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|---|---|---|---|
ABB_IRB7600_Product_Manual.pdf
|
https://search.abb.com/library/Download.aspx?DocumentID=3HAC022033-001&LanguageCode=en&DocumentPartId=&Action=Launch&DocumentRevisionId=AF
| 141
|
Note
Art. no.
Equipment
These procedures include refer-
ences to the tools required.
Other tools and procedures may
be required. See references to
these procedures in the step-by-
step instructions below.
Inspecting the oil level in axis-6 gearbox
Use this procedure to inspect the oil level in the axis-6 gearbox.
Note
Action
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page 38 .
1
Shown in the figure Location of
gearbox on page 139 .
Move axes 3 and 5 to a horizontal position, and
make sure that the oil plug, filling and inspection
(B1 or B2) is facing upwards.
2
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
3
This is a precaution to reduce the
temperature dependency of the
measurement.
Make sure that the oil temperature is +25°C ±10°C.
4
Open the oil plug, filling and inspection .
5
This is a precaution to avoid vacu-
um effects by allowing air to enter
at the top of the gearbox.
Note
If equipment that covers the oil
plug, draining is fitted on the robot
so that the oil plug cannot be
opened, then this step can be
skipped.
Open the oil plug, draining .
6
Slowly turn axis 4, while adjusting axis 6 so that the
oil plug, filling and inspection always faces upwards.
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
7
Continues on next page
140
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.7 Inspecting the oil level in axis-6 gearbox
Continued
Note
Action
A
B
C
xx1400002786
A
Oil plug hole
B
Required oil level
C
Gearbox oil
Inspect the oil level in the hole for the oil plug, filling
and inspection .
The oil should reach all the way up to the external
edge of the thread for the oil plug, filling and inspec-
tion .
Note
If the oil plug, draining is not opened, then use a
clean, narrow object, for example an oil stick or a
cable tie, to gently poke the oil surface. This will
avoid surface tension from stopping air to enter into
the gearbox.
8
Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
page 161 .
Adjust the oil level, if required.
9
Detailed in section Changing oil,
axis-6 gearbox on page 180 .
Tightening torque: 20 Nm
Refit the oil plugs.
10
WARNING
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in Technical
reference manual - Lubrication in gearboxes .
11
Product manual - IRB 7600
141
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.7 Inspecting the oil level in axis-6 gearbox
Continued
3.3.8 Inspecting the balancing device
General
Several points are to be checked on the balancing device during the inspection.
This section describes how to perform the inspection regarding:
•
dissonance
•
damage
•
leakage
•
contamination / lack of free space.
Action at detected faults
If any faults are detected during the inspection, a maintenance may be performed
according to specific maintenance kits.
If the balancing device is an older model, it must in some cases be upgraded
instead! The instruction for the current inspection details if a fault requires a
maintenance / upgrade and the table below specifies the different models and
which of the two actions they require.
The article number of the balancing device is located on a label at the rear cover,
shown in the figure Inspection points, balancing device on page 143 .
Action at detected faults
Balancing device, art. no.
Upgrade
3HAC10538-1
Maintenance
3HAC14675-1
Continues on next page
142
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.8 Inspecting the balancing device
|
ABB_IRB7600_Product_Manual.pdf
|
https://search.abb.com/library/Download.aspx?DocumentID=3HAC022033-001&LanguageCode=en&DocumentPartId=&Action=Launch&DocumentRevisionId=AF
| 142
|
Note
Action
A
B
C
xx1400002786
A
Oil plug hole
B
Required oil level
C
Gearbox oil
Inspect the oil level in the hole for the oil plug, filling
and inspection .
The oil should reach all the way up to the external
edge of the thread for the oil plug, filling and inspec-
tion .
Note
If the oil plug, draining is not opened, then use a
clean, narrow object, for example an oil stick or a
cable tie, to gently poke the oil surface. This will
avoid surface tension from stopping air to enter into
the gearbox.
8
Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
page 161 .
Adjust the oil level, if required.
9
Detailed in section Changing oil,
axis-6 gearbox on page 180 .
Tightening torque: 20 Nm
Refit the oil plugs.
10
WARNING
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in Technical
reference manual - Lubrication in gearboxes .
11
Product manual - IRB 7600
141
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.7 Inspecting the oil level in axis-6 gearbox
Continued
3.3.8 Inspecting the balancing device
General
Several points are to be checked on the balancing device during the inspection.
This section describes how to perform the inspection regarding:
•
dissonance
•
damage
•
leakage
•
contamination / lack of free space.
Action at detected faults
If any faults are detected during the inspection, a maintenance may be performed
according to specific maintenance kits.
If the balancing device is an older model, it must in some cases be upgraded
instead! The instruction for the current inspection details if a fault requires a
maintenance / upgrade and the table below specifies the different models and
which of the two actions they require.
The article number of the balancing device is located on a label at the rear cover,
shown in the figure Inspection points, balancing device on page 143 .
Action at detected faults
Balancing device, art. no.
Upgrade
3HAC10538-1
Maintenance
3HAC14675-1
Continues on next page
142
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.8 Inspecting the balancing device
Inspection points, balancing device
The balancing device is located at the top rear of the frame as shown in the figure.
The figure also shows the inspection points, further described in the instructions.
xx0300000580
Balancing device
A
Piston rod (inside)
B
Shaft, including securing screw
C
Ear, bearing and o-rings
D
Label with article number
E
Inspect the surroundings
F
Bearing, balancing device attachments
G
Required equipment
The table below specifies the equipment used if damage is detected on the
balancing device. See section Action at detected faults on page 142 to determine
whether to perform maintenance or upgrade!
Note
Art. no.
Spare part no.
Equipment, etc.
Includes:
•
kit with bearings, o-
rings and seals only
•
instructions for main-
tenance.
3HAC14962-1
Maintenance kit,
bearings and seals
Continues on next page
Product manual - IRB 7600
143
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.8 Inspecting the balancing device
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
https://search.abb.com/library/Download.aspx?DocumentID=3HAC022033-001&LanguageCode=en&DocumentPartId=&Action=Launch&DocumentRevisionId=AF
| 143
|
3.3.8 Inspecting the balancing device
General
Several points are to be checked on the balancing device during the inspection.
This section describes how to perform the inspection regarding:
•
dissonance
•
damage
•
leakage
•
contamination / lack of free space.
Action at detected faults
If any faults are detected during the inspection, a maintenance may be performed
according to specific maintenance kits.
If the balancing device is an older model, it must in some cases be upgraded
instead! The instruction for the current inspection details if a fault requires a
maintenance / upgrade and the table below specifies the different models and
which of the two actions they require.
The article number of the balancing device is located on a label at the rear cover,
shown in the figure Inspection points, balancing device on page 143 .
Action at detected faults
Balancing device, art. no.
Upgrade
3HAC10538-1
Maintenance
3HAC14675-1
Continues on next page
142
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.8 Inspecting the balancing device
Inspection points, balancing device
The balancing device is located at the top rear of the frame as shown in the figure.
The figure also shows the inspection points, further described in the instructions.
xx0300000580
Balancing device
A
Piston rod (inside)
B
Shaft, including securing screw
C
Ear, bearing and o-rings
D
Label with article number
E
Inspect the surroundings
F
Bearing, balancing device attachments
G
Required equipment
The table below specifies the equipment used if damage is detected on the
balancing device. See section Action at detected faults on page 142 to determine
whether to perform maintenance or upgrade!
Note
Art. no.
Spare part no.
Equipment, etc.
Includes:
•
kit with bearings, o-
rings and seals only
•
instructions for main-
tenance.
3HAC14962-1
Maintenance kit,
bearings and seals
Continues on next page
Product manual - IRB 7600
143
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.8 Inspecting the balancing device
Continued
Note
Art. no.
Spare part no.
Equipment, etc.
Includes
•
kit with piston rod,
support shaft etc.
Securing screw in the shaft.
Securing screw
M16 x 180
Locking liquid must be used
when fitting the screw (Loctite
243)!
3HAC15943-1
Toolkit for mainten-
ance
Used for removing the spher-
ical roller bearings.
4552-2 (Bahco)
Puller for separator
Used for removing the spher-
ical roller bearings.
4551-C (Bahco)
Separator
Content is defined in section
Standard tools on page 419 .
3HAC15571-1
Standard toolkit
These procedures include
references to the tools re-
quired.
Other tools and
procedures may be
required. See refer-
ences to these
procedures in the
step-by-step in-
structions below.
Check for dissonance
The check points are shown in the figure Inspection points, balancing device on
page 143 .
If dissonance is detected...
Check for dissonance
from...
... perform maintenance or upgrade according to given
instructions in Maintenance kit, bearings and seals /
Upgrade kit. The replacement of the bearing at the ear
is also detailed in section Replacement of spherical roller
bearing, balancing device on page 274 .
•
bearing at the link ear
•
bearings at the balan-
cing devices attach-
ments.
1
Art. no. for the kit and the documentation are specified
in section Required equipment on page 143 .
To decide whether to perform maintenance or upgrade,
see section Action at detected faults on page 142 .
...replace the balancing device or consult ABB Robotics.
•
balancing device (a
tapping sound,
caused by the springs
inside the cylinder).
2
How to replace the device is detailed in section Repla-
cing the balancing device on page279 . This section also
specifies the spare part number!
... perform maintenance or upgrade according to given
instructions in Maintenance kit, complete / Upgrade kit.
•
piston rod (squeaking
may indicate worn
plain bearings, intern-
al contamination or
insufficient lubrica-
tion).
3
Art. no. for the kit and the documentation are specified
in section Required equipment on page 143 .
To decide whether to perform maintenance or upgrade,
see section Action at detected faults on page 142 .
Continues on next page
144
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.8 Inspecting the balancing device
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
https://search.abb.com/library/Download.aspx?DocumentID=3HAC022033-001&LanguageCode=en&DocumentPartId=&Action=Launch&DocumentRevisionId=AF
| 144
|
Inspection points, balancing device
The balancing device is located at the top rear of the frame as shown in the figure.
The figure also shows the inspection points, further described in the instructions.
xx0300000580
Balancing device
A
Piston rod (inside)
B
Shaft, including securing screw
C
Ear, bearing and o-rings
D
Label with article number
E
Inspect the surroundings
F
Bearing, balancing device attachments
G
Required equipment
The table below specifies the equipment used if damage is detected on the
balancing device. See section Action at detected faults on page 142 to determine
whether to perform maintenance or upgrade!
Note
Art. no.
Spare part no.
Equipment, etc.
Includes:
•
kit with bearings, o-
rings and seals only
•
instructions for main-
tenance.
3HAC14962-1
Maintenance kit,
bearings and seals
Continues on next page
Product manual - IRB 7600
143
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.8 Inspecting the balancing device
Continued
Note
Art. no.
Spare part no.
Equipment, etc.
Includes
•
kit with piston rod,
support shaft etc.
Securing screw in the shaft.
Securing screw
M16 x 180
Locking liquid must be used
when fitting the screw (Loctite
243)!
3HAC15943-1
Toolkit for mainten-
ance
Used for removing the spher-
ical roller bearings.
4552-2 (Bahco)
Puller for separator
Used for removing the spher-
ical roller bearings.
4551-C (Bahco)
Separator
Content is defined in section
Standard tools on page 419 .
3HAC15571-1
Standard toolkit
These procedures include
references to the tools re-
quired.
Other tools and
procedures may be
required. See refer-
ences to these
procedures in the
step-by-step in-
structions below.
Check for dissonance
The check points are shown in the figure Inspection points, balancing device on
page 143 .
If dissonance is detected...
Check for dissonance
from...
... perform maintenance or upgrade according to given
instructions in Maintenance kit, bearings and seals /
Upgrade kit. The replacement of the bearing at the ear
is also detailed in section Replacement of spherical roller
bearing, balancing device on page 274 .
•
bearing at the link ear
•
bearings at the balan-
cing devices attach-
ments.
1
Art. no. for the kit and the documentation are specified
in section Required equipment on page 143 .
To decide whether to perform maintenance or upgrade,
see section Action at detected faults on page 142 .
...replace the balancing device or consult ABB Robotics.
•
balancing device (a
tapping sound,
caused by the springs
inside the cylinder).
2
How to replace the device is detailed in section Repla-
cing the balancing device on page279 . This section also
specifies the spare part number!
... perform maintenance or upgrade according to given
instructions in Maintenance kit, complete / Upgrade kit.
•
piston rod (squeaking
may indicate worn
plain bearings, intern-
al contamination or
insufficient lubrica-
tion).
3
Art. no. for the kit and the documentation are specified
in section Required equipment on page 143 .
To decide whether to perform maintenance or upgrade,
see section Action at detected faults on page 142 .
Continues on next page
144
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.8 Inspecting the balancing device
Continued
Check for damage
Check for damage, such as scratches, general wear, uneven surfaces or incorrect
positions.
The check points are shown in the figure Inspection points, balancing device on
page 143 .
If damage is detected...
Check for damage on...
... perform maintenance or upgrade accord-
ing to given instructions in Maintenance
kit, complete / Upgrade kit.
•
the piston rod (part of the piston
rod that is visible at the front of the
balancing device).
1
Art. no. for the kit and the documentation
are specified in section Required equip-
ment on page 143 .
To decide whether to perform maintenance
or upgrade, see section Action at detected
faults on page 142 .
...replace.
•
the securing screw in the front ear
shaft.
Also check the tightening torque (50 Nm).
2
Dimension is specified in section Required
equipment on page 143 .
Check for leakage
The front ear of the balancing device is lubricated with grease. After filling, excessive
grease may normally be forced out between the shaft and the sealing ring in the
sealing spacer. This is normal behaviour and must not be confused with incorrect
leaks from the ear.
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
145
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.8 Inspecting the balancing device
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
https://search.abb.com/library/Download.aspx?DocumentID=3HAC022033-001&LanguageCode=en&DocumentPartId=&Action=Launch&DocumentRevisionId=AF
| 145
|
Note
Art. no.
Spare part no.
Equipment, etc.
Includes
•
kit with piston rod,
support shaft etc.
Securing screw in the shaft.
Securing screw
M16 x 180
Locking liquid must be used
when fitting the screw (Loctite
243)!
3HAC15943-1
Toolkit for mainten-
ance
Used for removing the spher-
ical roller bearings.
4552-2 (Bahco)
Puller for separator
Used for removing the spher-
ical roller bearings.
4551-C (Bahco)
Separator
Content is defined in section
Standard tools on page 419 .
3HAC15571-1
Standard toolkit
These procedures include
references to the tools re-
quired.
Other tools and
procedures may be
required. See refer-
ences to these
procedures in the
step-by-step in-
structions below.
Check for dissonance
The check points are shown in the figure Inspection points, balancing device on
page 143 .
If dissonance is detected...
Check for dissonance
from...
... perform maintenance or upgrade according to given
instructions in Maintenance kit, bearings and seals /
Upgrade kit. The replacement of the bearing at the ear
is also detailed in section Replacement of spherical roller
bearing, balancing device on page 274 .
•
bearing at the link ear
•
bearings at the balan-
cing devices attach-
ments.
1
Art. no. for the kit and the documentation are specified
in section Required equipment on page 143 .
To decide whether to perform maintenance or upgrade,
see section Action at detected faults on page 142 .
...replace the balancing device or consult ABB Robotics.
•
balancing device (a
tapping sound,
caused by the springs
inside the cylinder).
2
How to replace the device is detailed in section Repla-
cing the balancing device on page279 . This section also
specifies the spare part number!
... perform maintenance or upgrade according to given
instructions in Maintenance kit, complete / Upgrade kit.
•
piston rod (squeaking
may indicate worn
plain bearings, intern-
al contamination or
insufficient lubrica-
tion).
3
Art. no. for the kit and the documentation are specified
in section Required equipment on page 143 .
To decide whether to perform maintenance or upgrade,
see section Action at detected faults on page 142 .
Continues on next page
144
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.8 Inspecting the balancing device
Continued
Check for damage
Check for damage, such as scratches, general wear, uneven surfaces or incorrect
positions.
The check points are shown in the figure Inspection points, balancing device on
page 143 .
If damage is detected...
Check for damage on...
... perform maintenance or upgrade accord-
ing to given instructions in Maintenance
kit, complete / Upgrade kit.
•
the piston rod (part of the piston
rod that is visible at the front of the
balancing device).
1
Art. no. for the kit and the documentation
are specified in section Required equip-
ment on page 143 .
To decide whether to perform maintenance
or upgrade, see section Action at detected
faults on page 142 .
...replace.
•
the securing screw in the front ear
shaft.
Also check the tightening torque (50 Nm).
2
Dimension is specified in section Required
equipment on page 143 .
Check for leakage
The front ear of the balancing device is lubricated with grease. After filling, excessive
grease may normally be forced out between the shaft and the sealing ring in the
sealing spacer. This is normal behaviour and must not be confused with incorrect
leaks from the ear.
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
145
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.8 Inspecting the balancing device
Continued
Check the o-rings in the front ear of the balancing device for leaks, as shown and
detailed below.
xx0300000284
Shaft
A
O-ring
B
Sealing spacer
C
Sealing ring in sealing spacer
D
Correct way out for excessive grease from inside the front ear
E
Incorrect leakage from the front ear
F
Note
Action
Clean the area at the front ear from old grease.
1
Run the robot for some minutes, in order to
move the balancing device piston.
2
The o-rings are included in the Main-
tenance kit, bearings and seals ,
already assembled with sealing
spacers and sealing rings.
Check the o-rings at the front ear for leakage.
Replace the o-rings, if any leaks are detected.
Excessive grease from between the shaft and
the sealing ring is normal and is not considered
as a leak!
3
Art. no. for the kit is specified in Re-
quired equipment on page 143 .
The replacement of the complete
bearing is also detailed in section
Replacement of spherical roller bear-
ing, balancing device on page 274 .
Incorrect leakage is shown in the
previous figure.
Continues on next page
146
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.8 Inspecting the balancing device
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
https://search.abb.com/library/Download.aspx?DocumentID=3HAC022033-001&LanguageCode=en&DocumentPartId=&Action=Launch&DocumentRevisionId=AF
| 146
|
Check for damage
Check for damage, such as scratches, general wear, uneven surfaces or incorrect
positions.
The check points are shown in the figure Inspection points, balancing device on
page 143 .
If damage is detected...
Check for damage on...
... perform maintenance or upgrade accord-
ing to given instructions in Maintenance
kit, complete / Upgrade kit.
•
the piston rod (part of the piston
rod that is visible at the front of the
balancing device).
1
Art. no. for the kit and the documentation
are specified in section Required equip-
ment on page 143 .
To decide whether to perform maintenance
or upgrade, see section Action at detected
faults on page 142 .
...replace.
•
the securing screw in the front ear
shaft.
Also check the tightening torque (50 Nm).
2
Dimension is specified in section Required
equipment on page 143 .
Check for leakage
The front ear of the balancing device is lubricated with grease. After filling, excessive
grease may normally be forced out between the shaft and the sealing ring in the
sealing spacer. This is normal behaviour and must not be confused with incorrect
leaks from the ear.
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
145
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.8 Inspecting the balancing device
Continued
Check the o-rings in the front ear of the balancing device for leaks, as shown and
detailed below.
xx0300000284
Shaft
A
O-ring
B
Sealing spacer
C
Sealing ring in sealing spacer
D
Correct way out for excessive grease from inside the front ear
E
Incorrect leakage from the front ear
F
Note
Action
Clean the area at the front ear from old grease.
1
Run the robot for some minutes, in order to
move the balancing device piston.
2
The o-rings are included in the Main-
tenance kit, bearings and seals ,
already assembled with sealing
spacers and sealing rings.
Check the o-rings at the front ear for leakage.
Replace the o-rings, if any leaks are detected.
Excessive grease from between the shaft and
the sealing ring is normal and is not considered
as a leak!
3
Art. no. for the kit is specified in Re-
quired equipment on page 143 .
The replacement of the complete
bearing is also detailed in section
Replacement of spherical roller bear-
ing, balancing device on page 274 .
Incorrect leakage is shown in the
previous figure.
Continues on next page
146
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.8 Inspecting the balancing device
Continued
Check for contamination / lack of free space
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the safeguarded space.
1
Check that there are no obstacles inside the frame, that could prevent the balancing
device from moving freely. See the figure Inspection points, balancing device on
page 143 .
2
Keep the areas around the balancing device clean and free from objects, such as
service tools.
Product manual - IRB 7600
147
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.8 Inspecting the balancing device
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
https://search.abb.com/library/Download.aspx?DocumentID=3HAC022033-001&LanguageCode=en&DocumentPartId=&Action=Launch&DocumentRevisionId=AF
| 147
|
Check the o-rings in the front ear of the balancing device for leaks, as shown and
detailed below.
xx0300000284
Shaft
A
O-ring
B
Sealing spacer
C
Sealing ring in sealing spacer
D
Correct way out for excessive grease from inside the front ear
E
Incorrect leakage from the front ear
F
Note
Action
Clean the area at the front ear from old grease.
1
Run the robot for some minutes, in order to
move the balancing device piston.
2
The o-rings are included in the Main-
tenance kit, bearings and seals ,
already assembled with sealing
spacers and sealing rings.
Check the o-rings at the front ear for leakage.
Replace the o-rings, if any leaks are detected.
Excessive grease from between the shaft and
the sealing ring is normal and is not considered
as a leak!
3
Art. no. for the kit is specified in Re-
quired equipment on page 143 .
The replacement of the complete
bearing is also detailed in section
Replacement of spherical roller bear-
ing, balancing device on page 274 .
Incorrect leakage is shown in the
previous figure.
Continues on next page
146
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© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.8 Inspecting the balancing device
Continued
Check for contamination / lack of free space
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the safeguarded space.
1
Check that there are no obstacles inside the frame, that could prevent the balancing
device from moving freely. See the figure Inspection points, balancing device on
page 143 .
2
Keep the areas around the balancing device clean and free from objects, such as
service tools.
Product manual - IRB 7600
147
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.8 Inspecting the balancing device
Continued
3.3.9 Inspecting the cable harness
Location of cable harness, axes 1-4
The robot cable harness, axes 1-4, is located as shown in the figure below.
xx0200000097
Lower arm
A
Cables attached with velcro straps and mounting plate
B
Connectors at cable harness division point, R2.M5/6
C
Connectors at base
D
Required equipment
Note
Art. no.
Equipment, etc.
Content is defined in section Standard
tools on page 419 .
-
Standard toolkit
These procedures include references
to the tools required.
Other tools and procedures
may be required. See refer-
ences to these procedures in
the step-by-step instructions
below.
See chapter Circuit diagram on
page 427 .
Circuit diagram
Continues on next page
148
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.9 Inspecting the cable harness
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| 148
|
Check for contamination / lack of free space
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the safeguarded space.
1
Check that there are no obstacles inside the frame, that could prevent the balancing
device from moving freely. See the figure Inspection points, balancing device on
page 143 .
2
Keep the areas around the balancing device clean and free from objects, such as
service tools.
Product manual - IRB 7600
147
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.8 Inspecting the balancing device
Continued
3.3.9 Inspecting the cable harness
Location of cable harness, axes 1-4
The robot cable harness, axes 1-4, is located as shown in the figure below.
xx0200000097
Lower arm
A
Cables attached with velcro straps and mounting plate
B
Connectors at cable harness division point, R2.M5/6
C
Connectors at base
D
Required equipment
Note
Art. no.
Equipment, etc.
Content is defined in section Standard
tools on page 419 .
-
Standard toolkit
These procedures include references
to the tools required.
Other tools and procedures
may be required. See refer-
ences to these procedures in
the step-by-step instructions
below.
See chapter Circuit diagram on
page 427 .
Circuit diagram
Continues on next page
148
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.9 Inspecting the cable harness
Inspection, cable harness 1-4
The procedure below details how to inspect the cable harness of axes 1-4.
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
1
Make an overall visual inspection of the cable
harness, in order to detect wear and damage.
2
Shown in the figure Location of cable
harness, axes 1-4 on page 148 .
Check the connectors at the division point and
at the base.
3
Location is shown in the figure Location
of cable harness, axes 1-4 on page148 .
Check that velcro straps and the mounting
plate are properly attached to the frame. Also
check the cabling, leading into the lower arm.
Make sure it is attached by the straps and not
damaged.
4
A certain wear of the hose at the en-
trance to the lower arm is natural.
Described in Replacement of cable
harness, axes 1-4 on page 214 .
Replace the cable harness if wear, cracks or
damage is detected.
5
Location of cabling axes 5-6
The robot cable harness, axes 5-6, is located as shown in the figure below.
xx0200000155
Cable attachment, upper arm tube
A
Cable attachment, rear of upper arm
B
Connectors at cable harness division point, R2.M5/6
C
Continues on next page
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149
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.9 Inspecting the cable harness
Continued
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| 149
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3.3.9 Inspecting the cable harness
Location of cable harness, axes 1-4
The robot cable harness, axes 1-4, is located as shown in the figure below.
xx0200000097
Lower arm
A
Cables attached with velcro straps and mounting plate
B
Connectors at cable harness division point, R2.M5/6
C
Connectors at base
D
Required equipment
Note
Art. no.
Equipment, etc.
Content is defined in section Standard
tools on page 419 .
-
Standard toolkit
These procedures include references
to the tools required.
Other tools and procedures
may be required. See refer-
ences to these procedures in
the step-by-step instructions
below.
See chapter Circuit diagram on
page 427 .
Circuit diagram
Continues on next page
148
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.9 Inspecting the cable harness
Inspection, cable harness 1-4
The procedure below details how to inspect the cable harness of axes 1-4.
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
1
Make an overall visual inspection of the cable
harness, in order to detect wear and damage.
2
Shown in the figure Location of cable
harness, axes 1-4 on page 148 .
Check the connectors at the division point and
at the base.
3
Location is shown in the figure Location
of cable harness, axes 1-4 on page148 .
Check that velcro straps and the mounting
plate are properly attached to the frame. Also
check the cabling, leading into the lower arm.
Make sure it is attached by the straps and not
damaged.
4
A certain wear of the hose at the en-
trance to the lower arm is natural.
Described in Replacement of cable
harness, axes 1-4 on page 214 .
Replace the cable harness if wear, cracks or
damage is detected.
5
Location of cabling axes 5-6
The robot cable harness, axes 5-6, is located as shown in the figure below.
xx0200000155
Cable attachment, upper arm tube
A
Cable attachment, rear of upper arm
B
Connectors at cable harness division point, R2.M5/6
C
Continues on next page
Product manual - IRB 7600
149
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.9 Inspecting the cable harness
Continued
Inspection, cable harness, axes 5-6
The procedure below details how to inspect the cable harness of axes 5-6.
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
1
Make an overall visual inspection of the cable
harness, in order to detect wear and damage.
2
Shown in the figure Location of cabling
axes 5-6 on page 149 .
Check the attachments at the rear of the up-
per arm and in the upper arm tube.
Check the connectors at the cable harness
division. Make sure the attachment plate is
not bent or in any other way damaged.
3
Described in section Replacement of
cable harness, axes 5-6 on page 224
Replace the cable harness if wear, cracks or
damage is detected.
4
150
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© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.9 Inspecting the cable harness
Continued
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| 150
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Inspection, cable harness 1-4
The procedure below details how to inspect the cable harness of axes 1-4.
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
1
Make an overall visual inspection of the cable
harness, in order to detect wear and damage.
2
Shown in the figure Location of cable
harness, axes 1-4 on page 148 .
Check the connectors at the division point and
at the base.
3
Location is shown in the figure Location
of cable harness, axes 1-4 on page148 .
Check that velcro straps and the mounting
plate are properly attached to the frame. Also
check the cabling, leading into the lower arm.
Make sure it is attached by the straps and not
damaged.
4
A certain wear of the hose at the en-
trance to the lower arm is natural.
Described in Replacement of cable
harness, axes 1-4 on page 214 .
Replace the cable harness if wear, cracks or
damage is detected.
5
Location of cabling axes 5-6
The robot cable harness, axes 5-6, is located as shown in the figure below.
xx0200000155
Cable attachment, upper arm tube
A
Cable attachment, rear of upper arm
B
Connectors at cable harness division point, R2.M5/6
C
Continues on next page
Product manual - IRB 7600
149
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.9 Inspecting the cable harness
Continued
Inspection, cable harness, axes 5-6
The procedure below details how to inspect the cable harness of axes 5-6.
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
1
Make an overall visual inspection of the cable
harness, in order to detect wear and damage.
2
Shown in the figure Location of cabling
axes 5-6 on page 149 .
Check the attachments at the rear of the up-
per arm and in the upper arm tube.
Check the connectors at the cable harness
division. Make sure the attachment plate is
not bent or in any other way damaged.
3
Described in section Replacement of
cable harness, axes 5-6 on page 224
Replace the cable harness if wear, cracks or
damage is detected.
4
150
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3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.9 Inspecting the cable harness
Continued
3.3.10 Inspecting the axis-1 mechanical stop pin
WARNING
Mechanical stop pin can not be fitted onto robot if the option 561-1 Extended
working range is used for axis 1.
Location of mechanical stop pin
The axis-1 mechanical stop is located as shown in the figure.
xx0200000151
Mechanical stop pin
A
Required equipment
Visual inspection, no tools are required.
Inspecting, mechanical stop pin
Use this procedure to inspect the axis-1 mechanical stop pin.
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the safeguarded
space.
1
Continues on next page
Product manual - IRB 7600
151
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.10 Inspecting the axis-1 mechanical stop pin
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| 151
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Inspection, cable harness, axes 5-6
The procedure below details how to inspect the cable harness of axes 5-6.
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
1
Make an overall visual inspection of the cable
harness, in order to detect wear and damage.
2
Shown in the figure Location of cabling
axes 5-6 on page 149 .
Check the attachments at the rear of the up-
per arm and in the upper arm tube.
Check the connectors at the cable harness
division. Make sure the attachment plate is
not bent or in any other way damaged.
3
Described in section Replacement of
cable harness, axes 5-6 on page 224
Replace the cable harness if wear, cracks or
damage is detected.
4
150
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3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.9 Inspecting the cable harness
Continued
3.3.10 Inspecting the axis-1 mechanical stop pin
WARNING
Mechanical stop pin can not be fitted onto robot if the option 561-1 Extended
working range is used for axis 1.
Location of mechanical stop pin
The axis-1 mechanical stop is located as shown in the figure.
xx0200000151
Mechanical stop pin
A
Required equipment
Visual inspection, no tools are required.
Inspecting, mechanical stop pin
Use this procedure to inspect the axis-1 mechanical stop pin.
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the safeguarded
space.
1
Continues on next page
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151
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.10 Inspecting the axis-1 mechanical stop pin
Note
Action
Inspect the axis-1 mechanical stop pin.
2
If the mechanical stop pin is bent or damaged, it
must be replaced.
Note
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.
3
152
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3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.10 Inspecting the axis-1 mechanical stop pin
Continued
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ABB_IRB7600_Product_Manual.pdf
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| 152
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3.3.10 Inspecting the axis-1 mechanical stop pin
WARNING
Mechanical stop pin can not be fitted onto robot if the option 561-1 Extended
working range is used for axis 1.
Location of mechanical stop pin
The axis-1 mechanical stop is located as shown in the figure.
xx0200000151
Mechanical stop pin
A
Required equipment
Visual inspection, no tools are required.
Inspecting, mechanical stop pin
Use this procedure to inspect the axis-1 mechanical stop pin.
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the safeguarded
space.
1
Continues on next page
Product manual - IRB 7600
151
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.10 Inspecting the axis-1 mechanical stop pin
Note
Action
Inspect the axis-1 mechanical stop pin.
2
If the mechanical stop pin is bent or damaged, it
must be replaced.
Note
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.
3
152
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.10 Inspecting the axis-1 mechanical stop pin
Continued
3.3.11 Inspecting the mechanical stops on axes 1, 2, and 3
Location of the mechanical stops
The figure below shows the location of the additional mechanical stops on axes
1, 2 and 3.
xx0200000150
Additional stop
A
Fixed stop
B
Required equipment
Note
Art. no.
Equipment etc.
Limits the robot working range to
7.5°.
3HAC11076-1
Mechanical stop ax 1
Limits the robot working range to
15°.
3HAC11076-2
Mechanical stop ax 1
3HAC11077-1
Mechanical stop ax 2
3HAC13128-2
Mechanical stop ax 3
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Continues on next page
Product manual - IRB 7600
153
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.11 Inspecting the mechanical stops on axes 1, 2, and 3
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| 153
|
Note
Action
Inspect the axis-1 mechanical stop pin.
2
If the mechanical stop pin is bent or damaged, it
must be replaced.
Note
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.
3
152
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.10 Inspecting the axis-1 mechanical stop pin
Continued
3.3.11 Inspecting the mechanical stops on axes 1, 2, and 3
Location of the mechanical stops
The figure below shows the location of the additional mechanical stops on axes
1, 2 and 3.
xx0200000150
Additional stop
A
Fixed stop
B
Required equipment
Note
Art. no.
Equipment etc.
Limits the robot working range to
7.5°.
3HAC11076-1
Mechanical stop ax 1
Limits the robot working range to
15°.
3HAC11076-2
Mechanical stop ax 1
3HAC11077-1
Mechanical stop ax 2
3HAC13128-2
Mechanical stop ax 3
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Continues on next page
Product manual - IRB 7600
153
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.11 Inspecting the mechanical stops on axes 1, 2, and 3
Inspection, mechanical stops
The procedure below details how to inspect the additional mechanical stops on
axes 1, 2 and 3.
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working area.
1
Shown in the figure Location of
the mechanical stops on
page 153 .
Check the additional stops on axes 1, 2 and 3 for
damage.
2
Make sure the stops are properly attached.
3
Correct tightening torque: 115 Nm.
Art. no. is specified in Required
equipment on page 153 !
If any damage is detected, the mechanical stops
must be replaced!
Correct attachment screws:
•
Axis 1: M16 x 35
•
Axis 2: M16 x 50
•
Axis 3: M16 x 80
4
154
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.11 Inspecting the mechanical stops on axes 1, 2, and 3
Continued
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ABB_IRB7600_Product_Manual.pdf
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| 154
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3.3.11 Inspecting the mechanical stops on axes 1, 2, and 3
Location of the mechanical stops
The figure below shows the location of the additional mechanical stops on axes
1, 2 and 3.
xx0200000150
Additional stop
A
Fixed stop
B
Required equipment
Note
Art. no.
Equipment etc.
Limits the robot working range to
7.5°.
3HAC11076-1
Mechanical stop ax 1
Limits the robot working range to
15°.
3HAC11076-2
Mechanical stop ax 1
3HAC11077-1
Mechanical stop ax 2
3HAC13128-2
Mechanical stop ax 3
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Continues on next page
Product manual - IRB 7600
153
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.11 Inspecting the mechanical stops on axes 1, 2, and 3
Inspection, mechanical stops
The procedure below details how to inspect the additional mechanical stops on
axes 1, 2 and 3.
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working area.
1
Shown in the figure Location of
the mechanical stops on
page 153 .
Check the additional stops on axes 1, 2 and 3 for
damage.
2
Make sure the stops are properly attached.
3
Correct tightening torque: 115 Nm.
Art. no. is specified in Required
equipment on page 153 !
If any damage is detected, the mechanical stops
must be replaced!
Correct attachment screws:
•
Axis 1: M16 x 35
•
Axis 2: M16 x 50
•
Axis 3: M16 x 80
4
154
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© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.11 Inspecting the mechanical stops on axes 1, 2, and 3
Continued
3.3.12 Inspecting the damper on axes 2 to 5
Location of dampers
The figure below shows the location of all the dampers to be inspected.
xx0200000099
Damper, axis 2 (2 pcs)
A
Damper, axis 3 (2 pcs)
B
Damper, axis 4 (2 pcs)
C
Damper, axis 5 (2 pcs)
D
Required equipment
Note
Art. no.
Equipment
Replace if damaged!
3HAC12990-1
Damper axis 2
Replace if damaged!
3HAC11750-1
Damper axis 3
Continues on next page
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155
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.12 Inspecting the damper on axes 2 to 5
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ABB_IRB7600_Product_Manual.pdf
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| 155
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Inspection, mechanical stops
The procedure below details how to inspect the additional mechanical stops on
axes 1, 2 and 3.
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working area.
1
Shown in the figure Location of
the mechanical stops on
page 153 .
Check the additional stops on axes 1, 2 and 3 for
damage.
2
Make sure the stops are properly attached.
3
Correct tightening torque: 115 Nm.
Art. no. is specified in Required
equipment on page 153 !
If any damage is detected, the mechanical stops
must be replaced!
Correct attachment screws:
•
Axis 1: M16 x 35
•
Axis 2: M16 x 50
•
Axis 3: M16 x 80
4
154
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© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.11 Inspecting the mechanical stops on axes 1, 2, and 3
Continued
3.3.12 Inspecting the damper on axes 2 to 5
Location of dampers
The figure below shows the location of all the dampers to be inspected.
xx0200000099
Damper, axis 2 (2 pcs)
A
Damper, axis 3 (2 pcs)
B
Damper, axis 4 (2 pcs)
C
Damper, axis 5 (2 pcs)
D
Required equipment
Note
Art. no.
Equipment
Replace if damaged!
3HAC12990-1
Damper axis 2
Replace if damaged!
3HAC11750-1
Damper axis 3
Continues on next page
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155
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.12 Inspecting the damper on axes 2 to 5
Note
Art. no.
Equipment
Replace if damaged!
3HAC13564-1
Damper axis 4
Replace if damaged!
3HAC10503-8
Damper axis 5
Content is defined in section Standard
tools on page 419 .
-
Standard toolkit
Inspection, damper axis 2-5
The procedure below details how to inspect the dampers, axis 2-5.
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working area.
1
Shown in the figure Location
of dampers on page 155 .
Check all dampers for damage, such as cracks or ex-
isting impressions larger than 1 mm.
In order to inspect dampers, axis 4, the two covers on
top of the upper arm must be removed!
2
Check attachment screws for deformation.
3
Art. no. is specified in Re-
quired equipment on page155 .
If any damage is detected, the damper must be re-
placed with a new one!
4
156
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© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.12 Inspecting the damper on axes 2 to 5
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 156
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3.3.12 Inspecting the damper on axes 2 to 5
Location of dampers
The figure below shows the location of all the dampers to be inspected.
xx0200000099
Damper, axis 2 (2 pcs)
A
Damper, axis 3 (2 pcs)
B
Damper, axis 4 (2 pcs)
C
Damper, axis 5 (2 pcs)
D
Required equipment
Note
Art. no.
Equipment
Replace if damaged!
3HAC12990-1
Damper axis 2
Replace if damaged!
3HAC11750-1
Damper axis 3
Continues on next page
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155
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© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.12 Inspecting the damper on axes 2 to 5
Note
Art. no.
Equipment
Replace if damaged!
3HAC13564-1
Damper axis 4
Replace if damaged!
3HAC10503-8
Damper axis 5
Content is defined in section Standard
tools on page 419 .
-
Standard toolkit
Inspection, damper axis 2-5
The procedure below details how to inspect the dampers, axis 2-5.
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working area.
1
Shown in the figure Location
of dampers on page 155 .
Check all dampers for damage, such as cracks or ex-
isting impressions larger than 1 mm.
In order to inspect dampers, axis 4, the two covers on
top of the upper arm must be removed!
2
Check attachment screws for deformation.
3
Art. no. is specified in Re-
quired equipment on page155 .
If any damage is detected, the damper must be re-
placed with a new one!
4
156
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© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.12 Inspecting the damper on axes 2 to 5
Continued
3.3.13 Inspecting the information labels
Location of labels
These figures show the location of the information labels to be inspected. The
symbols are described in section Safety symbols on manipulator labels on page27 .
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
xx0200000100
Warning label concerning high temperature
A
Warning sign, symbol of a lightning flash (located on motor cover)
B
Instruction label
C
Warning label concerning brake release
D
Warning label, tools are not allowed around the balancing device during operation
E
Warning label concerning shutting off power
F
Label, type of oil in gearbox
G
Label, type of oil in gearbox
H
Label, type of grease in ear
I
Information labels at gearboxes and at robot base, specifying which oil is used
in gearboxes
-
Continues on next page
Product manual - IRB 7600
157
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© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.13 Inspecting the information labels
|
ABB_IRB7600_Product_Manual.pdf
|
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| 157
|
Note
Art. no.
Equipment
Replace if damaged!
3HAC13564-1
Damper axis 4
Replace if damaged!
3HAC10503-8
Damper axis 5
Content is defined in section Standard
tools on page 419 .
-
Standard toolkit
Inspection, damper axis 2-5
The procedure below details how to inspect the dampers, axis 2-5.
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working area.
1
Shown in the figure Location
of dampers on page 155 .
Check all dampers for damage, such as cracks or ex-
isting impressions larger than 1 mm.
In order to inspect dampers, axis 4, the two covers on
top of the upper arm must be removed!
2
Check attachment screws for deformation.
3
Art. no. is specified in Re-
quired equipment on page155 .
If any damage is detected, the damper must be re-
placed with a new one!
4
156
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.12 Inspecting the damper on axes 2 to 5
Continued
3.3.13 Inspecting the information labels
Location of labels
These figures show the location of the information labels to be inspected. The
symbols are described in section Safety symbols on manipulator labels on page27 .
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
xx0200000100
Warning label concerning high temperature
A
Warning sign, symbol of a lightning flash (located on motor cover)
B
Instruction label
C
Warning label concerning brake release
D
Warning label, tools are not allowed around the balancing device during operation
E
Warning label concerning shutting off power
F
Label, type of oil in gearbox
G
Label, type of oil in gearbox
H
Label, type of grease in ear
I
Information labels at gearboxes and at robot base, specifying which oil is used
in gearboxes
-
Continues on next page
Product manual - IRB 7600
157
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.13 Inspecting the information labels
![Image]
xx0200000101
Instruction label concerning lifting the robot
J
Warning label concerning risk of tipping
K
Foundry logotype
L
Warning label concerning stored energy
M
Information label, specifying with type of oil is used in gearboxes of each axis
N
Label, type of oil in gearbox
O
Required tools and equipment
Visual inspection, no tools are required.
Inspecting, labels
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the safeguarded space.
1
Inspect the labels, located as shown in the figures.
2
Article numbers for the labels and
plate set is specified in Spare part
lists on page 425 .
Replace any missing or damaged labels.
3
158
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.13 Inspecting the information labels
Continued
|
ABB_IRB7600_Product_Manual.pdf
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| 158
|
3.3.13 Inspecting the information labels
Location of labels
These figures show the location of the information labels to be inspected. The
symbols are described in section Safety symbols on manipulator labels on page27 .
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
xx0200000100
Warning label concerning high temperature
A
Warning sign, symbol of a lightning flash (located on motor cover)
B
Instruction label
C
Warning label concerning brake release
D
Warning label, tools are not allowed around the balancing device during operation
E
Warning label concerning shutting off power
F
Label, type of oil in gearbox
G
Label, type of oil in gearbox
H
Label, type of grease in ear
I
Information labels at gearboxes and at robot base, specifying which oil is used
in gearboxes
-
Continues on next page
Product manual - IRB 7600
157
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.13 Inspecting the information labels
![Image]
xx0200000101
Instruction label concerning lifting the robot
J
Warning label concerning risk of tipping
K
Foundry logotype
L
Warning label concerning stored energy
M
Information label, specifying with type of oil is used in gearboxes of each axis
N
Label, type of oil in gearbox
O
Required tools and equipment
Visual inspection, no tools are required.
Inspecting, labels
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the safeguarded space.
1
Inspect the labels, located as shown in the figures.
2
Article numbers for the labels and
plate set is specified in Spare part
lists on page 425 .
Replace any missing or damaged labels.
3
158
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.13 Inspecting the information labels
Continued
3.3.14 Inspecting the UL lamp
Location of UL-lamp
The UL-lamp is located as shown in figure below. Notice that the location can vary
depending on how the customer harness for axes 4-6 is mounted.
xx0200000117
UL signal lamp
A
Warning sign
B
Warning label
C
Position for cable gland
D
Required equipment
Note
Spare part no.
Equipment, etc.
To be replaced in case of detected
damage.
3HAC10830-1
Signal lamp
Includes UL signal lamp, 3HAC 13097-
1, Warning label, 3HAC 4431-1,
Warning sign, 3HAC 1589-1
Content is defined in section Standard
tools on page 419 .
-
Standard toolkit
These procedures include references
to the tools required.
Other tools and procedures may
be required. See references to
these procedures in the step-by-
step instructions below.
Continues on next page
Product manual - IRB 7600
159
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.14 Inspecting the UL lamp
|
ABB_IRB7600_Product_Manual.pdf
|
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| 159
|
![Image]
xx0200000101
Instruction label concerning lifting the robot
J
Warning label concerning risk of tipping
K
Foundry logotype
L
Warning label concerning stored energy
M
Information label, specifying with type of oil is used in gearboxes of each axis
N
Label, type of oil in gearbox
O
Required tools and equipment
Visual inspection, no tools are required.
Inspecting, labels
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the safeguarded space.
1
Inspect the labels, located as shown in the figures.
2
Article numbers for the labels and
plate set is specified in Spare part
lists on page 425 .
Replace any missing or damaged labels.
3
158
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.13 Inspecting the information labels
Continued
3.3.14 Inspecting the UL lamp
Location of UL-lamp
The UL-lamp is located as shown in figure below. Notice that the location can vary
depending on how the customer harness for axes 4-6 is mounted.
xx0200000117
UL signal lamp
A
Warning sign
B
Warning label
C
Position for cable gland
D
Required equipment
Note
Spare part no.
Equipment, etc.
To be replaced in case of detected
damage.
3HAC10830-1
Signal lamp
Includes UL signal lamp, 3HAC 13097-
1, Warning label, 3HAC 4431-1,
Warning sign, 3HAC 1589-1
Content is defined in section Standard
tools on page 419 .
-
Standard toolkit
These procedures include references
to the tools required.
Other tools and procedures may
be required. See references to
these procedures in the step-by-
step instructions below.
Continues on next page
Product manual - IRB 7600
159
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.14 Inspecting the UL lamp
Inspection, UL-lamp
The procedure below details how to inspect the function of the UL-lamp.
Note
Action
Check that the UL-lamp is lit, when the motors are in
operation ("motors ON").
1
Part no. is specified in Re-
quired equipment on
page 159 !
If the lamp is not lit, trace the fault!
•
Check whether the UL-lamp is broken. If so, re-
place it.
•
Check the cable connections.
•
Measure the voltage in connectors motor axis 3
(=24V).
•
Check the cabling. Replace cabling if a fault is
detected.
2
160
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.14 Inspecting the UL lamp
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 160
|
3.3.14 Inspecting the UL lamp
Location of UL-lamp
The UL-lamp is located as shown in figure below. Notice that the location can vary
depending on how the customer harness for axes 4-6 is mounted.
xx0200000117
UL signal lamp
A
Warning sign
B
Warning label
C
Position for cable gland
D
Required equipment
Note
Spare part no.
Equipment, etc.
To be replaced in case of detected
damage.
3HAC10830-1
Signal lamp
Includes UL signal lamp, 3HAC 13097-
1, Warning label, 3HAC 4431-1,
Warning sign, 3HAC 1589-1
Content is defined in section Standard
tools on page 419 .
-
Standard toolkit
These procedures include references
to the tools required.
Other tools and procedures may
be required. See references to
these procedures in the step-by-
step instructions below.
Continues on next page
Product manual - IRB 7600
159
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.14 Inspecting the UL lamp
Inspection, UL-lamp
The procedure below details how to inspect the function of the UL-lamp.
Note
Action
Check that the UL-lamp is lit, when the motors are in
operation ("motors ON").
1
Part no. is specified in Re-
quired equipment on
page 159 !
If the lamp is not lit, trace the fault!
•
Check whether the UL-lamp is broken. If so, re-
place it.
•
Check the cable connections.
•
Measure the voltage in connectors motor axis 3
(=24V).
•
Check the cabling. Replace cabling if a fault is
detected.
2
160
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.14 Inspecting the UL lamp
Continued
3.4 Changing/replacement activities
3.4.1 Type of lubrication in gearboxes
Introduction
This section describes where to find information about the type of lubrication,
article number and the amount of lubrication in the specific gearbox. It also
describes the equipment needed when working with lubrication.
Type and amount of oil in gearboxes
Information about the type of lubrication, article number as well as the amount in
the specific gearbox can be found in Technical reference manual - Lubrication in
gearboxes available for registered users on myABB Business Portal,
www.abb.com/myABB .
Location of gearboxes
The figure shows the location of the gearboxes.
xx0400000798
Axis 1 gearbox
A
Axis 2 gearbox
B
Axis 3 gearbox
C
Axis 4 primary gearbox
D
Axis 4 secondary gearbox
E
Axis 5 primary gearbox
F
Axis 5 secondary gearbox
G
Axis 6 gearbox
H
Continues on next page
Product manual - IRB 7600
161
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.1 Type of lubrication in gearboxes
|
ABB_IRB7600_Product_Manual.pdf
|
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| 161
|
Inspection, UL-lamp
The procedure below details how to inspect the function of the UL-lamp.
Note
Action
Check that the UL-lamp is lit, when the motors are in
operation ("motors ON").
1
Part no. is specified in Re-
quired equipment on
page 159 !
If the lamp is not lit, trace the fault!
•
Check whether the UL-lamp is broken. If so, re-
place it.
•
Check the cable connections.
•
Measure the voltage in connectors motor axis 3
(=24V).
•
Check the cabling. Replace cabling if a fault is
detected.
2
160
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.3.14 Inspecting the UL lamp
Continued
3.4 Changing/replacement activities
3.4.1 Type of lubrication in gearboxes
Introduction
This section describes where to find information about the type of lubrication,
article number and the amount of lubrication in the specific gearbox. It also
describes the equipment needed when working with lubrication.
Type and amount of oil in gearboxes
Information about the type of lubrication, article number as well as the amount in
the specific gearbox can be found in Technical reference manual - Lubrication in
gearboxes available for registered users on myABB Business Portal,
www.abb.com/myABB .
Location of gearboxes
The figure shows the location of the gearboxes.
xx0400000798
Axis 1 gearbox
A
Axis 2 gearbox
B
Axis 3 gearbox
C
Axis 4 primary gearbox
D
Axis 4 secondary gearbox
E
Axis 5 primary gearbox
F
Axis 5 secondary gearbox
G
Axis 6 gearbox
H
Continues on next page
Product manual - IRB 7600
161
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.1 Type of lubrication in gearboxes
Equipment
Note
Equipment
Includes pump with outlet pipe.
Oil dispenser
Use the suggested dispenser or a similar one:
•
Orion OriCan article number 22590
(pneumatic)
Nipple for quick connect fitting, with o-ring
162
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.1 Type of lubrication in gearboxes
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
https://search.abb.com/library/Download.aspx?DocumentID=3HAC022033-001&LanguageCode=en&DocumentPartId=&Action=Launch&DocumentRevisionId=AF
| 162
|
3.4 Changing/replacement activities
3.4.1 Type of lubrication in gearboxes
Introduction
This section describes where to find information about the type of lubrication,
article number and the amount of lubrication in the specific gearbox. It also
describes the equipment needed when working with lubrication.
Type and amount of oil in gearboxes
Information about the type of lubrication, article number as well as the amount in
the specific gearbox can be found in Technical reference manual - Lubrication in
gearboxes available for registered users on myABB Business Portal,
www.abb.com/myABB .
Location of gearboxes
The figure shows the location of the gearboxes.
xx0400000798
Axis 1 gearbox
A
Axis 2 gearbox
B
Axis 3 gearbox
C
Axis 4 primary gearbox
D
Axis 4 secondary gearbox
E
Axis 5 primary gearbox
F
Axis 5 secondary gearbox
G
Axis 6 gearbox
H
Continues on next page
Product manual - IRB 7600
161
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.1 Type of lubrication in gearboxes
Equipment
Note
Equipment
Includes pump with outlet pipe.
Oil dispenser
Use the suggested dispenser or a similar one:
•
Orion OriCan article number 22590
(pneumatic)
Nipple for quick connect fitting, with o-ring
162
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.1 Type of lubrication in gearboxes
Continued
3.4.2 Changing oil, axis-1 gearbox
Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure
below.
The oil is drained with a hose that may be reached behind the rear cover of the
robot base.
xx0200000111
Gearbox, axis 1
A
Oil plug, filling
B
Motor, axis 1
C
Oil plug, inspection (not in all designs)
D
Label, specifies the type of oil in the gearbox
E
Continues on next page
Product manual - IRB 7600
163
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.2 Changing oil, axis-1 gearbox
|
ABB_IRB7600_Product_Manual.pdf
|
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| 163
|
Equipment
Note
Equipment
Includes pump with outlet pipe.
Oil dispenser
Use the suggested dispenser or a similar one:
•
Orion OriCan article number 22590
(pneumatic)
Nipple for quick connect fitting, with o-ring
162
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.1 Type of lubrication in gearboxes
Continued
3.4.2 Changing oil, axis-1 gearbox
Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure
below.
The oil is drained with a hose that may be reached behind the rear cover of the
robot base.
xx0200000111
Gearbox, axis 1
A
Oil plug, filling
B
Motor, axis 1
C
Oil plug, inspection (not in all designs)
D
Label, specifies the type of oil in the gearbox
E
Continues on next page
Product manual - IRB 7600
163
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.2 Changing oil, axis-1 gearbox
Oil plug in the base
In some early versions of the robot, the oil plug for draining may be located in the
base, as shown in the figure below.
xx0300000065
Oil plug in the base
A
Required equipment
Note
Amount
Art. no.
Equipment, etc.
See Type
and
amount of
oil in gear-
boxes on
page 161 .
See Type and
amount of oil in
gearboxes on
page 161 .
Lubricating oil
Capacity: 8,000 ml.
Oil collecting vessel
Content is defined in section
Special tools on page 420 .
3HAC17313-1
Oil exchange equipment
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
These procedures include refer-
ences to the tools required.
Other tools and proced-
ures may be required. See
references to these pro-
cedures in the step-by-
step instructions below.
Note
The specified amount of oil is based on the total volume of the gearbox. When
changing the oil, the amount of refilled oil may differ from the specified amount,
depending on how much oil has previously been drained from the gearbox.
Continues on next page
164
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.2 Changing oil, axis-1 gearbox
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
https://search.abb.com/library/Download.aspx?DocumentID=3HAC022033-001&LanguageCode=en&DocumentPartId=&Action=Launch&DocumentRevisionId=AF
| 164
|
3.4.2 Changing oil, axis-1 gearbox
Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure
below.
The oil is drained with a hose that may be reached behind the rear cover of the
robot base.
xx0200000111
Gearbox, axis 1
A
Oil plug, filling
B
Motor, axis 1
C
Oil plug, inspection (not in all designs)
D
Label, specifies the type of oil in the gearbox
E
Continues on next page
Product manual - IRB 7600
163
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.2 Changing oil, axis-1 gearbox
Oil plug in the base
In some early versions of the robot, the oil plug for draining may be located in the
base, as shown in the figure below.
xx0300000065
Oil plug in the base
A
Required equipment
Note
Amount
Art. no.
Equipment, etc.
See Type
and
amount of
oil in gear-
boxes on
page 161 .
See Type and
amount of oil in
gearboxes on
page 161 .
Lubricating oil
Capacity: 8,000 ml.
Oil collecting vessel
Content is defined in section
Special tools on page 420 .
3HAC17313-1
Oil exchange equipment
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
These procedures include refer-
ences to the tools required.
Other tools and proced-
ures may be required. See
references to these pro-
cedures in the step-by-
step instructions below.
Note
The specified amount of oil is based on the total volume of the gearbox. When
changing the oil, the amount of refilled oil may differ from the specified amount,
depending on how much oil has previously been drained from the gearbox.
Continues on next page
164
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.2 Changing oil, axis-1 gearbox
Continued
Draining, oil, gearbox axis 1
The procedure below details how to drain the oil from the gearbox axis 1.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 164 .
Note
Action
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page38 .
1
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working
area.
2
Remove the rear cover on the base by unscrewing
its attachment screws.
3
Pull the oil hose out of the rear of the base.
4
Some early versions of the robot has the oil
draining plug in the base as shown in the figure
Oil plug in the base on page 164 instead of the
hose.
Vessel capacity specified in Re-
quired equipment on page 164 .
Place an oil vessel close to the hose end.
5
Remove the oil plug, filling, in order to drain the
oil quicker!
6
Note
The draining is time-consuming.
Elapsed time depends on the tem-
perature of the oil.
Open the hose end and drain the oil into the ves-
sel.
CAUTION
Drain as much oil as possible.
7
Close the oil drain hose, and put it back inside
the base.
8
Close the rear cover by securing it with its attach-
ment screws.
9
Continues on next page
Product manual - IRB 7600
165
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.2 Changing oil, axis-1 gearbox
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 165
|
Oil plug in the base
In some early versions of the robot, the oil plug for draining may be located in the
base, as shown in the figure below.
xx0300000065
Oil plug in the base
A
Required equipment
Note
Amount
Art. no.
Equipment, etc.
See Type
and
amount of
oil in gear-
boxes on
page 161 .
See Type and
amount of oil in
gearboxes on
page 161 .
Lubricating oil
Capacity: 8,000 ml.
Oil collecting vessel
Content is defined in section
Special tools on page 420 .
3HAC17313-1
Oil exchange equipment
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
These procedures include refer-
ences to the tools required.
Other tools and proced-
ures may be required. See
references to these pro-
cedures in the step-by-
step instructions below.
Note
The specified amount of oil is based on the total volume of the gearbox. When
changing the oil, the amount of refilled oil may differ from the specified amount,
depending on how much oil has previously been drained from the gearbox.
Continues on next page
164
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.2 Changing oil, axis-1 gearbox
Continued
Draining, oil, gearbox axis 1
The procedure below details how to drain the oil from the gearbox axis 1.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 164 .
Note
Action
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page38 .
1
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working
area.
2
Remove the rear cover on the base by unscrewing
its attachment screws.
3
Pull the oil hose out of the rear of the base.
4
Some early versions of the robot has the oil
draining plug in the base as shown in the figure
Oil plug in the base on page 164 instead of the
hose.
Vessel capacity specified in Re-
quired equipment on page 164 .
Place an oil vessel close to the hose end.
5
Remove the oil plug, filling, in order to drain the
oil quicker!
6
Note
The draining is time-consuming.
Elapsed time depends on the tem-
perature of the oil.
Open the hose end and drain the oil into the ves-
sel.
CAUTION
Drain as much oil as possible.
7
Close the oil drain hose, and put it back inside
the base.
8
Close the rear cover by securing it with its attach-
ment screws.
9
Continues on next page
Product manual - IRB 7600
165
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.2 Changing oil, axis-1 gearbox
Continued
Filling, oil, gearbox axis 1
The procedure below details how to fill oil in gearbox, axis 1.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 164 .
Note
Action
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page38 .
1
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working
area.
2
Shown in the figure Location of
gearbox on page 163 .
Open the oil plug, filling .
3
Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
page 161 .
Refill the gearbox with lubricating oil .
The amount of oil to be refilled depends on the
amount previously being drained. The correct oil
level is detailed in section Inspecting the oil level
in axis-1 gearbox on page 124 .
4
WARNING
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in Technical
reference manual - Lubrication in gearboxes .
5
Tightening torque: 24 Nm.
Refit the oil plug, filling.
6
166
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.2 Changing oil, axis-1 gearbox
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 166
|
Draining, oil, gearbox axis 1
The procedure below details how to drain the oil from the gearbox axis 1.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 164 .
Note
Action
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page38 .
1
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working
area.
2
Remove the rear cover on the base by unscrewing
its attachment screws.
3
Pull the oil hose out of the rear of the base.
4
Some early versions of the robot has the oil
draining plug in the base as shown in the figure
Oil plug in the base on page 164 instead of the
hose.
Vessel capacity specified in Re-
quired equipment on page 164 .
Place an oil vessel close to the hose end.
5
Remove the oil plug, filling, in order to drain the
oil quicker!
6
Note
The draining is time-consuming.
Elapsed time depends on the tem-
perature of the oil.
Open the hose end and drain the oil into the ves-
sel.
CAUTION
Drain as much oil as possible.
7
Close the oil drain hose, and put it back inside
the base.
8
Close the rear cover by securing it with its attach-
ment screws.
9
Continues on next page
Product manual - IRB 7600
165
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.2 Changing oil, axis-1 gearbox
Continued
Filling, oil, gearbox axis 1
The procedure below details how to fill oil in gearbox, axis 1.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 164 .
Note
Action
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page38 .
1
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working
area.
2
Shown in the figure Location of
gearbox on page 163 .
Open the oil plug, filling .
3
Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
page 161 .
Refill the gearbox with lubricating oil .
The amount of oil to be refilled depends on the
amount previously being drained. The correct oil
level is detailed in section Inspecting the oil level
in axis-1 gearbox on page 124 .
4
WARNING
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in Technical
reference manual - Lubrication in gearboxes .
5
Tightening torque: 24 Nm.
Refit the oil plug, filling.
6
166
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.2 Changing oil, axis-1 gearbox
Continued
3.4.3 Changing oil, axis-2 gearbox
Location of oil plugs
The axis-2 gearbox is located in the lower arm rotational center, underneath the
motor attachment.
A
C
B
D
E
A
C
B
D
xx0200000112
Gearbox, axis 2
A
Oil plug, filling/inspection (later design)
B
Oil plug, draining
C
Label, specifies the type of oil in the gearbox
D
Oil plug, ventilation (later design)
E
The early design of the gearbox cover is shown in Oil plug, early design on page127 .
Required equipment
Note
Amount
Art. no.
Equipment, etc.
Note! Do not mix with other oil
types!
See Type and
amount of oil in
gearboxes on
page 161 .
See Type and
amount of oil in
gearboxes on
page 161 .
Lubricating oil
Capacity: 5,000 ml.
-
Oil collecting vessel
Content is defined in section
Special tools on page 420 .
3HAC021745-001
Oil exchange equip-
ment
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Continues on next page
Product manual - IRB 7600
167
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.3 Changing oil, axis-2 gearbox
|
ABB_IRB7600_Product_Manual.pdf
|
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| 167
|
Filling, oil, gearbox axis 1
The procedure below details how to fill oil in gearbox, axis 1.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 164 .
Note
Action
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page38 .
1
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working
area.
2
Shown in the figure Location of
gearbox on page 163 .
Open the oil plug, filling .
3
Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
page 161 .
Refill the gearbox with lubricating oil .
The amount of oil to be refilled depends on the
amount previously being drained. The correct oil
level is detailed in section Inspecting the oil level
in axis-1 gearbox on page 124 .
4
WARNING
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in Technical
reference manual - Lubrication in gearboxes .
5
Tightening torque: 24 Nm.
Refit the oil plug, filling.
6
166
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.2 Changing oil, axis-1 gearbox
Continued
3.4.3 Changing oil, axis-2 gearbox
Location of oil plugs
The axis-2 gearbox is located in the lower arm rotational center, underneath the
motor attachment.
A
C
B
D
E
A
C
B
D
xx0200000112
Gearbox, axis 2
A
Oil plug, filling/inspection (later design)
B
Oil plug, draining
C
Label, specifies the type of oil in the gearbox
D
Oil plug, ventilation (later design)
E
The early design of the gearbox cover is shown in Oil plug, early design on page127 .
Required equipment
Note
Amount
Art. no.
Equipment, etc.
Note! Do not mix with other oil
types!
See Type and
amount of oil in
gearboxes on
page 161 .
See Type and
amount of oil in
gearboxes on
page 161 .
Lubricating oil
Capacity: 5,000 ml.
-
Oil collecting vessel
Content is defined in section
Special tools on page 420 .
3HAC021745-001
Oil exchange equip-
ment
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Continues on next page
Product manual - IRB 7600
167
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.3 Changing oil, axis-2 gearbox
Draining, oil
The procedure below details how to drain the oil in gearbox axis 2.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 167 .
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
1
WARNING
Handling gearbox oil involves several safety
risks, see Gearbox lubricants (oil or grease)
on page 38 .
2
Shown in the figure Location of oil plugs
on page 167 .
Remove the oil plug, draining, and drain the
gearbox oil using a hose with nipple and an
oil collecting vessel.
CAUTION
Drain as much oil as possible.
3
Vessel capacity is specified in Required
equipment on page 167 .
Note
Draining is time-consuming. Elapsed
time varies depending on the temperat-
ure of the oil.
Tightening torque: 24 Nm.
Refit the oil plug.
4
Filling, oil
Use this procedure to fill oil into the axis-2 gearbox.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 167 .
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
1
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page38 .
2
Continues on next page
168
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.3 Changing oil, axis-2 gearbox
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 168
|
3.4.3 Changing oil, axis-2 gearbox
Location of oil plugs
The axis-2 gearbox is located in the lower arm rotational center, underneath the
motor attachment.
A
C
B
D
E
A
C
B
D
xx0200000112
Gearbox, axis 2
A
Oil plug, filling/inspection (later design)
B
Oil plug, draining
C
Label, specifies the type of oil in the gearbox
D
Oil plug, ventilation (later design)
E
The early design of the gearbox cover is shown in Oil plug, early design on page127 .
Required equipment
Note
Amount
Art. no.
Equipment, etc.
Note! Do not mix with other oil
types!
See Type and
amount of oil in
gearboxes on
page 161 .
See Type and
amount of oil in
gearboxes on
page 161 .
Lubricating oil
Capacity: 5,000 ml.
-
Oil collecting vessel
Content is defined in section
Special tools on page 420 .
3HAC021745-001
Oil exchange equip-
ment
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Continues on next page
Product manual - IRB 7600
167
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.3 Changing oil, axis-2 gearbox
Draining, oil
The procedure below details how to drain the oil in gearbox axis 2.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 167 .
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
1
WARNING
Handling gearbox oil involves several safety
risks, see Gearbox lubricants (oil or grease)
on page 38 .
2
Shown in the figure Location of oil plugs
on page 167 .
Remove the oil plug, draining, and drain the
gearbox oil using a hose with nipple and an
oil collecting vessel.
CAUTION
Drain as much oil as possible.
3
Vessel capacity is specified in Required
equipment on page 167 .
Note
Draining is time-consuming. Elapsed
time varies depending on the temperat-
ure of the oil.
Tightening torque: 24 Nm.
Refit the oil plug.
4
Filling, oil
Use this procedure to fill oil into the axis-2 gearbox.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 167 .
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
1
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page38 .
2
Continues on next page
168
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.3 Changing oil, axis-2 gearbox
Continued
Note
Action
Shown in the figure Location of oil
plugs on page 167 .
Remove the oil plug for filling and the plug from
the vent hole.
3
Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
page 161 .
Refill the gearbox with clean lubricating oil.
The correct oil level is detailed in section Inspect-
ing the oil level in axis-2 gearbox on page 127 .
4
WARNING
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in Technical
reference manual - Lubrication in gearboxes .
5
Tightening torque: 24 Nm.
Refit the oil plug.
6
Product manual - IRB 7600
169
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.3 Changing oil, axis-2 gearbox
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 169
|
Draining, oil
The procedure below details how to drain the oil in gearbox axis 2.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 167 .
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
1
WARNING
Handling gearbox oil involves several safety
risks, see Gearbox lubricants (oil or grease)
on page 38 .
2
Shown in the figure Location of oil plugs
on page 167 .
Remove the oil plug, draining, and drain the
gearbox oil using a hose with nipple and an
oil collecting vessel.
CAUTION
Drain as much oil as possible.
3
Vessel capacity is specified in Required
equipment on page 167 .
Note
Draining is time-consuming. Elapsed
time varies depending on the temperat-
ure of the oil.
Tightening torque: 24 Nm.
Refit the oil plug.
4
Filling, oil
Use this procedure to fill oil into the axis-2 gearbox.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 167 .
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
1
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page38 .
2
Continues on next page
168
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.3 Changing oil, axis-2 gearbox
Continued
Note
Action
Shown in the figure Location of oil
plugs on page 167 .
Remove the oil plug for filling and the plug from
the vent hole.
3
Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
page 161 .
Refill the gearbox with clean lubricating oil.
The correct oil level is detailed in section Inspect-
ing the oil level in axis-2 gearbox on page 127 .
4
WARNING
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in Technical
reference manual - Lubrication in gearboxes .
5
Tightening torque: 24 Nm.
Refit the oil plug.
6
Product manual - IRB 7600
169
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.3 Changing oil, axis-2 gearbox
Continued
3.4.4 Changing oil, axis-3 gearbox
Location of gearbox
The axis-3 gearbox is located in the upper arm rotational center as shown in the
following figure.
xx0200000113
Gearbox, axis 3
A
Oil plug, filling
B
Oil plug, draining
C
Label, specifies the type of oil in gearbox
D
Required equipment
Note
Amount
Art. no.
Equipment, etc.
Note! Do not mix with other oil
types!
See Type
and
amount of
oil in gear-
boxes on
page 161 .
See Type and
amount of oil in
gearboxes on
page 161 .
Lubricating oil
Continues on next page
170
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.4 Changing oil, axis-3 gearbox
|
ABB_IRB7600_Product_Manual.pdf
|
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| 170
|
Note
Action
Shown in the figure Location of oil
plugs on page 167 .
Remove the oil plug for filling and the plug from
the vent hole.
3
Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
page 161 .
Refill the gearbox with clean lubricating oil.
The correct oil level is detailed in section Inspect-
ing the oil level in axis-2 gearbox on page 127 .
4
WARNING
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in Technical
reference manual - Lubrication in gearboxes .
5
Tightening torque: 24 Nm.
Refit the oil plug.
6
Product manual - IRB 7600
169
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.3 Changing oil, axis-2 gearbox
Continued
3.4.4 Changing oil, axis-3 gearbox
Location of gearbox
The axis-3 gearbox is located in the upper arm rotational center as shown in the
following figure.
xx0200000113
Gearbox, axis 3
A
Oil plug, filling
B
Oil plug, draining
C
Label, specifies the type of oil in gearbox
D
Required equipment
Note
Amount
Art. no.
Equipment, etc.
Note! Do not mix with other oil
types!
See Type
and
amount of
oil in gear-
boxes on
page 161 .
See Type and
amount of oil in
gearboxes on
page 161 .
Lubricating oil
Continues on next page
170
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.4 Changing oil, axis-3 gearbox
Note
Amount
Art. no.
Equipment, etc.
Content is defined in section
Special tools on page 420 .
3HAC021745-001
Oil exchange equipment
Capacity: 5,000 ml.
-
Oil collecting vessel
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Draining, oil
The procedure below details how to drain oil from the gearbox, axis 3.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 170 .
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
1
WARNING
Handling gearbox oil involves several safety
risks, see Gearbox lubricants (oil or grease)
on page 38 .
2
Remove the oil plug, filling .
3
Shown in the figure Location of gearbox
on page 170 .
Remove the oil plug, draining, and drain the
gearbox oil using a hose with nipple and an
oil collecting vessel.
CAUTION
Drain as much oil as possible.
4
Vessel capacity is specified in Required
equipment on page 170 .
Note
Draining is time-consuming. Elapsed time
varies depending on the temperature of
the oil.
Tightening torque: 24 Nm.
Refit the oil plug.
5
Continues on next page
Product manual - IRB 7600
171
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.4 Changing oil, axis-3 gearbox
Continued
|
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|
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| 171
|
3.4.4 Changing oil, axis-3 gearbox
Location of gearbox
The axis-3 gearbox is located in the upper arm rotational center as shown in the
following figure.
xx0200000113
Gearbox, axis 3
A
Oil plug, filling
B
Oil plug, draining
C
Label, specifies the type of oil in gearbox
D
Required equipment
Note
Amount
Art. no.
Equipment, etc.
Note! Do not mix with other oil
types!
See Type
and
amount of
oil in gear-
boxes on
page 161 .
See Type and
amount of oil in
gearboxes on
page 161 .
Lubricating oil
Continues on next page
170
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.4 Changing oil, axis-3 gearbox
Note
Amount
Art. no.
Equipment, etc.
Content is defined in section
Special tools on page 420 .
3HAC021745-001
Oil exchange equipment
Capacity: 5,000 ml.
-
Oil collecting vessel
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Draining, oil
The procedure below details how to drain oil from the gearbox, axis 3.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 170 .
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
1
WARNING
Handling gearbox oil involves several safety
risks, see Gearbox lubricants (oil or grease)
on page 38 .
2
Remove the oil plug, filling .
3
Shown in the figure Location of gearbox
on page 170 .
Remove the oil plug, draining, and drain the
gearbox oil using a hose with nipple and an
oil collecting vessel.
CAUTION
Drain as much oil as possible.
4
Vessel capacity is specified in Required
equipment on page 170 .
Note
Draining is time-consuming. Elapsed time
varies depending on the temperature of
the oil.
Tightening torque: 24 Nm.
Refit the oil plug.
5
Continues on next page
Product manual - IRB 7600
171
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.4 Changing oil, axis-3 gearbox
Continued
Filling, oil
The procedure below details how to fill oil into the gearbox, axis 3.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 170 .
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
1
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page 38 .
2
Shown in the figure Location of
gearbox on page 170 .
Remove the oil plug, filling.
3
Where to find type of oil and
total amount is detailed in Type
and amount of oil in gearboxes
on page 161 .
Refill the gearbox with clean lubricating oil.
The correct oil level is detailed in section Inspecting
the oil level in axis-3 gearbox on page 130 .
4
WARNING
Do not mix oil types! If wrong oil is refilled, the gear-
box must be rinsed as detailed in Technical reference
manual - Lubrication in gearboxes .
5
Note
Do not mix Kyodo Yushi TMO 150 with other oil types!
6
Tightening torque: 24 Nm.
Refit the oil plug.
7
172
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.4 Changing oil, axis-3 gearbox
Continued
|
ABB_IRB7600_Product_Manual.pdf
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| 172
|
Note
Amount
Art. no.
Equipment, etc.
Content is defined in section
Special tools on page 420 .
3HAC021745-001
Oil exchange equipment
Capacity: 5,000 ml.
-
Oil collecting vessel
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Draining, oil
The procedure below details how to drain oil from the gearbox, axis 3.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 170 .
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
1
WARNING
Handling gearbox oil involves several safety
risks, see Gearbox lubricants (oil or grease)
on page 38 .
2
Remove the oil plug, filling .
3
Shown in the figure Location of gearbox
on page 170 .
Remove the oil plug, draining, and drain the
gearbox oil using a hose with nipple and an
oil collecting vessel.
CAUTION
Drain as much oil as possible.
4
Vessel capacity is specified in Required
equipment on page 170 .
Note
Draining is time-consuming. Elapsed time
varies depending on the temperature of
the oil.
Tightening torque: 24 Nm.
Refit the oil plug.
5
Continues on next page
Product manual - IRB 7600
171
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.4 Changing oil, axis-3 gearbox
Continued
Filling, oil
The procedure below details how to fill oil into the gearbox, axis 3.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 170 .
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
1
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page 38 .
2
Shown in the figure Location of
gearbox on page 170 .
Remove the oil plug, filling.
3
Where to find type of oil and
total amount is detailed in Type
and amount of oil in gearboxes
on page 161 .
Refill the gearbox with clean lubricating oil.
The correct oil level is detailed in section Inspecting
the oil level in axis-3 gearbox on page 130 .
4
WARNING
Do not mix oil types! If wrong oil is refilled, the gear-
box must be rinsed as detailed in Technical reference
manual - Lubrication in gearboxes .
5
Note
Do not mix Kyodo Yushi TMO 150 with other oil types!
6
Tightening torque: 24 Nm.
Refit the oil plug.
7
172
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.4 Changing oil, axis-3 gearbox
Continued
3.4.5 Changing oil, axis-4 gearbox
Different types of oil
The primary and secondary gear may require different types of oil, that must never
be mixed!
If they are mixed, the gear must be rinsed according to section Flushing a
contaminated gearbox on page 191 .
Location of gearbox
The axis 4 gearbox is located at the rear of the upper arm as shown in the figure
below.
xx0200000107
Upper arm housing
A
Cover, axis 4 gearbox
B
Oil plug, filling, secondary gear
C
Oil plug, draining, secondary gear
D
Oil plug, filling, primary gearbox (draining not shown in figure, located further
down on the motor flange)
E
Label, specifies the type of oil in the secondary gear
F
Label, specifies the type of oil in the primary gear
G
Continues on next page
Product manual - IRB 7600
173
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.5 Changing oil, axis-4 gearbox
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ABB_IRB7600_Product_Manual.pdf
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| 173
|
Filling, oil
The procedure below details how to fill oil into the gearbox, axis 3.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 170 .
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
1
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page 38 .
2
Shown in the figure Location of
gearbox on page 170 .
Remove the oil plug, filling.
3
Where to find type of oil and
total amount is detailed in Type
and amount of oil in gearboxes
on page 161 .
Refill the gearbox with clean lubricating oil.
The correct oil level is detailed in section Inspecting
the oil level in axis-3 gearbox on page 130 .
4
WARNING
Do not mix oil types! If wrong oil is refilled, the gear-
box must be rinsed as detailed in Technical reference
manual - Lubrication in gearboxes .
5
Note
Do not mix Kyodo Yushi TMO 150 with other oil types!
6
Tightening torque: 24 Nm.
Refit the oil plug.
7
172
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.4 Changing oil, axis-3 gearbox
Continued
3.4.5 Changing oil, axis-4 gearbox
Different types of oil
The primary and secondary gear may require different types of oil, that must never
be mixed!
If they are mixed, the gear must be rinsed according to section Flushing a
contaminated gearbox on page 191 .
Location of gearbox
The axis 4 gearbox is located at the rear of the upper arm as shown in the figure
below.
xx0200000107
Upper arm housing
A
Cover, axis 4 gearbox
B
Oil plug, filling, secondary gear
C
Oil plug, draining, secondary gear
D
Oil plug, filling, primary gearbox (draining not shown in figure, located further
down on the motor flange)
E
Label, specifies the type of oil in the secondary gear
F
Label, specifies the type of oil in the primary gear
G
Continues on next page
Product manual - IRB 7600
173
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.5 Changing oil, axis-4 gearbox
Required equipment
Note
Amount
Art. no.
Equipment, etc.
See Type
and
amount of
oil in gear-
boxes on
page 161 .
See Type and
amount of oil in
gearboxes on
page 161 .
Lubricating oil
Capacity: 1,000 ml.
Oil collecting vessel,
primary gearbox
Capacity: 4,000 ml.
Oil collecting vessel,
secondary gearbox
Content is defined in section Special
tools on page 420 .
3HAC17313-1
Oil exchange equip-
ment
Content is defined in section Stand-
ard tools on page 419 .
-
Standard toolkit
Draining, oil, gearbox axis 4
The procedure below details how to drain the oil from the gearbox, axis 4.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 174 .
Note
Action
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page 38 .
1
Shown in the figure Location of
gearbox on page 173 .
Open the oil plug, draining, secondary gear .
2
Vessel capacity specified in Re-
quired equipment on page 174 .
Drain the oil from the secondary gearbox by running
the upper arm -45° from calibration position.
3
Detailed in section Synchroniza-
tion marks and synchronization
position for axes on page 376 .
Run the robot back to its calibration position.
4
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working area.
5
Vessel capacity specified in Re-
quired equipment on page 174 .
Drain the primary gear by opening the oil plug,
draining, primary gearbox.
CAUTION
Drain as much oil as possible.
6
Continues on next page
174
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.5 Changing oil, axis-4 gearbox
Continued
|
ABB_IRB7600_Product_Manual.pdf
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| 174
|
3.4.5 Changing oil, axis-4 gearbox
Different types of oil
The primary and secondary gear may require different types of oil, that must never
be mixed!
If they are mixed, the gear must be rinsed according to section Flushing a
contaminated gearbox on page 191 .
Location of gearbox
The axis 4 gearbox is located at the rear of the upper arm as shown in the figure
below.
xx0200000107
Upper arm housing
A
Cover, axis 4 gearbox
B
Oil plug, filling, secondary gear
C
Oil plug, draining, secondary gear
D
Oil plug, filling, primary gearbox (draining not shown in figure, located further
down on the motor flange)
E
Label, specifies the type of oil in the secondary gear
F
Label, specifies the type of oil in the primary gear
G
Continues on next page
Product manual - IRB 7600
173
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.5 Changing oil, axis-4 gearbox
Required equipment
Note
Amount
Art. no.
Equipment, etc.
See Type
and
amount of
oil in gear-
boxes on
page 161 .
See Type and
amount of oil in
gearboxes on
page 161 .
Lubricating oil
Capacity: 1,000 ml.
Oil collecting vessel,
primary gearbox
Capacity: 4,000 ml.
Oil collecting vessel,
secondary gearbox
Content is defined in section Special
tools on page 420 .
3HAC17313-1
Oil exchange equip-
ment
Content is defined in section Stand-
ard tools on page 419 .
-
Standard toolkit
Draining, oil, gearbox axis 4
The procedure below details how to drain the oil from the gearbox, axis 4.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 174 .
Note
Action
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page 38 .
1
Shown in the figure Location of
gearbox on page 173 .
Open the oil plug, draining, secondary gear .
2
Vessel capacity specified in Re-
quired equipment on page 174 .
Drain the oil from the secondary gearbox by running
the upper arm -45° from calibration position.
3
Detailed in section Synchroniza-
tion marks and synchronization
position for axes on page 376 .
Run the robot back to its calibration position.
4
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working area.
5
Vessel capacity specified in Re-
quired equipment on page 174 .
Drain the primary gear by opening the oil plug,
draining, primary gearbox.
CAUTION
Drain as much oil as possible.
6
Continues on next page
174
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.5 Changing oil, axis-4 gearbox
Continued
Note
Action
Tightening torque: 24 Nm.
Refit the both oil plugs, draining.
7
Filling, oil, gearbox axis 4
The procedure below details how to fill oil in gearbox, axis 4.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 174 .
Note
Action
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page 38 .
1
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working area.
2
Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
page 161 .
Refill the secondary gear with lubricating oil through
the oil plug, filling, secondary gear .
3
Shown in the figure Location of
gearbox on page 173 .
Kyodo Yushi TMO 150
Refill the primary gearbox with oil through the oil
plug, filling, primary gear . Make sure the air is
ventilated through the oil plug during filling, to avoid
overpressure in the gearbox.
The amount of oil to be refilled depends on the
amount previously being drained. The correct oil
level is detailed in section Inspecting the oil level
in axis-4 gearbox on page 133 .
4
Shown in the figure Location of
gearbox on page 173 .
Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
page 161 .
WARNING
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in Technical
reference manual - Lubrication in gearboxes .
5
Shown in the figure Location of
gearbox on page 173 .
Refit the both oil plugs, filling.
6
Tightening torque: 24 Nm.
Product manual - IRB 7600
175
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.5 Changing oil, axis-4 gearbox
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 175
|
Required equipment
Note
Amount
Art. no.
Equipment, etc.
See Type
and
amount of
oil in gear-
boxes on
page 161 .
See Type and
amount of oil in
gearboxes on
page 161 .
Lubricating oil
Capacity: 1,000 ml.
Oil collecting vessel,
primary gearbox
Capacity: 4,000 ml.
Oil collecting vessel,
secondary gearbox
Content is defined in section Special
tools on page 420 .
3HAC17313-1
Oil exchange equip-
ment
Content is defined in section Stand-
ard tools on page 419 .
-
Standard toolkit
Draining, oil, gearbox axis 4
The procedure below details how to drain the oil from the gearbox, axis 4.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 174 .
Note
Action
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page 38 .
1
Shown in the figure Location of
gearbox on page 173 .
Open the oil plug, draining, secondary gear .
2
Vessel capacity specified in Re-
quired equipment on page 174 .
Drain the oil from the secondary gearbox by running
the upper arm -45° from calibration position.
3
Detailed in section Synchroniza-
tion marks and synchronization
position for axes on page 376 .
Run the robot back to its calibration position.
4
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working area.
5
Vessel capacity specified in Re-
quired equipment on page 174 .
Drain the primary gear by opening the oil plug,
draining, primary gearbox.
CAUTION
Drain as much oil as possible.
6
Continues on next page
174
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.5 Changing oil, axis-4 gearbox
Continued
Note
Action
Tightening torque: 24 Nm.
Refit the both oil plugs, draining.
7
Filling, oil, gearbox axis 4
The procedure below details how to fill oil in gearbox, axis 4.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 174 .
Note
Action
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page 38 .
1
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working area.
2
Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
page 161 .
Refill the secondary gear with lubricating oil through
the oil plug, filling, secondary gear .
3
Shown in the figure Location of
gearbox on page 173 .
Kyodo Yushi TMO 150
Refill the primary gearbox with oil through the oil
plug, filling, primary gear . Make sure the air is
ventilated through the oil plug during filling, to avoid
overpressure in the gearbox.
The amount of oil to be refilled depends on the
amount previously being drained. The correct oil
level is detailed in section Inspecting the oil level
in axis-4 gearbox on page 133 .
4
Shown in the figure Location of
gearbox on page 173 .
Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
page 161 .
WARNING
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in Technical
reference manual - Lubrication in gearboxes .
5
Shown in the figure Location of
gearbox on page 173 .
Refit the both oil plugs, filling.
6
Tightening torque: 24 Nm.
Product manual - IRB 7600
175
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.5 Changing oil, axis-4 gearbox
Continued
3.4.6 Changing oil, axis-5 gearbox
Different types of oil
The primary and secondary gear may require different types of oil, that must never
be mixed!
If they are mixed, the gear must be rinsed according to section Flushing a
contaminated gearbox on page 191 .
Location of gearbox
The axis-5 gearbox is located in the wrist unit as shown in the following figure.
A
E
F
D
G
C
B
xx0200000108
Wrist housing
A
Oil plug, filling/inspection, primary gearbox
B
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
C
Continues on next page
176
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.6 Changing oil, axis-5 gearbox
|
ABB_IRB7600_Product_Manual.pdf
|
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| 176
|
Note
Action
Tightening torque: 24 Nm.
Refit the both oil plugs, draining.
7
Filling, oil, gearbox axis 4
The procedure below details how to fill oil in gearbox, axis 4.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 174 .
Note
Action
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page 38 .
1
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working area.
2
Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
page 161 .
Refill the secondary gear with lubricating oil through
the oil plug, filling, secondary gear .
3
Shown in the figure Location of
gearbox on page 173 .
Kyodo Yushi TMO 150
Refill the primary gearbox with oil through the oil
plug, filling, primary gear . Make sure the air is
ventilated through the oil plug during filling, to avoid
overpressure in the gearbox.
The amount of oil to be refilled depends on the
amount previously being drained. The correct oil
level is detailed in section Inspecting the oil level
in axis-4 gearbox on page 133 .
4
Shown in the figure Location of
gearbox on page 173 .
Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
page 161 .
WARNING
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in Technical
reference manual - Lubrication in gearboxes .
5
Shown in the figure Location of
gearbox on page 173 .
Refit the both oil plugs, filling.
6
Tightening torque: 24 Nm.
Product manual - IRB 7600
175
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.5 Changing oil, axis-4 gearbox
Continued
3.4.6 Changing oil, axis-5 gearbox
Different types of oil
The primary and secondary gear may require different types of oil, that must never
be mixed!
If they are mixed, the gear must be rinsed according to section Flushing a
contaminated gearbox on page 191 .
Location of gearbox
The axis-5 gearbox is located in the wrist unit as shown in the following figure.
A
E
F
D
G
C
B
xx0200000108
Wrist housing
A
Oil plug, filling/inspection, primary gearbox
B
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
C
Continues on next page
176
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.6 Changing oil, axis-5 gearbox
Oil plug, draining/inspection, secondary gearbox
D
Label, specifies the type of oil in the axis-5 secondary gearbox
E
Oil plug, filling, secondary gearbox
F
Cover, axis-5 gearbox
G
Required equipment
Note
Art. no.
Equipment, etc.
See Type and amount of
oil in gearboxes on
page 161 .
Lubricating oil
Capacity: 1 liter
Oil collecting vessel
Capacity: 4 liters
Oil collecting vessel
Content is defined in section Special
tools on page 420 .
3HAC17313-1
Oil exchange equipment
Content is defined in section Standard
tools on page 419 .
-
Standard toolkit
Note
The specified amount of oil is based on the total volume of the gearbox. When
changing the oil, the amount of refilled oil may differ from the specified amount,
depending on how much oil has previously been drained from the gearbox.
Draining oil, axis-5 gearbox
The procedure below details how to drain the oil from the gearbox, axis 5.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 177 .
Note
Action
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page 38 .
1
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working area.
2
Open the oil plug, draining, primary gearbox .
3
Vessel capacity: 1 liter
Drain the oil from the primary gearbox.
4
Run axis 4 to a position +90° from the calibration
position.
5
Continues on next page
Product manual - IRB 7600
177
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.6 Changing oil, axis-5 gearbox
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 177
|
3.4.6 Changing oil, axis-5 gearbox
Different types of oil
The primary and secondary gear may require different types of oil, that must never
be mixed!
If they are mixed, the gear must be rinsed according to section Flushing a
contaminated gearbox on page 191 .
Location of gearbox
The axis-5 gearbox is located in the wrist unit as shown in the following figure.
A
E
F
D
G
C
B
xx0200000108
Wrist housing
A
Oil plug, filling/inspection, primary gearbox
B
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
C
Continues on next page
176
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3 Maintenance
3.4.6 Changing oil, axis-5 gearbox
Oil plug, draining/inspection, secondary gearbox
D
Label, specifies the type of oil in the axis-5 secondary gearbox
E
Oil plug, filling, secondary gearbox
F
Cover, axis-5 gearbox
G
Required equipment
Note
Art. no.
Equipment, etc.
See Type and amount of
oil in gearboxes on
page 161 .
Lubricating oil
Capacity: 1 liter
Oil collecting vessel
Capacity: 4 liters
Oil collecting vessel
Content is defined in section Special
tools on page 420 .
3HAC17313-1
Oil exchange equipment
Content is defined in section Standard
tools on page 419 .
-
Standard toolkit
Note
The specified amount of oil is based on the total volume of the gearbox. When
changing the oil, the amount of refilled oil may differ from the specified amount,
depending on how much oil has previously been drained from the gearbox.
Draining oil, axis-5 gearbox
The procedure below details how to drain the oil from the gearbox, axis 5.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 177 .
Note
Action
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page 38 .
1
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working area.
2
Open the oil plug, draining, primary gearbox .
3
Vessel capacity: 1 liter
Drain the oil from the primary gearbox.
4
Run axis 4 to a position +90° from the calibration
position.
5
Continues on next page
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177
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3 Maintenance
3.4.6 Changing oil, axis-5 gearbox
Continued
Note
Action
Shown in the figure Location of
gearbox on page 176 .
Open the oil plug, draining/inspection, secondary
gearbox .
6
Vessel capacity: 4 liters
Drain the oil from the secondary gear.
CAUTION
Drain as much oil as possible.
7
Shown in the figure Location of
gearbox on page 176 .
Refit the oil plugs.
8
Tightening torque: 24 Nm.
Filling oil, axis-5 gearbox
The procedure below details how to fill oil in gearbox, axis 5.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 177 .
Note
Action
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page 38 .
1
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working area.
2
Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
page 161 .
Refill the primary gearbox with lubricating oil through
the oil plug, filling . Make sure the air is ventilated
through the oil plug during filling, to avoid overpres-
sure in the gearbox.
The amount of oil to be refilled depends on the
amount previously being drained. The correct oil
level is detailed in section Inspecting the oil level in
axis-5 gearbox on page 136 .
3
Shown in the figure Location of
gearbox on page 176 .
Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
page 161 .
Refill the secondary gearbox with lubricating oil
through the oil plug, filling .
The amount of oil to be refilled depends on the
amount previously being drained. The correct oil
level is detailed in section Inspecting the oil level in
axis-5 gearbox on page 136 .
4
Shown in the figure Location of
gearbox on page 176 .
WARNING
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in Technical
reference manual - Lubrication in gearboxes .
5
Continues on next page
178
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3 Maintenance
3.4.6 Changing oil, axis-5 gearbox
Continued
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Oil plug, draining/inspection, secondary gearbox
D
Label, specifies the type of oil in the axis-5 secondary gearbox
E
Oil plug, filling, secondary gearbox
F
Cover, axis-5 gearbox
G
Required equipment
Note
Art. no.
Equipment, etc.
See Type and amount of
oil in gearboxes on
page 161 .
Lubricating oil
Capacity: 1 liter
Oil collecting vessel
Capacity: 4 liters
Oil collecting vessel
Content is defined in section Special
tools on page 420 .
3HAC17313-1
Oil exchange equipment
Content is defined in section Standard
tools on page 419 .
-
Standard toolkit
Note
The specified amount of oil is based on the total volume of the gearbox. When
changing the oil, the amount of refilled oil may differ from the specified amount,
depending on how much oil has previously been drained from the gearbox.
Draining oil, axis-5 gearbox
The procedure below details how to drain the oil from the gearbox, axis 5.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 177 .
Note
Action
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page 38 .
1
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working area.
2
Open the oil plug, draining, primary gearbox .
3
Vessel capacity: 1 liter
Drain the oil from the primary gearbox.
4
Run axis 4 to a position +90° from the calibration
position.
5
Continues on next page
Product manual - IRB 7600
177
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© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.6 Changing oil, axis-5 gearbox
Continued
Note
Action
Shown in the figure Location of
gearbox on page 176 .
Open the oil plug, draining/inspection, secondary
gearbox .
6
Vessel capacity: 4 liters
Drain the oil from the secondary gear.
CAUTION
Drain as much oil as possible.
7
Shown in the figure Location of
gearbox on page 176 .
Refit the oil plugs.
8
Tightening torque: 24 Nm.
Filling oil, axis-5 gearbox
The procedure below details how to fill oil in gearbox, axis 5.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 177 .
Note
Action
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page 38 .
1
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working area.
2
Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
page 161 .
Refill the primary gearbox with lubricating oil through
the oil plug, filling . Make sure the air is ventilated
through the oil plug during filling, to avoid overpres-
sure in the gearbox.
The amount of oil to be refilled depends on the
amount previously being drained. The correct oil
level is detailed in section Inspecting the oil level in
axis-5 gearbox on page 136 .
3
Shown in the figure Location of
gearbox on page 176 .
Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
page 161 .
Refill the secondary gearbox with lubricating oil
through the oil plug, filling .
The amount of oil to be refilled depends on the
amount previously being drained. The correct oil
level is detailed in section Inspecting the oil level in
axis-5 gearbox on page 136 .
4
Shown in the figure Location of
gearbox on page 176 .
WARNING
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in Technical
reference manual - Lubrication in gearboxes .
5
Continues on next page
178
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3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.6 Changing oil, axis-5 gearbox
Continued
Note
Action
Shown in the figure Location of
gearbox on page 176 .
Refit the oil plugs.
6
Tightening torque: 24 Nm.
Product manual - IRB 7600
179
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.6 Changing oil, axis-5 gearbox
Continued
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|
Note
Action
Shown in the figure Location of
gearbox on page 176 .
Open the oil plug, draining/inspection, secondary
gearbox .
6
Vessel capacity: 4 liters
Drain the oil from the secondary gear.
CAUTION
Drain as much oil as possible.
7
Shown in the figure Location of
gearbox on page 176 .
Refit the oil plugs.
8
Tightening torque: 24 Nm.
Filling oil, axis-5 gearbox
The procedure below details how to fill oil in gearbox, axis 5.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 177 .
Note
Action
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page 38 .
1
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working area.
2
Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
page 161 .
Refill the primary gearbox with lubricating oil through
the oil plug, filling . Make sure the air is ventilated
through the oil plug during filling, to avoid overpres-
sure in the gearbox.
The amount of oil to be refilled depends on the
amount previously being drained. The correct oil
level is detailed in section Inspecting the oil level in
axis-5 gearbox on page 136 .
3
Shown in the figure Location of
gearbox on page 176 .
Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
page 161 .
Refill the secondary gearbox with lubricating oil
through the oil plug, filling .
The amount of oil to be refilled depends on the
amount previously being drained. The correct oil
level is detailed in section Inspecting the oil level in
axis-5 gearbox on page 136 .
4
Shown in the figure Location of
gearbox on page 176 .
WARNING
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in Technical
reference manual - Lubrication in gearboxes .
5
Continues on next page
178
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© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.6 Changing oil, axis-5 gearbox
Continued
Note
Action
Shown in the figure Location of
gearbox on page 176 .
Refit the oil plugs.
6
Tightening torque: 24 Nm.
Product manual - IRB 7600
179
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.6 Changing oil, axis-5 gearbox
Continued
3.4.7 Changing oil, axis-6 gearbox
Location of gearbox
The axis-6 gearbox is located in the center of the wrist unit as shown in the following
figure.
xx0200000114
Gearbox, axis 6
A
Oil plug, filling/inspection (notice the different locations of the plug, shown as
B 1 and B 2 )
B
Oil plug, draining (can be located on the turning disk instead)
C
Label, specifies the type of oil in gearbox axis 6
D
Required equipment
Note
Amount
Art. no.
Equipment, etc.
See Type and
amount of oil in
gearboxes on
page 161 .
See Type and
amount of oil in
gearboxes on
page 161 .
Lubricating oil
Vessel capacity: 1,000 ml.
Oil collecting vessel
Content is defined in section
Special tools on page 420 .
3HAC17313-1
Oil exchange equip-
ment
Continues on next page
180
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.7 Changing oil, axis-6 gearbox
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| 180
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Note
Action
Shown in the figure Location of
gearbox on page 176 .
Refit the oil plugs.
6
Tightening torque: 24 Nm.
Product manual - IRB 7600
179
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.6 Changing oil, axis-5 gearbox
Continued
3.4.7 Changing oil, axis-6 gearbox
Location of gearbox
The axis-6 gearbox is located in the center of the wrist unit as shown in the following
figure.
xx0200000114
Gearbox, axis 6
A
Oil plug, filling/inspection (notice the different locations of the plug, shown as
B 1 and B 2 )
B
Oil plug, draining (can be located on the turning disk instead)
C
Label, specifies the type of oil in gearbox axis 6
D
Required equipment
Note
Amount
Art. no.
Equipment, etc.
See Type and
amount of oil in
gearboxes on
page 161 .
See Type and
amount of oil in
gearboxes on
page 161 .
Lubricating oil
Vessel capacity: 1,000 ml.
Oil collecting vessel
Content is defined in section
Special tools on page 420 .
3HAC17313-1
Oil exchange equip-
ment
Continues on next page
180
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.7 Changing oil, axis-6 gearbox
Note
Amount
Art. no.
Equipment, etc.
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Note
The specified amount of oil is based on the total volume of the gearbox. When
changing the oil, the amount of refilled oil may differ from the specified amount,
depending on how much oil has previously been drained from the gearbox.
Draining oil, gearbox axis 6
The procedure below details how to drain the oil in the gearbox, axis 6.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 180 .
Note
Action
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page 38 .
1
Shown in the figure Location of
gearbox on page 180 !
Move the wrist so that the oil plug, d raining of axis
6 gearbox faces downwards.
If the oil plug, draining is located on the turning
disc, rotate the disc so that the plug faces down-
wards.
2
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working
area.
3
Vessel capacity: 1000 ml.
Drain the oil from gearbox 6 by removing the oil
plug. Collect the oil with a suitable vessel.
CAUTION
Drain as much oil as possible.
4
The amount of oil to be refilled de-
pends on the amount previously
being drained. The correct oil level
is detailed in section Inspecting
the oil level in axis-6 gearbox on
page 139 .
Measure the amount of oil drained.
Continues on next page
Product manual - IRB 7600
181
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.7 Changing oil, axis-6 gearbox
Continued
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3.4.7 Changing oil, axis-6 gearbox
Location of gearbox
The axis-6 gearbox is located in the center of the wrist unit as shown in the following
figure.
xx0200000114
Gearbox, axis 6
A
Oil plug, filling/inspection (notice the different locations of the plug, shown as
B 1 and B 2 )
B
Oil plug, draining (can be located on the turning disk instead)
C
Label, specifies the type of oil in gearbox axis 6
D
Required equipment
Note
Amount
Art. no.
Equipment, etc.
See Type and
amount of oil in
gearboxes on
page 161 .
See Type and
amount of oil in
gearboxes on
page 161 .
Lubricating oil
Vessel capacity: 1,000 ml.
Oil collecting vessel
Content is defined in section
Special tools on page 420 .
3HAC17313-1
Oil exchange equip-
ment
Continues on next page
180
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.7 Changing oil, axis-6 gearbox
Note
Amount
Art. no.
Equipment, etc.
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Note
The specified amount of oil is based on the total volume of the gearbox. When
changing the oil, the amount of refilled oil may differ from the specified amount,
depending on how much oil has previously been drained from the gearbox.
Draining oil, gearbox axis 6
The procedure below details how to drain the oil in the gearbox, axis 6.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 180 .
Note
Action
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page 38 .
1
Shown in the figure Location of
gearbox on page 180 !
Move the wrist so that the oil plug, d raining of axis
6 gearbox faces downwards.
If the oil plug, draining is located on the turning
disc, rotate the disc so that the plug faces down-
wards.
2
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working
area.
3
Vessel capacity: 1000 ml.
Drain the oil from gearbox 6 by removing the oil
plug. Collect the oil with a suitable vessel.
CAUTION
Drain as much oil as possible.
4
The amount of oil to be refilled de-
pends on the amount previously
being drained. The correct oil level
is detailed in section Inspecting
the oil level in axis-6 gearbox on
page 139 .
Measure the amount of oil drained.
Continues on next page
Product manual - IRB 7600
181
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.7 Changing oil, axis-6 gearbox
Continued
Filling oil, gearbox axis 6
The procedure below details how to fill oil in the gearbox axis 6.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 180 .
Note
Action
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page 38 .
1
Run the robot to a position where the oil plug,
filling (B1 or B2) of axis 6 gearbox, is facing up-
wards.
2
If the oil plug for draining is located on the turning
disk, rotate the disk so that the oil plug faces up-
wards.
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working
area.
3
Shown in the figure Location of
gearbox on page 180 .
Remove the oil plug, filling .
4
Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
page 161 .
Refill the wrist with lubricating oil .
Make sure the air is ventilated through the oil plug
during filling, to avoid overpressure in the gearbox.
If the plug hole for draining is located on the turn-
ing disk, the air is ventilated through the open plug
hole.
5
WARNING
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in Technical
reference manual - Lubrication in gearboxes .
6
Tightening torque: 20 Nm.
Refit both oil plugs.
7
182
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.7 Changing oil, axis-6 gearbox
Continued
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| 182
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Note
Amount
Art. no.
Equipment, etc.
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Note
The specified amount of oil is based on the total volume of the gearbox. When
changing the oil, the amount of refilled oil may differ from the specified amount,
depending on how much oil has previously been drained from the gearbox.
Draining oil, gearbox axis 6
The procedure below details how to drain the oil in the gearbox, axis 6.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 180 .
Note
Action
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page 38 .
1
Shown in the figure Location of
gearbox on page 180 !
Move the wrist so that the oil plug, d raining of axis
6 gearbox faces downwards.
If the oil plug, draining is located on the turning
disc, rotate the disc so that the plug faces down-
wards.
2
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working
area.
3
Vessel capacity: 1000 ml.
Drain the oil from gearbox 6 by removing the oil
plug. Collect the oil with a suitable vessel.
CAUTION
Drain as much oil as possible.
4
The amount of oil to be refilled de-
pends on the amount previously
being drained. The correct oil level
is detailed in section Inspecting
the oil level in axis-6 gearbox on
page 139 .
Measure the amount of oil drained.
Continues on next page
Product manual - IRB 7600
181
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.7 Changing oil, axis-6 gearbox
Continued
Filling oil, gearbox axis 6
The procedure below details how to fill oil in the gearbox axis 6.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 180 .
Note
Action
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page 38 .
1
Run the robot to a position where the oil plug,
filling (B1 or B2) of axis 6 gearbox, is facing up-
wards.
2
If the oil plug for draining is located on the turning
disk, rotate the disk so that the oil plug faces up-
wards.
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working
area.
3
Shown in the figure Location of
gearbox on page 180 .
Remove the oil plug, filling .
4
Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
page 161 .
Refill the wrist with lubricating oil .
Make sure the air is ventilated through the oil plug
during filling, to avoid overpressure in the gearbox.
If the plug hole for draining is located on the turn-
ing disk, the air is ventilated through the open plug
hole.
5
WARNING
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in Technical
reference manual - Lubrication in gearboxes .
6
Tightening torque: 20 Nm.
Refit both oil plugs.
7
182
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3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.7 Changing oil, axis-6 gearbox
Continued
3.4.8 Replacing the SMB battery
Note
The battery low alert (38213 Battery charge low ) is displayed when the battery
needs to be replaced. The recommendation to avoid an unsynchronized robot
is to keep the power to the controller turned on until the battery is to be replaced.
For a SMB board with 3-pole battery contact (RMU101 3HAC044168-001 or
RMU102 3HAC043904-001), the lifetime of a new battery is typically 36 months.
For a SMB board with 2-pole battery contact (DSQC), the typical lifetime of a new
battery is 36 months if the robot is powered off 2 days/week or 18 months if the
robot is powered off 16 h/day. The lifetime can be extended for longer production
breaks with a battery shutdown service routine. See the operating manual for
the robot controller for instructions.
WARNING
See Hazards related to batteries on page 40 .
Continues on next page
Product manual - IRB 7600
183
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3 Maintenance
3.4.8 Replacing the SMB battery
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| 183
|
Filling oil, gearbox axis 6
The procedure below details how to fill oil in the gearbox axis 6.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 180 .
Note
Action
WARNING
Handling gearbox oil involves several safety risks,
see Gearbox lubricants (oil or grease) on page 38 .
1
Run the robot to a position where the oil plug,
filling (B1 or B2) of axis 6 gearbox, is facing up-
wards.
2
If the oil plug for draining is located on the turning
disk, rotate the disk so that the oil plug faces up-
wards.
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working
area.
3
Shown in the figure Location of
gearbox on page 180 .
Remove the oil plug, filling .
4
Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
page 161 .
Refill the wrist with lubricating oil .
Make sure the air is ventilated through the oil plug
during filling, to avoid overpressure in the gearbox.
If the plug hole for draining is located on the turn-
ing disk, the air is ventilated through the open plug
hole.
5
WARNING
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in Technical
reference manual - Lubrication in gearboxes .
6
Tightening torque: 20 Nm.
Refit both oil plugs.
7
182
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© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.7 Changing oil, axis-6 gearbox
Continued
3.4.8 Replacing the SMB battery
Note
The battery low alert (38213 Battery charge low ) is displayed when the battery
needs to be replaced. The recommendation to avoid an unsynchronized robot
is to keep the power to the controller turned on until the battery is to be replaced.
For a SMB board with 3-pole battery contact (RMU101 3HAC044168-001 or
RMU102 3HAC043904-001), the lifetime of a new battery is typically 36 months.
For a SMB board with 2-pole battery contact (DSQC), the typical lifetime of a new
battery is 36 months if the robot is powered off 2 days/week or 18 months if the
robot is powered off 16 h/day. The lifetime can be extended for longer production
breaks with a battery shutdown service routine. See the operating manual for
the robot controller for instructions.
WARNING
See Hazards related to batteries on page 40 .
Continues on next page
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183
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.8 Replacing the SMB battery
Location of SMB battery
The SMB battery (SMB = serial measurement board) is located on the left hand
side of the frame as shown in the figure.
Battery pack with a 2-pole battery contact (DSQC)
xx0200000238
SMB battery cover
A
SMB battery pack with 2-pole battery contact.
B
Battery cable
C
Continues on next page
184
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3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.8 Replacing the SMB battery
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 184
|
3.4.8 Replacing the SMB battery
Note
The battery low alert (38213 Battery charge low ) is displayed when the battery
needs to be replaced. The recommendation to avoid an unsynchronized robot
is to keep the power to the controller turned on until the battery is to be replaced.
For a SMB board with 3-pole battery contact (RMU101 3HAC044168-001 or
RMU102 3HAC043904-001), the lifetime of a new battery is typically 36 months.
For a SMB board with 2-pole battery contact (DSQC), the typical lifetime of a new
battery is 36 months if the robot is powered off 2 days/week or 18 months if the
robot is powered off 16 h/day. The lifetime can be extended for longer production
breaks with a battery shutdown service routine. See the operating manual for
the robot controller for instructions.
WARNING
See Hazards related to batteries on page 40 .
Continues on next page
Product manual - IRB 7600
183
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.8 Replacing the SMB battery
Location of SMB battery
The SMB battery (SMB = serial measurement board) is located on the left hand
side of the frame as shown in the figure.
Battery pack with a 2-pole battery contact (DSQC)
xx0200000238
SMB battery cover
A
SMB battery pack with 2-pole battery contact.
B
Battery cable
C
Continues on next page
184
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.8 Replacing the SMB battery
Continued
Battery pack with a 3-pole battery contact (RMU)
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
A
B
xx1300000308
A Battery pack RMU
B Battery holder
Required equipment
Note
There are two variants of SMB units and batteries. One with 2-pole battery contact
(DSQC) and one with 3-pole battery contact (RMU). The variant with the 3-pole
battery contact has longer lifetime for the battery.
It is important that the SMB unit uses the correct battery. Make sure to order the
correct spare parts. Do not exchange battery contacts!
Note
Spare part no.
Equipment, etc.
Battery includes protection circuits. Only re-
place with a specified spare part or an ABB-
approved equivalent.
For spare part no.
see:
•
Spare part
lists on
page 425
Battery unit
Content is defined in section Standard tools
on page 419 .
-
Standard toolkit
See chapter Circuit diagram on page 427 .
-
Circuit diagram
Removing, battery
Use this procedure to remove the SMB battery.
Note
Action
This is done in order to facilitate
updating of the revolution counter.
Move the robot to its calibration position.
1
Continues on next page
Product manual - IRB 7600
185
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.8 Replacing the SMB battery
Continued
|
ABB_IRB7600_Product_Manual.pdf
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| 185
|
Location of SMB battery
The SMB battery (SMB = serial measurement board) is located on the left hand
side of the frame as shown in the figure.
Battery pack with a 2-pole battery contact (DSQC)
xx0200000238
SMB battery cover
A
SMB battery pack with 2-pole battery contact.
B
Battery cable
C
Continues on next page
184
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.8 Replacing the SMB battery
Continued
Battery pack with a 3-pole battery contact (RMU)
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
A
B
xx1300000308
A Battery pack RMU
B Battery holder
Required equipment
Note
There are two variants of SMB units and batteries. One with 2-pole battery contact
(DSQC) and one with 3-pole battery contact (RMU). The variant with the 3-pole
battery contact has longer lifetime for the battery.
It is important that the SMB unit uses the correct battery. Make sure to order the
correct spare parts. Do not exchange battery contacts!
Note
Spare part no.
Equipment, etc.
Battery includes protection circuits. Only re-
place with a specified spare part or an ABB-
approved equivalent.
For spare part no.
see:
•
Spare part
lists on
page 425
Battery unit
Content is defined in section Standard tools
on page 419 .
-
Standard toolkit
See chapter Circuit diagram on page 427 .
-
Circuit diagram
Removing, battery
Use this procedure to remove the SMB battery.
Note
Action
This is done in order to facilitate
updating of the revolution counter.
Move the robot to its calibration position.
1
Continues on next page
Product manual - IRB 7600
185
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.8 Replacing the SMB battery
Continued
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the safeguarded
space.
2
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the
unit please read the safety information in the sec-
tion The unit is sensitive to ESD on page 61
3
Shown in figure Location of SMB
battery on page 184 .
Remove the SMB battery cover by unscrewing the
attachment screws.
CAUTION
Clean cover from metal residues before opening.
Metal residues can cause shortage on the boards
which can result in hazardous failures.
4
Shown in figure Location of SMB
battery on page 184 .
Pull out the battery and disconnect the battery
cable .
5
Shown in figure Location of SMB
battery on page 184 .
Remove the SMB battery.
Battery includes protection circuits. Only replace
with a specified spare part or with an ABB- ap-
proved equivalent.
6
Refitting, battery
Use this procedure to refit the SMB battery.
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the safeguarded
space.
1
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the
unit please read the safety information in the sec-
tion The unit is sensitive to ESD on page 61
2
Continues on next page
186
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.8 Replacing the SMB battery
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 186
|
Battery pack with a 3-pole battery contact (RMU)
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
A
B
xx1300000308
A Battery pack RMU
B Battery holder
Required equipment
Note
There are two variants of SMB units and batteries. One with 2-pole battery contact
(DSQC) and one with 3-pole battery contact (RMU). The variant with the 3-pole
battery contact has longer lifetime for the battery.
It is important that the SMB unit uses the correct battery. Make sure to order the
correct spare parts. Do not exchange battery contacts!
Note
Spare part no.
Equipment, etc.
Battery includes protection circuits. Only re-
place with a specified spare part or an ABB-
approved equivalent.
For spare part no.
see:
•
Spare part
lists on
page 425
Battery unit
Content is defined in section Standard tools
on page 419 .
-
Standard toolkit
See chapter Circuit diagram on page 427 .
-
Circuit diagram
Removing, battery
Use this procedure to remove the SMB battery.
Note
Action
This is done in order to facilitate
updating of the revolution counter.
Move the robot to its calibration position.
1
Continues on next page
Product manual - IRB 7600
185
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.8 Replacing the SMB battery
Continued
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the safeguarded
space.
2
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the
unit please read the safety information in the sec-
tion The unit is sensitive to ESD on page 61
3
Shown in figure Location of SMB
battery on page 184 .
Remove the SMB battery cover by unscrewing the
attachment screws.
CAUTION
Clean cover from metal residues before opening.
Metal residues can cause shortage on the boards
which can result in hazardous failures.
4
Shown in figure Location of SMB
battery on page 184 .
Pull out the battery and disconnect the battery
cable .
5
Shown in figure Location of SMB
battery on page 184 .
Remove the SMB battery.
Battery includes protection circuits. Only replace
with a specified spare part or with an ABB- ap-
proved equivalent.
6
Refitting, battery
Use this procedure to refit the SMB battery.
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the safeguarded
space.
1
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the
unit please read the safety information in the sec-
tion The unit is sensitive to ESD on page 61
2
Continues on next page
186
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3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.8 Replacing the SMB battery
Continued
Note
Action
Art. no. is specified in Required
equipment on page 185 .
Reconnect the battery cable and install the battery
pack into the SMB/battery recess.
Note
RMU batteries are installed together with a battery
holder to be properly secured inside the recess.
See figure.
3
Shown in figure Location of SMB
battery on page 184 .
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
A
B
xx1300000308
A
Battery pack RMU
B
Battery holder
Shown in figure Location of SMB
battery on page 184 .
Secure the SMB battery cover with its attachment
screws.
4
Detailed in chapter Calibration -
section Updating revolution coun-
ters on IRC5 robots on page 378 .
Update the revolution counters.
5
DANGER
Make sure all safety requirements are met when
performing the first test run.
6
Product manual - IRB 7600
187
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.8 Replacing the SMB battery
Continued
|
ABB_IRB7600_Product_Manual.pdf
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| 187
|
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the safeguarded
space.
2
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the
unit please read the safety information in the sec-
tion The unit is sensitive to ESD on page 61
3
Shown in figure Location of SMB
battery on page 184 .
Remove the SMB battery cover by unscrewing the
attachment screws.
CAUTION
Clean cover from metal residues before opening.
Metal residues can cause shortage on the boards
which can result in hazardous failures.
4
Shown in figure Location of SMB
battery on page 184 .
Pull out the battery and disconnect the battery
cable .
5
Shown in figure Location of SMB
battery on page 184 .
Remove the SMB battery.
Battery includes protection circuits. Only replace
with a specified spare part or with an ABB- ap-
proved equivalent.
6
Refitting, battery
Use this procedure to refit the SMB battery.
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the safeguarded
space.
1
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the
unit please read the safety information in the sec-
tion The unit is sensitive to ESD on page 61
2
Continues on next page
186
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3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.8 Replacing the SMB battery
Continued
Note
Action
Art. no. is specified in Required
equipment on page 185 .
Reconnect the battery cable and install the battery
pack into the SMB/battery recess.
Note
RMU batteries are installed together with a battery
holder to be properly secured inside the recess.
See figure.
3
Shown in figure Location of SMB
battery on page 184 .
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
A
B
xx1300000308
A
Battery pack RMU
B
Battery holder
Shown in figure Location of SMB
battery on page 184 .
Secure the SMB battery cover with its attachment
screws.
4
Detailed in chapter Calibration -
section Updating revolution coun-
ters on IRC5 robots on page 378 .
Update the revolution counters.
5
DANGER
Make sure all safety requirements are met when
performing the first test run.
6
Product manual - IRB 7600
187
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.8 Replacing the SMB battery
Continued
3.5 Lubrication activities
3.5.1 Lubrication of spherical roller bearing, balancing device
Location of bearing
The spherical roller bearing is located at the front ear of the balancing device, as
shown in the figure below.
Note! The balancing device must be mounted on the robot when lubricating the
bearing!
xx0200000109
Ear (spherical roller bearing located inside)
A
Lubrication nipple or securing screw
B
Sealing spacer
C
Hole through which the shaft is pressed
D
Required equipment
Note
Art. no.
Equipment, etc.
Tribol GR 100-0-PD, 150 ml
3HAC042534-001
Grease
Continues on next page
188
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.5.1 Lubrication of spherical roller bearing, balancing device
|
ABB_IRB7600_Product_Manual.pdf
|
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| 188
|
Note
Action
Art. no. is specified in Required
equipment on page 185 .
Reconnect the battery cable and install the battery
pack into the SMB/battery recess.
Note
RMU batteries are installed together with a battery
holder to be properly secured inside the recess.
See figure.
3
Shown in figure Location of SMB
battery on page 184 .
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
A
B
xx1300000308
A
Battery pack RMU
B
Battery holder
Shown in figure Location of SMB
battery on page 184 .
Secure the SMB battery cover with its attachment
screws.
4
Detailed in chapter Calibration -
section Updating revolution coun-
ters on IRC5 robots on page 378 .
Update the revolution counters.
5
DANGER
Make sure all safety requirements are met when
performing the first test run.
6
Product manual - IRB 7600
187
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.4.8 Replacing the SMB battery
Continued
3.5 Lubrication activities
3.5.1 Lubrication of spherical roller bearing, balancing device
Location of bearing
The spherical roller bearing is located at the front ear of the balancing device, as
shown in the figure below.
Note! The balancing device must be mounted on the robot when lubricating the
bearing!
xx0200000109
Ear (spherical roller bearing located inside)
A
Lubrication nipple or securing screw
B
Sealing spacer
C
Hole through which the shaft is pressed
D
Required equipment
Note
Art. no.
Equipment, etc.
Tribol GR 100-0-PD, 150 ml
3HAC042534-001
Grease
Continues on next page
188
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.5.1 Lubrication of spherical roller bearing, balancing device
Note
Art. no.
Equipment, etc.
M6.
Lubrication nipple
-
Grease pump
Lubrication, balancing device bearing (Design 1)
The procedure below details how to lubricate the spherical roller bearing.
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the safeguarded
space.
1
Art. no. and amount is specified in Re-
quired equipment on page 188 !
Lubricate the spherical roller bearing through
the lubrication nipple in the ear with grease.
Fill until excessive grease is forced out
between the shaft and the sealing spacer.
2
Shown in the figure Location of bearing
on page 188 !
The balancing device must be mounted
on the robot when lubricating the
bearing!
Read more about the inspection in
section Inspection, balancing device -
Check for leakage on page 145 .
Clean the area from any excessive grease
and check the area once again after operation
of the robot, in order to make sure there is
no incorrect leakage from the o-rings.
3
Lubrication, balancing device bearing (Design 2)
The procedure below details how to lubricate the spherical roller bearing.
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the safeguarded
space.
1
Art. no. and amount is specified in Re-
quired equipment on page 188 !
Lubricate the spherical roller bearing through
the lubrication nipple in the ear with grease.
Fill until excessive grease is forced out
through the hole of the lower securing screw.
2
Shown in the figure Location of bearing
on page 188 !
The balancing device must be mounted
on the robot when lubricating the
bearing!
M6 x 10, washer: D=6,4/12 T=1,6
Refit the lower securing screw and washer.
Tightening torque: 6 Nm.
Continues on next page
Product manual - IRB 7600
189
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.5.1 Lubrication of spherical roller bearing, balancing device
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 189
|
3.5 Lubrication activities
3.5.1 Lubrication of spherical roller bearing, balancing device
Location of bearing
The spherical roller bearing is located at the front ear of the balancing device, as
shown in the figure below.
Note! The balancing device must be mounted on the robot when lubricating the
bearing!
xx0200000109
Ear (spherical roller bearing located inside)
A
Lubrication nipple or securing screw
B
Sealing spacer
C
Hole through which the shaft is pressed
D
Required equipment
Note
Art. no.
Equipment, etc.
Tribol GR 100-0-PD, 150 ml
3HAC042534-001
Grease
Continues on next page
188
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.5.1 Lubrication of spherical roller bearing, balancing device
Note
Art. no.
Equipment, etc.
M6.
Lubrication nipple
-
Grease pump
Lubrication, balancing device bearing (Design 1)
The procedure below details how to lubricate the spherical roller bearing.
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the safeguarded
space.
1
Art. no. and amount is specified in Re-
quired equipment on page 188 !
Lubricate the spherical roller bearing through
the lubrication nipple in the ear with grease.
Fill until excessive grease is forced out
between the shaft and the sealing spacer.
2
Shown in the figure Location of bearing
on page 188 !
The balancing device must be mounted
on the robot when lubricating the
bearing!
Read more about the inspection in
section Inspection, balancing device -
Check for leakage on page 145 .
Clean the area from any excessive grease
and check the area once again after operation
of the robot, in order to make sure there is
no incorrect leakage from the o-rings.
3
Lubrication, balancing device bearing (Design 2)
The procedure below details how to lubricate the spherical roller bearing.
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the safeguarded
space.
1
Art. no. and amount is specified in Re-
quired equipment on page 188 !
Lubricate the spherical roller bearing through
the lubrication nipple in the ear with grease.
Fill until excessive grease is forced out
through the hole of the lower securing screw.
2
Shown in the figure Location of bearing
on page 188 !
The balancing device must be mounted
on the robot when lubricating the
bearing!
M6 x 10, washer: D=6,4/12 T=1,6
Refit the lower securing screw and washer.
Tightening torque: 6 Nm.
Continues on next page
Product manual - IRB 7600
189
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.5.1 Lubrication of spherical roller bearing, balancing device
Continued
Note
Action
Read more about the inspection in
section Inspection, balancing device -
Check for leakage on page 145 .
Clean the area from any excessive grease
and check the area once again after operation
of the robot, in order to make sure there is
no incorrect leakage from the o-rings.
3
190
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.5.1 Lubrication of spherical roller bearing, balancing device
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 190
|
Note
Art. no.
Equipment, etc.
M6.
Lubrication nipple
-
Grease pump
Lubrication, balancing device bearing (Design 1)
The procedure below details how to lubricate the spherical roller bearing.
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the safeguarded
space.
1
Art. no. and amount is specified in Re-
quired equipment on page 188 !
Lubricate the spherical roller bearing through
the lubrication nipple in the ear with grease.
Fill until excessive grease is forced out
between the shaft and the sealing spacer.
2
Shown in the figure Location of bearing
on page 188 !
The balancing device must be mounted
on the robot when lubricating the
bearing!
Read more about the inspection in
section Inspection, balancing device -
Check for leakage on page 145 .
Clean the area from any excessive grease
and check the area once again after operation
of the robot, in order to make sure there is
no incorrect leakage from the o-rings.
3
Lubrication, balancing device bearing (Design 2)
The procedure below details how to lubricate the spherical roller bearing.
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the safeguarded
space.
1
Art. no. and amount is specified in Re-
quired equipment on page 188 !
Lubricate the spherical roller bearing through
the lubrication nipple in the ear with grease.
Fill until excessive grease is forced out
through the hole of the lower securing screw.
2
Shown in the figure Location of bearing
on page 188 !
The balancing device must be mounted
on the robot when lubricating the
bearing!
M6 x 10, washer: D=6,4/12 T=1,6
Refit the lower securing screw and washer.
Tightening torque: 6 Nm.
Continues on next page
Product manual - IRB 7600
189
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3 Maintenance
3.5.1 Lubrication of spherical roller bearing, balancing device
Continued
Note
Action
Read more about the inspection in
section Inspection, balancing device -
Check for leakage on page 145 .
Clean the area from any excessive grease
and check the area once again after operation
of the robot, in order to make sure there is
no incorrect leakage from the o-rings.
3
190
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.5.1 Lubrication of spherical roller bearing, balancing device
Continued
3.6 Cleaning activities
3.6.1 Flushing a contaminated gearbox
Different types of oil
As the Shell Tivela S 150 is not compatible with mineral oil, contamination with
other types of oils used in the gearboxes is not accepted. Equipment used in
handling of Tivela S 150 must be carefully cleaned.
This section details how to flush the primary gears of axis 4 and 5, and the gearbox
of axis 6 in case of contamination with other type of oil.
Required equipment
Note
Art. no.
Equipment
Kyodo Yushi TMO 150
3HAC032140-001
Lubricating oil
Amount: 700 ml for each gearbox and flush.
Three flushes required.
-
Oil collecting vessel
D inside =4 mm, L= 400 mm.
-
Syringe + plastic hose
Content is defined in section Standard tools
on page 419 .
3HAC15571-1
Standard toolkit
Service program
Create a program with motions on axis 3, 4, 5 and 6. There is no need to remove
the tool and equipment installed on the robot if the Service program can be created
and is possible to run.
Recommended motion
•
axis 3: ± 15 degrees
•
axis 4-6: maximum working range with regard to the installation (limitation:
axis 4 and 5: ± 90 degrees, axis 6: ± 180 degrees).
Draining the gearbox properly
The contaminated gearbox must be drained properly before and during the flushing
procedure:
•
Axis 4 gearbox: open both oil plugs (filling and draining) and run axis 3 in
different directions. Draw out the last volume (approx. 40 –60 ml) by using
a syringe with a prepared hose end.
•
Axis 5 gearbox: open both oil plugs (filling and draining) and run axis 4 back
and forward until the oil draining has stopped.
•
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
191
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3 Maintenance
3.6.1 Flushing a contaminated gearbox
|
ABB_IRB7600_Product_Manual.pdf
|
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| 191
|
Note
Action
Read more about the inspection in
section Inspection, balancing device -
Check for leakage on page 145 .
Clean the area from any excessive grease
and check the area once again after operation
of the robot, in order to make sure there is
no incorrect leakage from the o-rings.
3
190
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.5.1 Lubrication of spherical roller bearing, balancing device
Continued
3.6 Cleaning activities
3.6.1 Flushing a contaminated gearbox
Different types of oil
As the Shell Tivela S 150 is not compatible with mineral oil, contamination with
other types of oils used in the gearboxes is not accepted. Equipment used in
handling of Tivela S 150 must be carefully cleaned.
This section details how to flush the primary gears of axis 4 and 5, and the gearbox
of axis 6 in case of contamination with other type of oil.
Required equipment
Note
Art. no.
Equipment
Kyodo Yushi TMO 150
3HAC032140-001
Lubricating oil
Amount: 700 ml for each gearbox and flush.
Three flushes required.
-
Oil collecting vessel
D inside =4 mm, L= 400 mm.
-
Syringe + plastic hose
Content is defined in section Standard tools
on page 419 .
3HAC15571-1
Standard toolkit
Service program
Create a program with motions on axis 3, 4, 5 and 6. There is no need to remove
the tool and equipment installed on the robot if the Service program can be created
and is possible to run.
Recommended motion
•
axis 3: ± 15 degrees
•
axis 4-6: maximum working range with regard to the installation (limitation:
axis 4 and 5: ± 90 degrees, axis 6: ± 180 degrees).
Draining the gearbox properly
The contaminated gearbox must be drained properly before and during the flushing
procedure:
•
Axis 4 gearbox: open both oil plugs (filling and draining) and run axis 3 in
different directions. Draw out the last volume (approx. 40 –60 ml) by using
a syringe with a prepared hose end.
•
Axis 5 gearbox: open both oil plugs (filling and draining) and run axis 4 back
and forward until the oil draining has stopped.
•
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
191
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.6.1 Flushing a contaminated gearbox
Flushing
The procedure below details how to flush a contaminated gearbox. The procedure
is the same for all gearboxes.
Note
Action
Recommended service program
described in section Service
program on page 191 .
Run the Service program until the castings of the
gearboxes axis 4, 5 and 6 have reached a temperat-
ure of about 30-35º C. Use the finger tips to measure
the temperature.
1
Described in section above:
Draining the gearbox properly
on page 191 .
Drain the gearbox properly.
2
Kyodo Yushi TMO 150
Fill the gearbox with 700 ml of lubricating oil .
3
Art. no . is specified in Required
equipment on page 191 .
Tightening torque: 24 Nm.
Refit the oil plug.
4
Run the Service program at low speed (25%) during
10 minutes.
5
Drain the gearbox properly.
6
Repeat the steps above until the gearbox is flushed
three times.
7
192
Product manual - IRB 7600
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© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.6.1 Flushing a contaminated gearbox
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 192
|
3.6 Cleaning activities
3.6.1 Flushing a contaminated gearbox
Different types of oil
As the Shell Tivela S 150 is not compatible with mineral oil, contamination with
other types of oils used in the gearboxes is not accepted. Equipment used in
handling of Tivela S 150 must be carefully cleaned.
This section details how to flush the primary gears of axis 4 and 5, and the gearbox
of axis 6 in case of contamination with other type of oil.
Required equipment
Note
Art. no.
Equipment
Kyodo Yushi TMO 150
3HAC032140-001
Lubricating oil
Amount: 700 ml for each gearbox and flush.
Three flushes required.
-
Oil collecting vessel
D inside =4 mm, L= 400 mm.
-
Syringe + plastic hose
Content is defined in section Standard tools
on page 419 .
3HAC15571-1
Standard toolkit
Service program
Create a program with motions on axis 3, 4, 5 and 6. There is no need to remove
the tool and equipment installed on the robot if the Service program can be created
and is possible to run.
Recommended motion
•
axis 3: ± 15 degrees
•
axis 4-6: maximum working range with regard to the installation (limitation:
axis 4 and 5: ± 90 degrees, axis 6: ± 180 degrees).
Draining the gearbox properly
The contaminated gearbox must be drained properly before and during the flushing
procedure:
•
Axis 4 gearbox: open both oil plugs (filling and draining) and run axis 3 in
different directions. Draw out the last volume (approx. 40 –60 ml) by using
a syringe with a prepared hose end.
•
Axis 5 gearbox: open both oil plugs (filling and draining) and run axis 4 back
and forward until the oil draining has stopped.
•
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
191
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.6.1 Flushing a contaminated gearbox
Flushing
The procedure below details how to flush a contaminated gearbox. The procedure
is the same for all gearboxes.
Note
Action
Recommended service program
described in section Service
program on page 191 .
Run the Service program until the castings of the
gearboxes axis 4, 5 and 6 have reached a temperat-
ure of about 30-35º C. Use the finger tips to measure
the temperature.
1
Described in section above:
Draining the gearbox properly
on page 191 .
Drain the gearbox properly.
2
Kyodo Yushi TMO 150
Fill the gearbox with 700 ml of lubricating oil .
3
Art. no . is specified in Required
equipment on page 191 .
Tightening torque: 24 Nm.
Refit the oil plug.
4
Run the Service program at low speed (25%) during
10 minutes.
5
Drain the gearbox properly.
6
Repeat the steps above until the gearbox is flushed
three times.
7
192
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.6.1 Flushing a contaminated gearbox
Continued
3.6.2 Cleaning the IRB 7600
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the safeguarded space.
General
To secure high uptime it is important that the IRB 7600 is cleaned regularly. The
frequency of cleaning depends on the environment in which the product works.
Different cleaning methods are allowed depending on the type of protection of the
IRB 7600.
Note
Always verify the protection type of the robot before cleaning.
Oil spills
Oil spills from gearboxes
Use the following procedure if any oil spills are detected that can be suspected to
originate from a gearbox.
1
Inspect that the oil level in the suspected gearbox is according to the
recommendations, see Inspection activities on page 122 .
2
Write down the oil level.
3
Inspect the oil level again after, for example, 6 months.
4
If the oil level is decreased then replace the gearbox.
Special cleaning considerations
This section specifies some special considerations when cleaning the robot.
•
Always use cleaning equipment as specified. Any other cleaning equipment
may shorten the life of the robot.
•
Always check that all protective covers are fitted to the robot before cleaning.
•
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.
•
Do not remove any covers or other protective devices before cleaning the
robot.
Continues on next page
Product manual - IRB 7600
193
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.6.2 Cleaning the IRB 7600
|
ABB_IRB7600_Product_Manual.pdf
|
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| 193
|
Flushing
The procedure below details how to flush a contaminated gearbox. The procedure
is the same for all gearboxes.
Note
Action
Recommended service program
described in section Service
program on page 191 .
Run the Service program until the castings of the
gearboxes axis 4, 5 and 6 have reached a temperat-
ure of about 30-35º C. Use the finger tips to measure
the temperature.
1
Described in section above:
Draining the gearbox properly
on page 191 .
Drain the gearbox properly.
2
Kyodo Yushi TMO 150
Fill the gearbox with 700 ml of lubricating oil .
3
Art. no . is specified in Required
equipment on page 191 .
Tightening torque: 24 Nm.
Refit the oil plug.
4
Run the Service program at low speed (25%) during
10 minutes.
5
Drain the gearbox properly.
6
Repeat the steps above until the gearbox is flushed
three times.
7
192
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.6.1 Flushing a contaminated gearbox
Continued
3.6.2 Cleaning the IRB 7600
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the safeguarded space.
General
To secure high uptime it is important that the IRB 7600 is cleaned regularly. The
frequency of cleaning depends on the environment in which the product works.
Different cleaning methods are allowed depending on the type of protection of the
IRB 7600.
Note
Always verify the protection type of the robot before cleaning.
Oil spills
Oil spills from gearboxes
Use the following procedure if any oil spills are detected that can be suspected to
originate from a gearbox.
1
Inspect that the oil level in the suspected gearbox is according to the
recommendations, see Inspection activities on page 122 .
2
Write down the oil level.
3
Inspect the oil level again after, for example, 6 months.
4
If the oil level is decreased then replace the gearbox.
Special cleaning considerations
This section specifies some special considerations when cleaning the robot.
•
Always use cleaning equipment as specified. Any other cleaning equipment
may shorten the life of the robot.
•
Always check that all protective covers are fitted to the robot before cleaning.
•
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.
•
Do not remove any covers or other protective devices before cleaning the
robot.
Continues on next page
Product manual - IRB 7600
193
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.6.2 Cleaning the IRB 7600
Cleaning methods
The following table defines what cleaning methods are allowed depending on the
protection type.
Cleaning method
Protection
type
High pressure water or
steam
Rinse with water
Wipe with cloth
Vacuum
cleaner
No
Yes. It is highly re-
commended that
the water contains
a rust-prevention
solution and that
the manipulator is
dried afterwards.
Yes. With light
cleaning deter-
gent.
Yes
Standard
Yes i .
Yes. It is highly re-
commended that
the water contains
a rust-prevention
solution.
Yes. With light
cleaning deter-
gent or spirit.
Yes
Foundry Plus
It is highly recommended
that the water and steam
contains rust preventive,
without cleaning deter-
gents.
i
Perform according to section Cleaning with water and steam on page 194 .
Cleaning with water and steam
Instructions for rinsing with water
ABB robots with protection types Standard , Foundry Plus , Wash , or Foundry Prime
can be cleaned by rinsing with water (water cleaner). 1
The following list defines the prerequisites:
•
Maximum water pressure at the nozzle: 700 kN/m 2 (7 bar) I
•
Fan jet nozzle should be used, min. 45° spread
•
Minimum distance from nozzle to encapsulation: 0.4 meters
•
Maximum flow: 20 liters/min I
I
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. 2
The following list defines the prerequisites:
•
Maximum water pressure at the nozzle: 2500 kN/m 2 (25 bar)
•
Fan jet nozzle should be used, min. 45° spread
•
Minimum distance from nozzle to encapsulation: 0.4 meters
•
Maximum water temperature: 80° C
Cables
Movable cables need to be able to move freely:
•
Remove waste material, such as sand, dust and chips, if it prevents cable
movement.
1
See Cleaning methods on page 194 for exceptions.
2
See Cleaning methods on page 194 for exceptions.
Continues on next page
194
Product manual - IRB 7600
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© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.6.2 Cleaning the IRB 7600
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 194
|
3.6.2 Cleaning the IRB 7600
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the safeguarded space.
General
To secure high uptime it is important that the IRB 7600 is cleaned regularly. The
frequency of cleaning depends on the environment in which the product works.
Different cleaning methods are allowed depending on the type of protection of the
IRB 7600.
Note
Always verify the protection type of the robot before cleaning.
Oil spills
Oil spills from gearboxes
Use the following procedure if any oil spills are detected that can be suspected to
originate from a gearbox.
1
Inspect that the oil level in the suspected gearbox is according to the
recommendations, see Inspection activities on page 122 .
2
Write down the oil level.
3
Inspect the oil level again after, for example, 6 months.
4
If the oil level is decreased then replace the gearbox.
Special cleaning considerations
This section specifies some special considerations when cleaning the robot.
•
Always use cleaning equipment as specified. Any other cleaning equipment
may shorten the life of the robot.
•
Always check that all protective covers are fitted to the robot before cleaning.
•
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.
•
Do not remove any covers or other protective devices before cleaning the
robot.
Continues on next page
Product manual - IRB 7600
193
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.6.2 Cleaning the IRB 7600
Cleaning methods
The following table defines what cleaning methods are allowed depending on the
protection type.
Cleaning method
Protection
type
High pressure water or
steam
Rinse with water
Wipe with cloth
Vacuum
cleaner
No
Yes. It is highly re-
commended that
the water contains
a rust-prevention
solution and that
the manipulator is
dried afterwards.
Yes. With light
cleaning deter-
gent.
Yes
Standard
Yes i .
Yes. It is highly re-
commended that
the water contains
a rust-prevention
solution.
Yes. With light
cleaning deter-
gent or spirit.
Yes
Foundry Plus
It is highly recommended
that the water and steam
contains rust preventive,
without cleaning deter-
gents.
i
Perform according to section Cleaning with water and steam on page 194 .
Cleaning with water and steam
Instructions for rinsing with water
ABB robots with protection types Standard , Foundry Plus , Wash , or Foundry Prime
can be cleaned by rinsing with water (water cleaner). 1
The following list defines the prerequisites:
•
Maximum water pressure at the nozzle: 700 kN/m 2 (7 bar) I
•
Fan jet nozzle should be used, min. 45° spread
•
Minimum distance from nozzle to encapsulation: 0.4 meters
•
Maximum flow: 20 liters/min I
I
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. 2
The following list defines the prerequisites:
•
Maximum water pressure at the nozzle: 2500 kN/m 2 (25 bar)
•
Fan jet nozzle should be used, min. 45° spread
•
Minimum distance from nozzle to encapsulation: 0.4 meters
•
Maximum water temperature: 80° C
Cables
Movable cables need to be able to move freely:
•
Remove waste material, such as sand, dust and chips, if it prevents cable
movement.
1
See Cleaning methods on page 194 for exceptions.
2
See Cleaning methods on page 194 for exceptions.
Continues on next page
194
Product manual - IRB 7600
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© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.6.2 Cleaning the IRB 7600
Continued
•
Clean the cables if they have a crusty surface, for example from dry release
agents.
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
195
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© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.6.2 Cleaning the IRB 7600
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
https://search.abb.com/library/Download.aspx?DocumentID=3HAC022033-001&LanguageCode=en&DocumentPartId=&Action=Launch&DocumentRevisionId=AF
| 195
|
Cleaning methods
The following table defines what cleaning methods are allowed depending on the
protection type.
Cleaning method
Protection
type
High pressure water or
steam
Rinse with water
Wipe with cloth
Vacuum
cleaner
No
Yes. It is highly re-
commended that
the water contains
a rust-prevention
solution and that
the manipulator is
dried afterwards.
Yes. With light
cleaning deter-
gent.
Yes
Standard
Yes i .
Yes. It is highly re-
commended that
the water contains
a rust-prevention
solution.
Yes. With light
cleaning deter-
gent or spirit.
Yes
Foundry Plus
It is highly recommended
that the water and steam
contains rust preventive,
without cleaning deter-
gents.
i
Perform according to section Cleaning with water and steam on page 194 .
Cleaning with water and steam
Instructions for rinsing with water
ABB robots with protection types Standard , Foundry Plus , Wash , or Foundry Prime
can be cleaned by rinsing with water (water cleaner). 1
The following list defines the prerequisites:
•
Maximum water pressure at the nozzle: 700 kN/m 2 (7 bar) I
•
Fan jet nozzle should be used, min. 45° spread
•
Minimum distance from nozzle to encapsulation: 0.4 meters
•
Maximum flow: 20 liters/min I
I
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. 2
The following list defines the prerequisites:
•
Maximum water pressure at the nozzle: 2500 kN/m 2 (25 bar)
•
Fan jet nozzle should be used, min. 45° spread
•
Minimum distance from nozzle to encapsulation: 0.4 meters
•
Maximum water temperature: 80° C
Cables
Movable cables need to be able to move freely:
•
Remove waste material, such as sand, dust and chips, if it prevents cable
movement.
1
See Cleaning methods on page 194 for exceptions.
2
See Cleaning methods on page 194 for exceptions.
Continues on next page
194
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.6.2 Cleaning the IRB 7600
Continued
•
Clean the cables if they have a crusty surface, for example from dry release
agents.
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
195
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.6.2 Cleaning the IRB 7600
Continued
3.7 Service Information System, M2000
3.7.1 Using the SIS system
General
This is a brief description of how to use the Service Information System, SIS for
M2000 robot systems. Details may be found in:
•
Service Information System, SIS
•
Defining the SIS input parameters
•
Setting the SIS parameters
•
Importing/exporting SIS data
•
Reading the SIS output logs
The section is only valid for M2000 systems. For information regarding M2004
robot systems, see additional documentation, Operating manual - Service
Information System . Article number is specified in section References on page 10 .
Basic procedure
Reference
Action
These are described in Description of
Service Information System (SIS) on
page 197 .
Determine which of the system functions
you require.
1
Recommendations on how to define these
are given in SIS system parameters on
page 200 .
Define what values are adequate and suit-
able for your application in your production
environment.
2
How to do this is detailed in Setting the
SIS parameters on page 201 .
Enter these parameters in the system.
3
Run the robot in normal operation.
4
The TPU displays for resetting any SIS
value are shown in Description of Service
Information System (SIS) on page 197 .
Reset the counter if a repair is made, or if a
counter for any other reason is restarted.
5
How to access this is detailed in Reading
the SIS output logs on page 202 .
When a time limit, set in the parameters, is
exceeded, a message may be read on the
Tech Pendant Unit (TPU).
6
These are described in Exporting the SIS
data on page 203 .
If the log containing the message is to be
available from an external PC, or if the SIS
parameters are to be entered from an extern-
al PC, a set of software tools are available
to build such an application.
7
196
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© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.7.1 Using the SIS system
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ABB_IRB7600_Product_Manual.pdf
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| 196
|
•
Clean the cables if they have a crusty surface, for example from dry release
agents.
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
195
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.6.2 Cleaning the IRB 7600
Continued
3.7 Service Information System, M2000
3.7.1 Using the SIS system
General
This is a brief description of how to use the Service Information System, SIS for
M2000 robot systems. Details may be found in:
•
Service Information System, SIS
•
Defining the SIS input parameters
•
Setting the SIS parameters
•
Importing/exporting SIS data
•
Reading the SIS output logs
The section is only valid for M2000 systems. For information regarding M2004
robot systems, see additional documentation, Operating manual - Service
Information System . Article number is specified in section References on page 10 .
Basic procedure
Reference
Action
These are described in Description of
Service Information System (SIS) on
page 197 .
Determine which of the system functions
you require.
1
Recommendations on how to define these
are given in SIS system parameters on
page 200 .
Define what values are adequate and suit-
able for your application in your production
environment.
2
How to do this is detailed in Setting the
SIS parameters on page 201 .
Enter these parameters in the system.
3
Run the robot in normal operation.
4
The TPU displays for resetting any SIS
value are shown in Description of Service
Information System (SIS) on page 197 .
Reset the counter if a repair is made, or if a
counter for any other reason is restarted.
5
How to access this is detailed in Reading
the SIS output logs on page 202 .
When a time limit, set in the parameters, is
exceeded, a message may be read on the
Tech Pendant Unit (TPU).
6
These are described in Exporting the SIS
data on page 203 .
If the log containing the message is to be
available from an external PC, or if the SIS
parameters are to be entered from an extern-
al PC, a set of software tools are available
to build such an application.
7
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3 Maintenance
3.7.1 Using the SIS system
3.7.2 Description of Service Information System (SIS)
General
Service Information System (SIS) is a software function within the robot controller,
which simplifies maintenance of the robot system. It supervises the operating time
and mode of the robot, and alerts the operator when a maintenance activity is
scheduled.
Maintenance is scheduled by setting the system parameters of the type SIS
Parameters, see section Setting the SIS parameters on page 201 . All system
parameters are described in User´s Guide - System Parameters .
Supervised functions
The following counters are available:
•
Calendar time counter, a general alarm based on calendar time
•
Operation time counter, a general alarm based on operational time
•
Gearbox 1 operation time counter, based on percentage of the axis 1 gearbox
service interval
•
Gearbox 2 operation time counter, based on percentage of the axis 2 gearbox
service interval
•
Gearbox 3 operation time counter, based on percentage of the axis 3 gearbox
service interval
•
Gearbox 6 operation time counter, based on percentage of the axis 6 gearbox
service interval
Counters are reset when maintenance has been performed.
The counter status is displayed after running the service routine for maintenance.
Status “OK” indicates that no service interval limit has been exceeded by that
counter.
Calendar time
This is a clock within the control system that keeps track of the service interval,
based on calendar time.
When the calendar time limit for maintenance is reached, a message is displayed
on the TPU. How to access this is detailed in section Reading the SIS output logs
on page 202 .
The following information is available about the calendar time in the service routine.
Date when the counter was reset last time, i.e. after the last service.
Prev service
Elapsed time since the counter was reset the last time.
Elapsed time
Date when next scheduled service is planned. This date is calcu-
lated using system parameters, as detailed in section Setting the
SIS parameters on page 201 .
Next service
Remaining time to next scheduled service date.
Remaining time
Continues on next page
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3 Maintenance
3.7.2 Description of Service Information System (SIS)
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3.7 Service Information System, M2000
3.7.1 Using the SIS system
General
This is a brief description of how to use the Service Information System, SIS for
M2000 robot systems. Details may be found in:
•
Service Information System, SIS
•
Defining the SIS input parameters
•
Setting the SIS parameters
•
Importing/exporting SIS data
•
Reading the SIS output logs
The section is only valid for M2000 systems. For information regarding M2004
robot systems, see additional documentation, Operating manual - Service
Information System . Article number is specified in section References on page 10 .
Basic procedure
Reference
Action
These are described in Description of
Service Information System (SIS) on
page 197 .
Determine which of the system functions
you require.
1
Recommendations on how to define these
are given in SIS system parameters on
page 200 .
Define what values are adequate and suit-
able for your application in your production
environment.
2
How to do this is detailed in Setting the
SIS parameters on page 201 .
Enter these parameters in the system.
3
Run the robot in normal operation.
4
The TPU displays for resetting any SIS
value are shown in Description of Service
Information System (SIS) on page 197 .
Reset the counter if a repair is made, or if a
counter for any other reason is restarted.
5
How to access this is detailed in Reading
the SIS output logs on page 202 .
When a time limit, set in the parameters, is
exceeded, a message may be read on the
Tech Pendant Unit (TPU).
6
These are described in Exporting the SIS
data on page 203 .
If the log containing the message is to be
available from an external PC, or if the SIS
parameters are to be entered from an extern-
al PC, a set of software tools are available
to build such an application.
7
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© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.7.1 Using the SIS system
3.7.2 Description of Service Information System (SIS)
General
Service Information System (SIS) is a software function within the robot controller,
which simplifies maintenance of the robot system. It supervises the operating time
and mode of the robot, and alerts the operator when a maintenance activity is
scheduled.
Maintenance is scheduled by setting the system parameters of the type SIS
Parameters, see section Setting the SIS parameters on page 201 . All system
parameters are described in User´s Guide - System Parameters .
Supervised functions
The following counters are available:
•
Calendar time counter, a general alarm based on calendar time
•
Operation time counter, a general alarm based on operational time
•
Gearbox 1 operation time counter, based on percentage of the axis 1 gearbox
service interval
•
Gearbox 2 operation time counter, based on percentage of the axis 2 gearbox
service interval
•
Gearbox 3 operation time counter, based on percentage of the axis 3 gearbox
service interval
•
Gearbox 6 operation time counter, based on percentage of the axis 6 gearbox
service interval
Counters are reset when maintenance has been performed.
The counter status is displayed after running the service routine for maintenance.
Status “OK” indicates that no service interval limit has been exceeded by that
counter.
Calendar time
This is a clock within the control system that keeps track of the service interval,
based on calendar time.
When the calendar time limit for maintenance is reached, a message is displayed
on the TPU. How to access this is detailed in section Reading the SIS output logs
on page 202 .
The following information is available about the calendar time in the service routine.
Date when the counter was reset last time, i.e. after the last service.
Prev service
Elapsed time since the counter was reset the last time.
Elapsed time
Date when next scheduled service is planned. This date is calcu-
lated using system parameters, as detailed in section Setting the
SIS parameters on page 201 .
Next service
Remaining time to next scheduled service date.
Remaining time
Continues on next page
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3 Maintenance
3.7.2 Description of Service Information System (SIS)
Operation time
This is a function within the control system that keeps track of the amount of time
the "MOTORS ON" signal is active, i.e. the amount of time the robot is in the
operating mode.
When the operation time limit for maintenance is reached, a message is displayed
on the TPU. How to access this is detailed in section Reading the SIS output logs
on page 202 .
The following information is available about the operation time in the service routine.
The specified service interval until another service will be required.
This parameter was entered manually as detailed in section Setting
the SIS parameters on page 201 .
Service interval
Operation time since the service interval was set the last time.
Elapsed time
Remaining operation time until the time set in service interval has
expired.
Remaining time
Gearbox
Based on measurements, torque and RPM, for example, the system calculates an
expected service interval for each gearbox. When service is due, a message will
be shown on the TPU. How to access this is detailed in section Reading the SIS
output logs on page 202 .
The following information is available about the joint service status in the service
routine.
Service status for axis x, i.e. the automatically calculated time
parameter has not been exceeded.
Joint x OK
The service interval for the axis in question has been reached.
Joint x NOK
No service time parameter calculation available.
Joint x N/A
Applies to axes 4 and 5 (IRB 6600 and IRB 7600).
The following information is available for the axis service status in the service
routine.
The consumed time as a percentage of the total amount of time.
Consumed time
Operation time for axis x since calculation began.
Elapsed time
Remaining operation time for axis x until the service time parameter
value has been reached.
Remaining time
Reset values
Counters may be reset at any time by running the service routine.
When resetting, the counter variables are reset. The variables are described in
section Exporting the SIS data on page 203 !
Service interval exceeded
When the service time has been exceeded for the selection made, an error message
(Service interval exceeded!) is displayed.
Continues on next page
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3 Maintenance
3.7.2 Description of Service Information System (SIS)
Continued
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3.7.2 Description of Service Information System (SIS)
General
Service Information System (SIS) is a software function within the robot controller,
which simplifies maintenance of the robot system. It supervises the operating time
and mode of the robot, and alerts the operator when a maintenance activity is
scheduled.
Maintenance is scheduled by setting the system parameters of the type SIS
Parameters, see section Setting the SIS parameters on page 201 . All system
parameters are described in User´s Guide - System Parameters .
Supervised functions
The following counters are available:
•
Calendar time counter, a general alarm based on calendar time
•
Operation time counter, a general alarm based on operational time
•
Gearbox 1 operation time counter, based on percentage of the axis 1 gearbox
service interval
•
Gearbox 2 operation time counter, based on percentage of the axis 2 gearbox
service interval
•
Gearbox 3 operation time counter, based on percentage of the axis 3 gearbox
service interval
•
Gearbox 6 operation time counter, based on percentage of the axis 6 gearbox
service interval
Counters are reset when maintenance has been performed.
The counter status is displayed after running the service routine for maintenance.
Status “OK” indicates that no service interval limit has been exceeded by that
counter.
Calendar time
This is a clock within the control system that keeps track of the service interval,
based on calendar time.
When the calendar time limit for maintenance is reached, a message is displayed
on the TPU. How to access this is detailed in section Reading the SIS output logs
on page 202 .
The following information is available about the calendar time in the service routine.
Date when the counter was reset last time, i.e. after the last service.
Prev service
Elapsed time since the counter was reset the last time.
Elapsed time
Date when next scheduled service is planned. This date is calcu-
lated using system parameters, as detailed in section Setting the
SIS parameters on page 201 .
Next service
Remaining time to next scheduled service date.
Remaining time
Continues on next page
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3 Maintenance
3.7.2 Description of Service Information System (SIS)
Operation time
This is a function within the control system that keeps track of the amount of time
the "MOTORS ON" signal is active, i.e. the amount of time the robot is in the
operating mode.
When the operation time limit for maintenance is reached, a message is displayed
on the TPU. How to access this is detailed in section Reading the SIS output logs
on page 202 .
The following information is available about the operation time in the service routine.
The specified service interval until another service will be required.
This parameter was entered manually as detailed in section Setting
the SIS parameters on page 201 .
Service interval
Operation time since the service interval was set the last time.
Elapsed time
Remaining operation time until the time set in service interval has
expired.
Remaining time
Gearbox
Based on measurements, torque and RPM, for example, the system calculates an
expected service interval for each gearbox. When service is due, a message will
be shown on the TPU. How to access this is detailed in section Reading the SIS
output logs on page 202 .
The following information is available about the joint service status in the service
routine.
Service status for axis x, i.e. the automatically calculated time
parameter has not been exceeded.
Joint x OK
The service interval for the axis in question has been reached.
Joint x NOK
No service time parameter calculation available.
Joint x N/A
Applies to axes 4 and 5 (IRB 6600 and IRB 7600).
The following information is available for the axis service status in the service
routine.
The consumed time as a percentage of the total amount of time.
Consumed time
Operation time for axis x since calculation began.
Elapsed time
Remaining operation time for axis x until the service time parameter
value has been reached.
Remaining time
Reset values
Counters may be reset at any time by running the service routine.
When resetting, the counter variables are reset. The variables are described in
section Exporting the SIS data on page 203 !
Service interval exceeded
When the service time has been exceeded for the selection made, an error message
(Service interval exceeded!) is displayed.
Continues on next page
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3 Maintenance
3.7.2 Description of Service Information System (SIS)
Continued
No data available
When no data is available for the selection made, a message (No data available!)
is displayed when trying to display the data.
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3 Maintenance
3.7.2 Description of Service Information System (SIS)
Continued
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Operation time
This is a function within the control system that keeps track of the amount of time
the "MOTORS ON" signal is active, i.e. the amount of time the robot is in the
operating mode.
When the operation time limit for maintenance is reached, a message is displayed
on the TPU. How to access this is detailed in section Reading the SIS output logs
on page 202 .
The following information is available about the operation time in the service routine.
The specified service interval until another service will be required.
This parameter was entered manually as detailed in section Setting
the SIS parameters on page 201 .
Service interval
Operation time since the service interval was set the last time.
Elapsed time
Remaining operation time until the time set in service interval has
expired.
Remaining time
Gearbox
Based on measurements, torque and RPM, for example, the system calculates an
expected service interval for each gearbox. When service is due, a message will
be shown on the TPU. How to access this is detailed in section Reading the SIS
output logs on page 202 .
The following information is available about the joint service status in the service
routine.
Service status for axis x, i.e. the automatically calculated time
parameter has not been exceeded.
Joint x OK
The service interval for the axis in question has been reached.
Joint x NOK
No service time parameter calculation available.
Joint x N/A
Applies to axes 4 and 5 (IRB 6600 and IRB 7600).
The following information is available for the axis service status in the service
routine.
The consumed time as a percentage of the total amount of time.
Consumed time
Operation time for axis x since calculation began.
Elapsed time
Remaining operation time for axis x until the service time parameter
value has been reached.
Remaining time
Reset values
Counters may be reset at any time by running the service routine.
When resetting, the counter variables are reset. The variables are described in
section Exporting the SIS data on page 203 !
Service interval exceeded
When the service time has been exceeded for the selection made, an error message
(Service interval exceeded!) is displayed.
Continues on next page
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3 Maintenance
3.7.2 Description of Service Information System (SIS)
Continued
No data available
When no data is available for the selection made, a message (No data available!)
is displayed when trying to display the data.
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3 Maintenance
3.7.2 Description of Service Information System (SIS)
Continued
3.7.3 SIS system parameters
General
This section details the system parameters that may be set with estimated values.
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.
E.g. by setting the value "20,000", the SIS will save this as the nominal time for
activating the alarm, not counting the percentage described below.
Operation time warning
A percentage of the "Operation time limit" specified above.
E.g. by setting the value "90", the SIS will alert the operator 18,000 hours after an
operation time "Reset" was made the last time.
Calendar time limit (service level)
The number of calendar years selected as service interval.
E.g. by setting the value "2", the SIS will save this as the nominal time for activating
the alarm, not counting the percentage described below.
Calendar time warning
A percentage of the "Calendar time limit" specified above.
E.g. by setting the value "90", the SIS will alert the operator after 90% of two years,
i.e. 657 days after a calendar time "Reset" was made the last time.
Gearbox warning
A percentage of the gearbox service interval as calculated by the system. E.g. by
setting the value "90", the SIS will alert the operator after 90% of the expected
service interval of each gearbox.
The robot system automatically detects and stores all required variables to calculate
the expected service interval (estimated remaining lifetime) of each gearbox. This
is done by extrapolating data from earlier operation into a function of time, using
a formula including:
•
input and output torque
•
gearbox spindle speed
•
other variables
200
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3.7.3 SIS system parameters
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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.
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3 Maintenance
3.7.2 Description of Service Information System (SIS)
Continued
3.7.3 SIS system parameters
General
This section details the system parameters that may be set with estimated values.
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.
E.g. by setting the value "20,000", the SIS will save this as the nominal time for
activating the alarm, not counting the percentage described below.
Operation time warning
A percentage of the "Operation time limit" specified above.
E.g. by setting the value "90", the SIS will alert the operator 18,000 hours after an
operation time "Reset" was made the last time.
Calendar time limit (service level)
The number of calendar years selected as service interval.
E.g. by setting the value "2", the SIS will save this as the nominal time for activating
the alarm, not counting the percentage described below.
Calendar time warning
A percentage of the "Calendar time limit" specified above.
E.g. by setting the value "90", the SIS will alert the operator after 90% of two years,
i.e. 657 days after a calendar time "Reset" was made the last time.
Gearbox warning
A percentage of the gearbox service interval as calculated by the system. E.g. by
setting the value "90", the SIS will alert the operator after 90% of the expected
service interval of each gearbox.
The robot system automatically detects and stores all required variables to calculate
the expected service interval (estimated remaining lifetime) of each gearbox. This
is done by extrapolating data from earlier operation into a function of time, using
a formula including:
•
input and output torque
•
gearbox spindle speed
•
other variables
200
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3 Maintenance
3.7.3 SIS system parameters
3.7.4 Setting the SIS parameters
General
If the SIS system is to function properly, a number of parameters must be set. This
is detailed below.
Procedure M2000
This is an instruction of how to enter SIS parameters to the M2000 robot system.
Note
Action
Detailed in the User's Guide.
Open "System parameters"
using the TPU.
1
Go to "System paramet-
ers/Manipulator/types 2".
2
Select "0 SIS parameters"
and press "Enter".
3
Select the required system
The parameter list is dis-
played.
4
Available parameters are described in section SIS system
parameters on page 200 .
Select the required paramet-
ers by stepping up and
down through the parameter
list.
5
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3 Maintenance
3.7.4 Setting the SIS parameters
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3.7.3 SIS system parameters
General
This section details the system parameters that may be set with estimated values.
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.
E.g. by setting the value "20,000", the SIS will save this as the nominal time for
activating the alarm, not counting the percentage described below.
Operation time warning
A percentage of the "Operation time limit" specified above.
E.g. by setting the value "90", the SIS will alert the operator 18,000 hours after an
operation time "Reset" was made the last time.
Calendar time limit (service level)
The number of calendar years selected as service interval.
E.g. by setting the value "2", the SIS will save this as the nominal time for activating
the alarm, not counting the percentage described below.
Calendar time warning
A percentage of the "Calendar time limit" specified above.
E.g. by setting the value "90", the SIS will alert the operator after 90% of two years,
i.e. 657 days after a calendar time "Reset" was made the last time.
Gearbox warning
A percentage of the gearbox service interval as calculated by the system. E.g. by
setting the value "90", the SIS will alert the operator after 90% of the expected
service interval of each gearbox.
The robot system automatically detects and stores all required variables to calculate
the expected service interval (estimated remaining lifetime) of each gearbox. This
is done by extrapolating data from earlier operation into a function of time, using
a formula including:
•
input and output torque
•
gearbox spindle speed
•
other variables
200
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3 Maintenance
3.7.3 SIS system parameters
3.7.4 Setting the SIS parameters
General
If the SIS system is to function properly, a number of parameters must be set. This
is detailed below.
Procedure M2000
This is an instruction of how to enter SIS parameters to the M2000 robot system.
Note
Action
Detailed in the User's Guide.
Open "System parameters"
using the TPU.
1
Go to "System paramet-
ers/Manipulator/types 2".
2
Select "0 SIS parameters"
and press "Enter".
3
Select the required system
The parameter list is dis-
played.
4
Available parameters are described in section SIS system
parameters on page 200 .
Select the required paramet-
ers by stepping up and
down through the parameter
list.
5
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3 Maintenance
3.7.4 Setting the SIS parameters
3.7.5 Reading the SIS output logs
General
Whenever a set condition has expired (e.g. max allowed operation time before
service), a message to this effect will be shown in the Operational log.
Access to logs
How to open a log and show its contents is detailed in the User's Guide, chapter
Service .
Available messages
The following messages may be shown:
Meaning:
SIS message in the
log:
Available in:
The manually set calendar time limit has expired.
How to set the limit is detailed in section Setting
the SIS parameters on page 201 .
Service Message
Service is due!
X calendar days
since last service.
Calendar time
Proceed with the required service as detailed in
chapter Repair on page205 or chapter Maintenance
on page 115 depending on which type of service.
X number of calendar days remain until the
manually set calendar time limit expires.
Service Message
X calendar days to
next service.
Calendar time
How to set the value determining when the mes-
sage is to be shown, is detailed in section Setting
the SIS parameters on page 201 .
The manually set operation time limit has expired.
How to set the limit is detailed in section Setting
the SIS parameters on page 201 .
Service Message
Service is due!
X production hours
since last service.
Operation time
Proceed with the required service as detailed in
chapter Repair on page205 or chapter Maintenance
on page 115 depending on which type of service.
X number of operation hours remain until the
manually set operation time limit expires.
Service Message
X production hours
to next service.
Operation time
How to set the value determining when the mes-
sage is to be shown, is detailed in section Setting
the SIS parameters on page 201 .
The automatically calculated gearbox time limit
has expired.
Service Message
Gearbox x requires
service!
Gearbox time
Proceed with the required service as detailed in
chapter Repair on page205 or chapter Maintenance
on page 115 depending on which type of service.
X percent of gearbox hours remain until the auto-
matically calculated gearbox time limit expires.
Service Message
X% of the service in-
terval has expired for
gearbox x!
Gearbox time
How to set the value determining when the mes-
sage is to be shown, is detailed in section Setting
the SIS parameters on page 201 .
202
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3 Maintenance
3.7.5 Reading the SIS output logs
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| 202
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3.7.4 Setting the SIS parameters
General
If the SIS system is to function properly, a number of parameters must be set. This
is detailed below.
Procedure M2000
This is an instruction of how to enter SIS parameters to the M2000 robot system.
Note
Action
Detailed in the User's Guide.
Open "System parameters"
using the TPU.
1
Go to "System paramet-
ers/Manipulator/types 2".
2
Select "0 SIS parameters"
and press "Enter".
3
Select the required system
The parameter list is dis-
played.
4
Available parameters are described in section SIS system
parameters on page 200 .
Select the required paramet-
ers by stepping up and
down through the parameter
list.
5
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201
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3 Maintenance
3.7.4 Setting the SIS parameters
3.7.5 Reading the SIS output logs
General
Whenever a set condition has expired (e.g. max allowed operation time before
service), a message to this effect will be shown in the Operational log.
Access to logs
How to open a log and show its contents is detailed in the User's Guide, chapter
Service .
Available messages
The following messages may be shown:
Meaning:
SIS message in the
log:
Available in:
The manually set calendar time limit has expired.
How to set the limit is detailed in section Setting
the SIS parameters on page 201 .
Service Message
Service is due!
X calendar days
since last service.
Calendar time
Proceed with the required service as detailed in
chapter Repair on page205 or chapter Maintenance
on page 115 depending on which type of service.
X number of calendar days remain until the
manually set calendar time limit expires.
Service Message
X calendar days to
next service.
Calendar time
How to set the value determining when the mes-
sage is to be shown, is detailed in section Setting
the SIS parameters on page 201 .
The manually set operation time limit has expired.
How to set the limit is detailed in section Setting
the SIS parameters on page 201 .
Service Message
Service is due!
X production hours
since last service.
Operation time
Proceed with the required service as detailed in
chapter Repair on page205 or chapter Maintenance
on page 115 depending on which type of service.
X number of operation hours remain until the
manually set operation time limit expires.
Service Message
X production hours
to next service.
Operation time
How to set the value determining when the mes-
sage is to be shown, is detailed in section Setting
the SIS parameters on page 201 .
The automatically calculated gearbox time limit
has expired.
Service Message
Gearbox x requires
service!
Gearbox time
Proceed with the required service as detailed in
chapter Repair on page205 or chapter Maintenance
on page 115 depending on which type of service.
X percent of gearbox hours remain until the auto-
matically calculated gearbox time limit expires.
Service Message
X% of the service in-
terval has expired for
gearbox x!
Gearbox time
How to set the value determining when the mes-
sage is to be shown, is detailed in section Setting
the SIS parameters on page 201 .
202
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© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.7.5 Reading the SIS output logs
3.7.6 Exporting the SIS data
General
This section describes the available variables for entering SIS parameters as well
as showing any values of exceeded time limits as detected by the SIS counters.
In a M2000 robot system, the values can be read on a PC using "Webware SDK".
How to access these variables and how to perform the actual programming
sequences are detailed in the robot system User's Guide.
Definitions
The table below defines the names and functions of all software variables available
for communication between the SIS and an external computer.
Function
Counter type
Unit
Signal
The date on which the supervision was star-
ted/reset last time.
Calendar time
seconds
sisRestartDate
The number of hours since start/last reset.
Calendar time
seconds
sisCalendarT
Total number of operation hours since the
system was started. Corresponds to the oper-
ating time counter on the control cabinet.
Operation time
seconds
sisTotRunT
The number of operation hours since start/last
reset of the operation time counter. Corres-
ponds to the operating time counter on the
control cabinet.
Operation time
seconds
sisRunT
Estimated life of gearbox axis 1
Gearbox time
hours
sisL10h_1
Operation time of gearbox axis 1
Gearbox time
seconds
sisL10h_Time_1
Estimated life of gearbox axis 2
Gearbox time
hours
sisL10h_2
Operation time of gearbox axis 2
Gearbox time
seconds
sisL10h_Time_2
Estimated life of gearbox axis 3
Gearbox time
hours
sisL10h_3
Operation time of gearbox axis 3
Gearbox time
seconds
sisL10h_Time_3
Estimated life of gearbox axis 6
Gearbox time
hours
sisL10h_6
Operation time of gearbox axis 6
Gearbox time
hours
sisL10h_Time_6
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3 Maintenance
3.7.6 Exporting the SIS data
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| 203
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3.7.5 Reading the SIS output logs
General
Whenever a set condition has expired (e.g. max allowed operation time before
service), a message to this effect will be shown in the Operational log.
Access to logs
How to open a log and show its contents is detailed in the User's Guide, chapter
Service .
Available messages
The following messages may be shown:
Meaning:
SIS message in the
log:
Available in:
The manually set calendar time limit has expired.
How to set the limit is detailed in section Setting
the SIS parameters on page 201 .
Service Message
Service is due!
X calendar days
since last service.
Calendar time
Proceed with the required service as detailed in
chapter Repair on page205 or chapter Maintenance
on page 115 depending on which type of service.
X number of calendar days remain until the
manually set calendar time limit expires.
Service Message
X calendar days to
next service.
Calendar time
How to set the value determining when the mes-
sage is to be shown, is detailed in section Setting
the SIS parameters on page 201 .
The manually set operation time limit has expired.
How to set the limit is detailed in section Setting
the SIS parameters on page 201 .
Service Message
Service is due!
X production hours
since last service.
Operation time
Proceed with the required service as detailed in
chapter Repair on page205 or chapter Maintenance
on page 115 depending on which type of service.
X number of operation hours remain until the
manually set operation time limit expires.
Service Message
X production hours
to next service.
Operation time
How to set the value determining when the mes-
sage is to be shown, is detailed in section Setting
the SIS parameters on page 201 .
The automatically calculated gearbox time limit
has expired.
Service Message
Gearbox x requires
service!
Gearbox time
Proceed with the required service as detailed in
chapter Repair on page205 or chapter Maintenance
on page 115 depending on which type of service.
X percent of gearbox hours remain until the auto-
matically calculated gearbox time limit expires.
Service Message
X% of the service in-
terval has expired for
gearbox x!
Gearbox time
How to set the value determining when the mes-
sage is to be shown, is detailed in section Setting
the SIS parameters on page 201 .
202
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3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
3 Maintenance
3.7.5 Reading the SIS output logs
3.7.6 Exporting the SIS data
General
This section describes the available variables for entering SIS parameters as well
as showing any values of exceeded time limits as detected by the SIS counters.
In a M2000 robot system, the values can be read on a PC using "Webware SDK".
How to access these variables and how to perform the actual programming
sequences are detailed in the robot system User's Guide.
Definitions
The table below defines the names and functions of all software variables available
for communication between the SIS and an external computer.
Function
Counter type
Unit
Signal
The date on which the supervision was star-
ted/reset last time.
Calendar time
seconds
sisRestartDate
The number of hours since start/last reset.
Calendar time
seconds
sisCalendarT
Total number of operation hours since the
system was started. Corresponds to the oper-
ating time counter on the control cabinet.
Operation time
seconds
sisTotRunT
The number of operation hours since start/last
reset of the operation time counter. Corres-
ponds to the operating time counter on the
control cabinet.
Operation time
seconds
sisRunT
Estimated life of gearbox axis 1
Gearbox time
hours
sisL10h_1
Operation time of gearbox axis 1
Gearbox time
seconds
sisL10h_Time_1
Estimated life of gearbox axis 2
Gearbox time
hours
sisL10h_2
Operation time of gearbox axis 2
Gearbox time
seconds
sisL10h_Time_2
Estimated life of gearbox axis 3
Gearbox time
hours
sisL10h_3
Operation time of gearbox axis 3
Gearbox time
seconds
sisL10h_Time_3
Estimated life of gearbox axis 6
Gearbox time
hours
sisL10h_6
Operation time of gearbox axis 6
Gearbox time
hours
sisL10h_Time_6
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3 Maintenance
3.7.6 Exporting the SIS data
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|
3.7.6 Exporting the SIS data
General
This section describes the available variables for entering SIS parameters as well
as showing any values of exceeded time limits as detected by the SIS counters.
In a M2000 robot system, the values can be read on a PC using "Webware SDK".
How to access these variables and how to perform the actual programming
sequences are detailed in the robot system User's Guide.
Definitions
The table below defines the names and functions of all software variables available
for communication between the SIS and an external computer.
Function
Counter type
Unit
Signal
The date on which the supervision was star-
ted/reset last time.
Calendar time
seconds
sisRestartDate
The number of hours since start/last reset.
Calendar time
seconds
sisCalendarT
Total number of operation hours since the
system was started. Corresponds to the oper-
ating time counter on the control cabinet.
Operation time
seconds
sisTotRunT
The number of operation hours since start/last
reset of the operation time counter. Corres-
ponds to the operating time counter on the
control cabinet.
Operation time
seconds
sisRunT
Estimated life of gearbox axis 1
Gearbox time
hours
sisL10h_1
Operation time of gearbox axis 1
Gearbox time
seconds
sisL10h_Time_1
Estimated life of gearbox axis 2
Gearbox time
hours
sisL10h_2
Operation time of gearbox axis 2
Gearbox time
seconds
sisL10h_Time_2
Estimated life of gearbox axis 3
Gearbox time
hours
sisL10h_3
Operation time of gearbox axis 3
Gearbox time
seconds
sisL10h_Time_3
Estimated life of gearbox axis 6
Gearbox time
hours
sisL10h_6
Operation time of gearbox axis 6
Gearbox time
hours
sisL10h_Time_6
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3 Maintenance
3.7.6 Exporting the SIS data
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4 Repair
4.1 Introduction
Structure of this chapter
This chapter describes repair activities for the IRB 7600. Each procedure contains
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.
Report replaced units
Note
When replacing a part on the IRB 7600, report to your local ABB the serial number,
the article number, and the revision of both the replaced unit and the replacement
unit.
This is particularly important for safety equipment to maintain the safety integrity
of the installation.
Safety information
Make sure to read through the chapter Safety on page 23 before commencing any
service work.
Note
If the IRB 7600 is connected to power, always make sure that the IRB 7600 is
connected to protective earth and a residual current device (RCD) before starting
any repair work.
For more information see:
•
Product manual - IRC5
•
Product manual - IRC5 Panel Mounted Controller
Product manual - IRB 7600
205
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.1 Introduction
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4 Repair
4.1 Introduction
Structure of this chapter
This chapter describes repair activities for the IRB 7600. Each procedure contains
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.
Report replaced units
Note
When replacing a part on the IRB 7600, report to your local ABB the serial number,
the article number, and the revision of both the replaced unit and the replacement
unit.
This is particularly important for safety equipment to maintain the safety integrity
of the installation.
Safety information
Make sure to read through the chapter Safety on page 23 before commencing any
service work.
Note
If the IRB 7600 is connected to power, always make sure that the IRB 7600 is
connected to protective earth and a residual current device (RCD) before starting
any repair work.
For more information see:
•
Product manual - IRC5
•
Product manual - IRC5 Panel Mounted Controller
Product manual - IRB 7600
205
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.1 Introduction
4.2 General procedures
4.2.1 Performing a leak-down test
When to perform a leak-down test
After refitting any motor and gearbox, the integrity of all seals enclosing the gearbox
oil must be tested. This is done in a leak-down test.
Required equipment
Note
Article number
Equipment, etc.
-
Leak-down tester
-
Leak detection spray
Performing a leak-down test
Note
Action
Finish the refitting procedure of the motor or gear in
question.
1
Remove the upper oil plug on the gear and replace
it with the leak-down tester.
2
Regulators, which are included in the leak-down test,
may be required.
Correct value:
Use caution, apply compressed air and raise the
pressure with the knob until the correct value is
shown on the manometer.
CAUTION
The pressure must under no circumstance be higher
than 0.25 bar (20-25 kPa). Also during the time when
the pressure is raised.
3
0.2-0.25 bar (20-25 kPa)
Disconnect the compressed air supply.
4
If the compressed air is signific-
antly colder or warmer than the
gearbox to be tested, a slight
pressure increase or decrease
may occur. This is quite normal.
Wait for approximately 8-10 minutes and make sure
that no pressure loss occurs.
5
If any pressure drop occurred, then localize the leak
as described in step 7 .
6
If no pressure drop occurred, then remove the leak-
down tester and refit the oil plug. The test is complete.
Spray any suspected leak areas with the leak detec-
tion spray. Bubbles indicate a leak.
7
When the leak has been localized, take the necessary
measures to correct the leak.
8
206
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© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.2.1 Performing a leak-down test
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| 206
|
4 Repair
4.1 Introduction
Structure of this chapter
This chapter describes repair activities for the IRB 7600. Each procedure contains
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.
Report replaced units
Note
When replacing a part on the IRB 7600, report to your local ABB the serial number,
the article number, and the revision of both the replaced unit and the replacement
unit.
This is particularly important for safety equipment to maintain the safety integrity
of the installation.
Safety information
Make sure to read through the chapter Safety on page 23 before commencing any
service work.
Note
If the IRB 7600 is connected to power, always make sure that the IRB 7600 is
connected to protective earth and a residual current device (RCD) before starting
any repair work.
For more information see:
•
Product manual - IRC5
•
Product manual - IRC5 Panel Mounted Controller
Product manual - IRB 7600
205
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.1 Introduction
4.2 General procedures
4.2.1 Performing a leak-down test
When to perform a leak-down test
After refitting any motor and gearbox, the integrity of all seals enclosing the gearbox
oil must be tested. This is done in a leak-down test.
Required equipment
Note
Article number
Equipment, etc.
-
Leak-down tester
-
Leak detection spray
Performing a leak-down test
Note
Action
Finish the refitting procedure of the motor or gear in
question.
1
Remove the upper oil plug on the gear and replace
it with the leak-down tester.
2
Regulators, which are included in the leak-down test,
may be required.
Correct value:
Use caution, apply compressed air and raise the
pressure with the knob until the correct value is
shown on the manometer.
CAUTION
The pressure must under no circumstance be higher
than 0.25 bar (20-25 kPa). Also during the time when
the pressure is raised.
3
0.2-0.25 bar (20-25 kPa)
Disconnect the compressed air supply.
4
If the compressed air is signific-
antly colder or warmer than the
gearbox to be tested, a slight
pressure increase or decrease
may occur. This is quite normal.
Wait for approximately 8-10 minutes and make sure
that no pressure loss occurs.
5
If any pressure drop occurred, then localize the leak
as described in step 7 .
6
If no pressure drop occurred, then remove the leak-
down tester and refit the oil plug. The test is complete.
Spray any suspected leak areas with the leak detec-
tion spray. Bubbles indicate a leak.
7
When the leak has been localized, take the necessary
measures to correct the leak.
8
206
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3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.2.1 Performing a leak-down test
4.2.2 Mounting instructions for bearings
General
This section describes how to mount and grease different types of bearings on the
robot.
Equipment
Note
Article number
Equipment, etc.
Shell Gadus S2
3HAC042536-001
Grease
Used to grease the bearings, if not
specified otherwise.
Assembly of all bearings
Attend to the following instructions while mounting a bearing on the robot.
Note
Action
To avoid contamination, let a new bearing remain in its wrapping
until it is time for fitting.
1
Ensure that the parts included in the bearing fitting are free from
burrs, grinding waste, and other contamination. Cast components
must be free of foundry sand.
2
Bearing rings, inner rings, and roller elements must not be subjec-
ted to direct impact. The roller elements must not be exposed to
any stresses during the assembly work.
3
Assembly of tapered bearings
Follow the preceding instructions for the assembly of the bearings when mounting
a tapered bearing on the robot.
In addition to those instructions, the following procedure must be carried out to
enable the roller elements to adjust to the correct position against the race flange.
Note
Action
Tension the bearing gradually until the recommended pre-tension is achieved.
Note
The roller elements must be rotated a specified number of turns before pre-
tensioning is carried out and also rotated during the pre-tensioning sequence.
1
Make sure the bearing is properly aligned as this will directly affect the durab-
ility of the bearing.
2
Greasing of bearings
Note
This instruction is not valid for solid oil bearings.
Continues on next page
Product manual - IRB 7600
207
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© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.2.2 Mounting instructions for bearings
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| 207
|
4.2 General procedures
4.2.1 Performing a leak-down test
When to perform a leak-down test
After refitting any motor and gearbox, the integrity of all seals enclosing the gearbox
oil must be tested. This is done in a leak-down test.
Required equipment
Note
Article number
Equipment, etc.
-
Leak-down tester
-
Leak detection spray
Performing a leak-down test
Note
Action
Finish the refitting procedure of the motor or gear in
question.
1
Remove the upper oil plug on the gear and replace
it with the leak-down tester.
2
Regulators, which are included in the leak-down test,
may be required.
Correct value:
Use caution, apply compressed air and raise the
pressure with the knob until the correct value is
shown on the manometer.
CAUTION
The pressure must under no circumstance be higher
than 0.25 bar (20-25 kPa). Also during the time when
the pressure is raised.
3
0.2-0.25 bar (20-25 kPa)
Disconnect the compressed air supply.
4
If the compressed air is signific-
antly colder or warmer than the
gearbox to be tested, a slight
pressure increase or decrease
may occur. This is quite normal.
Wait for approximately 8-10 minutes and make sure
that no pressure loss occurs.
5
If any pressure drop occurred, then localize the leak
as described in step 7 .
6
If no pressure drop occurred, then remove the leak-
down tester and refit the oil plug. The test is complete.
Spray any suspected leak areas with the leak detec-
tion spray. Bubbles indicate a leak.
7
When the leak has been localized, take the necessary
measures to correct the leak.
8
206
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.2.1 Performing a leak-down test
4.2.2 Mounting instructions for bearings
General
This section describes how to mount and grease different types of bearings on the
robot.
Equipment
Note
Article number
Equipment, etc.
Shell Gadus S2
3HAC042536-001
Grease
Used to grease the bearings, if not
specified otherwise.
Assembly of all bearings
Attend to the following instructions while mounting a bearing on the robot.
Note
Action
To avoid contamination, let a new bearing remain in its wrapping
until it is time for fitting.
1
Ensure that the parts included in the bearing fitting are free from
burrs, grinding waste, and other contamination. Cast components
must be free of foundry sand.
2
Bearing rings, inner rings, and roller elements must not be subjec-
ted to direct impact. The roller elements must not be exposed to
any stresses during the assembly work.
3
Assembly of tapered bearings
Follow the preceding instructions for the assembly of the bearings when mounting
a tapered bearing on the robot.
In addition to those instructions, the following procedure must be carried out to
enable the roller elements to adjust to the correct position against the race flange.
Note
Action
Tension the bearing gradually until the recommended pre-tension is achieved.
Note
The roller elements must be rotated a specified number of turns before pre-
tensioning is carried out and also rotated during the pre-tensioning sequence.
1
Make sure the bearing is properly aligned as this will directly affect the durab-
ility of the bearing.
2
Greasing of bearings
Note
This instruction is not valid for solid oil bearings.
Continues on next page
Product manual - IRB 7600
207
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© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.2.2 Mounting instructions for bearings
The bearings must be greased after assembly according to the following
instructions:
•
The bearings must not be completely filled with grease. However, if space
is available beside the bearing fitting, the bearing may be totally filled with
grease when mounted, as excessive grease will be pressed out from the
bearing when the robot is started.
•
During operation, the bearing should be filled to 70-80% of the available
volume.
•
Ensure that grease is handled and stored properly to avoid contamination.
Grease the different types of bearings as following description:
•
Grooved ball bearings must be filled with grease from both sides.
•
Tapered roller bearings and axial needle bearings must be greased in the
split condition.
208
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4 Repair
4.2.2 Mounting instructions for bearings
Continued
|
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| 208
|
4.2.2 Mounting instructions for bearings
General
This section describes how to mount and grease different types of bearings on the
robot.
Equipment
Note
Article number
Equipment, etc.
Shell Gadus S2
3HAC042536-001
Grease
Used to grease the bearings, if not
specified otherwise.
Assembly of all bearings
Attend to the following instructions while mounting a bearing on the robot.
Note
Action
To avoid contamination, let a new bearing remain in its wrapping
until it is time for fitting.
1
Ensure that the parts included in the bearing fitting are free from
burrs, grinding waste, and other contamination. Cast components
must be free of foundry sand.
2
Bearing rings, inner rings, and roller elements must not be subjec-
ted to direct impact. The roller elements must not be exposed to
any stresses during the assembly work.
3
Assembly of tapered bearings
Follow the preceding instructions for the assembly of the bearings when mounting
a tapered bearing on the robot.
In addition to those instructions, the following procedure must be carried out to
enable the roller elements to adjust to the correct position against the race flange.
Note
Action
Tension the bearing gradually until the recommended pre-tension is achieved.
Note
The roller elements must be rotated a specified number of turns before pre-
tensioning is carried out and also rotated during the pre-tensioning sequence.
1
Make sure the bearing is properly aligned as this will directly affect the durab-
ility of the bearing.
2
Greasing of bearings
Note
This instruction is not valid for solid oil bearings.
Continues on next page
Product manual - IRB 7600
207
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.2.2 Mounting instructions for bearings
The bearings must be greased after assembly according to the following
instructions:
•
The bearings must not be completely filled with grease. However, if space
is available beside the bearing fitting, the bearing may be totally filled with
grease when mounted, as excessive grease will be pressed out from the
bearing when the robot is started.
•
During operation, the bearing should be filled to 70-80% of the available
volume.
•
Ensure that grease is handled and stored properly to avoid contamination.
Grease the different types of bearings as following description:
•
Grooved ball bearings must be filled with grease from both sides.
•
Tapered roller bearings and axial needle bearings must be greased in the
split condition.
208
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3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.2.2 Mounting instructions for bearings
Continued
4.2.3 Mounting instructions for sealings
General
This section describes how to mount different types of sealings.
Equipment
Note
Article number
Consumable
Shell Gadus S2
3HAC042536-001
Grease
Rotating sealings
The procedure below describes how to fit rotating sealings.
CAUTION
Please observe the following before commencing any assembly of sealings:
•
Protect the sealing during transport and mounting, especially the main lip.
•
Keep the sealing in its original wrappings or protect it well before actual
mounting.
•
The fitting of sealings and gears must be carried out on clean workbenches.
•
Use a protective sleeve for the main lip during mounting, when sliding over
threads, keyways or other sharp edges.
Note
Action
Check the sealing to ensure that:
•
The sealing is of the correct type.
•
There is no damage on the main lip.
1
Inspect the shaft surface before mounting. If scratches
or damage are found, the shaft must be replaced since
it may result in future leakage. Do not try to grind or
polish the shaft surface to get rid of the defect.
2
Article number is specified in
Equipment on page 209 .
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
A
B
C
xx2000000071
A
Main lip
B
Grease
C
Dust lip
Lubricate the sealing with grease just before fitting.
(Not too early - there is a risk of dirt and foreign
particles adhering to the sealing.)
Fill 2/3 of the space between the dust lip and the main
lip with grease. If the sealing is without dust lip, just
lubricate the main lip with a thin layer of grease.
3
Continues on next page
Product manual - IRB 7600
209
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.2.3 Mounting instructions for sealings
|
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| 209
|
The bearings must be greased after assembly according to the following
instructions:
•
The bearings must not be completely filled with grease. However, if space
is available beside the bearing fitting, the bearing may be totally filled with
grease when mounted, as excessive grease will be pressed out from the
bearing when the robot is started.
•
During operation, the bearing should be filled to 70-80% of the available
volume.
•
Ensure that grease is handled and stored properly to avoid contamination.
Grease the different types of bearings as following description:
•
Grooved ball bearings must be filled with grease from both sides.
•
Tapered roller bearings and axial needle bearings must be greased in the
split condition.
208
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.2.2 Mounting instructions for bearings
Continued
4.2.3 Mounting instructions for sealings
General
This section describes how to mount different types of sealings.
Equipment
Note
Article number
Consumable
Shell Gadus S2
3HAC042536-001
Grease
Rotating sealings
The procedure below describes how to fit rotating sealings.
CAUTION
Please observe the following before commencing any assembly of sealings:
•
Protect the sealing during transport and mounting, especially the main lip.
•
Keep the sealing in its original wrappings or protect it well before actual
mounting.
•
The fitting of sealings and gears must be carried out on clean workbenches.
•
Use a protective sleeve for the main lip during mounting, when sliding over
threads, keyways or other sharp edges.
Note
Action
Check the sealing to ensure that:
•
The sealing is of the correct type.
•
There is no damage on the main lip.
1
Inspect the shaft surface before mounting. If scratches
or damage are found, the shaft must be replaced since
it may result in future leakage. Do not try to grind or
polish the shaft surface to get rid of the defect.
2
Article number is specified in
Equipment on page 209 .
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
A
B
C
xx2000000071
A
Main lip
B
Grease
C
Dust lip
Lubricate the sealing with grease just before fitting.
(Not too early - there is a risk of dirt and foreign
particles adhering to the sealing.)
Fill 2/3 of the space between the dust lip and the main
lip with grease. If the sealing is without dust lip, just
lubricate the main lip with a thin layer of grease.
3
Continues on next page
Product manual - IRB 7600
209
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.2.3 Mounting instructions for sealings
Note
Action
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
A
xx2000000072
A
Gap
Mount the sealing correctly with a mounting tool.
Never hammer directly on the sealing as this may
result in leakage.
4
Flange sealings and static sealings
The following procedure describes how to fit flange sealings and static sealings.
Action
Check the flange surfaces. They must be even and free from pores.
1
It is easy to check flatness using a gauge on the fastened joint (without sealing com-
pound).
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.
2
Distribute the sealing compound evenly over the surface, preferably with a brush.
3
Tighten the screws evenly when fastening the flange joint.
4
O-rings
The following procedure describes how to fit o-rings.
Note
Action
Ensure that the correct o-ring size is used.
1
Defective o-rings, including damaged
or deformed o-rings, may not be used.
Check the o-ring for surface defects, burrs,
shape accuracy, or deformation.
2
Continues on next page
210
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.2.3 Mounting instructions for sealings
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 210
|
4.2.3 Mounting instructions for sealings
General
This section describes how to mount different types of sealings.
Equipment
Note
Article number
Consumable
Shell Gadus S2
3HAC042536-001
Grease
Rotating sealings
The procedure below describes how to fit rotating sealings.
CAUTION
Please observe the following before commencing any assembly of sealings:
•
Protect the sealing during transport and mounting, especially the main lip.
•
Keep the sealing in its original wrappings or protect it well before actual
mounting.
•
The fitting of sealings and gears must be carried out on clean workbenches.
•
Use a protective sleeve for the main lip during mounting, when sliding over
threads, keyways or other sharp edges.
Note
Action
Check the sealing to ensure that:
•
The sealing is of the correct type.
•
There is no damage on the main lip.
1
Inspect the shaft surface before mounting. If scratches
or damage are found, the shaft must be replaced since
it may result in future leakage. Do not try to grind or
polish the shaft surface to get rid of the defect.
2
Article number is specified in
Equipment on page 209 .
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
A
B
C
xx2000000071
A
Main lip
B
Grease
C
Dust lip
Lubricate the sealing with grease just before fitting.
(Not too early - there is a risk of dirt and foreign
particles adhering to the sealing.)
Fill 2/3 of the space between the dust lip and the main
lip with grease. If the sealing is without dust lip, just
lubricate the main lip with a thin layer of grease.
3
Continues on next page
Product manual - IRB 7600
209
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.2.3 Mounting instructions for sealings
Note
Action
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
A
xx2000000072
A
Gap
Mount the sealing correctly with a mounting tool.
Never hammer directly on the sealing as this may
result in leakage.
4
Flange sealings and static sealings
The following procedure describes how to fit flange sealings and static sealings.
Action
Check the flange surfaces. They must be even and free from pores.
1
It is easy to check flatness using a gauge on the fastened joint (without sealing com-
pound).
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.
2
Distribute the sealing compound evenly over the surface, preferably with a brush.
3
Tighten the screws evenly when fastening the flange joint.
4
O-rings
The following procedure describes how to fit o-rings.
Note
Action
Ensure that the correct o-ring size is used.
1
Defective o-rings, including damaged
or deformed o-rings, may not be used.
Check the o-ring for surface defects, burrs,
shape accuracy, or deformation.
2
Continues on next page
210
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.2.3 Mounting instructions for sealings
Continued
Note
Action
Check the o-ring grooves.
3
The grooves must be geometrically correct and
should be free of pores and contamination.
Lubricate the o-ring with grease.
4
Tighten the screws evenly while assembling.
5
Check that the o-ring is not squashed outside
the o-ring groove.
6
Product manual - IRB 7600
211
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.2.3 Mounting instructions for sealings
Continued
|
ABB_IRB7600_Product_Manual.pdf
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| 211
|
Note
Action
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
A
xx2000000072
A
Gap
Mount the sealing correctly with a mounting tool.
Never hammer directly on the sealing as this may
result in leakage.
4
Flange sealings and static sealings
The following procedure describes how to fit flange sealings and static sealings.
Action
Check the flange surfaces. They must be even and free from pores.
1
It is easy to check flatness using a gauge on the fastened joint (without sealing com-
pound).
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.
2
Distribute the sealing compound evenly over the surface, preferably with a brush.
3
Tighten the screws evenly when fastening the flange joint.
4
O-rings
The following procedure describes how to fit o-rings.
Note
Action
Ensure that the correct o-ring size is used.
1
Defective o-rings, including damaged
or deformed o-rings, may not be used.
Check the o-ring for surface defects, burrs,
shape accuracy, or deformation.
2
Continues on next page
210
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.2.3 Mounting instructions for sealings
Continued
Note
Action
Check the o-ring grooves.
3
The grooves must be geometrically correct and
should be free of pores and contamination.
Lubricate the o-ring with grease.
4
Tighten the screws evenly while assembling.
5
Check that the o-ring is not squashed outside
the o-ring groove.
6
Product manual - IRB 7600
211
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.2.3 Mounting instructions for sealings
Continued
4.2.4 Cut the paint or surface on the robot before replacing parts
General
Follow the procedures in this section whenever breaking the paint of the robot
during replacement of parts.
Required equipment
Note
Spare parts
Equipment
Ethanol
Cleaning agent
Knife
Lint free cloth
Graphite White
3HAC067974-001
Touch up paint Standard/Foundry
Plus
ABB Orange
3HAC037052-001
Touch up paint Standard/Foundry
Plus
Removing
Description
Action
![Image]
![Image]
xx0900000121
Cut the paint with a knife in the joint between
the part that will be removed and the struc-
ture, to avoid that the paint cracks.
1
Carefully grind the paint edge that is left on
the structure to a smooth surface.
2
212
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.2.4 Cut the paint or surface on the robot before replacing parts
|
ABB_IRB7600_Product_Manual.pdf
|
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| 212
|
Note
Action
Check the o-ring grooves.
3
The grooves must be geometrically correct and
should be free of pores and contamination.
Lubricate the o-ring with grease.
4
Tighten the screws evenly while assembling.
5
Check that the o-ring is not squashed outside
the o-ring groove.
6
Product manual - IRB 7600
211
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.2.3 Mounting instructions for sealings
Continued
4.2.4 Cut the paint or surface on the robot before replacing parts
General
Follow the procedures in this section whenever breaking the paint of the robot
during replacement of parts.
Required equipment
Note
Spare parts
Equipment
Ethanol
Cleaning agent
Knife
Lint free cloth
Graphite White
3HAC067974-001
Touch up paint Standard/Foundry
Plus
ABB Orange
3HAC037052-001
Touch up paint Standard/Foundry
Plus
Removing
Description
Action
![Image]
![Image]
xx0900000121
Cut the paint with a knife in the joint between
the part that will be removed and the struc-
ture, to avoid that the paint cracks.
1
Carefully grind the paint edge that is left on
the structure to a smooth surface.
2
212
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.2.4 Cut the paint or surface on the robot before replacing parts
4.2.5 The brake release buttons may be jammed after service work
Description
The brake release unit has push-buttons for the brake release of each axis motor.
When service work is performed inside the SMB recess that includes removal and
refitting of the brake release unit, the brake release buttons may be jammed after
refitting.
DANGER
If the power is turned on while a brake release button is jammed in depressed
position, the affected motor brake is released. This may cause serious personal
injuries and damage to the robot.
Elimination
To eliminate the danger after service work has been performed inside the SMB
recess, follow the procedure below.
Action
Make sure the power is turned off.
1
Remove the push-button guard, if necessary.
2
Verify that the push-buttons of the brake release unit are working by pressing them
down, one by one.
3
Make sure none of the buttons are jammed in the tube.
If a button gets jammed in the depressed position, the alignment of the brake release
unit must be adjusted so that the buttons can move freely in their tubes.
4
Product manual - IRB 7600
213
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.2.5 The brake release buttons may be jammed after service work
|
ABB_IRB7600_Product_Manual.pdf
|
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| 213
|
4.2.4 Cut the paint or surface on the robot before replacing parts
General
Follow the procedures in this section whenever breaking the paint of the robot
during replacement of parts.
Required equipment
Note
Spare parts
Equipment
Ethanol
Cleaning agent
Knife
Lint free cloth
Graphite White
3HAC067974-001
Touch up paint Standard/Foundry
Plus
ABB Orange
3HAC037052-001
Touch up paint Standard/Foundry
Plus
Removing
Description
Action
![Image]
![Image]
xx0900000121
Cut the paint with a knife in the joint between
the part that will be removed and the struc-
ture, to avoid that the paint cracks.
1
Carefully grind the paint edge that is left on
the structure to a smooth surface.
2
212
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.2.4 Cut the paint or surface on the robot before replacing parts
4.2.5 The brake release buttons may be jammed after service work
Description
The brake release unit has push-buttons for the brake release of each axis motor.
When service work is performed inside the SMB recess that includes removal and
refitting of the brake release unit, the brake release buttons may be jammed after
refitting.
DANGER
If the power is turned on while a brake release button is jammed in depressed
position, the affected motor brake is released. This may cause serious personal
injuries and damage to the robot.
Elimination
To eliminate the danger after service work has been performed inside the SMB
recess, follow the procedure below.
Action
Make sure the power is turned off.
1
Remove the push-button guard, if necessary.
2
Verify that the push-buttons of the brake release unit are working by pressing them
down, one by one.
3
Make sure none of the buttons are jammed in the tube.
If a button gets jammed in the depressed position, the alignment of the brake release
unit must be adjusted so that the buttons can move freely in their tubes.
4
Product manual - IRB 7600
213
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.2.5 The brake release buttons may be jammed after service work
4.3 Complete robot
4.3.1 Replacement of cable harness, axes 1-4
Location of cable harness
The cable harness for axes 1-4 is run throughout the base, frame and lower arm
as shown in the figure below.
The brake release unit can be located at two alternative places, either at the rear
of the base or at the side of the frame. Depending on the location, the two types
of harnesses are distinguished some from each other! Any differences are pointed
out in the procedures!
xx0100000140
Alternative with brake release at frame
1
Alternative with brake release at base
2
Connector at robot base, R1.MP and R1.SMB
A
Connectors at motor 1; R2.FB1 and R2.MP1
B
Connectors at motor 2; R2.FB2 and R2.MP2
C
Connectors at serial measurement board; R1.SMB1-3, R1.SMB4-6, R1.SMB1.7,
R2.FB7 and R2.SMB. Battery connector X3 R1.G and R2.G. If brake release
located at the frame: also connectors X8, X9 and X10!
D
Continues on next page
214
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
|
ABB_IRB7600_Product_Manual.pdf
|
https://search.abb.com/library/Download.aspx?DocumentID=3HAC022033-001&LanguageCode=en&DocumentPartId=&Action=Launch&DocumentRevisionId=AF
| 214
|
4.2.5 The brake release buttons may be jammed after service work
Description
The brake release unit has push-buttons for the brake release of each axis motor.
When service work is performed inside the SMB recess that includes removal and
refitting of the brake release unit, the brake release buttons may be jammed after
refitting.
DANGER
If the power is turned on while a brake release button is jammed in depressed
position, the affected motor brake is released. This may cause serious personal
injuries and damage to the robot.
Elimination
To eliminate the danger after service work has been performed inside the SMB
recess, follow the procedure below.
Action
Make sure the power is turned off.
1
Remove the push-button guard, if necessary.
2
Verify that the push-buttons of the brake release unit are working by pressing them
down, one by one.
3
Make sure none of the buttons are jammed in the tube.
If a button gets jammed in the depressed position, the alignment of the brake release
unit must be adjusted so that the buttons can move freely in their tubes.
4
Product manual - IRB 7600
213
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.2.5 The brake release buttons may be jammed after service work
4.3 Complete robot
4.3.1 Replacement of cable harness, axes 1-4
Location of cable harness
The cable harness for axes 1-4 is run throughout the base, frame and lower arm
as shown in the figure below.
The brake release unit can be located at two alternative places, either at the rear
of the base or at the side of the frame. Depending on the location, the two types
of harnesses are distinguished some from each other! Any differences are pointed
out in the procedures!
xx0100000140
Alternative with brake release at frame
1
Alternative with brake release at base
2
Connector at robot base, R1.MP and R1.SMB
A
Connectors at motor 1; R2.FB1 and R2.MP1
B
Connectors at motor 2; R2.FB2 and R2.MP2
C
Connectors at serial measurement board; R1.SMB1-3, R1.SMB4-6, R1.SMB1.7,
R2.FB7 and R2.SMB. Battery connector X3 R1.G and R2.G. If brake release
located at the frame: also connectors X8, X9 and X10!
D
Continues on next page
214
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Connectors at motor 3; R2.FB3 and R2.MP3 and for signal lamp R2.H1 and
R2.H2
E
Connectors at motor 4; R2.FB4 and R2.MP4
F
Connectors at cable harness separation; R2.M5/6
G
Connectors at motor 5; R3.FB5 and R3.MP5
H
Connectors at motor 6; R3.FB6 and R3.MP6
J
Rear cover plate
K
Connector R1.MP
L
Connector R1.SMB
M
Connection of earth cable
N
Required equipment
Note
Art. no.
Spare part no.
Equipment, etc.
Brake release located at
base.
3HAC12782-1
Cable harness, axes 1-4
Brake release located in
frame.
3HAC14940-1
Cable harness, axes 1-4
Loctite 243
Locking liquid
Used to secure the attach-
ment screws for the attach-
ment plate inside the frame.
Content is defined in section
Standard tools on page419 .
-
Standard toolkit
These procedures include
references to the tools re-
quired.
Other tools and proced-
ures may be required. See
references to these proced-
ures in the step-by-step
instructions below.
See chapter Circuit diagram
on page 427 .
Circuit diagram
Removal, cable harness, axes 1-4
The procedure below details how to remove the cable harness, axes 1-4.
Note
Action
Axes 2 and 3 may be tilted
slightly to improve access.
In order to facilitate refitting of cable harness, run
the robot to the specified position:
•
Axis 1: 0 °
•
Axis 2: 0 °
•
Axis 3: 0 °
•
Axis 4: 0 °
•
Axis 5: +90 °
•
Axis 6: no significance
1
Continues on next page
Product manual - IRB 7600
215
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 215
|
4.3 Complete robot
4.3.1 Replacement of cable harness, axes 1-4
Location of cable harness
The cable harness for axes 1-4 is run throughout the base, frame and lower arm
as shown in the figure below.
The brake release unit can be located at two alternative places, either at the rear
of the base or at the side of the frame. Depending on the location, the two types
of harnesses are distinguished some from each other! Any differences are pointed
out in the procedures!
xx0100000140
Alternative with brake release at frame
1
Alternative with brake release at base
2
Connector at robot base, R1.MP and R1.SMB
A
Connectors at motor 1; R2.FB1 and R2.MP1
B
Connectors at motor 2; R2.FB2 and R2.MP2
C
Connectors at serial measurement board; R1.SMB1-3, R1.SMB4-6, R1.SMB1.7,
R2.FB7 and R2.SMB. Battery connector X3 R1.G and R2.G. If brake release
located at the frame: also connectors X8, X9 and X10!
D
Continues on next page
214
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Connectors at motor 3; R2.FB3 and R2.MP3 and for signal lamp R2.H1 and
R2.H2
E
Connectors at motor 4; R2.FB4 and R2.MP4
F
Connectors at cable harness separation; R2.M5/6
G
Connectors at motor 5; R3.FB5 and R3.MP5
H
Connectors at motor 6; R3.FB6 and R3.MP6
J
Rear cover plate
K
Connector R1.MP
L
Connector R1.SMB
M
Connection of earth cable
N
Required equipment
Note
Art. no.
Spare part no.
Equipment, etc.
Brake release located at
base.
3HAC12782-1
Cable harness, axes 1-4
Brake release located in
frame.
3HAC14940-1
Cable harness, axes 1-4
Loctite 243
Locking liquid
Used to secure the attach-
ment screws for the attach-
ment plate inside the frame.
Content is defined in section
Standard tools on page419 .
-
Standard toolkit
These procedures include
references to the tools re-
quired.
Other tools and proced-
ures may be required. See
references to these proced-
ures in the step-by-step
instructions below.
See chapter Circuit diagram
on page 427 .
Circuit diagram
Removal, cable harness, axes 1-4
The procedure below details how to remove the cable harness, axes 1-4.
Note
Action
Axes 2 and 3 may be tilted
slightly to improve access.
In order to facilitate refitting of cable harness, run
the robot to the specified position:
•
Axis 1: 0 °
•
Axis 2: 0 °
•
Axis 3: 0 °
•
Axis 4: 0 °
•
Axis 5: +90 °
•
Axis 6: no significance
1
Continues on next page
Product manual - IRB 7600
215
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
2
Shown in the figure Location of
cable harness on page 214 .
Remove the rear cover plate from the robot by remov-
ing its attachment screws.
3
Attachment point is shown in the
figure Location of cable harness
on page 214 !
Disconnect the earth cable .
4
Attachment points are shown in
the figure Location of cable har-
ness on page 214 .
Disconnect connectors R1.MP and R1.SMB .
5
Pull the cable and connectors up through the cable
guide in the center of the frame.
6
Specified and shown in the figure
Location of cable harness on
page 214 !
Disconnect all connectors at motors 1 and 2.
7
Open the SMB cover carefully.
8
The cable between the battery and the SMB-unit may
stay connected, in order to avoid an update of the
revolution counter. Be careful not to let the weight
of the cover strain the cable!
In order to remove the cover completely, the connect-
or R1.G must be disconnected! This causes a neces-
sary updating of the revolution counter!
xx0200000118
Disconnect connectors R2.SMB, R1.SMB1-3,
R1.SMB4-6 from the SMB unit.
Disconnect X8, X9 and X10 if the brake release board
is located in frame.
9
Continues on next page
216
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3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
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| 216
|
Connectors at motor 3; R2.FB3 and R2.MP3 and for signal lamp R2.H1 and
R2.H2
E
Connectors at motor 4; R2.FB4 and R2.MP4
F
Connectors at cable harness separation; R2.M5/6
G
Connectors at motor 5; R3.FB5 and R3.MP5
H
Connectors at motor 6; R3.FB6 and R3.MP6
J
Rear cover plate
K
Connector R1.MP
L
Connector R1.SMB
M
Connection of earth cable
N
Required equipment
Note
Art. no.
Spare part no.
Equipment, etc.
Brake release located at
base.
3HAC12782-1
Cable harness, axes 1-4
Brake release located in
frame.
3HAC14940-1
Cable harness, axes 1-4
Loctite 243
Locking liquid
Used to secure the attach-
ment screws for the attach-
ment plate inside the frame.
Content is defined in section
Standard tools on page419 .
-
Standard toolkit
These procedures include
references to the tools re-
quired.
Other tools and proced-
ures may be required. See
references to these proced-
ures in the step-by-step
instructions below.
See chapter Circuit diagram
on page 427 .
Circuit diagram
Removal, cable harness, axes 1-4
The procedure below details how to remove the cable harness, axes 1-4.
Note
Action
Axes 2 and 3 may be tilted
slightly to improve access.
In order to facilitate refitting of cable harness, run
the robot to the specified position:
•
Axis 1: 0 °
•
Axis 2: 0 °
•
Axis 3: 0 °
•
Axis 4: 0 °
•
Axis 5: +90 °
•
Axis 6: no significance
1
Continues on next page
Product manual - IRB 7600
215
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
2
Shown in the figure Location of
cable harness on page 214 .
Remove the rear cover plate from the robot by remov-
ing its attachment screws.
3
Attachment point is shown in the
figure Location of cable harness
on page 214 !
Disconnect the earth cable .
4
Attachment points are shown in
the figure Location of cable har-
ness on page 214 .
Disconnect connectors R1.MP and R1.SMB .
5
Pull the cable and connectors up through the cable
guide in the center of the frame.
6
Specified and shown in the figure
Location of cable harness on
page 214 !
Disconnect all connectors at motors 1 and 2.
7
Open the SMB cover carefully.
8
The cable between the battery and the SMB-unit may
stay connected, in order to avoid an update of the
revolution counter. Be careful not to let the weight
of the cover strain the cable!
In order to remove the cover completely, the connect-
or R1.G must be disconnected! This causes a neces-
sary updating of the revolution counter!
xx0200000118
Disconnect connectors R2.SMB, R1.SMB1-3,
R1.SMB4-6 from the SMB unit.
Disconnect X8, X9 and X10 if the brake release board
is located in frame.
9
Continues on next page
216
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3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
Note
Action
xx0300000560
Remove
•
the cable gland (A), by removing the four at-
tachment screws from inside the SMB recess
(B)
•
the attachment plate (C), by removing the at-
tachment screws and the velcro strap (D).
Note
Different robot versions are fitted with different ver-
sions of the attachment plate. When replacing the
cable harness, make sure the correct one is used to
avoid cable failure.
10
•
A: Cable gland
•
B: Attachment screws,
cable gland
•
C: Attachment plate
•
D: Velcro strap
Remove the cable gland securing the cables inside
the lower arm.
11
Continues on next page
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217
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
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| 217
|
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
2
Shown in the figure Location of
cable harness on page 214 .
Remove the rear cover plate from the robot by remov-
ing its attachment screws.
3
Attachment point is shown in the
figure Location of cable harness
on page 214 !
Disconnect the earth cable .
4
Attachment points are shown in
the figure Location of cable har-
ness on page 214 .
Disconnect connectors R1.MP and R1.SMB .
5
Pull the cable and connectors up through the cable
guide in the center of the frame.
6
Specified and shown in the figure
Location of cable harness on
page 214 !
Disconnect all connectors at motors 1 and 2.
7
Open the SMB cover carefully.
8
The cable between the battery and the SMB-unit may
stay connected, in order to avoid an update of the
revolution counter. Be careful not to let the weight
of the cover strain the cable!
In order to remove the cover completely, the connect-
or R1.G must be disconnected! This causes a neces-
sary updating of the revolution counter!
xx0200000118
Disconnect connectors R2.SMB, R1.SMB1-3,
R1.SMB4-6 from the SMB unit.
Disconnect X8, X9 and X10 if the brake release board
is located in frame.
9
Continues on next page
216
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3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
Note
Action
xx0300000560
Remove
•
the cable gland (A), by removing the four at-
tachment screws from inside the SMB recess
(B)
•
the attachment plate (C), by removing the at-
tachment screws and the velcro strap (D).
Note
Different robot versions are fitted with different ver-
sions of the attachment plate. When replacing the
cable harness, make sure the correct one is used to
avoid cable failure.
10
•
A: Cable gland
•
B: Attachment screws,
cable gland
•
C: Attachment plate
•
D: Velcro strap
Remove the cable gland securing the cables inside
the lower arm.
11
Continues on next page
Product manual - IRB 7600
217
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
Note
Action
![Image]
xx0100000143
Remove the cable gland securing the cables to the
arm house.
12
Shown in the figure Location of
cable harness on page 214 .
Remove the velcro strap from the harness at the
cable fixing bracket at the arm house.
13
Shown in the figure Location of
cable harness on page 214 !
Disconnect connector R2.M5/6 at the cable division
point.
14
Specified and shown in the figure
Location of cable harness on
page 214 !
Disconnect all connectors at motor 3 and motor 4.
15
Gently pull the cable harness out.
16
Refitting, cable harness, axes 1-4
The procedure below details how to refit the cable harness, axes 1-4.
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
1
Axes 2 and 3 may be tilted slightly
to improve access.
In order to facilitate refitting of cable harness,
move the robot to the specified position:
•
Axis 1: 0 degrees
•
Axis 2: 0 degrees
•
Axis 3: 0 degrees
•
Axis 4: 0 degrees
•
Axis 5: +90 degrees
•
Axis 6: no significance
2
Continues on next page
218
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3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
|
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| 218
|
Note
Action
xx0300000560
Remove
•
the cable gland (A), by removing the four at-
tachment screws from inside the SMB recess
(B)
•
the attachment plate (C), by removing the at-
tachment screws and the velcro strap (D).
Note
Different robot versions are fitted with different ver-
sions of the attachment plate. When replacing the
cable harness, make sure the correct one is used to
avoid cable failure.
10
•
A: Cable gland
•
B: Attachment screws,
cable gland
•
C: Attachment plate
•
D: Velcro strap
Remove the cable gland securing the cables inside
the lower arm.
11
Continues on next page
Product manual - IRB 7600
217
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
Note
Action
![Image]
xx0100000143
Remove the cable gland securing the cables to the
arm house.
12
Shown in the figure Location of
cable harness on page 214 .
Remove the velcro strap from the harness at the
cable fixing bracket at the arm house.
13
Shown in the figure Location of
cable harness on page 214 !
Disconnect connector R2.M5/6 at the cable division
point.
14
Specified and shown in the figure
Location of cable harness on
page 214 !
Disconnect all connectors at motor 3 and motor 4.
15
Gently pull the cable harness out.
16
Refitting, cable harness, axes 1-4
The procedure below details how to refit the cable harness, axes 1-4.
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
1
Axes 2 and 3 may be tilted slightly
to improve access.
In order to facilitate refitting of cable harness,
move the robot to the specified position:
•
Axis 1: 0 degrees
•
Axis 2: 0 degrees
•
Axis 3: 0 degrees
•
Axis 4: 0 degrees
•
Axis 5: +90 degrees
•
Axis 6: no significance
2
Continues on next page
218
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
Note
Action
Make sure the cables are not twis-
ted with each other or with eventual
customer harnesses!
Pull the cable and connectors down through the
cable guide in the center of the frame.
3
Make a note of the correct positions
of the connectors!
Tightening torque for R1.SMB: 10
Nm.
Reconnect connectors R1.MP and R1.SMB at the
rear cover plate.
4
Make a note of the correct positions
of the connectors!
Attachment point is shown in the
figure Location of cable harness on
page 214 .
Attachment point is shown in the
figure Location of cable harness on
page 214 !
Reconnect the earth cable.
5
Shown in the figure Location of
cable harness on page 214 .
Refit the rear cover plate to the robot with its at-
tachment screws.
6
Specified and shown in the figure
Location of cable harness on
page 214 !
Reconnect all connectors at motors 1 and 2.
7
Continues on next page
Product manual - IRB 7600
219
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
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| 219
|
Note
Action
![Image]
xx0100000143
Remove the cable gland securing the cables to the
arm house.
12
Shown in the figure Location of
cable harness on page 214 .
Remove the velcro strap from the harness at the
cable fixing bracket at the arm house.
13
Shown in the figure Location of
cable harness on page 214 !
Disconnect connector R2.M5/6 at the cable division
point.
14
Specified and shown in the figure
Location of cable harness on
page 214 !
Disconnect all connectors at motor 3 and motor 4.
15
Gently pull the cable harness out.
16
Refitting, cable harness, axes 1-4
The procedure below details how to refit the cable harness, axes 1-4.
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
1
Axes 2 and 3 may be tilted slightly
to improve access.
In order to facilitate refitting of cable harness,
move the robot to the specified position:
•
Axis 1: 0 degrees
•
Axis 2: 0 degrees
•
Axis 3: 0 degrees
•
Axis 4: 0 degrees
•
Axis 5: +90 degrees
•
Axis 6: no significance
2
Continues on next page
218
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
Note
Action
Make sure the cables are not twis-
ted with each other or with eventual
customer harnesses!
Pull the cable and connectors down through the
cable guide in the center of the frame.
3
Make a note of the correct positions
of the connectors!
Tightening torque for R1.SMB: 10
Nm.
Reconnect connectors R1.MP and R1.SMB at the
rear cover plate.
4
Make a note of the correct positions
of the connectors!
Attachment point is shown in the
figure Location of cable harness on
page 214 .
Attachment point is shown in the
figure Location of cable harness on
page 214 !
Reconnect the earth cable.
5
Shown in the figure Location of
cable harness on page 214 .
Refit the rear cover plate to the robot with its at-
tachment screws.
6
Specified and shown in the figure
Location of cable harness on
page 214 !
Reconnect all connectors at motors 1 and 2.
7
Continues on next page
Product manual - IRB 7600
219
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
Note
Action
Locking liquid is specified in Re-
quired equipment on page 215 .
xx0300000560
Secure the cable gland (A) with four attachment
screws (B) from inside the SMB recess.
Secure the correct attachment plate (C) to the
cable gland with its two attachment screws, using
locking liquid.
Refit the velcro strap (D).
Note
Different robot versions are fitted with different
versions of the attachment plate. Make sure the
correct one is used to avoid cable failure.
8
•
A: Cable gland
•
B: Attachment screws, cable
gland
•
C: Attachment plate
•
D: Velcro strap
Continues on next page
220
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
|
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| 220
|
Note
Action
Make sure the cables are not twis-
ted with each other or with eventual
customer harnesses!
Pull the cable and connectors down through the
cable guide in the center of the frame.
3
Make a note of the correct positions
of the connectors!
Tightening torque for R1.SMB: 10
Nm.
Reconnect connectors R1.MP and R1.SMB at the
rear cover plate.
4
Make a note of the correct positions
of the connectors!
Attachment point is shown in the
figure Location of cable harness on
page 214 .
Attachment point is shown in the
figure Location of cable harness on
page 214 !
Reconnect the earth cable.
5
Shown in the figure Location of
cable harness on page 214 .
Refit the rear cover plate to the robot with its at-
tachment screws.
6
Specified and shown in the figure
Location of cable harness on
page 214 !
Reconnect all connectors at motors 1 and 2.
7
Continues on next page
Product manual - IRB 7600
219
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
Note
Action
Locking liquid is specified in Re-
quired equipment on page 215 .
xx0300000560
Secure the cable gland (A) with four attachment
screws (B) from inside the SMB recess.
Secure the correct attachment plate (C) to the
cable gland with its two attachment screws, using
locking liquid.
Refit the velcro strap (D).
Note
Different robot versions are fitted with different
versions of the attachment plate. Make sure the
correct one is used to avoid cable failure.
8
•
A: Cable gland
•
B: Attachment screws, cable
gland
•
C: Attachment plate
•
D: Velcro strap
Continues on next page
220
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
Note
Action
xx0200000118
Reconnect connectors R2.SMB, R1.SMB1-3,
R1.SMB4-6 to the SMB unit.
Reconnect X8, X9 and X10 if the brake release
board is located in frame.
Reconnect R1.G if it has been disconnected.
9
Secure the SMB cover with its attachment screws.
10
If cabling is used for 7th axis (option), refit the
connector R2.FB7 to the SMB cover and tighten
with 6 Nm.
WARNING
Before continuing any service work, please ob-
serve the safety information in section The brake
release buttons may be jammed after service work
on page 213 !
11
Pull the cable harness through the lower arm.
12
xx0100000142
Refit the cable gland securing the cables inside
the lower arm.
13
![Image]
xx0100000143
Refit the cable gland securing the cables to the
arm house.
Make sure not to twist the harness!
14
Continues on next page
Product manual - IRB 7600
221
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
|
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| 221
|
Note
Action
Locking liquid is specified in Re-
quired equipment on page 215 .
xx0300000560
Secure the cable gland (A) with four attachment
screws (B) from inside the SMB recess.
Secure the correct attachment plate (C) to the
cable gland with its two attachment screws, using
locking liquid.
Refit the velcro strap (D).
Note
Different robot versions are fitted with different
versions of the attachment plate. Make sure the
correct one is used to avoid cable failure.
8
•
A: Cable gland
•
B: Attachment screws, cable
gland
•
C: Attachment plate
•
D: Velcro strap
Continues on next page
220
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
Note
Action
xx0200000118
Reconnect connectors R2.SMB, R1.SMB1-3,
R1.SMB4-6 to the SMB unit.
Reconnect X8, X9 and X10 if the brake release
board is located in frame.
Reconnect R1.G if it has been disconnected.
9
Secure the SMB cover with its attachment screws.
10
If cabling is used for 7th axis (option), refit the
connector R2.FB7 to the SMB cover and tighten
with 6 Nm.
WARNING
Before continuing any service work, please ob-
serve the safety information in section The brake
release buttons may be jammed after service work
on page 213 !
11
Pull the cable harness through the lower arm.
12
xx0100000142
Refit the cable gland securing the cables inside
the lower arm.
13
![Image]
xx0100000143
Refit the cable gland securing the cables to the
arm house.
Make sure not to twist the harness!
14
Continues on next page
Product manual - IRB 7600
221
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
Note
Action
Specified and shown in the figure
Location of cable harness on
page 214 !
Reconnect all connectors at motor 3 and motor
4.
15
Shown in the figure Location of
cable harness on page 214 !
Reconnect the connector R2.M5/6 gently at the
cable division point.
Be careful not to bend the attachment plate when
fastening the screws!
16
M6, 2 pcs.
Shown in the figure Location of
cable harness on page 214 !
Secure the cable harness to the upper arm house
by refitting the velcro strap to the cable bracket
at the upper arm house.
17
A
xx0500002320
Fit a cable protection to the lower arm, if not
already mounted, with two securing screws (A),
M6x16.
18
B
xx1900001419
Secure the cable harness with five velcro straps
(B), according to the figure. Fix the strap by
wrapping it two turns around the largest cable
before wrapping around the complete harness.
19
Shown in the figure Location of
cable harness on page 214 .
Refit the cable harness to the guide plate axis 2 .
20
Shown in the figure Location of
cable harness on page 214 .
Refit the velcro strap at the guide plate axis 2.
21
Continues on next page
222
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3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
|
ABB_IRB7600_Product_Manual.pdf
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| 222
|
Note
Action
xx0200000118
Reconnect connectors R2.SMB, R1.SMB1-3,
R1.SMB4-6 to the SMB unit.
Reconnect X8, X9 and X10 if the brake release
board is located in frame.
Reconnect R1.G if it has been disconnected.
9
Secure the SMB cover with its attachment screws.
10
If cabling is used for 7th axis (option), refit the
connector R2.FB7 to the SMB cover and tighten
with 6 Nm.
WARNING
Before continuing any service work, please ob-
serve the safety information in section The brake
release buttons may be jammed after service work
on page 213 !
11
Pull the cable harness through the lower arm.
12
xx0100000142
Refit the cable gland securing the cables inside
the lower arm.
13
![Image]
xx0100000143
Refit the cable gland securing the cables to the
arm house.
Make sure not to twist the harness!
14
Continues on next page
Product manual - IRB 7600
221
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
Note
Action
Specified and shown in the figure
Location of cable harness on
page 214 !
Reconnect all connectors at motor 3 and motor
4.
15
Shown in the figure Location of
cable harness on page 214 !
Reconnect the connector R2.M5/6 gently at the
cable division point.
Be careful not to bend the attachment plate when
fastening the screws!
16
M6, 2 pcs.
Shown in the figure Location of
cable harness on page 214 !
Secure the cable harness to the upper arm house
by refitting the velcro strap to the cable bracket
at the upper arm house.
17
A
xx0500002320
Fit a cable protection to the lower arm, if not
already mounted, with two securing screws (A),
M6x16.
18
B
xx1900001419
Secure the cable harness with five velcro straps
(B), according to the figure. Fix the strap by
wrapping it two turns around the largest cable
before wrapping around the complete harness.
19
Shown in the figure Location of
cable harness on page 214 .
Refit the cable harness to the guide plate axis 2 .
20
Shown in the figure Location of
cable harness on page 214 .
Refit the velcro strap at the guide plate axis 2.
21
Continues on next page
222
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4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
Note
Action
Detailed in the Calibration chapter
- section Updating revolution coun-
ters on IRC5 robots on page 378 .
If the connection between the SMB battery and
the SMB unit has been broken, the revolution
counters must now be updated!
22
DANGER
Make sure all safety requirements are met when
performing the first test run.
23
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223
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4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
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|
Note
Action
Specified and shown in the figure
Location of cable harness on
page 214 !
Reconnect all connectors at motor 3 and motor
4.
15
Shown in the figure Location of
cable harness on page 214 !
Reconnect the connector R2.M5/6 gently at the
cable division point.
Be careful not to bend the attachment plate when
fastening the screws!
16
M6, 2 pcs.
Shown in the figure Location of
cable harness on page 214 !
Secure the cable harness to the upper arm house
by refitting the velcro strap to the cable bracket
at the upper arm house.
17
A
xx0500002320
Fit a cable protection to the lower arm, if not
already mounted, with two securing screws (A),
M6x16.
18
B
xx1900001419
Secure the cable harness with five velcro straps
(B), according to the figure. Fix the strap by
wrapping it two turns around the largest cable
before wrapping around the complete harness.
19
Shown in the figure Location of
cable harness on page 214 .
Refit the cable harness to the guide plate axis 2 .
20
Shown in the figure Location of
cable harness on page 214 .
Refit the velcro strap at the guide plate axis 2.
21
Continues on next page
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© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
Note
Action
Detailed in the Calibration chapter
- section Updating revolution coun-
ters on IRC5 robots on page 378 .
If the connection between the SMB battery and
the SMB unit has been broken, the revolution
counters must now be updated!
22
DANGER
Make sure all safety requirements are met when
performing the first test run.
23
Product manual - IRB 7600
223
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
4.3.2 Replacement of cable harness, axes 5-6
Location of cable harness ax 5-6
The location of the cable harness, axes 5-6, is shown in the figure below.
xx0100000145
Cable attachment, upper arm
A
Cable attachment, rear
B
Connector at cable harness division; R2.M5/6
C
Connectors at motor 5; R3.FB5 and R3.MP5
D
Connectors at motor 6; R3.FB6 and R3.MP6
E
Required equipment
Note
Spare part no.
Equipment, etc.
3HAC11440-1
Cable harness ax.5-6
Recommended to be changed for
Foundry Plus robots.
3HAC033489-001
Gasket
Content is defined in section Standard
tools on page 419 .
-
Standard toolkit
These procedures include references
to the tools required.
Other tools and procedures may
be required. See references to
these procedures in the step-by-
step instructions below.
Continues on next page
224
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3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.2 Replacement of cable harness, axes 5-6
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ABB_IRB7600_Product_Manual.pdf
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| 224
|
Note
Action
Detailed in the Calibration chapter
- section Updating revolution coun-
ters on IRC5 robots on page 378 .
If the connection between the SMB battery and
the SMB unit has been broken, the revolution
counters must now be updated!
22
DANGER
Make sure all safety requirements are met when
performing the first test run.
23
Product manual - IRB 7600
223
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.1 Replacement of cable harness, axes 1-4
Continued
4.3.2 Replacement of cable harness, axes 5-6
Location of cable harness ax 5-6
The location of the cable harness, axes 5-6, is shown in the figure below.
xx0100000145
Cable attachment, upper arm
A
Cable attachment, rear
B
Connector at cable harness division; R2.M5/6
C
Connectors at motor 5; R3.FB5 and R3.MP5
D
Connectors at motor 6; R3.FB6 and R3.MP6
E
Required equipment
Note
Spare part no.
Equipment, etc.
3HAC11440-1
Cable harness ax.5-6
Recommended to be changed for
Foundry Plus robots.
3HAC033489-001
Gasket
Content is defined in section Standard
tools on page 419 .
-
Standard toolkit
These procedures include references
to the tools required.
Other tools and procedures may
be required. See references to
these procedures in the step-by-
step instructions below.
Continues on next page
224
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3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.2 Replacement of cable harness, axes 5-6
Note
Spare part no.
Equipment, etc.
See chapter Circuit diagram on
page 427 .
Circuit diagram
Removal, cable harness, axes 5-6
The procedure below details how to remove the upper arm cable harness.
Note
Action
Position the upper arm as follows:
•
Axis 4: 0 degrees
•
Axis 5: +90 degrees
•
Axis 6: no significance
1
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
2
Remove the left hand side wrist cover by unscrewing its
attachment screws.
3
Note
Axis 5 must be oriented in the correct position (+90º) to
allow the motor 6 cover to open!
4
Specified in the figure Loca-
tion of cable harness ax 5-6
on page 224 .
Disconnect all connectors at motor 5 and motor 6.
5
Remove the plastic cover on the rear of the upper arm,
by removing the attachment screws.
6
Remove the spiral plate by unscrewing the screw at the
bottom of the spiral cup.
7
Remove eventual cable straps from the harness.
8
Shown in the figure Location
of cable harness ax 5-6 on
page 224 .
Disconnect connector R2.M5/6 at the cable harness di-
vision .
9
Remove the cable attachment inside the upper arm.
10
Gently pull the cable harness out.
11
Refitting, cable harness, axes 5-6
The procedure below details how to refit the upper cable harness.
Note
Action
Position the upper arm as follows:
•
Axis 4: 0 degrees
•
Axis 5: +90 degrees
•
Axis 6: no significance
1
Continues on next page
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225
3HAC022033-001 Revision: AF
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4 Repair
4.3.2 Replacement of cable harness, axes 5-6
Continued
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4.3.2 Replacement of cable harness, axes 5-6
Location of cable harness ax 5-6
The location of the cable harness, axes 5-6, is shown in the figure below.
xx0100000145
Cable attachment, upper arm
A
Cable attachment, rear
B
Connector at cable harness division; R2.M5/6
C
Connectors at motor 5; R3.FB5 and R3.MP5
D
Connectors at motor 6; R3.FB6 and R3.MP6
E
Required equipment
Note
Spare part no.
Equipment, etc.
3HAC11440-1
Cable harness ax.5-6
Recommended to be changed for
Foundry Plus robots.
3HAC033489-001
Gasket
Content is defined in section Standard
tools on page 419 .
-
Standard toolkit
These procedures include references
to the tools required.
Other tools and procedures may
be required. See references to
these procedures in the step-by-
step instructions below.
Continues on next page
224
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.2 Replacement of cable harness, axes 5-6
Note
Spare part no.
Equipment, etc.
See chapter Circuit diagram on
page 427 .
Circuit diagram
Removal, cable harness, axes 5-6
The procedure below details how to remove the upper arm cable harness.
Note
Action
Position the upper arm as follows:
•
Axis 4: 0 degrees
•
Axis 5: +90 degrees
•
Axis 6: no significance
1
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
2
Remove the left hand side wrist cover by unscrewing its
attachment screws.
3
Note
Axis 5 must be oriented in the correct position (+90º) to
allow the motor 6 cover to open!
4
Specified in the figure Loca-
tion of cable harness ax 5-6
on page 224 .
Disconnect all connectors at motor 5 and motor 6.
5
Remove the plastic cover on the rear of the upper arm,
by removing the attachment screws.
6
Remove the spiral plate by unscrewing the screw at the
bottom of the spiral cup.
7
Remove eventual cable straps from the harness.
8
Shown in the figure Location
of cable harness ax 5-6 on
page 224 .
Disconnect connector R2.M5/6 at the cable harness di-
vision .
9
Remove the cable attachment inside the upper arm.
10
Gently pull the cable harness out.
11
Refitting, cable harness, axes 5-6
The procedure below details how to refit the upper cable harness.
Note
Action
Position the upper arm as follows:
•
Axis 4: 0 degrees
•
Axis 5: +90 degrees
•
Axis 6: no significance
1
Continues on next page
Product manual - IRB 7600
225
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.2 Replacement of cable harness, axes 5-6
Continued
Note
Action
Gently insert the cable harness from the rear into
the upper arm.
2
Pull the small spiral plate past motor 5.
3
Route the cables outside the heat protection plate.
4
Secure the small plate to the large plate. Secure the
spiral cup with its attachment screw in the bottom
of the cup.
5
Excess cable length may be
present if upper arm length is not
the maximum.
Secure any excess cable length tightly to the large
plate in the wrist housing, using cable straps.
Use the attachment holes in the large plate intended
for the cable straps!
6
Specified in the figure Location
of cable harness ax 5-6 on
page 224 .
Reconnect all connectors at motor 5 and motor 6.
7
Secure the cable with the cable attachment inside
the upper arm.
8
Tightening torque: 14 Nm.
Refit the left hand side wrist cover with its attach-
ment screws.
9
Add Loctite to screw before
fastening. Screw 3HAB3409-25,
Washer 3HAC062379-001
Shown in the figure Location of
cable harness ax 5-6 on page224 .
Reconnect connector R2.M5/6 gently at the cable
harness division with two screws, M6.
Be careful not to bend the attachment plate when
fastening the screws!
10
M6, 2 pcs.
Refit the plastic cover on the rear of the upper arm.
11
Detailed in section Updating re-
volution counters on IRC5 robots
on page 378 .
Update the revolution counters.
12
226
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3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.2 Replacement of cable harness, axes 5-6
Continued
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| 226
|
Note
Spare part no.
Equipment, etc.
See chapter Circuit diagram on
page 427 .
Circuit diagram
Removal, cable harness, axes 5-6
The procedure below details how to remove the upper arm cable harness.
Note
Action
Position the upper arm as follows:
•
Axis 4: 0 degrees
•
Axis 5: +90 degrees
•
Axis 6: no significance
1
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
2
Remove the left hand side wrist cover by unscrewing its
attachment screws.
3
Note
Axis 5 must be oriented in the correct position (+90º) to
allow the motor 6 cover to open!
4
Specified in the figure Loca-
tion of cable harness ax 5-6
on page 224 .
Disconnect all connectors at motor 5 and motor 6.
5
Remove the plastic cover on the rear of the upper arm,
by removing the attachment screws.
6
Remove the spiral plate by unscrewing the screw at the
bottom of the spiral cup.
7
Remove eventual cable straps from the harness.
8
Shown in the figure Location
of cable harness ax 5-6 on
page 224 .
Disconnect connector R2.M5/6 at the cable harness di-
vision .
9
Remove the cable attachment inside the upper arm.
10
Gently pull the cable harness out.
11
Refitting, cable harness, axes 5-6
The procedure below details how to refit the upper cable harness.
Note
Action
Position the upper arm as follows:
•
Axis 4: 0 degrees
•
Axis 5: +90 degrees
•
Axis 6: no significance
1
Continues on next page
Product manual - IRB 7600
225
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.2 Replacement of cable harness, axes 5-6
Continued
Note
Action
Gently insert the cable harness from the rear into
the upper arm.
2
Pull the small spiral plate past motor 5.
3
Route the cables outside the heat protection plate.
4
Secure the small plate to the large plate. Secure the
spiral cup with its attachment screw in the bottom
of the cup.
5
Excess cable length may be
present if upper arm length is not
the maximum.
Secure any excess cable length tightly to the large
plate in the wrist housing, using cable straps.
Use the attachment holes in the large plate intended
for the cable straps!
6
Specified in the figure Location
of cable harness ax 5-6 on
page 224 .
Reconnect all connectors at motor 5 and motor 6.
7
Secure the cable with the cable attachment inside
the upper arm.
8
Tightening torque: 14 Nm.
Refit the left hand side wrist cover with its attach-
ment screws.
9
Add Loctite to screw before
fastening. Screw 3HAB3409-25,
Washer 3HAC062379-001
Shown in the figure Location of
cable harness ax 5-6 on page224 .
Reconnect connector R2.M5/6 gently at the cable
harness division with two screws, M6.
Be careful not to bend the attachment plate when
fastening the screws!
10
M6, 2 pcs.
Refit the plastic cover on the rear of the upper arm.
11
Detailed in section Updating re-
volution counters on IRC5 robots
on page 378 .
Update the revolution counters.
12
226
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.2 Replacement of cable harness, axes 5-6
Continued
4.3.3 Replacement of complete arm system
Location of complete arm system
The complete arm system is defined as the complete robot except for the base
and gearbox axis 1, that is the upper and lower arms, balancing device and frame.
This is shown in the figure below.
xx0100000150
Gearbox, axis 1
A
Motor, axis 1
B
Base attachment screws
C
Upper arm
D
Lower arm
E
Frame
F
Continues on next page
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227
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.3 Replacement of complete arm system
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| 227
|
Note
Action
Gently insert the cable harness from the rear into
the upper arm.
2
Pull the small spiral plate past motor 5.
3
Route the cables outside the heat protection plate.
4
Secure the small plate to the large plate. Secure the
spiral cup with its attachment screw in the bottom
of the cup.
5
Excess cable length may be
present if upper arm length is not
the maximum.
Secure any excess cable length tightly to the large
plate in the wrist housing, using cable straps.
Use the attachment holes in the large plate intended
for the cable straps!
6
Specified in the figure Location
of cable harness ax 5-6 on
page 224 .
Reconnect all connectors at motor 5 and motor 6.
7
Secure the cable with the cable attachment inside
the upper arm.
8
Tightening torque: 14 Nm.
Refit the left hand side wrist cover with its attach-
ment screws.
9
Add Loctite to screw before
fastening. Screw 3HAB3409-25,
Washer 3HAC062379-001
Shown in the figure Location of
cable harness ax 5-6 on page224 .
Reconnect connector R2.M5/6 gently at the cable
harness division with two screws, M6.
Be careful not to bend the attachment plate when
fastening the screws!
10
M6, 2 pcs.
Refit the plastic cover on the rear of the upper arm.
11
Detailed in section Updating re-
volution counters on IRC5 robots
on page 378 .
Update the revolution counters.
12
226
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.2 Replacement of cable harness, axes 5-6
Continued
4.3.3 Replacement of complete arm system
Location of complete arm system
The complete arm system is defined as the complete robot except for the base
and gearbox axis 1, that is the upper and lower arms, balancing device and frame.
This is shown in the figure below.
xx0100000150
Gearbox, axis 1
A
Motor, axis 1
B
Base attachment screws
C
Upper arm
D
Lower arm
E
Frame
F
Continues on next page
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227
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.3 Replacement of complete arm system
Balancing device
G
Block for calibration
H
Required equipment
Note
Art. no.
Equipment, etc.
Instruction 3HAC15971-2 enclosed!
3HAC15607-1
Lifting device, robot
Used to guide the complete arm sys-
tem when refitting.
-
Guide pins, M12 x 130
Content is defined in section Stand-
ard tools on page 419 .
-
Standard toolkit
These procedures include references
to the tools required.
Other tools and procedures
may be required. See refer-
ences to these procedures in
the step-by-step instructions
below.
Deciding calibration routine
Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Note
Action
Decide which calibration routine to use for
calibrating the robot.
•
Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
•
Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
1
Follow the instructions given in the refer-
ence calibration routine on the FlexPendant
to create reference values.
If the robot is to be calibrated with refer-
ence calibration:
Find previous reference values for the axis
or create new reference values. These val-
ues are to be used after the repair proced-
ure is completed, for calibration of the ro-
bot.
Creating new values requires possibility to
move the robot.
Read more about reference calibration for
Axis Calibration in Product manual - IRB
4600 .
If no previous reference values exist, and
no new reference values can be created,
then reference calibration is not possible.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
Removal, complete arm system
The procedure below details how to lift and remove the complete arm system.
Note
Action
Decide which calibration routine to use, and
take actions accordingly prior to beginning the
repair procedure.
1
Continues on next page
228
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3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.3 Replacement of complete arm system
Continued
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ABB_IRB7600_Product_Manual.pdf
|
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| 228
|
4.3.3 Replacement of complete arm system
Location of complete arm system
The complete arm system is defined as the complete robot except for the base
and gearbox axis 1, that is the upper and lower arms, balancing device and frame.
This is shown in the figure below.
xx0100000150
Gearbox, axis 1
A
Motor, axis 1
B
Base attachment screws
C
Upper arm
D
Lower arm
E
Frame
F
Continues on next page
Product manual - IRB 7600
227
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.3 Replacement of complete arm system
Balancing device
G
Block for calibration
H
Required equipment
Note
Art. no.
Equipment, etc.
Instruction 3HAC15971-2 enclosed!
3HAC15607-1
Lifting device, robot
Used to guide the complete arm sys-
tem when refitting.
-
Guide pins, M12 x 130
Content is defined in section Stand-
ard tools on page 419 .
-
Standard toolkit
These procedures include references
to the tools required.
Other tools and procedures
may be required. See refer-
ences to these procedures in
the step-by-step instructions
below.
Deciding calibration routine
Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Note
Action
Decide which calibration routine to use for
calibrating the robot.
•
Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
•
Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
1
Follow the instructions given in the refer-
ence calibration routine on the FlexPendant
to create reference values.
If the robot is to be calibrated with refer-
ence calibration:
Find previous reference values for the axis
or create new reference values. These val-
ues are to be used after the repair proced-
ure is completed, for calibration of the ro-
bot.
Creating new values requires possibility to
move the robot.
Read more about reference calibration for
Axis Calibration in Product manual - IRB
4600 .
If no previous reference values exist, and
no new reference values can be created,
then reference calibration is not possible.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
Removal, complete arm system
The procedure below details how to lift and remove the complete arm system.
Note
Action
Decide which calibration routine to use, and
take actions accordingly prior to beginning the
repair procedure.
1
Continues on next page
228
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3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.3 Replacement of complete arm system
Continued
Note
Action
If the brakes need to be released, see
section Manually releasing the brakes
on page 72 .
xx0100000103
Position the robot in its most stable position,
as shown in the figure to the right.
2
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working
area.
3
Detailed in section Changing oil, axis-
1 gearbox on page 163 .
Drain the oil from the gearbox, axis 1.
4
Disconnect the cabling in the rear of the robot
base and remove the cable support plate inside
of the base.
5
Pull the disconnected cabling up through the
center of the axis-1 gearbox.
6
Detailed in section Removal, motor
axis 1 on page 293 .
Remove the motor, axis 1.
7
Run the overhead crane to a position above
the robot.
8
CAUTION
The complete arm system weighs 2000 kg! All
lifting equipment used must be sized accord-
ingly!
9
Art. no. is specified in Required
equipment on page 228 !
Fit the lifting device and adjust it as detailed
in enclosed instruction.
10
Make sure the lift is done completely
level! How to adjust the lift is described
in the enclosed instruction to the lifting
device! Read the instructions before
lifting!
Shown in the figure Location of com-
plete arm system on page 227 !
Remove the block for calibration from the bot-
tom of the frame.
11
Continues on next page
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229
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© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.3 Replacement of complete arm system
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 229
|
Balancing device
G
Block for calibration
H
Required equipment
Note
Art. no.
Equipment, etc.
Instruction 3HAC15971-2 enclosed!
3HAC15607-1
Lifting device, robot
Used to guide the complete arm sys-
tem when refitting.
-
Guide pins, M12 x 130
Content is defined in section Stand-
ard tools on page 419 .
-
Standard toolkit
These procedures include references
to the tools required.
Other tools and procedures
may be required. See refer-
ences to these procedures in
the step-by-step instructions
below.
Deciding calibration routine
Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Note
Action
Decide which calibration routine to use for
calibrating the robot.
•
Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
•
Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
1
Follow the instructions given in the refer-
ence calibration routine on the FlexPendant
to create reference values.
If the robot is to be calibrated with refer-
ence calibration:
Find previous reference values for the axis
or create new reference values. These val-
ues are to be used after the repair proced-
ure is completed, for calibration of the ro-
bot.
Creating new values requires possibility to
move the robot.
Read more about reference calibration for
Axis Calibration in Product manual - IRB
4600 .
If no previous reference values exist, and
no new reference values can be created,
then reference calibration is not possible.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
Removal, complete arm system
The procedure below details how to lift and remove the complete arm system.
Note
Action
Decide which calibration routine to use, and
take actions accordingly prior to beginning the
repair procedure.
1
Continues on next page
228
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.3 Replacement of complete arm system
Continued
Note
Action
If the brakes need to be released, see
section Manually releasing the brakes
on page 72 .
xx0100000103
Position the robot in its most stable position,
as shown in the figure to the right.
2
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working
area.
3
Detailed in section Changing oil, axis-
1 gearbox on page 163 .
Drain the oil from the gearbox, axis 1.
4
Disconnect the cabling in the rear of the robot
base and remove the cable support plate inside
of the base.
5
Pull the disconnected cabling up through the
center of the axis-1 gearbox.
6
Detailed in section Removal, motor
axis 1 on page 293 .
Remove the motor, axis 1.
7
Run the overhead crane to a position above
the robot.
8
CAUTION
The complete arm system weighs 2000 kg! All
lifting equipment used must be sized accord-
ingly!
9
Art. no. is specified in Required
equipment on page 228 !
Fit the lifting device and adjust it as detailed
in enclosed instruction.
10
Make sure the lift is done completely
level! How to adjust the lift is described
in the enclosed instruction to the lifting
device! Read the instructions before
lifting!
Shown in the figure Location of com-
plete arm system on page 227 !
Remove the block for calibration from the bot-
tom of the frame.
11
Continues on next page
Product manual - IRB 7600
229
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.3 Replacement of complete arm system
Continued
Note
Action
Shown in the figure Location of com-
plete arm system on page 227 !
Remove the arm system from the base by un-
screwing the 24 base attachment screws.
12
Make sure all hooks and attachments
maintain in correct position while lifting
the robot!
Lift the arm system and secure it in a safe area.
13
Always move the robot at very low
speeds, making sure it does not tip.
Refitting, complete arm system
The procedure below details how to refit the complete arm system to the robot.
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot
working area.
1
CAUTION
The complete arm system weighs 2000 kg!
All lifting equipment used must be sized
accordingly!
2
Art. no. is specified in Required equip-
ment on page 228 .
Fit and adjust the lifting device as detailed
in enclosed instruction.
3
Make sure all the hooks and attachments
maintain in correct position while lifting
the robot!
Lift the complete arm system and move it
at very low speed, making sure it does not
tip!
4
Make sure the lift is done completely level,
adjust the length of the chains as detailed
in enclosed instruction!
xx0300000070
Fit two guide pins, M12 x 130, in the frame
attachment holes as shown in the figure to
the right.
Fit one guide pin next to the guiding hole
(for the spring pin in the gearbox) and the
other guide pin straight across the frame.
5
The figure above shows a view from be-
low of the frame.
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
230
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.3 Replacement of complete arm system
Continued
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| 230
|
Note
Action
If the brakes need to be released, see
section Manually releasing the brakes
on page 72 .
xx0100000103
Position the robot in its most stable position,
as shown in the figure to the right.
2
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working
area.
3
Detailed in section Changing oil, axis-
1 gearbox on page 163 .
Drain the oil from the gearbox, axis 1.
4
Disconnect the cabling in the rear of the robot
base and remove the cable support plate inside
of the base.
5
Pull the disconnected cabling up through the
center of the axis-1 gearbox.
6
Detailed in section Removal, motor
axis 1 on page 293 .
Remove the motor, axis 1.
7
Run the overhead crane to a position above
the robot.
8
CAUTION
The complete arm system weighs 2000 kg! All
lifting equipment used must be sized accord-
ingly!
9
Art. no. is specified in Required
equipment on page 228 !
Fit the lifting device and adjust it as detailed
in enclosed instruction.
10
Make sure the lift is done completely
level! How to adjust the lift is described
in the enclosed instruction to the lifting
device! Read the instructions before
lifting!
Shown in the figure Location of com-
plete arm system on page 227 !
Remove the block for calibration from the bot-
tom of the frame.
11
Continues on next page
Product manual - IRB 7600
229
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.3 Replacement of complete arm system
Continued
Note
Action
Shown in the figure Location of com-
plete arm system on page 227 !
Remove the arm system from the base by un-
screwing the 24 base attachment screws.
12
Make sure all hooks and attachments
maintain in correct position while lifting
the robot!
Lift the arm system and secure it in a safe area.
13
Always move the robot at very low
speeds, making sure it does not tip.
Refitting, complete arm system
The procedure below details how to refit the complete arm system to the robot.
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot
working area.
1
CAUTION
The complete arm system weighs 2000 kg!
All lifting equipment used must be sized
accordingly!
2
Art. no. is specified in Required equip-
ment on page 228 .
Fit and adjust the lifting device as detailed
in enclosed instruction.
3
Make sure all the hooks and attachments
maintain in correct position while lifting
the robot!
Lift the complete arm system and move it
at very low speed, making sure it does not
tip!
4
Make sure the lift is done completely level,
adjust the length of the chains as detailed
in enclosed instruction!
xx0300000070
Fit two guide pins, M12 x 130, in the frame
attachment holes as shown in the figure to
the right.
Fit one guide pin next to the guiding hole
(for the spring pin in the gearbox) and the
other guide pin straight across the frame.
5
The figure above shows a view from be-
low of the frame.
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
230
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.3 Replacement of complete arm system
Continued
Note
Action
This is a complex task to be performed
with outmost care in order to avoid injury
or damage!
Look through the empty mounting hole of
motor axis 1, to assist in aligning the as-
sembly during refitting of the arm system.
6
The guiding pin in the gearbox must be fitted
to the guiding hole of the frame (B).
Lower the arm system with guidance from
the guide pins previously fitted to the frame.
Refit 22 of the 24 attachment screws before
the arm system is completely lowered.
7
Shown in the figure Location of complete
arm system on page 227 .
Remove the guide pins and secure the arm
system to the base with the 24 base attach-
ment screws and washers.
8
24 pcs, M12 x 110; 12.9 quality UN-
BRAKO, tightening torque: 110 Nm.
Reused screws may be used, providing
they are lubricated as detailed in section
Screw joints on page 415 before fitting.
Shown in the figure Location of complete
arm system on page 227 .
Refit the block for calibration at the bottom
of the frame.
9
Detailed in section Refitting, motor axis
1 on page 294 .
Refit the motor, axis 1.
10
Detailed in section Performing a leak-
down test on page 206 .
Perform a leak-down test.
11
Detailed in section Filling, oil, gearbox
axis 1 on page 166 .
Refill the gearbox axis 1 with lubricating oil.
12
Pendulum Calibration is described in Op-
erating manual - Calibration Pendulum ,
enclosed with the calibration tools.
Recalibrate the robot.
13
Axis Calibration is described in Calibrat-
ing with Axis Calibration method on
page 383 .
General calibration information is included
in section Calibration on page 371 .
DANGER
Make sure all safety requirements are met
when performing the first test run.
14
Product manual - IRB 7600
231
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.3 Replacement of complete arm system
Continued
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| 231
|
Note
Action
Shown in the figure Location of com-
plete arm system on page 227 !
Remove the arm system from the base by un-
screwing the 24 base attachment screws.
12
Make sure all hooks and attachments
maintain in correct position while lifting
the robot!
Lift the arm system and secure it in a safe area.
13
Always move the robot at very low
speeds, making sure it does not tip.
Refitting, complete arm system
The procedure below details how to refit the complete arm system to the robot.
Note
Action
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot
working area.
1
CAUTION
The complete arm system weighs 2000 kg!
All lifting equipment used must be sized
accordingly!
2
Art. no. is specified in Required equip-
ment on page 228 .
Fit and adjust the lifting device as detailed
in enclosed instruction.
3
Make sure all the hooks and attachments
maintain in correct position while lifting
the robot!
Lift the complete arm system and move it
at very low speed, making sure it does not
tip!
4
Make sure the lift is done completely level,
adjust the length of the chains as detailed
in enclosed instruction!
xx0300000070
Fit two guide pins, M12 x 130, in the frame
attachment holes as shown in the figure to
the right.
Fit one guide pin next to the guiding hole
(for the spring pin in the gearbox) and the
other guide pin straight across the frame.
5
The figure above shows a view from be-
low of the frame.
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
230
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.3 Replacement of complete arm system
Continued
Note
Action
This is a complex task to be performed
with outmost care in order to avoid injury
or damage!
Look through the empty mounting hole of
motor axis 1, to assist in aligning the as-
sembly during refitting of the arm system.
6
The guiding pin in the gearbox must be fitted
to the guiding hole of the frame (B).
Lower the arm system with guidance from
the guide pins previously fitted to the frame.
Refit 22 of the 24 attachment screws before
the arm system is completely lowered.
7
Shown in the figure Location of complete
arm system on page 227 .
Remove the guide pins and secure the arm
system to the base with the 24 base attach-
ment screws and washers.
8
24 pcs, M12 x 110; 12.9 quality UN-
BRAKO, tightening torque: 110 Nm.
Reused screws may be used, providing
they are lubricated as detailed in section
Screw joints on page 415 before fitting.
Shown in the figure Location of complete
arm system on page 227 .
Refit the block for calibration at the bottom
of the frame.
9
Detailed in section Refitting, motor axis
1 on page 294 .
Refit the motor, axis 1.
10
Detailed in section Performing a leak-
down test on page 206 .
Perform a leak-down test.
11
Detailed in section Filling, oil, gearbox
axis 1 on page 166 .
Refill the gearbox axis 1 with lubricating oil.
12
Pendulum Calibration is described in Op-
erating manual - Calibration Pendulum ,
enclosed with the calibration tools.
Recalibrate the robot.
13
Axis Calibration is described in Calibrat-
ing with Axis Calibration method on
page 383 .
General calibration information is included
in section Calibration on page 371 .
DANGER
Make sure all safety requirements are met
when performing the first test run.
14
Product manual - IRB 7600
231
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.3 Replacement of complete arm system
Continued
4.4 Upper and lower arm
4.4.1 Replacing turning disk
Location of turning disk
The turning disk is located in the center of the wrist unit as shown in the figure
below.
xx0100000129
Turning disk
A
Oil plug, filling (oil plug for draining is located on the opposite side of the tilt-
house)
B
Turning disk attachment screws, 33 pcs
C
Required equipment
Note
Art. no.
Spare part no.
Equipment, etc.
Does not include o-ring!
3HAC13193-1
Turning disk, dia. 250
3HAC023124-002
Turning disk, insulated
Must be replaced when repla-
cing the turning disk!
3HAB3772-83
O-ring
Used to lubricate the o-ring.
3HAC042536-
001
Grease
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Continues on next page
232
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.1 Replacing turning disk
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| 232
|
Note
Action
This is a complex task to be performed
with outmost care in order to avoid injury
or damage!
Look through the empty mounting hole of
motor axis 1, to assist in aligning the as-
sembly during refitting of the arm system.
6
The guiding pin in the gearbox must be fitted
to the guiding hole of the frame (B).
Lower the arm system with guidance from
the guide pins previously fitted to the frame.
Refit 22 of the 24 attachment screws before
the arm system is completely lowered.
7
Shown in the figure Location of complete
arm system on page 227 .
Remove the guide pins and secure the arm
system to the base with the 24 base attach-
ment screws and washers.
8
24 pcs, M12 x 110; 12.9 quality UN-
BRAKO, tightening torque: 110 Nm.
Reused screws may be used, providing
they are lubricated as detailed in section
Screw joints on page 415 before fitting.
Shown in the figure Location of complete
arm system on page 227 .
Refit the block for calibration at the bottom
of the frame.
9
Detailed in section Refitting, motor axis
1 on page 294 .
Refit the motor, axis 1.
10
Detailed in section Performing a leak-
down test on page 206 .
Perform a leak-down test.
11
Detailed in section Filling, oil, gearbox
axis 1 on page 166 .
Refill the gearbox axis 1 with lubricating oil.
12
Pendulum Calibration is described in Op-
erating manual - Calibration Pendulum ,
enclosed with the calibration tools.
Recalibrate the robot.
13
Axis Calibration is described in Calibrat-
ing with Axis Calibration method on
page 383 .
General calibration information is included
in section Calibration on page 371 .
DANGER
Make sure all safety requirements are met
when performing the first test run.
14
Product manual - IRB 7600
231
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.3.3 Replacement of complete arm system
Continued
4.4 Upper and lower arm
4.4.1 Replacing turning disk
Location of turning disk
The turning disk is located in the center of the wrist unit as shown in the figure
below.
xx0100000129
Turning disk
A
Oil plug, filling (oil plug for draining is located on the opposite side of the tilt-
house)
B
Turning disk attachment screws, 33 pcs
C
Required equipment
Note
Art. no.
Spare part no.
Equipment, etc.
Does not include o-ring!
3HAC13193-1
Turning disk, dia. 250
3HAC023124-002
Turning disk, insulated
Must be replaced when repla-
cing the turning disk!
3HAB3772-83
O-ring
Used to lubricate the o-ring.
3HAC042536-
001
Grease
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Continues on next page
232
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.1 Replacing turning disk
Note
Art. no.
Spare part no.
Equipment, etc.
These procedures include
references to the tools re-
quired.
Other tools and proced-
ures may be required.
See references to
these procedures in
the step-by-step in-
structions below.
Removing turning disk
Use the procedure to remove the turning disk.
Information
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the ro-
bot
•
air pressure supply to the robot
Before entering the robot working area.
1
Detailed in section Changing oil, axis-6
gearbox on page 180 .
Drain the oil from gearbox 6.
2
Shown in the figure Location of turning
disk on page 232 .
Remove the attachment screws (33 pcs)
securing the turning disk.
3
![Image]
xx1000001135
Remove the turning disk .
4
Continues on next page
Product manual - IRB 7600
233
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.1 Replacing turning disk
Continued
|
ABB_IRB7600_Product_Manual.pdf
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| 233
|
4.4 Upper and lower arm
4.4.1 Replacing turning disk
Location of turning disk
The turning disk is located in the center of the wrist unit as shown in the figure
below.
xx0100000129
Turning disk
A
Oil plug, filling (oil plug for draining is located on the opposite side of the tilt-
house)
B
Turning disk attachment screws, 33 pcs
C
Required equipment
Note
Art. no.
Spare part no.
Equipment, etc.
Does not include o-ring!
3HAC13193-1
Turning disk, dia. 250
3HAC023124-002
Turning disk, insulated
Must be replaced when repla-
cing the turning disk!
3HAB3772-83
O-ring
Used to lubricate the o-ring.
3HAC042536-
001
Grease
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Continues on next page
232
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.1 Replacing turning disk
Note
Art. no.
Spare part no.
Equipment, etc.
These procedures include
references to the tools re-
quired.
Other tools and proced-
ures may be required.
See references to
these procedures in
the step-by-step in-
structions below.
Removing turning disk
Use the procedure to remove the turning disk.
Information
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the ro-
bot
•
air pressure supply to the robot
Before entering the robot working area.
1
Detailed in section Changing oil, axis-6
gearbox on page 180 .
Drain the oil from gearbox 6.
2
Shown in the figure Location of turning
disk on page 232 .
Remove the attachment screws (33 pcs)
securing the turning disk.
3
![Image]
xx1000001135
Remove the turning disk .
4
Continues on next page
Product manual - IRB 7600
233
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.1 Replacing turning disk
Continued
Refitting turning disk
Use this procedure to refit the turning disk.
Information
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the ro-
bot
•
air pressure supply to the robot
Before entering the robot working area.
1
Art. no. is specified in Required equipment
on page 232 .
xx0100000130
Lubricate the o-ring with grease and fit it to
the rear of the turning disk.
2
O-ring, turning disk
Attachment screws:
•
M10 x 25, 12.9 quality UNBRAKO
•
Tightening torque: 50 Nm .
Reused screws may be used, providing
they are lubricated as detailed in section
Screw joints on page 415 before fitting.
Secure the turning disk with its attachment
screws .
3
Refill the gearbox, axis 6, with oil.
4
DANGER
Make sure all safety requirements are met
when performing the first test run.
5
234
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.1 Replacing turning disk
Continued
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| 234
|
Note
Art. no.
Spare part no.
Equipment, etc.
These procedures include
references to the tools re-
quired.
Other tools and proced-
ures may be required.
See references to
these procedures in
the step-by-step in-
structions below.
Removing turning disk
Use the procedure to remove the turning disk.
Information
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the ro-
bot
•
air pressure supply to the robot
Before entering the robot working area.
1
Detailed in section Changing oil, axis-6
gearbox on page 180 .
Drain the oil from gearbox 6.
2
Shown in the figure Location of turning
disk on page 232 .
Remove the attachment screws (33 pcs)
securing the turning disk.
3
![Image]
xx1000001135
Remove the turning disk .
4
Continues on next page
Product manual - IRB 7600
233
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.1 Replacing turning disk
Continued
Refitting turning disk
Use this procedure to refit the turning disk.
Information
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the ro-
bot
•
air pressure supply to the robot
Before entering the robot working area.
1
Art. no. is specified in Required equipment
on page 232 .
xx0100000130
Lubricate the o-ring with grease and fit it to
the rear of the turning disk.
2
O-ring, turning disk
Attachment screws:
•
M10 x 25, 12.9 quality UNBRAKO
•
Tightening torque: 50 Nm .
Reused screws may be used, providing
they are lubricated as detailed in section
Screw joints on page 415 before fitting.
Secure the turning disk with its attachment
screws .
3
Refill the gearbox, axis 6, with oil.
4
DANGER
Make sure all safety requirements are met
when performing the first test run.
5
234
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.1 Replacing turning disk
Continued
4.4.2 Replacement of complete wrist unit
Location of wrist unit
The wrist unit is located in the frontmost part of the upper arm as shown in the
figure below.
A more detailed view of the component and its position may be found in Exploded
views in Product manual, spare parts - IRB 7600 .
xx0100000147
Wrist unit
A
Wrist unit attachment screws and washers
B
Attachment, cable harness axis 5-6
C
Connectors at cable harness division; R2.M5/6
D
Turning disk
E
Cover, axis 5
F
Rear cover
G
View with cable harness mounted on robot
H
Required equipment
Note
Art. no.
Equipment, etc.
For spare part num-
ber, see Spare part
lists on page 425 .
Wrist
Continues on next page
Product manual - IRB 7600
235
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.2 Replacement of complete wrist unit
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| 235
|
Refitting turning disk
Use this procedure to refit the turning disk.
Information
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the ro-
bot
•
air pressure supply to the robot
Before entering the robot working area.
1
Art. no. is specified in Required equipment
on page 232 .
xx0100000130
Lubricate the o-ring with grease and fit it to
the rear of the turning disk.
2
O-ring, turning disk
Attachment screws:
•
M10 x 25, 12.9 quality UNBRAKO
•
Tightening torque: 50 Nm .
Reused screws may be used, providing
they are lubricated as detailed in section
Screw joints on page 415 before fitting.
Secure the turning disk with its attachment
screws .
3
Refill the gearbox, axis 6, with oil.
4
DANGER
Make sure all safety requirements are met
when performing the first test run.
5
234
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.1 Replacing turning disk
Continued
4.4.2 Replacement of complete wrist unit
Location of wrist unit
The wrist unit is located in the frontmost part of the upper arm as shown in the
figure below.
A more detailed view of the component and its position may be found in Exploded
views in Product manual, spare parts - IRB 7600 .
xx0100000147
Wrist unit
A
Wrist unit attachment screws and washers
B
Attachment, cable harness axis 5-6
C
Connectors at cable harness division; R2.M5/6
D
Turning disk
E
Cover, axis 5
F
Rear cover
G
View with cable harness mounted on robot
H
Required equipment
Note
Art. no.
Equipment, etc.
For spare part num-
ber, see Spare part
lists on page 425 .
Wrist
Continues on next page
Product manual - IRB 7600
235
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.2 Replacement of complete wrist unit
Note
Art. no.
Equipment, etc.
A new friction washer must always
be used when refitting the wrist
unit.
3HAC11755-1
Friction washer
3HAC12734-1
Lifting tool, wrist unit
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Complete kit that also includes op-
erating manual.
3HAC15716-1
Calibration Pendulum toolkit
Required if Calibration Pendulum
is the valid calibration method for
the robot.
Delivered as a set of calibration
tools.
3HAC055412-001
Calibration tool box, Axis Calibra-
tion
Required if Axis Calibration is the
valid calibration method for the ro-
bot.
These procedures include refer-
ences to the tools required.
Other tools and procedures may
be required. See references to
these procedures in the step-by-
step instructions below.
See chapter Circuit diagram on
page 427 .
-
Circuit diagram
Deciding calibration routine
Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Note
Action
Decide which calibration routine to use for
calibrating the robot.
•
Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
•
Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
1
Follow the instructions given in the refer-
ence calibration routine on the FlexPendant
to create reference values.
If the robot is to be calibrated with refer-
ence calibration:
Find previous reference values for the axis
or create new reference values. These val-
ues are to be used after the repair proced-
ure is completed, for calibration of the ro-
bot.
Creating new values requires possibility to
move the robot.
Read more about reference calibration for
Axis Calibration in Product manual - IRB
4600 .
If no previous reference values exist, and
no new reference values can be created,
then reference calibration is not possible.
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
236
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.2 Replacement of complete wrist unit
Continued
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| 236
|
4.4.2 Replacement of complete wrist unit
Location of wrist unit
The wrist unit is located in the frontmost part of the upper arm as shown in the
figure below.
A more detailed view of the component and its position may be found in Exploded
views in Product manual, spare parts - IRB 7600 .
xx0100000147
Wrist unit
A
Wrist unit attachment screws and washers
B
Attachment, cable harness axis 5-6
C
Connectors at cable harness division; R2.M5/6
D
Turning disk
E
Cover, axis 5
F
Rear cover
G
View with cable harness mounted on robot
H
Required equipment
Note
Art. no.
Equipment, etc.
For spare part num-
ber, see Spare part
lists on page 425 .
Wrist
Continues on next page
Product manual - IRB 7600
235
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.2 Replacement of complete wrist unit
Note
Art. no.
Equipment, etc.
A new friction washer must always
be used when refitting the wrist
unit.
3HAC11755-1
Friction washer
3HAC12734-1
Lifting tool, wrist unit
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Complete kit that also includes op-
erating manual.
3HAC15716-1
Calibration Pendulum toolkit
Required if Calibration Pendulum
is the valid calibration method for
the robot.
Delivered as a set of calibration
tools.
3HAC055412-001
Calibration tool box, Axis Calibra-
tion
Required if Axis Calibration is the
valid calibration method for the ro-
bot.
These procedures include refer-
ences to the tools required.
Other tools and procedures may
be required. See references to
these procedures in the step-by-
step instructions below.
See chapter Circuit diagram on
page 427 .
-
Circuit diagram
Deciding calibration routine
Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Note
Action
Decide which calibration routine to use for
calibrating the robot.
•
Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
•
Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
1
Follow the instructions given in the refer-
ence calibration routine on the FlexPendant
to create reference values.
If the robot is to be calibrated with refer-
ence calibration:
Find previous reference values for the axis
or create new reference values. These val-
ues are to be used after the repair proced-
ure is completed, for calibration of the ro-
bot.
Creating new values requires possibility to
move the robot.
Read more about reference calibration for
Axis Calibration in Product manual - IRB
4600 .
If no previous reference values exist, and
no new reference values can be created,
then reference calibration is not possible.
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
236
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.2 Replacement of complete wrist unit
Continued
Removal, wrist unit
The procedure below details how to remove the complete wrist unit.
Note
Action
Decide which calibration routine to use, and take
actions accordingly prior to beginning the repair
procedure.
1
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
2
Remove all equipment fitted to the turning disk.
3
Shown in the figure Location of
wrist unit on page 235 .
Turn axis 4 to a position where the cover, axis 5
faces upwards.
4
Remove the cover, axis 5, by unscrewing its attach-
ment screws.
5
CAUTION
The complete wrist unit weighs 200 kg! All lifting
equipment used must be sized accordingly!
6
Art. no. is specified in Required
equipment on page 235 .
Fit the lifting tool, wrist unit to the two holes on the
sealing surface against the cover, axis 5.
7
If required, cut any cable ties
securing the cables in order to
fit the tool.
Shown in the figure Location of
wrist unit on page 235 .
Remove the rear cover by unscrewing its attach-
ments.
8
Shown in the figure Location of
wrist unit on page 235 .
Disconnect connector R2.M5/6 at the rear cable divi-
sion point .
9
Do not remove the attachments
from the cabling!
Remove all cable attachment inside the upper arm
and at the rear of the robot.
10
Slightly raise the wrist unit to unload the screw joint,
facilitating removal of the attachment screws.
11
Remove the wrist unit attachment screws and wash-
ers .
12
Make sure the attachments do
not get stuck inside the tube!
Pull the cabling forwards through the upper arm tube.
13
A new washer must always be
used on reassembly.
Remove the friction washer between the wrist unit
and the upper arm tube.
14
Lift the wrist unit down and place it on a secure sur-
face.
15
Continues on next page
Product manual - IRB 7600
237
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.2 Replacement of complete wrist unit
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 237
|
Note
Art. no.
Equipment, etc.
A new friction washer must always
be used when refitting the wrist
unit.
3HAC11755-1
Friction washer
3HAC12734-1
Lifting tool, wrist unit
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Complete kit that also includes op-
erating manual.
3HAC15716-1
Calibration Pendulum toolkit
Required if Calibration Pendulum
is the valid calibration method for
the robot.
Delivered as a set of calibration
tools.
3HAC055412-001
Calibration tool box, Axis Calibra-
tion
Required if Axis Calibration is the
valid calibration method for the ro-
bot.
These procedures include refer-
ences to the tools required.
Other tools and procedures may
be required. See references to
these procedures in the step-by-
step instructions below.
See chapter Circuit diagram on
page 427 .
-
Circuit diagram
Deciding calibration routine
Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Note
Action
Decide which calibration routine to use for
calibrating the robot.
•
Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
•
Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
1
Follow the instructions given in the refer-
ence calibration routine on the FlexPendant
to create reference values.
If the robot is to be calibrated with refer-
ence calibration:
Find previous reference values for the axis
or create new reference values. These val-
ues are to be used after the repair proced-
ure is completed, for calibration of the ro-
bot.
Creating new values requires possibility to
move the robot.
Read more about reference calibration for
Axis Calibration in Product manual - IRB
4600 .
If no previous reference values exist, and
no new reference values can be created,
then reference calibration is not possible.
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
236
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.2 Replacement of complete wrist unit
Continued
Removal, wrist unit
The procedure below details how to remove the complete wrist unit.
Note
Action
Decide which calibration routine to use, and take
actions accordingly prior to beginning the repair
procedure.
1
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
2
Remove all equipment fitted to the turning disk.
3
Shown in the figure Location of
wrist unit on page 235 .
Turn axis 4 to a position where the cover, axis 5
faces upwards.
4
Remove the cover, axis 5, by unscrewing its attach-
ment screws.
5
CAUTION
The complete wrist unit weighs 200 kg! All lifting
equipment used must be sized accordingly!
6
Art. no. is specified in Required
equipment on page 235 .
Fit the lifting tool, wrist unit to the two holes on the
sealing surface against the cover, axis 5.
7
If required, cut any cable ties
securing the cables in order to
fit the tool.
Shown in the figure Location of
wrist unit on page 235 .
Remove the rear cover by unscrewing its attach-
ments.
8
Shown in the figure Location of
wrist unit on page 235 .
Disconnect connector R2.M5/6 at the rear cable divi-
sion point .
9
Do not remove the attachments
from the cabling!
Remove all cable attachment inside the upper arm
and at the rear of the robot.
10
Slightly raise the wrist unit to unload the screw joint,
facilitating removal of the attachment screws.
11
Remove the wrist unit attachment screws and wash-
ers .
12
Make sure the attachments do
not get stuck inside the tube!
Pull the cabling forwards through the upper arm tube.
13
A new washer must always be
used on reassembly.
Remove the friction washer between the wrist unit
and the upper arm tube.
14
Lift the wrist unit down and place it on a secure sur-
face.
15
Continues on next page
Product manual - IRB 7600
237
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.2 Replacement of complete wrist unit
Continued
Refitting, wrist unit
The procedure below details how to refit the complete wrist unit.
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
1
CAUTION
The complete wrist unit weighs 200 kg! All lifting
equipment used must be sized accordingly!
2
Art. no. is specified in Required
equipment on page 235 .
Remove the cover, axis 5 from the wrist unit to be
fitted. Fit the lifting tool, wrist unit to the wrist unit.
3
Lift the wrist unit and move it to its mounting posi-
tion.
4
Art. no. is specified in Required
equipment on page 235 .
Fit a new friction washer between the upper arm
tube and the wrist unit.
5
Gently pull the wrist unit cable harness through the
upper arm and out the rear.
6
Screws: M12 x 50, UNBRAKO
quality 12.9, tightening torque:
115 Nm.
Secure the wrist unit with its attachment screws and
washers.
7
Reused screws may be used,
providing they are lubricated as
detailed in section Screw joints
on page 415 before fitting.
Make sure the cabling is not twis-
ted!
Secure the cable harness with the cable attachment
inside the upper arm as well as at the rear of the
upper arm.
8
Shown in the figure Location of
wrist unit on page 235 .
Remove the lifting tool and refit the cover, axis 5
with its attachment screws.
9
Refit any cable ties that were previously cut during
disassembly.
10
Shown in the figure Location of
wrist unit on page 235 .
Reconnect connector R2.M5/6 at the rear cable di-
vision point.
11
Shown in the figure Location of
wrist unit on page 235 .
Refit the rear cover with its attachment screws.
12
Detailed in sections:
•
Inspecting the oil level in
axis-5 gearbox on page136
•
Inspecting the oil level in
axis-6 gearbox on page139
Check the oil levels at gearboxes axis 5 and 6.
13
Continues on next page
238
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.2 Replacement of complete wrist unit
Continued
|
ABB_IRB7600_Product_Manual.pdf
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| 238
|
Removal, wrist unit
The procedure below details how to remove the complete wrist unit.
Note
Action
Decide which calibration routine to use, and take
actions accordingly prior to beginning the repair
procedure.
1
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
2
Remove all equipment fitted to the turning disk.
3
Shown in the figure Location of
wrist unit on page 235 .
Turn axis 4 to a position where the cover, axis 5
faces upwards.
4
Remove the cover, axis 5, by unscrewing its attach-
ment screws.
5
CAUTION
The complete wrist unit weighs 200 kg! All lifting
equipment used must be sized accordingly!
6
Art. no. is specified in Required
equipment on page 235 .
Fit the lifting tool, wrist unit to the two holes on the
sealing surface against the cover, axis 5.
7
If required, cut any cable ties
securing the cables in order to
fit the tool.
Shown in the figure Location of
wrist unit on page 235 .
Remove the rear cover by unscrewing its attach-
ments.
8
Shown in the figure Location of
wrist unit on page 235 .
Disconnect connector R2.M5/6 at the rear cable divi-
sion point .
9
Do not remove the attachments
from the cabling!
Remove all cable attachment inside the upper arm
and at the rear of the robot.
10
Slightly raise the wrist unit to unload the screw joint,
facilitating removal of the attachment screws.
11
Remove the wrist unit attachment screws and wash-
ers .
12
Make sure the attachments do
not get stuck inside the tube!
Pull the cabling forwards through the upper arm tube.
13
A new washer must always be
used on reassembly.
Remove the friction washer between the wrist unit
and the upper arm tube.
14
Lift the wrist unit down and place it on a secure sur-
face.
15
Continues on next page
Product manual - IRB 7600
237
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.2 Replacement of complete wrist unit
Continued
Refitting, wrist unit
The procedure below details how to refit the complete wrist unit.
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
1
CAUTION
The complete wrist unit weighs 200 kg! All lifting
equipment used must be sized accordingly!
2
Art. no. is specified in Required
equipment on page 235 .
Remove the cover, axis 5 from the wrist unit to be
fitted. Fit the lifting tool, wrist unit to the wrist unit.
3
Lift the wrist unit and move it to its mounting posi-
tion.
4
Art. no. is specified in Required
equipment on page 235 .
Fit a new friction washer between the upper arm
tube and the wrist unit.
5
Gently pull the wrist unit cable harness through the
upper arm and out the rear.
6
Screws: M12 x 50, UNBRAKO
quality 12.9, tightening torque:
115 Nm.
Secure the wrist unit with its attachment screws and
washers.
7
Reused screws may be used,
providing they are lubricated as
detailed in section Screw joints
on page 415 before fitting.
Make sure the cabling is not twis-
ted!
Secure the cable harness with the cable attachment
inside the upper arm as well as at the rear of the
upper arm.
8
Shown in the figure Location of
wrist unit on page 235 .
Remove the lifting tool and refit the cover, axis 5
with its attachment screws.
9
Refit any cable ties that were previously cut during
disassembly.
10
Shown in the figure Location of
wrist unit on page 235 .
Reconnect connector R2.M5/6 at the rear cable di-
vision point.
11
Shown in the figure Location of
wrist unit on page 235 .
Refit the rear cover with its attachment screws.
12
Detailed in sections:
•
Inspecting the oil level in
axis-5 gearbox on page136
•
Inspecting the oil level in
axis-6 gearbox on page139
Check the oil levels at gearboxes axis 5 and 6.
13
Continues on next page
238
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.2 Replacement of complete wrist unit
Continued
Note
Action
Pendulum Calibration is described
in Operating manual - Calibration
Pendulum , enclosed with the cal-
ibration tools.
Re-calibrate the robot.
14
Axis Calibration is described in
Calibrating with Axis Calibration
method on page 383 .
General calibration information is
included in section Calibration on
page 371 .
Refit any equipment previously removed from the
turning disk.
15
DANGER
Make sure all safety requirements are met when
performing the first test run.
16
Product manual - IRB 7600
239
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.2 Replacement of complete wrist unit
Continued
|
ABB_IRB7600_Product_Manual.pdf
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| 239
|
Refitting, wrist unit
The procedure below details how to refit the complete wrist unit.
Note
Action
DANGER
Turn off all:
•
electric power supply to the robot
•
hydraulic pressure supply to the robot
•
air pressure supply to the robot
Before entering the robot working area.
1
CAUTION
The complete wrist unit weighs 200 kg! All lifting
equipment used must be sized accordingly!
2
Art. no. is specified in Required
equipment on page 235 .
Remove the cover, axis 5 from the wrist unit to be
fitted. Fit the lifting tool, wrist unit to the wrist unit.
3
Lift the wrist unit and move it to its mounting posi-
tion.
4
Art. no. is specified in Required
equipment on page 235 .
Fit a new friction washer between the upper arm
tube and the wrist unit.
5
Gently pull the wrist unit cable harness through the
upper arm and out the rear.
6
Screws: M12 x 50, UNBRAKO
quality 12.9, tightening torque:
115 Nm.
Secure the wrist unit with its attachment screws and
washers.
7
Reused screws may be used,
providing they are lubricated as
detailed in section Screw joints
on page 415 before fitting.
Make sure the cabling is not twis-
ted!
Secure the cable harness with the cable attachment
inside the upper arm as well as at the rear of the
upper arm.
8
Shown in the figure Location of
wrist unit on page 235 .
Remove the lifting tool and refit the cover, axis 5
with its attachment screws.
9
Refit any cable ties that were previously cut during
disassembly.
10
Shown in the figure Location of
wrist unit on page 235 .
Reconnect connector R2.M5/6 at the rear cable di-
vision point.
11
Shown in the figure Location of
wrist unit on page 235 .
Refit the rear cover with its attachment screws.
12
Detailed in sections:
•
Inspecting the oil level in
axis-5 gearbox on page136
•
Inspecting the oil level in
axis-6 gearbox on page139
Check the oil levels at gearboxes axis 5 and 6.
13
Continues on next page
238
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.2 Replacement of complete wrist unit
Continued
Note
Action
Pendulum Calibration is described
in Operating manual - Calibration
Pendulum , enclosed with the cal-
ibration tools.
Re-calibrate the robot.
14
Axis Calibration is described in
Calibrating with Axis Calibration
method on page 383 .
General calibration information is
included in section Calibration on
page 371 .
Refit any equipment previously removed from the
turning disk.
15
DANGER
Make sure all safety requirements are met when
performing the first test run.
16
Product manual - IRB 7600
239
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.2 Replacement of complete wrist unit
Continued
4.4.3 Replacement of complete upper arm
Location of upper arm
The upper arm is located on top of the robot as shown in the figure below.
A more detailed view of the component and its position may be found in chapter
Exploded views in Product manual, spare parts - IRB 7600 .
xx0100000148
Upper arm
A
Attachment screws, upper arm
B
Connectors at cable harness division; R2.M5/6
C
Rear cable attachment
D
Oil plug, draining
E
Oil plug, filling
F
Attachment hole, M12
G
Sealing between lower arm and gearbox 3
H
Attachment holes for lifting device, upper arm
J
Attachment holes for lifting eye
K
Continues on next page
240
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.3 Replacement of complete upper arm
|
ABB_IRB7600_Product_Manual.pdf
|
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| 240
|
Note
Action
Pendulum Calibration is described
in Operating manual - Calibration
Pendulum , enclosed with the cal-
ibration tools.
Re-calibrate the robot.
14
Axis Calibration is described in
Calibrating with Axis Calibration
method on page 383 .
General calibration information is
included in section Calibration on
page 371 .
Refit any equipment previously removed from the
turning disk.
15
DANGER
Make sure all safety requirements are met when
performing the first test run.
16
Product manual - IRB 7600
239
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.2 Replacement of complete wrist unit
Continued
4.4.3 Replacement of complete upper arm
Location of upper arm
The upper arm is located on top of the robot as shown in the figure below.
A more detailed view of the component and its position may be found in chapter
Exploded views in Product manual, spare parts - IRB 7600 .
xx0100000148
Upper arm
A
Attachment screws, upper arm
B
Connectors at cable harness division; R2.M5/6
C
Rear cable attachment
D
Oil plug, draining
E
Oil plug, filling
F
Attachment hole, M12
G
Sealing between lower arm and gearbox 3
H
Attachment holes for lifting device, upper arm
J
Attachment holes for lifting eye
K
Continues on next page
240
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.3 Replacement of complete upper arm
Required equipment
Note
Art. no.
Equipment, etc.
Always use a new sealing
when reassembling!
3HAC17213-1
Sealing, axis 2/3
Replace if damaged!
3HAC11828-1
Washer
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
3HAC14457-3
Lifting eye, M12
3HAC15536-1
Lifting device, upper arm
3HAC15556-1
Lifting tool (chain)
Standard hoisting block, capa-
city 200 kg.
-
Hoisting block
80 mm.
3HAC14627-2
Guide pins, sealing axis 2/3
For guiding "Sealing, axis 2/3".
100 mm
3HAC14627-3
Guide pins, sealing axis 2/3
For guiding "Sealing, axis 2/3".
These procedures include ref-
erences to the tools required.
Other tools and procedures may be
required. See references to these
procedures in the step-by-step in-
structions below.
Deciding calibration routine
Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Note
Action
Decide which calibration routine to use for
calibrating the robot.
•
Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
•
Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
1
Follow the instructions given in the refer-
ence calibration routine on the FlexPendant
to create reference values.
If the robot is to be calibrated with refer-
ence calibration:
Find previous reference values for the axis
or create new reference values. These val-
ues are to be used after the repair proced-
ure is completed, for calibration of the ro-
bot.
Creating new values requires possibility to
move the robot.
Read more about reference calibration for
Axis Calibration in Product manual - IRB
4600 .
If no previous reference values exist, and
no new reference values can be created,
then reference calibration is not possible.
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
241
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.3 Replacement of complete upper arm
Continued
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