 The rear cover of the balancing device is a safety device for the piston rod during opera- tion! Make sure the cover is properly secured before commissioning of the robot! 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 318: 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 319 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 320 Lightly lubricate the o- equipment on page 319. ring with grease. CAUTION The motor weighs 32 kg! All lifting equipment used must be sized accordingly! Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 321 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 322: Replacement Of Motor Axis 2
O-ring 21522012-430 Must be replaced when re- assembling motor! Grease 3HAB3537-1 For lubricating the o-ring. Locking screw 3HAA1001-266 M16 x 60 For securing the lower arm. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 323 Location of motor on page 322. enough to its calibration position, to allow the lock screw to be inserted into the hole for lock screw . Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 324 Remove the removal tools and fit the Art. no. is specified in Required equipment on lifting tool, motor axis 2, 3, 4 to the page 322. motor. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 325 Make sure that the motor is turned the right direction, that is the cables facing downwards. Remove the lifting tool and allow the motor to rest on the guide pins. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 326 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 327: Replacement Of Motor, Axis 3
Use attachment screws 3HAB 3409-86 (M16 x 60). Grease 3HAB3537-1 For lubricating the o-ring. Removal tool, mo- 3HAC14973-1 Always use the removal tools tor M12x in pairs! Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 328 See refer- ences to these pro- cedures in the step-by-step in- structions below. Circuit Diagram See chapter Circuit diagram on page 457. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 329 Art. no. is specified in Required equipment on fitting removal tool, motor to the re- page 327. maining motor attachment screw Always use the removal tools in pairs! holes. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 330 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 331 Calibration is detailed in a separate calibration manual enclosed with the calibration tools. General calibration information is included in section Calibration in- formation on page 387. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 332 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 333: Replacement Of Motor, Axis 4
To be used if the upper arm is positioned vertically. Lifting tool, motor ax 2, 3, 4 3HAC15534-1 To be used if the upper arm is positioned horizontally. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 334 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 335 Remove the motor by gently lifting it straight Make sure the motor pinion is not dam- out. aged! Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 336 Fit the motor with guidance of the pins, 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 337 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 338: Replacement Of Motor, Axis 5
For lifting the motor in a ver- 4, 5 tical position Power supply 24 VDC, 1.5 A. For releasing the brakes. Extension 300mm for bits 3HAC12342-1 1/2" Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 339 Remove the motor by unscrewing its four attachment Art. no. is specified in Required screws and plain washers. equipment on page 338. If required, use the extension 300 mm for bits 1/2. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 341 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 342: Replacement Of Motor, Axis 6
Must be replaced when repla- cing motor Gasket, cover 3HAC033489-001 Must be replaced when opening cover. Removal tool, motor 3HAC14972-1 Always use the removal tools M10x in pairs! Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 343 In horizontal position: drain the oil from the axis 6 Detailed in section Draining, oil, gearbox. gearbox axis 6 on page 212. Remove the rear motor cover by unscrewing the five attachment screws. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 344 Make sure the cover is tightly sealed! attachment screws. Perform a leak-down test (if the gearbox has Detailed in section Performing a leak- been drained). down test on page 236. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 345 Before entering the robot working area. In horizontal position: drain the oil from the Detailed in section: Draining, oil, gear- axis 6 gearbox. box axis 6 on page 212. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 346 Continue to remove the motor unit, according to step 6 and forwards in Removal, motor on page 343. Note Keep the old rear motor cover with the air nipple. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 347 Loctite 570 on the tilt house (on the sur- face facing the motor end cover). Apply grease on the o-ring on the motor. Continue to refit the new motor according to section, Refitting, motor on page 344. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 348: Gearboxes
417. • all o-rings and sealing rings 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 349 Remove the complete arm system. Detailed in section Replacement of com- plete arm system on page 253. Unfasten the robot base from the foundation by removing the base attachment screws. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 350 Secure the support to the base and to the foundation. 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 351 A view from below: • A: Oil drain hose • B: Attachment screws, gearbox axis 1, 18 pcs • C: Washers, 3 pcs Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 352 Mounting of the support, base and gear 1 is detailed in section Removal, gear- box axis 1 on page 349. xx1000000364 A Support base (4 pcs) Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 353 C: O-ring 3HAB 3772-54 • D: O-ring 3HAB 3772-55 • E: Sealing ring 3HAC 11581-4 Make sure the small o-ring around the oil hole is fitted properly! xx1000001392 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 354 Required equipment on holes in the gearbox, parallel to each other. page 348. CAUTION The gearbox weighs 200 Kg. All lifting accessories used must be sized ac- cordingly! Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 355 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 356 B: Attachment screws, gearbox axis 1, 18 pcs • C: Washers, 3 pcs Refit the cable guide in the center of gearbox 1 with its attachment screws. xx1000001393 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 357 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 358: Replacement Of Gearbox, Axis 2
Hole for locking screw, lower arm, M16 x 60 Sealing (between gearbox and motor attachment, not shown in figure) Friction washer (between the gearbox and lower arm, not shown in figure) Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 359 Removal, gearbox The procedure below details how to remove gearbox, axis 2. Action Note Remove any equipment fitted to the turning disk. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 360 Art. no. is specified in Required the locking screw into the hole. equipment on page 359! Shown in the figure Location of gearbox on page 358! Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 361 359. tool. Remove the motor attachment. CAUTION The gearbox weighs 125 kg! All lifting equipment used must be sized accordingly! Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 362 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 363 Lift the gearbox to its mounting position. Fit the gearbox onto the guide pins and slide it Make sure the gearbox is seated into position. properly! Remove the lifting tool. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 364 Calibration is detailed in a separate calibration manual enclosed with the calibration tools. General calibration information is included in section Calibration in- formation on page 387. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 365 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 366: Replacement Of Gearbox, Axis 3
Attachment screws, gearbox Oil plug, filling Oil plug, draining Motor, axis 3 Attachment screws, upper arm Attachment screws, motor Sealing, axis 2/3 (between lower arm and gearbox 3) Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 367 Other tools and procedures These procedures include refer- may be required. See refer- ences to the tools required. ences to these procedures in the step-by-step instructions below. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 368 Fit the two guide pins in 180° rela- Art. no. is specified in Required equipment on tion to each other in the gearbox page 367. attachment screw holes. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 369 Art. no. is specified in Required equipment on tion to each other in the holes in page 367. the upper arm, used for the gearbox attachment screws. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 370 Recalibrate the robot! Calibration is detailed in a separate calibration manual enclosed with the calibration tools. General calibration information is included in section Calibration information on page 387. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 371 Make sure all safety require- ments are met when performing the first test run. These are fur- ther detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 372: Replacement Of Gearbox, Axis 4
Oil plug, filling, secondary gearbox Oil plug, draining, secondary gearbox Gear, Z3 Gear attachment screws Motor, axis 4 Motor flange Oil plug, filling, primary gearbox (draining not shown in figure) Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 373 Remove the plastic housing from the cover, axis 4 gearbox. Remove the cover, axis 4 gearbox by unscrewing Shown in the figure Location of its attachment screws. gearbox on page 372. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 374 Fit four guide pins symmetrically in the attach- ment holes in the upper arm housing. xx0200000067 A Attachment holes for guide pins, M10 Art. no. is specified in Required equipment on page 373. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 375 Calibration is detailed in a separate calibration manual enclosed with the calibration tools. General calibration information is in- cluded in section Calibration informa- tion on page 387. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 376 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 377: Replacement Of Gearbox, Axis 5
Attachment screws, gear Z3 Gearbox, axis 5 Oil plug, primary, filling (draining plug on the opposite side of the wrist housing, not shown in figure) VK-cover Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 378 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 379 377 and in the fig- Turn the gear Z4 in order to reach all the srews. ure below! 7 pcs: M6 x 16. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 380 Refit the gearbox, axis 5 to the wrist housing, by Shown in the figure Location of gently lowering it straight down, using the guide gearbox on page 377. pins. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 381 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in the section DANGER - First test run may cause injury or damage! on page Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 382 Shown in the figure Location of gearbox on page 377. Proceed with step 11 in the refitting detailed in the previous procedure (procedure Refitting, gearbox axis 5 on page 380). 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 383: Replacement Of Gearbox, Axis 6
Gearbox For spare part number, Includes o-ring. Spare part / part list on page 417. Washers 3HAC10122-13 Not included in the gearbox. Re- place if damaged! Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 384 If required, apply M10 screws to the holes shown in the figure to the right, to press the gearbox out. xx0200000220 • A: M10 holes for pressing out the gearbox Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 385 383. Shown in the figure Location of gearbox on page 383. Make sure the gears of the gearbox mate with the gears of the motor! Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 386 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 387: Calibration Information
The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration. The different methods are briefly described in the section Calibration methods on page 388 , and further detailed in separate calibration manuals.
Page 388: Calibration Methods
To regain 100% absolute accuracy perform- ance, the robot must be recalibrated for abso- lute accuracy! xx0400001197 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 389 Calibration Pendulum - standard method Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S) and is also the most accurate method for the standard type of calibration. It is the recommended method in order to achieve proper performance.
Page 390: Calibration Scale And Correct Axis Position
One of the marks is more narrow than the other and should be positioned within the limits of the wider mark. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 391: Calibration Movement Directions For All Axes
Note! The graphic shows an IRB 7600. The positive direction is the same for all 6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in the opposite direction! xx0200000089 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 392: Updating Revolution Counters
If the calibration marks seem to be wrong (even if the motor calibration data is correct), try to rotate the axis one turn, update the revolution counter and check the calibration marks again (try both directions, if needed). Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 393 Press OK when all axes that are to be updated are marked with an x. 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 394 • Tap Yes to update the revolution counters. • Tap No to cancel updating the revolution counters. Tapping Yes displays the axis selection window. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 395 If a revolution counter is incorrectly updated, it will cause incorrect manipulator posi- tioning, which in turn may cause damage or injury! Check the calibration position very carefully after each update. See Checking the calibration position on page 396. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 396: Checking The Calibration Position
Using the jogging window on the TPU, S4Cplus Use this procedure to jog the robot to zero position of all axes. Action Illustration/Note Open the Jogging window. xx0100000195 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 397 Check that the calibration marks for the Calibration scale and correct axis pos- axes align correctly. If they do not, update ition on page 390, and Updating revolution the revolution counters! counters on page 392. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
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Page 399: Decommissioning
Also note that: • 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. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 400: Decommissioning Of Balancing Device
The following procedure contains useful information about decommissioning. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 401 Middle spring: cut at least four coils! • Inner spring: cut at least four coils! Double-check the number of coils cut and make sure all the tension in the springs is removed. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
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Page 403: Reference Information
7 Reference information 7.1 Introduction 7 Reference information 7.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 404: Applicable Safety Standards
Safety of machinery - General requirements for the design and construction of fixed and movable guards Other standards Standard Description ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 405 7.2 Applicable safety standards Continued Standard Description ANSI/UL 1740 Safety standard for robots and robotic equipment (option 429-1) CAN/CSA Z 434-03 Industrial robots and robot Systems - General safety require- ments (option 429-1) 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 406: Unit Conversion
3.28 ft. 39.37 in Weight 1 kg 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 407: Screw Joints
UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below) and is extremely resistant to fatigue.
Page 408 Molycote 1000, Gleitmo 603 or equivalent with allen head screws. Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 409 The following table specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass. Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm - Nominal Min. Max. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 410: 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 411: Standard Tools
To be shortened to 12 mm 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 412: Special Tools
Fixture lower arm 3HAC13660-1 Guide pins M12 x 130 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 413 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 414 Includes: • Vacuum pump with regulator, hose and coupling • Couplings and adapters • Pump (manual) with hose and coupling • Graduated measuring glass • Oil gun • User instructions. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 415: Lifting Accessories And Lifting Instructions
The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting accessories. This implies that the instructions delivered with the lifting accessories should be stored for later reference. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
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Page 417: Spare Part / Part List
8 Spare part / part list 8.1 Introduction 8 Spare part / part list 8.1 Introduction Definitions This chapter specifies all spare parts and replacement articles of the robot. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 418: Spare Parts
This section specifies all articles considered spare parts of the robot. The spare parts are also specified as required equipment directly in the repair instruction of the current spare part. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 419: Spare Part List
Foundry Plus, Cable guard 3HAC035933-001 Option no. 908-1 Wrist, type 3 3HAC16628-4 Standard and Foundry, (103) 3HAC027295-001 Foundry Prime Wrist, insulated 3HAC16628-3 (103) Friction washer 3HAC11755-1 (108.205) Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 420 Turning disk, dia. 250 3HAC13193-1 (103.28.5) Turning disk, insulated 3HAC023124-002 (103.28.3) Balancing device 3HAC14214-1 (104) Maintenance kit 3HAC15834-1 For balancing device. Maintenance kit 3HAC14962-1 For balancing device. Only bearings. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 421 Location, spare parts The items are specified in the previous table. xx0600002679 Repair instructions Each spare part is replaced as described in corresponding repair instruction in the chapter Repair on page 235. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 422: Part List
This section specifies all the replacement articles of the robot. The parts are shown Exploded views on page 449. Specific spare parts are listed separately in a Spare part list. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 423: Rebuilding Parts
111.505 3HAC14207-2 Motor axis 1 109.306 3HAC14209-2 Motor axis 2 109.307 3HAC025819-001 Motor axis 2 109.307 3HAC14209-2 Motor axis 3 102.3.5 3HAC14210-2 Motor axis 4 102.1.2 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 424 8.3.2 Rebuilding parts Continued Art. no. Part 5 00 / 2 . 5 5 500/2.3 400/2.55 340/2.8 325/3.1 150/3.5 Item no. and type 3HAC16628-4 Wrist, type 3 3HAC16628-3 Wrist, insulated 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 425: Part List, Overview
340/2.8, - 400/2.55, - 500/2.55) on page 434. 3HAC13063-5 Axis 3-4 Foundry IRB 7600 - 500/2.3 See section Axis 3-4 Foundry, 3HAC13063-5 (IRB 7600 - 500/2.3) on page 435. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 426 Arm extension set 500 mm IRB 7600 - 325/3.1 See section XREF. 3HAC17637-1 Cover plate 4 or 9ADA618-56 Torx pan head screw Steel 8.8-A2F, M6x16 3HAC13416-1 Protection cover 3HAC18281-1 Cover 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 427: Mechanical Stop Axis 1, 3Hac12812-2
8 Spare part / part list 8.3.4 Mechanical stop axis 1, 3HAC12812-2 8.3.4 Mechanical stop axis 1, 3HAC12812-2 Part list Item Art. number Description Dimension 3HAC12812-1 Mechanical stop 9ABA142-92 Spring pin, slotted 10 x 30 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 428: Base Incl Frame Axis 1, 3Hac12304-1
Item Art. number Description Note 101.2.1 3HAC15865-1 Frame machining 101.2.2 3HAC10828-1 RV 500C-219,95 assembly 101.2.3 3HAB7700-77 Hex socket head cap screw UNBRAKO 12.9 Gleitmo 610, M12x110 101.2.4 3HAA1001-134 Washer 13x19x1,5 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 429: Axis 3-4, 3Hac13063-1
610, M16x35 102.1.16 3HAA1001-98 Gasket 102.1.17 9ADA183-37 Hex socket head cap screw Steel 8.8-A2F, M8x25 102.1.18 9ADA312-7 Plain washer M8 8,4x16x1,6 102.1.19 3HAA2103-21 Taper roller bearing Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 430: 8.3.6 Axis 3-4, 3Hac13063-1 (Irb 7600 - 150/3.5, - 325/3.1, -340/2.8, -400/2.55
Pinion RV 125F-97,909 102.1.2.3 21522012-430 O-ring RV 125F-97,909 assembly, 3HAC17810-1 Item Art. number Description Dimension 102.1.8.1 3HAC11384-1 RV 125F, i=97,909 102.1.8.2 3HAB3772-50 O-ring 196,52X2,62 102.1.8.3 3HAB3772-49 O-ring 189,3X3,1 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 431: 8.3.6 Axis 3-4, 3Hac13063-1 (Irb 7600 - 150/3.5, - 325/3.1, -340/2.8, -400/2.55
3HAC17272-1 RV 700F-269,21 assembly 102.3.2.2 3HAC11636-1 Gear Z2 /2.3 Rot ac motor incl pinion, 3HAC14724-1 Item Art. number Description Note 102.3.5.1 3HAC17484-1 Rotational ac motor M1 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 432: 8.3.6 Axis 3-4, 3Hac13063-1 (Irb 7600 - 150/3.5, - 325/3.1, -340/2.8, -400/2.55
8 Spare part / part list 8.3.6 Axis 3-4, 3HAC13063-1 (IRB 7600 - 150/3.5, - 325/3.1, -340/2.8, -400/2.55, -500/2.55) Continued Item Art. number Description Note 102.3.5.2 3HAC11632-1 Pinion Z1 /2.3 102.3.5.3 21522012-430 O-ring 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 433: Axis 3-4, 3Hac13063-2 (Irb 7600 - 500/2.3)
Axis 3 See table Axis 3, 3HAC13062-1 on page 431. Tube shaft 2,3, 3HAC10509-5 Item Art. number Description Note 102.2.1 3HAC10509-6 Tube shaft 2,55, cast 102.2.2 3HAC1383-2 Protection Cover compl. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 434: Axis 3-4, Foundry, 3Hac13063-4
Axis 3 See table Axis 3, 3HAC13062-1 on page 431. Tube shaft 2,55 Foundry, 3HAC15932-1 Item Art. number Description Note 102.2.1 3HAC10509-2 Tube shaft 2,55, cast 102.2.2 3HAC1383-2 Protection Cover compl. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 435: Axis 3-4 Foundry, 3Hac13063-5 (Irb 7600 - 500/2.3)
Axis 3 See table Axis 3, 3HAC13062-1 on page 431. Tube shaft 2,55 Foundry, 3HAC15932-2 Item Art. number Description Note 102.2.1 3HAC10509-6 Tube shaft 2,55, cast 102.2.2 3HAC1383-2 Protection Cover compl. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 436: Wrist, 3Hac16628-4 / 3Hac16628-3
Support shaft inc bearing See table Support shaft inc bearing, 3HAC10503-14 on page 438. 103.25 3HAC9953-1 Syncplate with nonie 103.26 9ADA618-56 Torx pan head screw M6x16 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 437 Pinion Z3 / 4,5 103.45 3HAC020619-001 Set of shims Z3 / 4,5 103.46 3HAB3409-71 Hex socket head cap M12x60 screw 103.47 3HAB3409-86 Hex socket head cap M16x60 screw Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 438 Description Dimension 103.33.1 3HAC020487-001 Gear Z4 / 5 103.33.2 3HAC10503-12 Bearing Washer 103.33.3 3HAB3710-19 Groove ball bearing 160x220x28 103.33.4 3HAC10503-15 Support Ring 103.33.5 3HAB7116-2 Locking liquid Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 439 O-ring 189.3x3.1 Rot AC motor incl pinion, 3HAC024842-001 Item Art. number Description Note 103.28.13.1 3HAC17484-3 Rotational AC motor M3 103.28.13.2 3HAC10122-19 Pinion RV125F-178.4 103.28.13.3 21522012-430 O-ring Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 440 Torx counters. head screw M8x20 103.51.12 3HAC024842-001 Rot. AC motor incl. pinion 103.51.15 9ADA312-7 Plain washer M8 103.51.16 6 ml 3HAB7116-1 Locking liquid 103.51.17 9ADA183-37 Hex socket head cap Steel 8.8-A2F, screw M8x25 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 441: Material Set Robot, 3Hac13079-1
108.230 3HAC14880-1 Cable fixing bracket 108.231 21662055-3 Cable straps, outdoors 108.232 3HAC16721-1 Magnetic plug R1/2" 108.233 2522122-1 Magnetic plug R1/4" 108.234 21520441-1 Washer 108.235 3HAC021071-001 Cable protection lower arm, type-b 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 442: Material Set Axis 1-2, 3Hac13077-1
DSQC 633 3HAC046277-001 Serial measurement unit RMU101 or RMU102 109.327 3HAC14788-3 Cover SMB and BRU See table Cover SMB and BRU, 3HAC14788- 3 on page 444. Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 443 Torx pan head screw M6x25 109.350 3HAC4813-1 Cover, push button guard 109.351 9ADA618-44 Torx pan head screw M5x12 109.352 3HAC14024-1 Protection screw and o- ring 109.353 3HAC17423-1 Washer Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 444 Pinion Z1 /2.3 109.307.3 21522012-430 O-ring D=89.5x3 Cover SMB and BRU, 3HAC14788-3 Item Art. number Description Note 109.327.1 3HAC023546-003 Cover SMB 109.327.2 3HAC14788-2 Gasket 109.327.3 3HAC023764-001 Rubber cloth Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 445 8 Spare part / part list 8.3.12 Material set axis 1-2, 3HAC13077-1 Continued Cover battery box, 3HAC14791-3 Item Art. number Description Note 109.332.1 3HAC14791-1 Cover 109.332.2 3HAC14791-2 Gasket 109.332.3 3HAC16977-1 Warning label battery 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 446: Material Set Balancing Device, 3Hac13082-1
3HAC12548-2 Protection washer 110.410 3HAC11427-1 Shaft, Balancing device 110.411 3HAA1001-186 Washer 17x25x3 110.412 120 ml 3HAA1001-294 Grease 110.413 3HAC4836-1 Protection plug 20x14.6x7.5x5.5 110.414 9ADA183-490 Hex socket head cap M16x80 screw 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 447: Arm Extension Set, 956 Mm, 3Hac12311-1 (Irb 7600 - 150/3.5)
Arm extender 956 mm 111.501 3HAC15932-4 Arm extender 956 mm, Foundry 111.502 3HAC11755-1 Friction washer 111.503 3HAB7700-69 Hex socket head cap screw M12x50 111.504 3HAA1001-134 Washer 13x19x1.5 111.505 9ABA107-56 Parallel pin 10x20 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 448: Arm Extension Set, 250 Mm, 3Hac12311-2 (Irb 7600 - 340/2,8)
Arm extender 250 mm 111.501 3HAC15932-3 Arm extender 250 mm Foundry 111.502 3HAC11755-1 Friction washer 111.503 3HAB7700-69 Hex socket head cap screw M12x50 111.504 3HAA1001-134 Washer 13x19x1.5 111.505 9ABA107-56 Parallel pin 10x20 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 449: Exploded Views
The numbered details are specified with item numbers in the Part List. The exploded views are divided into: • Base, incl. frame • Frame-Lower arm 1 • Frame-Lower arm 2 • Upper arm • Wrist complete 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 452: Frame-Lower Arm 2
9 Exploded views 9.4 Frame-Lower arm 2 9.4 Frame-Lower arm 2 Exploded view xx0200000331 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 453 M4x6 9ADA183-180 Hexagon bolt M8x190 9ADA315-7 Conical spring washer 8.4x16x1.6 3HAC029367-001 Shaft tap 3HAC041189-001 Short shaft sealing cover 3HAB3772-140 O-ring 3HAC041193-001 Sealing cover 3HAB3701-44 Radial sealing with dust lip 120x90x12 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 456 This page is intentionally left blank...
Page 457: Circuit Diagram
Circuit diagram - IRB 6600 type B 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6620 3HAC025090-001 Circuit diagram - IRB 6620 / IRB 6620LX 3HAC025090-001 Circuit diagram - IRB 6640 3HAC025744-001 Continues on next page 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 458 10.1 About circuit diagrams Continued Product Article numbers for circuit diagrams Circuit diagram - IRB 6650S 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6660 3HAC025744-001 3HAC029940-001 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 459: Validity Of Circuit Diagram 3Hac025744-1
Where to find the article number Action 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 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 460: Validity Of Circuit Diagram 3Hac13347-1
IRB 6600 3HAC 14940-1 IRB 6650, IRB 6650S 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 459. 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 461: Index
399 installation mechanical stop axis 1, 121 mechanical stop axis 2, 123 damage to mechanical stop, 178 mechanical stop axis 3, 125 danger levels, 41 installing dimensions position switches, 128 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 462 128 hot parts, 25 installing, 128 hydraulic system, 27 positive directions, axes, 391 installation, 22 protection classes, 67 oil change, 54 protection standards, 404 operational disturbance, 28 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 463 IRB 7600 - 500/2.3, 71 sync marks, 390 IRB 7600 - 500/2.55, 70 restricting axis 1, 121 restricting axis 2, 123 testing restricting axis 3, 125 brakes, 34 wrist unit, insulated, 419 3HAC022033-001 Revision: M © Copyright 2007-2013 ABB. All rights reserved.
Page 466 Telephone +46 (0) 21 344 400 ABB AS, Robotics Discrete Automation and Motion Box 265 N-4349 BRYNE, Norway Telephone: +47 51489000 ABB Engineering (Shanghai) Ltd. 5 Lane 369, ChuangYe Road KangQiao Town, PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc.

This manual is also suitable for:

Irb 7600 - 340/2.8 Irb 7600 - 150/3.5 Irb 7600 - 500/2.3 Irb 7600 - 325/3.1 Irb 7600 - 400/2.55

ABB IRB 7600 - 500/2.55 Product Manual

1 Safety

2 Installation and Commissioning

3 Maintenance

4 Repair

5 Calibration Information

6 Decommissioning

7 Reference Information

8 Spare Part / Part List

9 Exploded Views

10 Circuit Diagram

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Summary of Contents for ABB IRB 7600 - 500/2.55