irc5-irb7600 prod man part2 3hac022033-001_references_revb_en

8/9/2019 IRC5-IRB7600 Prod Man Part2 3HAC022033-001_references_revB_en

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Product manual (part 2 of 2), reference information

IRB 7600 - 500/2.3

IRB 7600 - 400/2.55

IRB 7600 - 340/2.8

IRB 7600 - 150/3.5

M2000

M2000A

M2004

Document ID: 3HAC 022033-001

Revision: B


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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.In no event shall ABB be liable for incidental or consequential damages arising from

use of this manual and products described herein.

This manual and parts thereof must not be reproduced or copied without ABB's written

permission, and contents thereof must not be imparted to a third party nor be used for

any unauthorized purpose. Contravention will be prosecuted.

Additional copies of this manual may be obtained from ABB at its then current charge.

Copyright 2004 ABB All right reserved.

ABB Automation Technologies AB

Robotics

SE-721 68 Vsters

Sweden


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Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1 Reference information 11

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.2 Applicable Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171.6 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.7 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.8 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.9 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2 Part list 25

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.2 Rebuilding parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262.2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.3 Part List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.3.1 Part list, overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.3.2 Mechanical stop ax 1, 3HAC 12812-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.3.3 Base incl frame ax 1, 3HAC 12304-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.3.4 Axis 3-4 400kg, 3HAC 13063-1 (IRB 7600 - 400/2.55, -340/2.8, 150/3.5) . . . . . . . . . . . . . . . . . 31

2.3.5 Axis 3-4 500kg, 3HAC 13063-2 (IRB 7600 - 500/2.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.3.6 Axis 3-4 400kg Foundry, 3HAC 13063-4 (IRB 7600 - 400/2.55, -340/2.8, 150/3.5) . . . . . . . . . . 33

2.3.7 Axis 3-4 500kg Foundry, 3HAC 13063-5 (IRB 7600 - 500/2.3). . . . . . . . . . . . . . . . . . . . . . . . . . 34

2.3.8 Wrist, 3HAC 10503-1 (Std) / 3HAC 15992-1 (Foundry) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.3.9 Material set manipulator, 3HAC 13079-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

2.3.10 Material set ax 1-2, 3HAC 13077-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2.3.11 Mtrl.set balancing device, 3HAC 13082-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2.3.12 Arm extension set, 956 mm, 3HAC 12311-1 (IRB 7600 - 150/3.5) . . . . . . . . . . . . . . . . . . . . . . 49

2.3.13 Arm extension set, 250 mm, 3HAC 12311-2 (IRB 7600 - 340/2.8) . . . . . . . . . . . . . . . . . . . . . . 50

3 Exploded views 513.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

3.2 Base incl. Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

3.3 Frame-Lower arm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

3.4 Frame-Lower arm 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

3.5 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

3 6 Wrist complete 56


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Table of Contents


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Overview

Overview

About this manual

This manual contains reference information for all procedures described in the Product

manual, procedures .

Usage

This manual should be used during

installation

maintenance work

repair work.

Who should read this manual?

This manual is intended for:

installation personnel

maintenance personnel

repair personnel.

Prerequisites

The reader should...

be a trained maintenance/repair craftsman

have the required knowledge of mechanical and electrical installation/repair/

maintenance work.


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Overview

Organization of chapters

The manual is organized in the following chapters:

Revisions

Chapter Contents

Reference information Useful information when performing installation, maintenance

or repair work (lists of necessary tools, reference documents,

safety standards).

Part list Complete list of manipulator parts, shown in the explodedviews or foldouts.

Exploded views / Foldouts Detailed illustrations of the manipulator with reference

numbers to the part list.

Circuit Diagram Circuit Diagram of the manipulator.

Revision Description

- First edition.

Replaces previous manuals:

Installation and Commssioning Manual

Maintenance Manual

Repair Manual, part 1

Repair Manual, part 2.

Changes made in the material from the previous manuals: Model M2004 implemented.

Various corrections due to technical revisions, changes in the

toolkits etc.

A Following updates are made:

Section Document references is completed with article numbers

for calibration manuals.

Section Part listis completed with the spare part number for a

variant of the cable harness/brake release unit.

B New lubricating oil in the gearboxes. Changes are made in the section

Part list.


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Product documentation, M2000/M2000A

Product documentation, M2000/M2000A

General

The complete product documentation kit for the M2000 robot system, including controller,

robot and any hardware option, consists of the manuals listed below:

Hardware manuals

All hardware, robots and controller cabinets, will be delivered with a Product manualwhichis divided into two parts:

Product manual, procedures

Safety information

Installation and commissioning (descriptions of mechanical installation, electrical

connections and loading system software)

Maintenance (descriptions of all required preventive maintenance procedures

including intervals)

Repair (descriptions of all recommended repair procedures including spare parts)

Additional procedures, if any (calibration, decommissioning)

Product manual, reference information

Reference information (article numbers for documentation referred to in Product

manual, procedures, lists of tools, safety standards)

Part list Foldouts or exploded views

Circuit diagrams

Software manuals

The software documentation consists of a wide range of manuals, ranging from manuals for

basic understanding of the operating system to manuals for entering parameters during

operation.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. Each

document set contains the types of information specified below:


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Product documentation, M2004


General

The robot documentation may be divided into a number of categories. This listing is based on

the type of information contained within the documents, regardless of whether the products

are standard or optional. This means that any given delivery of robot products will not contain

alldocuments listed, only the ones pertaining to the equipment delivered.

However, all documents listed may be ordered from ABB. The documents listed are valid forM2004 robot systems.

Hardware manuals

All hardware, robots and controller cabinets, will be delivered with a Product manualwhich

is divided into two parts:

Product manual, procedures

Safety information

Installation and commissioning (descriptions of mechanical installation, electrical

connections and loading system software)

Maintenance (descriptions of all required preventive maintenance procedures

including intervals)

Repair (descriptions of all recommended repair procedures including spare parts)

Additional procedures, if any (calibration, decommissioning)

Product manual, reference information

Reference information (article numbers for documentation referred to in Product

manual, procedures, lists of tools, safety standards)

Part list

Foldouts or exploded views

Circuit diagrams

RobotWare manuals

The following manuals describe the robot software in general and contain relevant reference

information:

RAPID Overview: An overview of the RAPID programming language.


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Application manuals

Specific applications (e.g. software or hardware options) are described in Application

manuals. An application manual can describe one or several applications.

An application manual generally contains information about:

The purpose of the application (what it does and when it is useful)

What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)

How to use the application Examples of how to use the application

Operator's manuals

This group of manuals is aimed at those having first hand operational contact with the robot,

i.e. production cell operators, programmers and trouble shooters. The group of manuals

include:

Operator's manual - IRC5 with FlexPendant Operator's manual - RobotStudio Online

Trouble shooting manualfor the controller and robot

Miscellaneous

A number of manuals provide generic descriptions of the robot and robot system. These

include:

Robot fundamentals(describing the fundamental aspects, functions, concept andsimilar, of a robot system to provide a basic understanding of the robot system)


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1 Reference information

1.1. Introduction

1 Reference information1.1. Introduction

General

This chapter includes general information, complementing the more specific information in

theProduct manual (part 1 of 2), procedures.


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1.2. Applicable Safety Standards

1.2. Applicable Safety Standards

Standards, general

The robot is designed in accordance with the requirements of:

EN 775 - Robot safety.

EN 292-1 - Basic terminology.

EN 292-2 - Technical principles.

EN 418 - Emergency stop.

EN 563 - Temperatures of surfaces.

EN 954-1 - Safety related parts of control systems.

EN 60204-1 - Electrical equipment of machines.

EN 1050 - Principles for risk assessment.

ANSI/RIA 15.06-1999 - Industrial robots, safety requirements.

DIN 19258 - Interbus-S, International Standard

Standards, robot cell

The following standards are applicable when the robot is part of a robot cell:

EN 953 - Fixed and moveable guards

EN 811 - Safety distances to prevent danger zones being reached by the lower limbs.

EN 349 - Minimum gaps to avoid crushing of parts of the human body. EN 294 - Safety distances to prevent danger zones being reached by the upper limbs.

EN 1088 - Interlocking devices

EN 999 - The positioning of protective equipment in respect of approach speeds of the

human body.

ISO 11 161 - Industrial automation systems - Safety of intergrated manufacturing

systems.


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1.3. Unit conversion

1.3. Unit conversion

Converter table

Use the table below to convert units used in this manual.

Quantity Units

Length 1 m 3.28 ft 39.37 inWeight 1 kg 2.21 lb

Pressure 1 bar 100 kPa 14.5 psi

Force 1 N 0.738 lbf

Moment 1 Nm 0.738 lbf-tn

Volume 1 L 0.264 US gal


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1.4. Screw joints

Tightening torque

Before tightening any screw, note the following:

Determine whether a standard tightening torque or special torque is to be applied. The

standard torques are specified in the tables below. Any special torques are specified in

the Repair, Maintenance or Installation procedure description. Any special torque

specified overrides the standard value.

Use the correct tightening torquefor each type of screw joint.

Only use correctly calibratedtorque keys.

Always tighten the joint by hand,and never use pneumatical tools.

Use the correct tightening technique, i.e. do notjerk. Tighten the screw in a slow,

flowing motion.

Maximum allowed total deviation from the specified value is 10%!

The table below specifies the recommended standard tightening torque for oil-lubricated

screwswithslotted or cross-recess head screws.

The table below specifies the recommended standard tightening torque for oil-lubricated

screwswithAllen head screws.

DimensionTightening torque (Nm)

Class 4.8, oil-lubricated

M2.5 0.25

M3 0.5

M4 1.2

M5 2.5

M6 5.0

Dimension

Tightening torque

(Nm)Class 8.8, oil-

lubricated

Tightening torque

(Nm)Class 10.9, oil-

lubricated

Tightening torque

(Nm)Class 12.9, oil-

lubricated

M5 6 - -

M6 10 - -


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1.4. Screw joints

The table below specifies the recommended standard tightening torque for water and air

connectorswhen oneor bothconnectors are made of brass.

M10 55 66

M12 96 115

M16 235 280

DimensionTightening torque

Nm - Nominal

Tightening torque

Nm - Min.

Tightening torque

Nm - Max.

1/8 12 8 15

1/4 15 10 20

3/8 20 15 25

1/2 40 30 50

3/4 70 55 90

Dimension Tightening torque (Nm)Class 10.9, Molycote-lubricated

Tightening torque (Nm)Class 12.9, Molycote-lubricated


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1.5. Weight specifications

1.5. Weight specifications

Definition

In all repair and maintenance procedures, weights of the components handled are sometimes

specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.

To avoid injury, ABB recommends the use of lifting equipment when handling components

with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each

manipulator model.

Example

Below is an example of how a weight specification is presented:

CAUTION!

Caution!

The motor weighs 32 kg! All lifting equipment used must be sized accordingly!


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1.6. Standard toolkit

1.6. Standard toolkit

General

All service (repairs, maintenance and installation) instructions contain lists of tools required

to perform the specified activity.

All special tools required are listed directly in the instructions while all the tools that are

considered standard are gathered in the Standard toolkit and defined in the table below.

In this way, the tools required are the sum of the Standard Toolkit and any tools listed in theinstruction.

Contents, standard toolkit, 3HAC 15571-1

Qty Art. no. Tool Rem.

1 - Ring-open-end spanner 8-19mm

1 - Socket head cap 5-17mm

1 - Torx socket no:20-60

1 - Box spanner set

1 - Torque wrench 10-100Nm

1 - Torque wrench 75-400Nm

1 - Ratchet head for torque wrench 1/2

2 - Hexagon-headed screw M10x100

1 - Socket head cap no:14, socket 40mm bit L 100mm

1 - Socket head cap no:14, socket 40mm bit L 20mm To be shorted to 12mm



1 R f i f ti


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1.7. Special tools

1.7. Special tools

General

All service instructions contain lists of tools required to perform the specified activity. The

required tools are a sum of standard tools, defined in section Standard toolkiton page 18, and

of special tools, listed directly in the instructions and also gathered in this section.

Basic tools

The table below specifies the tools in the basic toolkit (3HAC 15571-3) that are used for the

current robot model. This toolkit is necessary primarly when removing and refitting the

motors.

The tools are also listed directly in the instructions.

Special tools

The table below specifies the special tools required during several of the service procedures.

The tools may be ordered separately and are also specified directly in concerned instructions

in theProduct manual, procedures.

Description Qty Art. no.

Bolts (M16 x 80) for Mech stop ax 3 2 3HAB 3409-89Extension 300mm for bits 1/2" 1 3HAC 12342-1

Guide pins M10 x 100 2 3HAC 15521-1

Guide pins M10 x 150 2 3HAC 15521-2

Lifting tool, wrist unit 1 3HAC 12734-1

Lifting tool, motor ax 1, 4, 5 1 3HAC 14459-1

Lifting tool, motor ax 2, 3, 4 1 3HAC 15534-1

Mech stop ax 3 2 3HAC 12708-2Removal tool, motor M12x 1 3HAC 14973-1

Fits motors, axes 1, 2, 3, 4 and 5.

Rotation tool 1 3HAC 17105-1

Standard toolkit (content described in

section Standard toolkiton page 18)

1 3HAC 15571-1

Washers for mech stop axis 3 2 3HAA 1001-186


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1.7. Special tools

Calibration equipment, WylerThe table below specifies the calibration equipment required when calibrating the robot with

the Wyler method, using the Levelmeter 2000.

Calibration equipment, Pendulum

The table below specifies the calibration equipment needed when calibrating the robot with

the Pendulum method.

Oil exchange equipment

The table below specifies the recommended equipment for oil exhange.

Description Art. no. Note

Angel bracket 68080011-LP

Calibration bracket 3HAC 13908-9

Calibration tool ax1 3HAC 13908-4

Levelmeter 2000 kit 6369901-347 Includes one sensor.

Measuring pin 3HAC 13908-5

Sensor fixture 68080011-GM

Sensor plate 3HAC 0392-1

Sync. adapter 3HAC 13908-1

Turn disk fixture 3HAC 68080011-GU


CalPen (Calibration

Pendulum)

3HAC 15716-1 Complete kit that also includes user

instructions.


Oil exchange equipment 3HAC 021745-001 Includes

vacuum pump withregulator, hose and coupling

couplings and adapters

pump (manual) with hose

and coupling

graduated measuring glass



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1.8. Document references

1.8. Document references

General

The contents of this manual may include references to additional documentation necessary to

perform certain procedures. This section specifies the article numbers for the referenced

documentation.

Product specification, robot

The product specification includes generic technical data. The specification listed below is

the English version.

Product manuals, controller

The product manuals include information about installation and service activities. The table

below specifies the article numbers of the product manuals for all controller models. The part

number -001 is the English version.

Operators manual

The operators manual contains instructions for daily operation of robot systems. The table

below specifies the article numbers of the operators manuals for different robot systems.

Document name Document ID

Product specification 3HAC 13491-1

Document name Document ID

Product manual, S4Cplus M2000 3HAC 021333-001Product manual, S4Cplus M2000A 3HAC 021128-001

Product manual, IRC5 M2004 3HAC 021313-001

Document name Document ID Note

User's guide (S4Cplus) 3HAC 7793-1 Contains instructions for daily operation

of S4Cplus based robot systems.

Operator's manual (IRC5) 3HAC 16590-1


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1.9. Lifting equipment and lifting instructions

1.9. Lifting equipment and lifting instructions

General

Many repair and maintenance activities require different pieces of lifting equipment, which

are specified in each procedure.

The use of each piece of lifting equipment is notdetailed in the activity procedure, but in the

instruction delivered with each piece of lifting equipment.

This implies that the instructions delivered with the lifting equipment should be stored forlater reference.

2 Part list


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2.1. Introduction

2 Part list2.1. Introduction

Overview

This section specifies all the replacement articles of the robot. The parts are shown in

exploded views or in foldouts, either in this or in a separate chapter.

Specific spare parts are listed separately in a Spare part list.

2 Part list


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2.2.1. Overview

2.2 Rebuilding parts

2.2.1. Overview

General

The IRB 7600 have some rebuilding parts that differ from eachother, depending on the

version of the manipulator. The table below is a general overview of which parts belongs to

which versions.

Art. no. Part 500/2.3 400/2.55 340/2.8 150/3.5

3HAC 13063-1 Axis 3-4 400kg (Std) X X X

3HAC 13063-4 Axis 3-4 400kg (Foundry) X X X

3HAC 13063-2 Axis 3-4 500kg (Std) X

3HAC 13063-5 Axis 3-4 500kg (Foundry) X3HAC 10509-1 Tube shaft 2.55 (Std) X X X

3HAC 15932-1 Tube shaft 2.55 (Foundry) X X X

3HAC 10509-5 Tube shaft 2.3 (Std) X

3HAC 15932-2 Tube shaft 2.3 (Foundry) X

3HAC 9760-5 Arm extender 250mm (Std) X

3HAC 15932-3 Arm extender 250mm (Foundry) X

3HAC 9760-5 Arm extender 956mm (Std) X3HAC 15932-4 Arm extender 956mm (Foundry) X

3HAC 11755-1 Friction washer X X

3HAB 7700-69 Screw M12x50 20X 20X

3HAA 1001-134 Washer 13x19x1,5 20X 20X

9ABA 107-56 Parallel pin 10x20 X X

3HAC 14207-1 Motor axis 1 X X X X

3HAC 14209-1 Motor axis 2 X X X X3HAC 14209-1 Motor axis 3 X X X X

3HAC 14210-1 Motor axis 4 X X X X

3HAC 16628-1 Wrist 400-500kg X X X X

2 Part list


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2.3.1. Part list, overview

2.3 Part List


Overview

Item Qty Art. number Description Note/Dimension

5 1 3HAC 12812-2 Mechanical stop axis 1,

assembly

See

Mechanical stop ax 1, 3HAC

12812-2on page 29

6 1 3HAC 10499-7 Cover sheet

7 1 3HAB 7700-89 Hex socket head cap

screw

M16x90

8 1 3HAC 14222-1 Plate T=4

9 4 9ADA 618-56 Torx pan head screw M6x16

10 2 3HAC 10509-11 Cover

101 1 3HAC 12304-1 Base incl frame ax 1 See

Base incl frame ax 1, 3HAC

12304-1on page 30

102 1 3HAC 13063-1 Axis 3-4 400kg (IRB

7600 - 400/2.55, -340/

2.8, -150/3.5)

See

Axis 3-4 400kg, 3HAC

13063-1 (IRB 7600 - 400/

2.55, -340/2.8, 150/3.5)onpage 31

102 1 3HAC 13063-2 Axis 3-4 500kg (IRB

7600 - 500/2.3)

See

Axis 3-4 500kg, 3HAC

13063-2 (IRB 7600 - 500/

2.3)on page 32

102 1 3HAC 13063-4 Axis 3-4 400 kg Foundry

(IRB 7600 - 400/2.55, -

340/2.8, -150/3.5)

102 1 3HAC 13063-5 Axis 3-4 500 kg Foundry

(IRB 7600 - 500/2.3)

103 1 3HAC 10503-1 Wrist See

Wrist, 3HAC 10503-1 (Std) /

3HAC 15992-1 (Foundry)on

2 Part list


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108 1 3HAC 13079-1 Material set manipulator See

Material set manipulator,

3HAC 13079-1on page 44

109 1 3HAC 13077-1 Material set ax 1-2 See

Material set ax 1-2, 3HAC

13077-1on page 45

110 1 3HAC 13082-1 Mtrl.set balancing device See

Mtrl.set balancing device,3HAC 13082-1on page 48

111 1 3HAC 12311-1 Arm extension set

956mm ((IRB 7600 -150/

3.5)

See

Arm extension set, 956 mm,

3HAC 12311-1 (IRB 7600 -

150/3.5)on page 49

111 1 3HAC 12311-2 Arm extension set

250mm ((IRB 7600 -340/

2.8)

See

Arm extension set, 250 mm,

3HAC 12311-2 (IRB 7600 -340/2.8)on page 50

112 1 3HAC 12129-1 Cover plate

112 2 3HAC 12129-1 Cover plate

113 4 9ADA 618-56 Torx pan head screw M6x16

113 8 9ADA 618-56 Torx pan head screw

114 1 3HAC 13416-1 Protection cover



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2 Part list


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2.3.3 Base incl frame ax 1, 3HAC 12304-1

2.3.3 Base incl frame ax 1, 3HAC 12304-1

Overview

Base, machining, 3HAC 10044-1

Frame incl ax 1 gearbox, 3HAC 12303-1


101.1 1 3HAC 10044-1 Base, machining See

Base, machining, 3HAC

10044-1on page 30

101.2 1 3HAC 12303-1 Frame incl ax 1 gearbox See

Frame incl ax 1 gearbox,


101.3 3 3HAC 11732-1 Washer T=3

101.4 18 3HAB 7700-89 Hex socket head cap

screw

M16x90

101.5 1 3HAC 11529-1 Rubber lined clip D=28

101.6 1 3HAC 14453-1 Hose with flange

101.7 1 3HAC 14453-2 Plug

101.8 1 3HAC 4428-2 Hose Clip

101.9 1 9ADA 618-56 Torx pan head screw M6x16

Item Qty Art. number Description Note

101.1.1 1 3HAC 10044-2 Base, casting

101.1.2 5 3HAC 4836-7 Protection plug

101.1.3 1 3HAC 1383-2 Protection Cover compl.

101.1.4 1 3HAC 14024-1 Protection screw


101.2.1 1 3HAC 15865-1 Frame machining

2 Part list


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2.3.4 Axis 3-4 400kg, 3HAC 13063-1 (IRB 7600 - 400/2.55, -340/2.8, 150/3.5)

2.3.4 Axis 3-4 400kg, 3HAC 13063-1 (IRB 7600 - 400/2.55, -340/2.8, 150/3.5)

Overview


102.1 1 3HAC 13076-1 Material set ax 4 See

Material set ax 4, 3HAC

13076-1on page 34

102.2 1 3HAC 10509-1 Tube shaft 2,55 See

Tube shaft 2,55, 3HAC

10509-1on page 36

102.3 1 3HAC 13062-1 Axis 3 See

Axis 3, 3HAC 13062-1on

page 36


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2 Part list

2 3 6 A i 3 4 400k F d 3HAC 13063 4 (IRB 7600 400/2 55 340/2 8 150/3 5)


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2.3.6. Axis 3-4 400kg Foundry, 3HAC 13063-4 (IRB 7600 - 400/2.55, -340/2.8, 150/3.5)

2.3.6. Axis 3-4 400kg Foundry, 3HAC 13063-4 (IRB 7600 - 400/2.55, -340/2.8, 150/3.5)

Overview




13076-1on page 34

102.2 1 3HAC 15932-1 Tube shaft 2,55 foundry

102.3 1 3HAC 13062-1 Axis 3 See


page 36

2 Part list

2 3 7 Axis 3 4 500kg Foundry 3HAC 13063 5 (IRB 7600 500/2 3)


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2.3.7. Axis 3-4 500kg Foundry, 3HAC 13063-5 (IRB 7600 - 500/2.3)


Overview

Material set ax 4, 3HAC 13076-1




13076-1on page 34

102.2 1 3HAC 15932-2 Tube shaft 2,3 foundry

102.3 1 3HAC 13062-1 Axis 3 See


page 36


102.1.1 1 3HAC 11523-1 Gear Z4 / 4

102.1.2 1 3HAC 14725-1 Rot ac motor incl pinion See

Rot ac motor incl pinion,


102.1.3 4 3HAB 3409-50 Hex socket head cap

screw

M10x40

102.1.4 4 3HAB 4233-1 Washer

102.1.5 1 3HAC 11499-1 Motor flange, machin.


screw

M10x80

102.1.7 2 3HAC 10122-12 Washer, RV 125 F,

axis4,5

T=3

102.1.8 1 3HAC 12642-1 RV 125F incl. gear See

RV 125F incl. gear, 3HAC12642-1on page 35

102.1.9 1 3HAC 12640-1 Cover ax 4 incl. sealing See

Cover ax 4 incl. sealing,


102 1 10 10 3HAC 11409 6 Sh ld S M6 8 8

2 Part list

2 3 7 Axis 3 4 500kg Foundry 3HAC 13063 5 (IRB 7600 500/2 3)


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Rot ac motor incl pinion, 3HAC 14725-1

RV 125F incl. gear, 3HAC 12642-1

102.1.21 1 3HAB 3772-27 O-ring 170x5

102.1.22 1 3HAC 3774-7 Spacer ring

102.1.23 1 3HAC 11461-1 Sealing

102.1.24 1 3HAC 17219-1 Thrust washer

102.1.25 1 9ABA 135-45 Retaining ring, shaft 170

102.1.26 1 3HAC 11928-1 Protective ring housing

102.1.27 1 3HAC 17218-1 Set of shims

102.1.28 2 2522 122-1 Magnetic plug R1/4"

102.1.29 2 3HAC 16721-1 Magnetic plug R1/2"

102.1.30 900 ml 3HAC 021469-

001

Lubricating oil, Shell

Tivela S 150

102.1.31 3850 ml 1171 2016-604/

3HAC 021469-

001

Lubricating oil, X320

Lubricating oil, Shell

Tivela S 150

Do not mix the oils!

102.1.32 1 9ABA 107-56 Parallel pin 10x20

102.1.33 2 3HAC 10122-27 Friction washer T=0,5102.1.34 1 ml 3HAB 7116-1 Locking liquid

102.1.35 30 g 3HAB 3537-1 Bearing grease

Item Qty Art. number Description Dimension102.1.2.1 1 3HAC 17484-2 Rotational ac motor M2

102.1.2.2 1 3HAC 10122-17 Pinion RV 125F-97,909

102.1.2.3 0 2152 2012-430 O-ring 89,5x3


102.1.8.1 1 3HAC 17273-1 RV 125F-97,909 assembly See

RV 125F-97,909

assembly, 3HAC

17273-1on page 35


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2 Part list

2.3.8 Wrist, 3HAC 10503-1 (Std) / 3HAC 15992-1 (Foundry)


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, ( ) ( y)



103.1 1 3HAC 11409-7 Cover, right See

Cover, right, 3HAC

11409-7on page 39103.2 14 3HAC 11409-6 Shoulder Screw M6x8x8

103.5 2 3HAC 16721-1 Magnetic plug R1/2

103.6 1 3HAC 12642-1 RV 125F incl. gear See

RV 125F incl. gear,

3HAC 12642-1on

page 39

103.7 18 3HAB 3409-50 Hex socket head cap screw M10x40

103.8 2 3HAC 10122-12 Washer, RV 125 F, axis4,5 T=3

103.9 1 3HAC 10503-3 Wrist housing, machining

103.10 2 2522 122-1 Magnetic plug R1/4"

103.11 4 9ADA 183-35 Hex socket head cap screw

103.12 2 3HAC 10503-8 Damper ax 5

103.13 2 3HAC 10122-27 Friction washer


103.15 4 3HAB 4233-1 Washer

103.16 1 3HAC 14725-1 Rot ac motor incl pinion See

Rot ac motor incl

pinion, 3HAC 14725-1

on page 35

103.18 1 3HAC 11409-3 Cover, left machining


103.21 7 3HAB 3409-50 Hex socket head cap screw M10x40103.22 7 3HAB 4233-1 Washer

103.24 1 3HAC 10503-14 Support shaft inc bearing See

Support shaft inc

bearing, 3HAC 10503-

14 on page 40

2 Part list



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Cover, right, 3HAC 11409-7


103.33 1 3HAC 10503-13 Wheel Unit See

Wheel Unit, 3HAC

10503-13on page 43

103.34 1 3HAA 1001-628 Sealing

103.35 7 9ADA 624-56 Torx counters. head screw M6x16

103.37 1 3HAB 7116-1 Locking liquid

103.38 1 3HAC 11440-5 Heat protection plate

103.39 3 2166 2055-3 Cable straps, outdoors

103.40 1 3HAC 11440-1 Cable harness, manip ax5-6

103.41 3800 ml 1171 2016-604/

3HAC 021469-

001

Lubricating oil, X320/

Lubricating oil, Shell Tivela S

150


103.42 750 ml 3HAC 021469-

001

Lubricating oil, Shell Tivela S

150

103.43 1 3HAC 5984-1 Label

103.43 1 3HAC 17260-1 Sprbarhetsetikett

103.43 1 3HAC 17260-2 Sprbarhetsetikett Wrist,

Foundry


103.1.1 1 3HAC 11409-1 Cover, right machining

103.1.2 1 3HAC 11409-5 Gasket, right


103.6.1 1 3HAC 17273-1 RV 125F-97,909 assembly SeeRV 125F-97,909 assembly,


103.6.2 1 3HAC 11488-1 Gear Z3 / 4, 5

103.6.3 9 3HAB 7700-69 Hex socket head cap screw M12x50

103 6 4 6 3HAB 3409 86 H k t h d M16 60

2 Part list



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Support shaft inc bearing, 3HAC 10503-14

Axis 6 complete, 3HAC 12707-1

Item Qty Art. number Description Dimension

103.16.1 1 3HAC 17484-2 Rotational ac motor M2

103.16.2 1 3HAC 10122-17 Pinion RV 125F-97,909

103.16 3 2152 2012-430 O-ring 89,5x3


103.24.1 1 3HAC 11470-1 Support Shaft

103.24.2 1 3HAA 2325-12 Ball bearing W.two seal. 130x200x33

103.24.3 3 9ADA 618-56 Torx pan head screw M6x16

103.24.4 1 ml 3HAB 7116-1 Locking liquid


103.28.1 1 3HAC 10436-1 Tilt house RV125F

103.28.2 1 3HAC 17274-1 RV 125F-178,41assembly

SeeRV 125F-178,41

assembly, 3HAC 17274-

1on page 42

103.28.3 2 3HAC 10122-13 Washer, RV 125 F T=3


screw

M10x50

103.28.5 1 3HAC 13193-1 Turning disc, dia. 250

103.28.6 33 3HAB 7700-3 Hex socket head capscrew

M10x25

103.28.7 2 2522 122-1 Magnetic plug R1/4"

103.28.8 1 3HAC 11471-1 Sync. Plate

103.28.9 1 2152 2012-433 O-ring 104,5x3

2 Part list



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103.28.17 1 9ADA 624-69 Torx counters, head screw M8x20

2 Part list



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Axis 6 complete Foundry, 3HAC 12707-2

RV 125F-178,41 assembly, 3HAC 17274-1


103.28.1 1 3HAC 16010-1 Tilt house RV125F,

foundry

103.28.2 1 3HAC 17274-1 RV 125F-178,41

assembly

See

RV 125F-178,41

assembly, 3HAC 17274-1on page 42

103.28.3 2 3HAC 10122-13 Washer, RV 125 F T=3


screw

M10x50

103.28.5 1 3HAC 13193-1 Turning disc, dia. 250


screw

M10x25

103.28.7 2 2522 122-1 Magnetic plug R1/4"103.28.8 1 3HAC 11471-1 Sync. Plate

103.28.9 1 2152 2012-433 O-ring 104,5x3

103.28.10 2 9ADA 618-32 Torx pan head screw M4x8


103.28.12 850 ml 3HAC 021469-

001

Lubricating oil, Shell Tivela

S 150

103.28.13 1 3HAC 14726-1 Rot ac motor incl pinion SeeRot ac motor incl pinion,

3HAC 14725-1on page

35

103.28.14 4 9ADA 312-7 Plain washer 8,4x16x1,6

103.28.15 4 9ADA 183-37 Hex socket head cap

screw

M8x25

103.28.16 1 3HAC 14263-1 Protection cover

103.28.17 1 9ADA 624-69 Torx counters, head screw M8x20

2 Part list



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Wheel Unit, 3HAC 10503-13

103.28.13.4 1 3HAC 12877-1 Gasket


103.33.1 1 3HAC 11524-1 Gear Z4 / 5

103.33.2 1 3HAC 10503-12 Bearing Washer

103.33.3 1 3HAB 3710-19 Groove ball bearing 160x220x28

103.33.4 1 3HAC 10503-15 Support Ring


2 Part list

2.3.9. Material set manipulator, 3HAC 13079-1


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2.3.9. Material set manipulator, 3HAC 13079-1

Overview


108.201 2 3HAC 17213-1 Sealing axis 2/3


108.203 3 3HAC 11828-1 Washer axis 3

108.204 30 3HAA 1001-186 Washer 17x25x3

108.205 1 3HAC 11755-1 Friction Washer


108.207 20 3HAA 1001-134 Washer 13x19x1,5

108.210 1 3HAC 14300-1 Cable protector

108.212 1 3HAC 11771-1 Cable guide, end part

108.213 1 3HAC 13960-1 Connection plate, ax3

108.214 2 3HAC 11750-1 Damper axis 3

108.215 2 3HAC 12990-1 Damper axis 2

108.216 2 9ADA 624-65 Torx counters, head screw M6x60

108.217 2 9ADA 334-7 Spring washer, conical 8,4x18x2


108.220 2 3HAC 9953-1 Sync plate with nonie

108.222 1 3HAC 14658-1 Sync plate with nonie axis 3

108.223 2 9ADA 183-48 Hex socket head cap screw M10x16


108.228 1 3HAC 3261-1 Cover upperarmcovers

108.229 1 3HAC 15431-1 Cable protection

108.230 1 3HAC 14880-1 Cable fixing bracket

108.231 1 2166 2055-3 Cable straps, outdoors

108.232 5 3HAC 16721-1 Magnetic plug R1/2

108.233 1 2522 122-1 Magnetic plug R1/4"

2 Part list

2.3.10. Material set ax 1-2, 3HAC 13077-1


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Overview


109.301 1 3HAC 12641-1 RV 700F incl. gear See

RV 700F incl. gear,

3HAC 12641-1on page46

109.302 1 3HAC 11198-1 Cover, machining

109.303 1 3HAC 14698-1 Friction washer 381x438x1,0


109.305 20 3HAA 1001-186 Washer 17x25x3



3HAC 14725-1on page35



3HAC 14725-1on page

35


109.309 8 3HAB 4233-1 Washer

109.310 1 3HAC 12252-1 Bottom plate

109.311 1 3HAC 14131-1 Connection plate, base

109.312 1 3HAC 11774-3 Adapter, machined

109.313 1 3HAC 11769-1 Cable guide, ax.1

109.320 1 3HAC 12671-5 Profile with sync scale

109.321 1 3HAC 12671-6 Block for calibration

109.322 1 3HAC 14024-1 Protection screw



109.326 1 3HAC 16014-1 Serial measurement unit

109.327 1 3HAC 14788-3 Cover SMB and BRU See

C SMB d BRU

2 Part list



48/78


109.335 1 3HAA 2166-23 VK-Cover

109.336 1 3HAC 13914-1 Attachment plate

109.337 2 3HAC 12625-1 Strap, Velcro

109.338 1 3HAC 14793-1 Bracket

109.339 1 3HAC 15619-1 Cable, FB7-SMB7

109.341 7600 ml 3HAC 16843-1/

3HAC 021469-

001

Lubricating oil, RMO 150

Lubricating oil, Shell Tivela

S 150


109.342 4800 ml 3HAC 16843-1/3HAC 021469-

001

Lubricating oil, RMO 150Lubricating oil, Shell Tivela

S 150


109.344 1 ml 3HAB 7116-1 Locking liquid

109.345 2 9ADA 298-4 Prev. torque nut, non-met. M6

109.346 1 3HAC 16036-1 BU w. buttons DSQC 561

1 3HAC 14219-1 BU at the base See section Refitting of

brake release unit.

1 3HAC 12989-1 BU at the base See section Refitting of

brake release unit.

109.347 1 3HAC 2744-1 Push button guard

109.348 4 9ADA 629-56 Torx pan head roll. screw M6x16


109.350 1 3HAC 4813-1 Cover, push button guard


109.352 1 3HAC 14024-1 Protection screw

109.353 1 3HAC 17423-1 Washer

109.354 1 9ADA 269-4 Hexagon nut M8

Item Qty Art. number Description Note109.301.1 1 3HAC 17272-1 RV 700F-269,21 assembly See

RV 700F-269,21

assembly, 3HAC 17272-

1on page 46

109 301 2 1 3HAC 11636 1 G Z2 /2 3

2 Part list



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Cover SMB and BRU, 3HAC 14788-3

Cover battery box, 3HAC 14791-3



109.306.2 1 3HAC 11350-1 Pinion RV 500C & RV 320C

109.306.3 0 2152 2012-430 O-ring 89,5x3



109.307.2 1 3HAC 11632-1 Pinion Z1 /2.3

109.307.3 0 2152 2012-430 O-ring 89,5x3


109.327.1 1 3HAC 14788-1 Cover, casting

109.327.2 1 3HAC 14788-2 Gasket

109.327.3 1 3HAC 14692-4 Rubber cloth


109.332.1 1 3HAC 14791-1 Cover

109.332.2 1 3HAC 14791-2 Gasket

109.332.2 1 3HAC 16977-1 Warning label battery

2 Part list

2.3.11. Mtrl.set balancing device, 3HAC 13082-1


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2.3.11. Mtrl.set balancing device, 3HAC 13082-1

Overview


110.401 1 3HAC 4310-1 Sealed spherical bearing

110.402 1 3HAC 13124-1 Thrust washer

110.403 1 3HAC 13122-1 Bushing

110.404 1 9ABA 135-32 Retaining ring, shaft

110.405 1 3HAC 13123-1 Shaft

110.406 1 3HAC 4836-7 Protection plug 16x12,3x9x7


110.408 2 9ABA 107-56 Parallel pin 10x20

110.409 1 3HAC 12548-2 Protection washer

110.410 1 3HAC 11427-1 Shaft, Balancing device

110.411 4 3HAA 1001-186 Washer 17x25x3

110.412 120 ml 3HAA 1001-294 Grease

110.413 2 3HAC 4836-1 Protection plug 20x14,6x7,5x5,5

110.414 1 9ADA 183-490 Hex socket head cap screw M16x180

2 Part list

2.3.12. Arm extension set, 956 mm, 3HAC 12311-1 (IRB 7600 - 150/3.5)


51/78


Overview


111.501 1 3HAC 9760-5 Arm extender 956mm

111.501 1 3HAC 15932-4 Arm extender 956mm, Foundry



111.504 20 3HAA 1001-134 Washer 13x19x1,5


2 Part list



52/78


Overview


111.501 1 3HAC 9760-1 Arm extender 250mm

111.501 1 3HAC 15932-3 Arm extender 250mm, Foundry



111.504 20 3HAA 1001-134 Washer 13x19x1,5


3 Exploded views

3.1. Introduction


53/78

3 Exploded views

3.1. Introduction

Definitions

This chapter contains detailed views of the components on the manipulator.

The numbered details are specified with item numbers in the Part List.

The exploded views are divided into: Base, incl. frame

Frame-Lower arm 1

Frame-Lower arm 2

Upper arm

Wrist complete

3 Exploded views

3.2. Base incl. Frame


54/78

3.2. Base incl. Frame

3 Exploded views

3.3. Frame-Lower arm 1


55/78

3.3. Frame-Lower arm 1


56/78


57/78


58/78

4 Circuit Diagram

4.1. Introduction


59/78

4 Circuit Diagram

4.1. Introduction

Overview

This chapter includes the circuit diagram of the robot.


60/78

Circuit Diagram 3HAC 13347-1 / Rev. 02

CONTENTS


61/78

S h e e t

Contents ........................................................................................................................101

Connection Point Location ...........................................................................................102

Legend ..........................................................................................................................103

Brake Release Unit .......................................................................................................104

Serial Measurement Board ...........................................................................................105

Axis 1............................................................................................................................106

Axis 2............................................................................................................................107

Axis 3............................................................................................................................108

Axis 4............................................................................................................................109Axis 5 (IRB 7600) ........................................................................................................110

Axis 6............................................................................................................................111

Switches axis 1 .............................................................................................................113

Switches/Fan axis 2 ......................................................................................................114

Switches/Fan axis 3 ......................................................................................................115

Axis 5 (IRB 6600) ........................................................................................................901

Design changes, note 1.1 ..............................................................................................905

Design changes, note 2.1-2.7........................................................................................906


62/78

R e v i s i o n

02

s h e e t

CircuitDiagram3HAC

1334

7-1Contents 101


63/78

R e v i s i o n

02

s h e e t

CircuitDiagram3HAC

1334

7-1Connection Point Location 102


64/78

R e v i s i o n

02

s h e e t

CircuitDiagram3HAC

1334

7-1Legend 103


65/78

R e v i s i o n

02

s h e e t

CircuitDiagram3HAC

1334

7-1Brake Release Unit 104


66/78

R e v i s i o n

02

s h e e t

CircuitDiagram3HAC

1334

7-1Serial Measurement Board 105


67/78

R e v i s i o n

02

s h e e t

CircuitDiagram3HAC

1334

7-1Axis 1 106


68/78

R e v i s i o n

02

s h e e t

CircuitDiagra

m3HAC

1334

7-1Axis 2 107


69/78

R e v i s i o n

02

s h e e t

CircuitDiagra

m3HAC

1334

7-1Axis 3 108


70/78

R e v i s i o n

02

s h e e t

CircuitDiagra

m3HAC

1334

7-1Axis 4 109


71/78

R e v i s i o n

02

s h e e t

CircuitDiagra

m3HAC

1334

7-1Axis 5 (IRB 7600) 110


72/78

R e v i s i o n

02

s h e e t

CircuitDiagra

m3HAC

1334

7-1Axis 6 111


73/78


74/78

R e v i s i o n

02

s h e e t

CircuitDiagra

m3HAC

13347-1

Switches/Fan axis 2 114


75/78

R e v i s i o n

02

s h e e t

CircuitDiagra

m3HAC

13347-1

Switches/Fan axis 3 115


76/78


77/78

R e v i s i o n

02

s h e e t

CircuitDiagra

m3HAC

13347-1

Design changes, note 1.1 905


78/78

R e v i s i o n

02

s h e e t

CircuitDiagra

m3HAC

13347-1

Design changes, note 2.1-2.7 906

irc5-irb7600 prod man part2 3hac022033-001_references_revb_en

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