Page 1 ROBOTICS Product manual IRB 7600...
Page 2 Trace back information: Workspace R18-1 version a12 Checked in 2018-03-27 Skribenta version 5.2.025...
Page 3 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, IRC5 Document ID: 3HAC022033-001 Revision: V © Copyright 2007 - 2018 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
2.5.12 Installation of Foundry Plus Cable guard (option no. 908-1) ......2.5.13 Loads fitted to the robot, stopping time and braking distances ......2.5.14 Signal lamp (option) ................. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 6 Exporting the SIS data ................Repair Introduction ...................... General procedures ................... 4.2.1 Performing a leak-down test ..............4.2.2 Mounting instructions for bearings ............. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 7 Calibrating with Calibration Pendulum method ............Verifying the calibration ..................Checking the synchronization position ..............Decommissioning Environmental information .................. Scrapping of robot ..................... Decommissioning of balancing device ..............Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 8 Spare part lists and illustrations ................10 Circuit diagram 10.1 Circuit diagrams ....................10.2 Validity of circuit diagram 3HAC025744-1 .............. 10.3 Validity of circuit diagram 3HAC13347-1 ..............Index Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 9: Overview Of This Manual
• repair personnel. Prerequisites Maintenance/repair/installation personnel working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Organization of chapters The manual is organized in the following chapters: Chapter...
Page 10 This manual contains all safety instructions from the product manuals for the manipulators and the controllers. Additional document references Document name Document ID Application manual - CalibWare Field 5.0 3HAC030421-001 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 11 1 has been added. • New product name has been implemented throughout the manual: "Mobilgear 600 XP 320". Replaces "Mobil Gearlube X320". Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 12 Securing the base plate on page • Corrected part numbers, see Wrist, 3HAC16628-4. • Corrected exploded view, see Wrist complete. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 13: Product Manual, Spare Parts - Irb
This revision includes the following updates: • Instruction for inspection of oil level updated. • Spare part number, motor axis 2 corrected. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 14 415. • Added information about Axis Calibration when SafeMove is installed, Axis Calibration with SafeMove option on page 416. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 15 Changed direction of installed cooling fan on axis-2 motor and removed a faulty image showing the design of the cooling fan. Also added de- tailed images to installation procedure for the fan. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 16: 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 17: Product Documentation, Irc5
Product documentation, IRC5 Categories for user documentation from ABB Robotics The user documentation from ABB Robotics is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.
Page 18 The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 19: How To Read The Product Manual
Likewise, certain work methods or general information that is valid for several robot models, can be illustrated with illustrations that show a different robot model than the one that is described in the current manual. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 20 This page is intentionally left blank...
Page 21: Safety
Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment that can influence the safety of the entire system.
Page 22 Grippers/end effectors must be designed so that they retain work pieces in the event of a power failure or a disturbance to the controller. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 23 1.1.1 Limitation of liability Continued Unauthorized modifications of the originally delivered robot 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. CAUTION Ensure that a gripper is prevented from dropping a work piece, if such is used.
Page 24: Protective Stop And Emergency Stop
1.1.2 Protective stop and emergency stop 1.1.2 Protective stop and emergency stop Overview The protective stops and emergency stops are described in the product manual for the controller. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 25: Safety Actions
1.2 Safety actions 1.2.1 Fire extinguishing Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the manipulator or controller. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 26: Emergency Release Of The Robot Axes
When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways. Make sure no personnel is near or beneath the robot. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 27: Make Sure That The Main Power Has Been Switched Off
DANGER Even if the main switch is switched off, the capacitors can cause electric shock if not given the time to discharge. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 28: Safety Risks
Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 29 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 robot.
Page 30: Moving Robots Are Potentially Lethal
Make sure no personnel are present within the working range of the robot before pressing the start button. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 31: First Test Run May Cause Injury Or Damage
Collision risks CAUTION When programming the movements of the robot, always identify potential collision risks before the first test run. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 33: Enabling Device And Hold-To-Run Functionality
How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 34: Risks Associated With Live Electric Parts
The power supply for the motors (up to 800 VDC). • The user connections for tools or other parts of the installation (max. 230 VAC). Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 35 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. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 36: The Unit Is Sensitive To Esd
The mat must be grounded through a current-limit- ing resistor. Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 37: 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. Do not put anything on hot metal surfaces, e.g. paper or plastic. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 38: Safety Risks Related To Pneumatic/Hydraulic Systems
Dump valves should be used in case of emergency. Shot bolts should be used to prevent tools, etc., from falling due to gravity. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 39: Brake Testing
3 Inspect and verify that the axis maintains its position. If the robot does not change position as the motors are switched off, then the brake function is adequate. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 40: Safety Risks During Handling Of Batteries
Risk of fire or explosion. Operating temperatures are listed in Pre-installation procedure on page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 41: Safety Risks During Work With Gearbox Lubricants (Oil Or Grease)
Possible pressure build-up in gearbox Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 42 The magnetic oil plugs will take Contaminated oil in care of any remaining metal gear boxes chips. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 43: Safety Signals And Symbols
ELECTROSTATIC Warns for electrostatic hazards which could result DISCHARGE (ESD) in severe damage to the product. xx0200000023 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 44 Describes important facts and conditions. xx0100000004 Describes where to find additional information or how to do an operation in an easier way. xx0100000098 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 46 Brake release Pressing this button will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 47 The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 48 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 xx1500002616 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 49 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 50 Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 51: 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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 52: Robot Transportation Precautions
Pre-installation procedure on page 58 Method 2 - transportation with a tool mounted to the robot Transportation according to method 2 is approved by ABB, only if use of method 1 is not possible. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V ©...
Page 53 Always read and follow the instructions in section Securing the robot with a transport support on page 56 • Always place the robot in the ABB recommended transport position for robot with tool, described in sub section Transport position with a transport support on page •...
Page 54 Transport position with a transport support All transportation of the robot with tool must follow these instructions. IRB 7600 xx0800000040 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 55 2.2 Robot transportation precautions Continued Recommended transport support Always use the recommended transport support when transporting a robot with tool. IRB 7600 xx0800000039 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 56: Securing The Robot With A Transport Support
It must be done with great care and only when absolutely necessary. Fitting the transport support Illustration for fitting the transport support xx0800000062 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 57 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 77 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 58: Unpacking
It also contains information useful during later re-installation of the robot. Prerequisites for installation personnel Installation personnel working with an ABB product must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work • conform to all national and local codes.
Page 59 Floor mounted Force Endurance load (in operation) Max. load (emergency stop) Force xy ± 14 kN ± 31 kN Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 60 +55° C Maximum ambient temperature (less than 24 hrs) +70° C Maximum ambient humidity 95% at constant temperature (gaseous only) Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 61 The table shows the available protection types of the robot, with the corresponding protection class. Protection type Protection class Manipulator, protection type Standard IP 67 Manipulator, protection type Foundry Plus IP 67 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 62: Working Range, Irb 7600 - 150/3.5
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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 63: Working Range, Irb 7600 - 340/2.8
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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 64: Working Range, Irb 7600 - 400/2.55, Irb 7600
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: xx0100000100 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 65: Working Range, Irb 7600 - 500/2.3
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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 66: Risk Of Tipping/Stability
This figure shows the robot in its shipping position and transportation position. xx0100000103 WARNING The robot is likely to be mechanically unstable if not secured to the foundation. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 67: On-Site Installation
Attachment points, spacer and horizontal attachment screws Attachment points, horizontal attachment screws Attachment points, vertical attachment screws Attachment points, horizontal attachment screws Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 68 Fork lift pocket (2 pcs, 3HAC15766-1 , 3HAC11264-1) Spacer (2 pcs) Horizontal attachment screws (4 pcs/ fork lift pocket) Vertical attachment screws (2 pcs) Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 69 Attachment points are shown in figure Attachment points on robot on page CAUTION The fork lift pocket weighs 60 kg! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 70 Make sure the securing screw is removed from the fork lift pocket! It is only used for robot model IRB 6650S. xx0700000655 A Securing screw Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 71 Insert fork lift forks into the pockets. xx0200000380 Reposition harness, if any, before using a fork lift! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 72 Refit the cooling fan to the motor, if any. Detailed in section Installation of cool- ing fan for motors (option) on page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 73: Lifting Robot With 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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 74 Make sure all hooks and attachments maintain their correct positions while lifting the robot! Always move the robot at very low speeds, making sure it does not tip. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 75: Lifting Robot With Roundslings
Chain sling with shortener, 4250 kg, 3 pcs (0.5 m, 0.5 m, 0.265 m) Roundsling, 1000 kg, 2 pcs Roundsling, 2000 kg, 3 pcs (4 m) Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 76 Make sure all hooks and attachments maintain correct position while lifting the robot! Always move the robot at very low speeds, making sure it does not tip. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 77: Manually Releasing The Brakes
The figure below shows the unit located at the frame. xx0200000376 Internal brake release unit with push buttons, located on the robot frame Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 79: Lifting The Base Plate
Lift and move the base plate very slowly. If the base plate starts to swing it is a risk for injuries or damage. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 80: Securing The Base Plate
E, F, G, H Common tolerance zone (accuracy all over the base plate from one contact surface to the other) Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 81 2 Installation and commissioning 2.5.6 Securing the base plate Continued xx0400000715 Four holes for alternative clamping, 4x Ø18 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 82 The illustration below shows the orienting grooves and attachment holes for leveling bolts in the base plate. xx1500000312 Orienting grooves (3 pcs) Levelling bolts, attachment holes (4 pcs) Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 83 This section details how to secure the base plate to the foundation. Action Note Make sure the foundation is levelled. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 84 0.3 mm. If it is not, use pieces of sheet metal or similar to bring the base plate to a levelled position. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 85: Orienting And Securing The Robot
Quality 8.8 Suitable washer: Thickness: 4 mm Outer diameter: 44 mm Inner diameter: 25 mm Tightening torque: 725 Nm Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 86 Lightly lubricate screws before as- sembly! Tighten bolts in a criss-cross pattern to ensure that the base is not distorted. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 87 This illustration shows the hole configuration used when securing the robot. xx0300000046 Cross section, guide sleeve hole This illustration shows the cross section of the guide sleeve holes. xx0100000109 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 88: Fitting Equipment On Robot
2192 mm IRB 7600 - 400/2.55 2442 mm IRB 7600 - 340/2.8 2692 mm IRB 7600 - 325/3.1 2942 mm Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 89 Illustration, fitting of extra equipment on upper arm The illustration below shows the mounting holes available for fitting extra equipment on the upper arm. xx0100000116 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 90 Illustration, fitting of extra equipment on frame The mounting holes available for fitting extra equipment on the frame are shown below. xx0100000117 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 91 Tool flange, standard The illustration below shows the mounting holes available for fitting equipment on the turning disc. xx0100000119 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 92 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. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 93: Installation Of Base Spacers (Option)
Base plate 3HAC12937-7 Standard toolkit Content is defined in section Standard tools on page 439. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 94 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 95: Extended Working Range, Axis 1 (Option 561-1)
The system parameters that must be = 220 degrees. changed (Upper joint bound and Lower joint bound) are described in Technical reference manual - System parameters. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 96: Installation Of Cooling Fan For Motors (Option)
The fans are installed on the motors, axes 1 or 2, as shown in the figure below. xx1800000169 xx1800000170 Cooling fan, axis 1 Cooling fan, axis 2 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 97 The set includes: • fan axes 1 & 2 cable harness • plate, customer • attachment screws and nuts. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 98 Plate for customer connections, at base xx0500002301 Plate for customer connections Attachment screws, 3 pcs, M6x16 quality 8.8-A2F Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 99 Separate cabling for axis 1 or 2 The figure below shows the cabling used only for the fan on axis 1 or 2. xx0500002173 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 100 Run the cabling up through the base and frame, beneath the balancing device. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 101 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. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 102: Installation Of Foundry Plus Cable Guard (Option No. 908-1)
Separate instructions for IRB 2600, 4600, 6620, 6640, 6650S, 6660 and 7600 are available in English, German, French, Spanish and Italian and can be found for registered users on myABB Business Portal (www.myportal.abb.com) and delivered with the Cable guard, article number 3HAC035933-001.
Page 103: Loads Fitted To The Robot, Stopping Time And Braking Distances
The performance of the motor brake depends on if there are any loads attached to the robot. For more information, see product specification for the robot. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 104: Signal Lamp (Option)
The lamp is active in MOTORS ON mode. Further information Further information about the MOTORS ON/MOTORS OFF mode may be found in the product manual for the controller. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 105: Restricting The Working Range
Note Adjustments must also be made in the robot configuration software (system parameters). References to relevant manuals are included in the installation procedures. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 106: 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 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 107 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 108: Mechanically Restricting The Working Range Of Axis 2
15°. Includes attachment screws. Standard toolkit Content is defined in section Standard tools on page 439. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 109 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 110: Mechanically Restricting The Working Range Of 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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 111 Art. no. is specified in section Refer- Ware OS 4.0) (RobotWare 4.0) ences on page Technical reference manu- al - System parameters Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 112 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 113: 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 114 R1.SW1. xx0100000158 Position switch, axis 1 Set screw, cam (cam stop) Protection sheet Rail Rail attachment Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 115 Position switch, axis 2 Set screw, cam (cam stop) Rail Rail Attachment Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 116 Rail attachment Specifications Maximum voltage/current for the position switches: Parameter Value Voltage Max. 50 VDC Current Max. 1 A Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 117 Install the cabling for axes 2 and/or 3. Detailed in section Installation of cable harness for position switches and fans on page 121. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 118 Illustration, cutting the cam The illustration below show how to cut the position switch cam. xx0100000114 Remove the gray section Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 119 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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 120 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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 121 • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 122 Cable harness for pos- ition switches and fans, axes 1-3 on page 121. B Velcro strap C Connector R2.SW2 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 123 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 121. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 124 Install additional cabling to and inside the Cabling is specified in section: control cabinet. • Position switch cables, robot base to controller (option) on page 127 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 125: Electrical Connections
Robot cable, signals Transfers resolver data from R1.SMB and power supply to the serial measurement board. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 126 Bending radius for static floor cables The minimum bending radius is 10 times the cable diameter for static floor cables. xx1600002016 Diameter Diameter x10 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 127 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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 128 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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 129 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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 130: Start Of Robot In Cold Environments
If the program consists of large wrist movements, it is possible that the reorientation velocity, which is always high in predefined velocities, needs to be included in the ramping up. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 131: 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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 132: Maintenance Schedule And Expected Life
40000 hours. ABB Connected Services and its Assessment tools can help you to identify the real stress level of your robot, and define the optimal ABB support to maintain your robot working. Contact your local ABB Customer Service to get more information.
Page 133: Maintenance Schedule
Replace when damage or cracks is detected or life limit is approaching that specified in section Expected component life on page 137. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 134 193 6,000 hours Second change when DTC reads: 24,000 hours Following changes: Every 24,000 hours Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 135 24,000 hours Following changes: Every 24,000 hours DTC = Duty Time Counter. Shows the operational time of the robot. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 136 Inspection Motor fans, axes Every 12 Inspect the fans for 1-2-3 months contamination that could hinder the air supply. Clean if ne- cessary. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 137: 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 138: Inspection Activities
Robots with protection type Foundry Plus have a transparent plug/sight glass installed in the evacuation holes. xx1800000101 xx1800000102 Protection filter (Standard). Transparent plug (Foundry Plus). Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 140: Inspecting The Oil Level In Axis-1 Gearbox
181. Standard toolkit Content is defined in section Standard tools on page 439. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 141 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technic- al reference manual - Lubrication in gearboxes. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 142 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 143: Inspecting The Oil Level In Axis-2 Gearbox
Gearbox, axis 2 (behind the motor attachment, not shown in figure) Oil plug, filling (early design) Oil plug, draining Label, specifies the type of oil in the axis-2 gearbox Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 144 Before proceeding, please read the safety information in the section Safety risks during work with gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 145 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 146: Inspecting The Oil Level In Axis-3 Gearbox
181. Standard toolkit Content is defined in section Standard tools on page 439. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 147 Measure the oil level. Required oil level: 0-20 mm xx1400002785 A Oil plug hole B Required oil level C Gearbox oil Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 148 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 149: Inspecting The Oil Level In Axis-4 Gearbox
Required equipment Equipment, etc. Art. no. Note Lubricating oil Type and amount of oil in gearboxes on page 181. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 150 Measure the oil level. Required oil level: 30-40 mm xx1400002859 A Oil plug hole B Required oil level C Gearbox oil Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 151 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 152: Inspecting The Oil Level In Axis-5 Gearbox
Label, specifies the type of oil in the axis-5 secondary gearbox Oil plug, filling, secondary gearbox Cover, axis-5 gearbox Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 153 Required oil level to the upper edge of the filling and inspection oil plug hole (a): 80-96 mm xx0500002222 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 154 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 155: Inspecting The Oil Level In Axis-6 Gearbox
181. Standard toolkit Content is defined in section Standard tools on page 439. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 156 Turn axis 4 until the axis-4 angle reads: • -36° to -39° for oil plug position B1 • -80° to -83° for oil plug position B2 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 157 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 158: Inspecting The Balancing Device
Inspection points, balancing device on page 159. Balancing device, art. no. Action at detected faults 3HAC10538-1 Upgrade 3HAC14675-1 Maintenance Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 159 3HAC14962-1 Includes: bearings and seals • kit with bearings, o- rings and seals only • instructions for main- tenance. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 160 To decide whether to perform maintenance or upgrade, tion). see section Action at detected faults on page 158. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 161 Leaks at the o-rings and/or sealings, are not acceptable and must be attended to immediately in order to avoid any damage to the bearing! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 162 Replacement of spherical roller bear- ing, balancing device on page 293. Incorrect leakage is shown in the previous figure. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 163 Inspection points, balancing device on page 159. Keep the areas around the balancing device clean and free from objects, such as service tools. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 164: Inspecting The Cable Harness
Circuit diagram See chapter Circuit diagram on page 447. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 165 Cable attachment, upper arm tube Cable attachment, rear of upper arm Connectors at cable harness division point, R2.M5/6 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 166 Replace the cable harness if wear, cracks or Described in section Replacement of damage is detected. cable harness, axes 5-6 on page 242 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 167: Inspecting The Axis-1 Mechanical Stop Pin
The axis-1 mechanical stop is located as shown in the figure. xx0200000151 Mechanical stop pin Required equipment Visual inspection, no tools are required. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 168 The expected life of gearboxes can be reduced after collision with the mechanical stop. Make sure the mechanical stop pin can move in both directions. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 169: Inspecting The Mechanical Stops On Axes 1, 2, And 3
Mechanical stop ax 2 3HAC11077-1 Mechanical stop ax 3 3HAC13128-2 Standard toolkit Content is defined in section Standard tools on page 439. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 171: Inspecting The Damper On Axes 2 To 5
Required equipment Equipment Art. no. Note Damper axis 2 3HAC12990-1 Replace if damaged! Damper axis 3 3HAC11750-1 Replace if damaged! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 172 If any damage is detected, the damper must be re- Art. no. is specified in placed with a new one! quired equipment on page 171. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 173: Inspecting The Position Switch On 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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 174 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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 175 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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 176 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. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 177: Inspecting The Information Labels
Label, type of grease in ear Information labels at gearboxes and at robot base, specifying which oil is used in gearboxes Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 178 Replace any missing or damaged labels. Article numbers for the labels and plate set is specified in Spare part lists on page 445. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 179: Inspecting The Ul Lamp
These procedures include references be required. See references to to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 180 Check the cable connections. • Measure the voltage in connectors motor axis 3 (=24V). • Check the cabling. Replace cabling if a fault is detected. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 181: Changing/Replacement Activities
Before starting any inspection, maintenance, or changing activities of lubrication, always contact the local ABB Service organization for more information. For ABB personnel: Always check ABB Library for the latest revision of the manual Technical reference manual - Lubrication in gearboxes, in order to always get the latest information of updates about lubrication in gearboxes.
Page 182 Includes pump with outlet pipe. Use the suggested dispenser or a similar one: • Orion OriCan article number 22590 (pneumatic) Nipple for quick connect fitting, with o-ring Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 183: Changing Oil, Axis-1 Gearbox
Motor, axis 1 Oil plug, inspection (not in all designs) Label, specifies the type of oil in the gearbox Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 185 Close the oil drain hose, and put it back inside the base. Close the rear cover by securing it with its attach- ment screws. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 186 Technical reference manual - Lubrication in gearboxes. Refit the oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 187: Changing Oil, Axis-2 Gearbox
Content is defined in section ment Special tools on page 440. Standard toolkit Content is defined in section Standard tools on page 439. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 188 • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 189 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Refit the oil plug. Tightening torque: 24 Nm. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 190: Changing Oil, Axis-3 Gearbox
Note! Do not mix with other oil amount of oil in types! gearboxes on amount of page 181. oil in gear- boxes on page 181. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 192 - Lubrication in gearboxes. Note Do not mix Kyodo Yushi TMO 150 with other oil types! Refit the oil plug. Tightening torque: 24 Nm. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 193: Changing Oil, Axis-4 Gearbox
Label, specifies the type of oil in the secondary gear Label, specifies the type of oil in the primary gear Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 194 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 195 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 196 Continued Action Note Refit the both oil plugs, filling. Shown in the figure Location of gearbox on page 193. Tightening torque: 24 Nm. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 197: Changing Oil, Axis-5 Gearbox
The oil plug for draining of the primary gearbox is on the opposite side of the wrist housing, not shown in the figure. Label, specifies the type of oil in the axis-5 primary gearbox Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 198 Open the oil plug, draining, primary gearbox. Drain the oil from the primary gearbox. Vessel capacity: 1 liter Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 199 Inspecting the oil level in Shown in the figure Location of axis-5 gearbox on page 152. gearbox on page 197. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 200 - Lubrication in gearboxes. Refit the oil plugs. Shown in the figure Location of gearbox on page 197. Tightening torque: 24 Nm. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 201: Changing Oil, Axis-6 Gearbox
Vessel capacity: 1,000 ml. Oil exchange equip- 3HAC17313-1 Content is defined in section ment Special tools on page 440. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 202 The correct oil level is detailed in section Inspecting the oil level in axis-6 gearbox on page 155. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 203 Technical reference manual - Lubrication in gearboxes. Refit the both oil plugs. Tightening torque: 24 Nm. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 204: Replacing The Smb Battery
See Operating manual - IRC5 with FlexPendant for instructions. WARNING See instructions for batteries, Safety risks during handling of batteries on page Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 205 Battery pack with a 2-pole battery contact (DSQC) xx0200000238 SMB battery cover SMB battery pack with 2-pole battery contact. Battery cable Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 206 Equipment, etc. Spare part no. Note Battery unit For spare part no. Battery includes protection circuits. Only re- see: place with a specified spare part or an ABB- • Spare part approved equivalent. lists on page 445 Standard toolkit Content is defined in section...
Page 207 Shown in figure Location of SMB Battery includes protection circuits. Only replace battery on page 205. 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 208 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 209: Lubrication Activities
Hole through which the shaft is pressed Required equipment Equipment, etc. Art. no. Note Grease 3HAC042534-001 Optimol PDO, 150 ml Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 210 Refit the lower securing screw and washer. M6 x 10, washer: D=6,4/12 T=1,6 Tightening torque: 6 Nm. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 211 Inspection, balancing device - of the robot, in order to make sure there is Check for leakage on page 161. no incorrect leakage from the o-rings. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 212: Cleaning Activities
Axis 6 gearbox: open both oil plugs (filling and draining) and run axis 5 and 6 in different directions until the oil draining has stopped. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 213 Run the Service program at low speed (25%) during 10 minutes. Drain the gearbox properly. Repeat the steps above until the gearbox is flushed three times. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 214: Cleaning The Irb 7600
Never point the water jet at connectors, joints, sealings, or gaskets. • Do not use compressed air to clean the robot. • Never use solvents that are not approved by ABB to clean the robot. • Do not spray from a distance closer than 0.4 m. Continues on next page...
Page 215 Typical tap water pressure and flow Instructions for steam or high pressure water cleaning ABB robots with protection types Foundry Plus, Wash, or Foundry Prime can be cleaned using a steam cleaner or high pressure water cleaner. The following list defines the prerequisites: •...
Page 216 Cooling fans Inspect the air supply inlet of the the motor cooling fans. Clean to remove any contamination that could hinder the air supply. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 217: Service Information System, M2000
224. parameters are to be entered from an extern- al PC, a set of software tools are available to build such an application. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 218: Description Of Service Information System (Sis)
Setting the SIS parameters on page 222. Remaining time Remaining time to next scheduled service date. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 219 When the service time has been exceeded for the selection made, an error message (Service interval exceeded!) is displayed. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 220 No data available When no data is available for the selection made, a message (No data available!) is displayed when trying to display the data. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 221: Sis System Parameters
The values can be defined by the operating organization as knowledge of the robot's working conditions are accumulated. Since the counters are to be used for purposes defined by the user, ABB cannot give any recommendations regarding their definitions. Operation time limit (service level) The number of operation hours selected as service interval.
Page 222: Setting The Sis Parameters
Select the required paramet- Available parameters are described in section SIS system ers by stepping up and parameters on page 221. down through the parameter list. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 223: 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 222. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 224: Exporting The Sis Data
Operation time of gearbox axis 3 sisL10h_6 hours Gearbox time Estimated life of gearbox axis 6 sisL10h_Time_6 hours Gearbox time Operation time of gearbox axis 6 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 225: Repair
Each procedure contains all the information required to perform the activity, for example spare parts numbers, required special tools, and materials. WARNING Repair activities not described in this chapter must only be carried out by ABB. Otherwise damage to the mechanics and electronics may occur. Required equipment The details of the equipment required to perform a specific repair activity are listed in the respective procedures.
Page 226: General Procedures
Spray any suspected leak areas with the leak detec- tion spray. Bubbles indicate a leak. When the leak has been localized, take the necessary measures to correct the leak. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 227: Mounting Instructions For Bearings
Make sure the bearing is properly aligned as this will directly affect the durab- ility of the bearing. Greasing of bearings Note This instruction is not valid for solid oil bearings. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 228: Product Manual - Irb
Grooved ball bearings must be filled with grease from both sides. • Tapered roller bearings and axial needle bearings must be greased in the split condition. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 229: Mounting Instructions For Seals
Never hammer directly on the seal as this may result in leakage. Make sure no grease left on the robot surface. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 230 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 231: Cut The Paint Or Surface On The Robot Before Replacing Parts
Carefully grind the paint edge that is left on the structure to a smooth surface. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 232: The Brake Release Buttons May Be Jammed After Service Work
If a button gets jammed in the depressed position, the alignment of the brake release unit must be adjusted so that the buttons can move freely in their tubes. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 233: Complete Robot
R2.FB7 and R2.SMB. Battery connector X3 R1.G and R2.G. If brake release located at the frame: also connectors X8, X9 and X10! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 234 Axis 3: 0 ° • Axis 4: 0 ° • Axis 5: +90 ° • Axis 6: no significance Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 235 R1.SMB4-6 from the SMB unit. Disconnect X8, X9 and X10 if the brake release board is located in frame. xx0200000118 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 236 • C: Attachment plate • D: Velcro strap Remove the cable gland securing the cables inside the lower arm. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 237 Axis 3: 0 degrees • Axis 4: 0 degrees • Axis 5: +90 degrees • Axis 6: no significance Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 238 Reconnect all connectors at motors 1 and 2. Specified and shown in the figure Location of cable harness on page 233! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 239 • A: Cable gland • B: Attachment screws, cable gland • C: Attachment plate • D: Velcro strap Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 240 Refit the cable gland securing the cables to the arm house. Make sure not to twist the harness! xx0100000143 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 241 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 242: Replacement Of Cable Harness, Axes
These procedures include references be required. See references to to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 243 Position the upper arm as follows: • Axis 4: 0 degrees • Axis 5: +90 degrees • Axis 6: no significance Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 244 Refit the plastic cover on the rear of the upper arm. Update the revolution counters. Detailed in section Updating re- volution counters on page 403. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 245: Replacement Of Complete Arm System
This is shown in the figure below. xx0100000150 Gearbox, axis 1 Motor, axis 1 Base attachment screws Upper arm Lower arm Frame Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 246 The procedure below details how to lift and remove the complete arm system. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 247 Remove the block for calibration from the bot- Shown in the figure Location of com- tom of the frame. plete arm system on page 245! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 248 A Attachment holes for the guide pins, M12. B Guiding hole for the spring pin loc- ated in the gearbox, axis 1. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 249 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 250: Upper And Lower Arm
Grease 3HAB3537-1 Used to lubricate the o-ring. Standard toolkit Content is defined in section Standard tools on page 439. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 251 Shown in the figure Location of turning securing the turning disk. disk on page 250. Remove the turning disk. xx1000001135 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 252 Screw joints on page 435 before fitting. Refill the gearbox, axis 6, with oil. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 253 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 254: Replacement Of Complete Wrist Unit
Required equipment Equipment, etc. Art. no. Note Wrist For spare part num- ber, see Spare part lists on page 445. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 255 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 257 Inspecting the oil level in axis-5 gearbox on page 152 • Inspecting the oil level in axis-6 gearbox on page 155 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 258 These are further de- tailed in the section First test run may cause injury or damage on page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 259: Replacement Of Complete Upper Arm
Sealing between lower arm and gearbox 3 Attachment holes for lifting device, upper arm Attachment holes for lifting eye Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 260 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 261 30 pcs. upper arm! Lift the upper arm and place it on a secure surface. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 263 These are further de- tailed in the section First test run may cause injury or damage on page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 264: Replacement Of Complete Lower Arm
The figure (2) shows a cut view through the lower arm pivot point in axis 2 (item B in the figure above!), valid for robots with protection Standard. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 265 Shaft hole Sealing, axis 2/3 Attachment screw Washer Bearing Thrust washer Bushing Retaining ring Shaft Protection plug Protection washer Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 266 VK cover 3HAA2166-23 Replace if damaged. Only used on lower arms with a hole in the upper end (axis 3). Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 267 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 268 Remove the securing screw from the balancing Shown in the figure Location of lower device front shaft. arm on page 264. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 269 264. gearbox 2. Lift the lower arm down and place it on a se- cure surface. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 271 226. Refill the axis 2 gearbox with oil. Detailed in section Filling, oil on page 188. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 272 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 273: Replacement Of Lower Arm Shaft
The figure shows components fitted to the lower arm shaft when the robot has protection Standard. xx0300000487 Protection plug Lower arm shaft (axis 2 shaft) Thrust washer Bearing Protection washer Retaining ring Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 274 • Spare part lists on page 445. Puller device, axis 2 shaft 3HAC021563-001 Press device, axis 2 shaft 3HAC021600-001 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 275 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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 276 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 278 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 279 Art. no. is specified in Required shaft. equipment on page 274! Tighten the M16 nut. Tightening torque: 20 Nm. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 280 Clean the shaft with isopropanol and lubricate it Art. no. is specified in Required with grease. equipment on page 274! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 281 Apply grease to the location of the shaft where the Art. no. is specified in Required bearing is to be mounted. equipment on page 274 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 282 Use locking liquid. Proceed with the refitting procedure of the lower arm, detailed in section Replacement of complete lower arm on page 264. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 283: Frame And Base
It is important that the SMB unit uses the correct battery. Make sure to order the correct spare parts. Do not replace the battery contact! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 284 Use caution and disconnect the connectors from the Connectors R1.SMB1-3, SMB unit when pulling the board out. R1.SMB4-6 and R2.SMB Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 285 Be careful not to damage the sockets or pins. Make sure the connector and its locking arms are snapped down properly. xx1700000978 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 286 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 287: Replacement Of Brake Release Board
Brake release circuit (brake release unit inside) Attachment screws, brake release circuit, 4 pcs Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 288 Brake release unit at the frame, according harness, at frame to figure Location of brake release board, frame on page 288. DSQC1052 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 289 287. Disconnect the cable from the brake release circuit and remove the circuit from the base. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 290 Remove the brake release board from the Shown in the figure Location of brake re- plate. lease board, frame on page 288! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 291 Be careful not to damage the sockets or pins. Make sure the connector and its locking arms are snapped down properly. xx1700000978 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 292 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 293: Replacement Of Spherical Roller Bearing, Balancing Device
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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 294 • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 295 Before entering the robot working area. Grease the inside walls of the front ear. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 296 Make sure no incorrect leakage occurs. It This is detailed in section Check for leak- could indicate damaged o-rings. age on page 161. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 297 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 298: Replacement Of Balancing Device
Attachment screws, rear cover Balancing device shaft, including screw and washer Bearing attachment Parallel pin (inside bearing attachment) Attachment screws, bearing attachment Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 300 To be used with the hydraul- ic cylinder. Standard toolkit Content is defined in sec- tion Standard tools on page 439. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 301 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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 302 • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 304 Make sure the cover is properly secured before commissioning of the robot! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 305 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 306: Unloading The Balancing Device Using 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 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 307 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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 308 Press tool and hydraulic to lock the tool in loaded condition. cylinder on page 306. Unload the hydraulic cylinder. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 309 4.5.4.2 Unloading the balancing device using hydraulic press tool Continued Action Note The hydraulic cylinder may now be removed from the tool, when necessary. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 310: 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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 311 Lubricate and refit the o-ring on the support Make sure the o-ring is seated prop- shaft. erly! Replace if damaged. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 312 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! Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 313: Motors
The motor axis 1 is located on the left hand side of the robot as shown in the figure below. xx0100000123 Motor, axis 1 Cable gland cover, motor axis Cover for connector access Motor attachment screws Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 315 Before entering the robot working area. Remove the cover for connector access on top of the motor by unscrewing its four attachment screws. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 316 Art no. is specified in Required motor is seated properly. Lightly lubricate the o- equipment on page 314. ring with grease. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 317 These are further de- tailed in the section First test run may cause injury or damage on page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 318: Replacement Of Motor Axis 2
Guide pins M10 x 100 3HAC15521-1 For guiding the motor. Guides are to be used in pairs! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 319 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 320 Make sure the gasket is not damaged! tachment screws. Disconnect all connectors beneath the motor cover. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 321 • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 322 Remove the lifting tool and allow the motor to rest on the guide pins. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 323 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 324: Replacement Of Motor, Axis 3
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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 326 Fit the mechanical stop to the third and final attach- ment hole (A), below the fixed stop (B) in the upper arm. See the figure above! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 327 Remove the motor by gently lifting Make sure the motor pinion is not damaged! it straight out and disconnect the brake release voltage. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 328 In order to release the brake, connect the 24 VDC Connect to connector R2.MP3 power supply. • +: pin 2 • -: pin 5 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 329 Axis Calibration meth- od on page 408. General calibration information is included in section Calibration on page 395. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 330 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 331: Replacement Of Motor, Axis 4
Lifting tool, motor ax 2, 3, 4 3HAC15534-1 To be used if the upper arm is positioned horizontally. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 332 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 333 In horizontal position: drain the gearbox, Detailed in section Draining, oil, gearbox axis 4. axis 4 on page 194. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 334 • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 335 Make sure the motor pinion does not get making sure the motor pinion is properly damaged! mated to the gear of gearbox 4. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 336 Axis Calibration method on page 408. General calibration information is included in section Calibration on page 395. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 337 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 338: Replacement Of Motor, Axis 5
For releasing the brakes. Extension 300mm for bits 1/2" 3HAC12342-1 Removal tool, motor M12x 3HAC14973-1 Always use the removal tools in pairs! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 339 The procedure below details how to remove the motor, axis 5. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 340 Remove the motor by gently lifting it straight out. Make sure the motor pinion is not damaged! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 341 If required, use the extension 300 mm for bits 1/2". Art. no. is specified in Required equipment on page 338. Disconnect the brake release voltage. Reconnect all connectors beneath the motor cover. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 342 These are further de- tailed in the section First test run may cause injury or damage on page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 343: Replacement Of Motor, Axis 6
Removal tool, motor 3HAC14972-1 Always use the removal tools M10x in pairs! Extension 300mm for 3HAC12342-1 bits 1/2" Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 344 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 345 Draining oil, gearbox. gearbox axis 6 on page 202. Remove the rear motor cover by unscrewing the five attachment screws. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 346 Perform a leak-down test (if the gearbox has Detailed in section Performing a leak- been drained). down test on page 226. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 347 In horizontal position: drain the oil from the Detailed in section: Draining oil, gear- axis 6 gearbox. box axis 6 on page 202. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 348 6 and forwards in Removal, motor on page 345. Note Keep the old rear motor cover with the air nipple. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 349 Apply grease on the o-ring on the motor. Continue to refit the new motor according to section, Refitting, motor on page 346. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 350: Gearboxes
445. O-ring 3HAB3772-54 Replace if damaged! O-ring 3HAB3772-55 Replace if damaged! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 351 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 352 245. Unfasten the robot base from the foundation by removing the base attachment screws. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 353 Make sure the base remains in a stable position before performing any work under- neath the base! xx1000000364 A Support base (4 pcs) Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 354 • A: Oil drain hose • B: Attachment screws, gearbox axis 1, 18 pcs • C: Washers, 3 pcs Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 355 Turn the gearbox, and remove the protec- tion pipe by unscrewing two attachment screws. Note Move the protective pipe over to the new gearbox. xx1400000786 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 356 A: Guide pin • C: O-ring 3HAB 3772-54 • D: O-ring 3HAB 3772-55 • E: Sealing ring 3HAC 11581-4 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 357 350. CAUTION The gearbox weighs 200 Kg. All lifting accessories used must be sized ac- cordingly! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 358 Lift gearbox axis 1 onto the guide pins and Always use guide pins in pairs! lower it carefully to its mounting position. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 359 C: Washers, 3 pcs Refit the cable guide in the center of gearbox 1 with its attachment screws. xx1000001393 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 360 Axis Calibration method on page 408. General calibration information is in- cluded in section Calibration on page 395. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 361 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 362: Replacement Of Gearbox, Axis 2
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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 363 See refer- references to the tools re- ences to these procedures quired. in the step-by-step instruc- tions below. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 364 The lowered position, as in figure A, is recommen- ded as it gives the least load on the tool. xx0200000260 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 365 Detailed in section Draining, oil on page 188. Remove the motor, axis 2. Detailed in section Removal, motor on page 320. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 366 A: M16 holes for pressing the gearbox out Remove the gearbox using an overhead crane or similar. Remove the friction washer and clean it. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 367 Fit the lifting tool, gearbox axis 2, to the gearbox. Article number is specified in quired equipment on page 363. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 368 Screw joints on page 435 before fitting. Remove the guide pins and tighten the remaining two screws as above. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 369 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 370: Replacement Of Gearbox, Axis 3
Motor, axis 3 Attachment screws, upper arm Attachment screws, motor Sealing, axis 2/3 (between lower arm and gearbox 3) Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 371 Delivered as a set of calib- Axis Calibration ration tools. Required if Axis Calibra- tion is the valid calibration method for the robot. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 372 Action Note Decide which calibration routine to use, and take actions accord- ingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 373 (A) shown in the figure to the right to press the gearbox free. xx0200000033 • A: M16 holed for pressing the gearbox out Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 374 Fit the lifting eye to the gearbox. Art. no. is specified in Required equipment on page 371. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 375 Calibrating with Axis Calibration method on page 408. General calibration information is included in section Calibration on page 395. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 376 These are fur- ther detailed in the section First test run may cause injury or damage on page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 377: Replacement Of Gearbox, Axis 4
Gear, Z3 Gear attachment screws Motor, axis 4 Motor flange Oil plug, filling, primary gearbox (draining not shown in figure) Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 378 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 379 15 gear attachment screws. gearbox on page 377. If required, insert screws into three holes in gear Z3 to press it out. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 380 Spare part no. is specified in Required equipment on page 378. Note Make sure the surface beneath the friction washers is clean and dry! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 381 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 382: Replacement Of 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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 383 See references to these quired. procedures in the step- by-step instructions be- low. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 384 Remove the cover, axis 5 gearbox by unscrewing its Shown in the figure Location of attachment screws. gearbox on page 382! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 385 Turn the gear Z4 in order to reach all the srews. ure below! 7 pcs: M6 x 16. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 386 Shown in the figure Location of gently lowering it straight down, using the guide gearbox on page 382. pins. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 387 These are further de- tailed in the section First test run may cause injury or damage on page Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 388 382. Proceed with step 11 in the refitting detailed in the previous procedure (procedure Refitting, gearbox axis 5 on page 386). Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 389: Replacement Of Gearbox, Axis 6
Spare part lists on page 445. Washers 3HAC10122-13 Not included in the gear- box. Replace if damaged! Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 390 Read more about reference calibration for then reference calibration is not possible. Pendulum Calibration in Operating manu- al - Calibration Pendulum. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 392 Required equipment the gearbox. Lubricate the o-ring with on page 389. grease. xx0200000221 • A: O-ring, gearbox axis 6 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 393 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 394 This page is intentionally left blank...
Page 395: Calibration
A calibration routine to make a rough calibration of each manipulator axis. Synchronization mark Visual marks on the robot axes. When marks are aligned, the robot is in synchronization position. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 396: Calibration Methods
FlexPendant. If no data is found related to standard calibration, Calibration Pendulum is used as default. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 397 Brief description of calibration methods Calibration Pendulum method Calibration Pendulum is a standard calibration method for calibration of all ABB robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S). Two different routines are available for the Calibration Pendulum method: •...
Page 398 The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including the Operating manual - Calibration Pendulum, which describes the method and the different routines further. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 399: When To Calibrate
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, according to information in this manual. If the robot has absolute accuracy calibration, it is also recommended, but not always necessary to calibrate for new absolute accuracy.
Page 400: Synchronization Marks And Axis Movement Directions
Synchronization mark, axis 3 (early design) Synchronization mark, axis 3 (later design) Synchronization mark, axis 4 Synchronization mark, axis 5 Synchronization mark, axis 6 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 401 One of the marks is more narrow than the other and should be positioned within the limits of the wider mark. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 402: 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 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 404 CANCEL returns to the Calibration window. Press OK again to confirm and start the update. CANCEL returns to the Revolution Counter Update window. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 405 Use this procedure to update the revolution counter with the FlexPendant (IRC5). Action On the ABB menu, tap Calibration. xx1500000942 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 406 Calibration method used at factory for each axis is shown, as well as calibration method used during last field calibration. Tap Manual Method (Advanced). xx1500000944 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 407 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 421. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 408: Calibrating With Axis Calibration Method
FlexPendant. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. WARNING The calibration tool must be fully inserted into the calibration bushing, until the steel spring ring snaps into place.
Page 409 A benefit with reference calibration is that the current state of the robot is stored and not the state when the robot left the ABB factory. The reference value will be named according to tool name, date etc.
Page 410: Calibration Tools For Axis Calibration
There is no risk for bad calibrations as long as the calibration tool is in one piece. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. Equipment, etc. Article number...
Page 411 It is possible to make the calibration tool identifiable with, for example, an RFID chip. The procedure of how to install an RFID chip is described below. Note The tool identifier is NOT delivered from ABB, it is a customized solution. Action Note It is possible to use any RFID solution, with the correct dimensions.
Page 412: Installation Locations For The Calibration Tools
Replace damaged parts with new, if needed. Spare part Article number Note Protection cover and plug set 3HAC056806-001 Contains replacement calibration pin covers and protective plugs for the bushing. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 413: Axis Calibration - Running The Calibration Procedure
WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration holes may cause severe damage to the robot and/or personnel. Equipment, etc.
Page 414 Use this procedure to call for the Axis Calibration method on the FlexPendant. Action Note On the ABB menu, tap Calibration. xx1500000942 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 415 The three-position enabling device on the Press and hold the three-position enabling FlexPendant has been released during robot device and press Play. movement. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 416 Confirm unsynchronized state by pressing Ac- knowledge to continue Axis Calibration proced- ure. Restart Axis Calibration procedure by pressing Play. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 417 (anytime). xx1500002482 Press OK to continue Axis Calibration procedure. Restart Axis Calibration procedure by pressing Play. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 418 Ensure that the sealing is not damaged. Replace the plug and the sealing with new spare part, if missing or damaged. xx1500000952 Protection cover and plug set: 3HAC056806-001. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 419: Calibrating With Calibration Pendulum Method
Where to find information for Calibration Pendulum Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 420: Verifying The Calibration
Write down the values on a new label and stick it on top of the calibration label. The label is located on the lower arm. Remove any calibration equipment from the robot. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 421: Checking The Synchronization Position
If they do not, update the revolu- synchronization position for axes on tion counters. page 400 Updating revolution counters on page 403. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 422 If they do not, up- ization position for axes on page 400 date the revolution counters. Updating revolution counters on page 403. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 423: Decommissioning
Incineration must be carried out under controlled conditions in accordance with local regulations. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 424 Spills can form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. • Spillage can penetrate the soil causing ground water contamination. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 425: Scrapping Of Robot
• When motors are removed from the robot, the robot will collapse if it is not properly supported before the motor is removed. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 426: Decommissioning Of Balancing Device
The following procedure contains useful information about decommissioning. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 427 Cut a hole in the housing as shown in the Use a cutting torch with a long shaft. figure. The measurements shown below are maxim- um values! xx0200000082 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 428 Inner spring: cut at least four coils! Double-check the number of coils cut and make sure all the tension in the springs are removed. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 429: Robot Description
Use the table to identify which type of motor is installed on each robot axis by article number. The article numbers specified are found in WebConfig. Contact ABB Service for further assistance regarding which motor type is installed on the robot, if needed.
Page 430 B motor: 3HAC062450-005 (ABB Orange) / 3HAC062450- 004 (Graphite White). xx1800000129 Not interchangeable. The complete wrist unit must be replaced. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 431: Reference Information
8 Reference information 8.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 432: Applicable Standards
Terminology and general principles EN 574:1996 + A1:2008 Safety of machinery - Two-hand control devices - Functional aspects - Principles for design Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 433 Safety requirements for industrial robots and robot systems ANSI/UL 1740 Safety standard for robots and robotic equipment CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require- ments Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 434: Unit Conversion
2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 435: 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 436 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 437 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm - Nominal Min. Max. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 438: 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 439: Standard Tools
Hex bit socket head cap no. 6 socket 40 mm L=145 mm Hex bit socket head cap no. 6 socket 40mm bit L=220 mm Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 440: Special Tools
3HAC022637-001 Guide pins M16 x 150 3HAC13120-2 Guide pins M16 x 200 3HAC13120-3 Guide pins M16 x 250 3HAC13120-4 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 441 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 442 Delivered as a set of calibration tools. ibration Required if Axis Calibration is the valid calibration method for the robot. Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 443 • Couplings and adapters • Pump (manual) with hose and coupling • Graduated measuring glass • Oil gun • User instructions. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 444: Lifting Accessories And Lifting Instructions
This implies that the instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 445: Spare Part Lists
Spare parts and exploded views are not included in the manual but delivered as a separate document for registered users on myABB Business Portal, www.mypo- rtal.abb.com. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 446 This page is intentionally left blank...
Page 447: Circuit Diagram
3HAC8935-1 Circuit diagram - IRB 6600 type A 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6600 type B 3HAC13347-1 3HAC025744-001 Continues on next page Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 448 Circuit diagram - IRB 6700 3HAC043446-005 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 14000 3HAC050778-003 Circuit diagram - IRB 910SC 3HAC056159-002 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 449: Validity Of Circuit Diagram 3Hac025744-1
Label on the cable harness The label is located at the connectors in the base. Remove the rear cover plate to see the label. WebConfig Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 450: Validity Of Circuit Diagram 3Hac13347-1
3HAC 16331-1 IRB 7600 3HAC 14940-1 revision 0-2 For remaining cable harness assemblies, see section Validity of circuit diagram 3HAC025744-1 on page 449. Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 451: Index
Absolute Accuracy, 397 location of, 181 calibration manuals, 398 grease calibration marks, 400 disposal, 423 calibration position guide pins, base plate, 80 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 452 1, 106 lower arm shaft, 273 axis 2, 108 motor axis 1, 313 axis 3, 110 motor axis 2, 318 mechanical stop location, 167 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 453 301, 303 securing the robot to foundation, attachment screws, 85 base plate, 79, 84 signal lamp, 104 complete arm system, 247–248 signals Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 454 256–257 restricting axis 3, 110 working range IRB 7600 - 150/3.5, 62 zero position IRB 7600 - 340/2.8, 63 checking, 421 Product manual - IRB 7600 3HAC022033-001 Revision: V © Copyright 2007 - 2018 ABB. All rights reserved.
Page 456 No. 4528 Kangxin Highway PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics and Motion 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2007 - 2018 ABB. All rights reserved.

This manual is also suitable for:

Irb 7600-500/2.3 Irb 7600-325/3.1 Irb 7600-150/3.5 M2000 M2000a Irc5 ... Show all

ABB IRB 7600 Series Product Manual

1 Safety

2 Installation and Commissioning

3 Maintenance

4 Repair

5 Calibration

6 Decommissioning

7 Robot Description

8 Reference Information

9 Spare Part Lists

10 Circuit Diagram

Quick Links

Related Manuals for ABB IRB 7600 Series

Summary of Contents for ABB IRB 7600 Series