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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
| 241
|
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
Removal, upper arm
The procedure below details how to remove the complete upper arm.
Note
Action
Decide which calibration routine to use, and take ac-
tions accordingly prior to beginning the repair proced-
ure.
1
Run the upper arm to a horizontal position.
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
CAUTION
The complete upper arm weighs 450 kg without any
additional equipment fitted! Use a suitable lifting
device to avoid injury to personnel!
4
Shown in the figure Location of
upper arm on page 240 .
Fit the lifting eye to the attachment hole in the wrist
unit.
5
Art. no. is specified in Required
equipment on page 241 .
Shown in the figure Location of
upper arm on page 240 .
Fit one of the pieces included in the lifting device,
upper arm to the attachment holes for lifting device,
upper arm using the included attachment screws.
6
Art. no. is specified in Required
equipment on page 241 .
Art. no. is specified in Required
equipment on page 241 .
Run the lifting chain from the rear lifting point through
the overhead crane hook, through the hoisting block
to the lifting eye in the front.
7
Use the hoisting block to adjust the tension in the
chain in order to lift the upper arm completely level.
8
Detailed in section Changing
oil, axis-3 gearbox on page170 .
Drain the oil from gearbox 3.
9
Disconnect connector R2.M5/6 at the rear cable divi-
sion point as well as all remaining connections to the
upper arm.
10
Disconnect all connectors inside motors 3 and 4.
11
Remove all brackets securing cabling to the upper
arm by unscrewing their attachment screws respect-
ively.
12
Raise the lifting equipment to take the weight of the
upper arm.
13
Shown in the figure Location of
upper arm on page 240 .
Carefully remove the upper arm attachment screws .
Make sure that the upper arm is lifted in a completely
level position in all planes in order not to damage the
upper arm!
14
30 pcs.
Lift the upper arm and place it on a secure surface.
15
Continues on next page
242
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
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
https://search.abb.com/library/Download.aspx?DocumentID=3HAC022033-001&LanguageCode=en&DocumentPartId=&Action=Launch&DocumentRevisionId=AF
| 242
|
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
Removal, upper arm
The procedure below details how to remove the complete upper arm.
Note
Action
Decide which calibration routine to use, and take ac-
tions accordingly prior to beginning the repair proced-
ure.
1
Run the upper arm to a horizontal position.
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
CAUTION
The complete upper arm weighs 450 kg without any
additional equipment fitted! Use a suitable lifting
device to avoid injury to personnel!
4
Shown in the figure Location of
upper arm on page 240 .
Fit the lifting eye to the attachment hole in the wrist
unit.
5
Art. no. is specified in Required
equipment on page 241 .
Shown in the figure Location of
upper arm on page 240 .
Fit one of the pieces included in the lifting device,
upper arm to the attachment holes for lifting device,
upper arm using the included attachment screws.
6
Art. no. is specified in Required
equipment on page 241 .
Art. no. is specified in Required
equipment on page 241 .
Run the lifting chain from the rear lifting point through
the overhead crane hook, through the hoisting block
to the lifting eye in the front.
7
Use the hoisting block to adjust the tension in the
chain in order to lift the upper arm completely level.
8
Detailed in section Changing
oil, axis-3 gearbox on page170 .
Drain the oil from gearbox 3.
9
Disconnect connector R2.M5/6 at the rear cable divi-
sion point as well as all remaining connections to the
upper arm.
10
Disconnect all connectors inside motors 3 and 4.
11
Remove all brackets securing cabling to the upper
arm by unscrewing their attachment screws respect-
ively.
12
Raise the lifting equipment to take the weight of the
upper arm.
13
Shown in the figure Location of
upper arm on page 240 .
Carefully remove the upper arm attachment screws .
Make sure that the upper arm is lifted in a completely
level position in all planes in order not to damage the
upper arm!
14
30 pcs.
Lift the upper arm and place it on a secure surface.
15
Continues on next page
242
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
Continued
Note
Action
Remove the sealing from the lower arm.
16
Refitting, upper arm
The procedure below details how to refit the upper arm to the robot.
Note/Illustration
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
Always use a new sealing when
reassembling!
Fit the new sealing, axis 2/3 onto the axis-3 gearbox
and keep it in place by also fitting the two guide
pins, sealing axis 2/3 in two of the attachment screw
holes on the gearbox, see figure to the right.
2
Art. no. is specified in Required
equipment on page 241 .
xx0200000125
Holes for guide pins in the
gearbox.
CAUTION
The complete upper arm weighs 450 kg without any
additional equipment fitted! Use a suitable lifting
device to avoid injury to personnel!
3
Shown in the figure Location of
upper arm on page 240 .
Fit the lifting eye to the attachment hole in the wrist
unit.
4
Art. no. is specified in Required
equipment on page 241 .
Shown in the figure Location of
upper arm on page 240 .
Fit one of the pieces included in the lifting device,
upper arm to the attachment holes for lifting device,
upper arm using the included attachment screws.
5
Art. no. is specified in Required
equipment on page 241 .
Art. no. is specified in Required
equipment on page 241 .
Run the lifting chain from the rear lifting point
through the overhead crane hook, through the
hoisting block to the lifting eye in the front.
6
Continues on next page
Product manual - IRB 7600
243
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.3 Replacement of complete upper arm
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
https://search.abb.com/library/Download.aspx?DocumentID=3HAC022033-001&LanguageCode=en&DocumentPartId=&Action=Launch&DocumentRevisionId=AF
| 243
|
Removal, upper arm
The procedure below details how to remove the complete upper arm.
Note
Action
Decide which calibration routine to use, and take ac-
tions accordingly prior to beginning the repair proced-
ure.
1
Run the upper arm to a horizontal position.
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
CAUTION
The complete upper arm weighs 450 kg without any
additional equipment fitted! Use a suitable lifting
device to avoid injury to personnel!
4
Shown in the figure Location of
upper arm on page 240 .
Fit the lifting eye to the attachment hole in the wrist
unit.
5
Art. no. is specified in Required
equipment on page 241 .
Shown in the figure Location of
upper arm on page 240 .
Fit one of the pieces included in the lifting device,
upper arm to the attachment holes for lifting device,
upper arm using the included attachment screws.
6
Art. no. is specified in Required
equipment on page 241 .
Art. no. is specified in Required
equipment on page 241 .
Run the lifting chain from the rear lifting point through
the overhead crane hook, through the hoisting block
to the lifting eye in the front.
7
Use the hoisting block to adjust the tension in the
chain in order to lift the upper arm completely level.
8
Detailed in section Changing
oil, axis-3 gearbox on page170 .
Drain the oil from gearbox 3.
9
Disconnect connector R2.M5/6 at the rear cable divi-
sion point as well as all remaining connections to the
upper arm.
10
Disconnect all connectors inside motors 3 and 4.
11
Remove all brackets securing cabling to the upper
arm by unscrewing their attachment screws respect-
ively.
12
Raise the lifting equipment to take the weight of the
upper arm.
13
Shown in the figure Location of
upper arm on page 240 .
Carefully remove the upper arm attachment screws .
Make sure that the upper arm is lifted in a completely
level position in all planes in order not to damage the
upper arm!
14
30 pcs.
Lift the upper arm and place it on a secure surface.
15
Continues on next page
242
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
Continued
Note
Action
Remove the sealing from the lower arm.
16
Refitting, upper arm
The procedure below details how to refit the upper arm to the robot.
Note/Illustration
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
Always use a new sealing when
reassembling!
Fit the new sealing, axis 2/3 onto the axis-3 gearbox
and keep it in place by also fitting the two guide
pins, sealing axis 2/3 in two of the attachment screw
holes on the gearbox, see figure to the right.
2
Art. no. is specified in Required
equipment on page 241 .
xx0200000125
Holes for guide pins in the
gearbox.
CAUTION
The complete upper arm weighs 450 kg without any
additional equipment fitted! Use a suitable lifting
device to avoid injury to personnel!
3
Shown in the figure Location of
upper arm on page 240 .
Fit the lifting eye to the attachment hole in the wrist
unit.
4
Art. no. is specified in Required
equipment on page 241 .
Shown in the figure Location of
upper arm on page 240 .
Fit one of the pieces included in the lifting device,
upper arm to the attachment holes for lifting device,
upper arm using the included attachment screws.
5
Art. no. is specified in Required
equipment on page 241 .
Art. no. is specified in Required
equipment on page 241 .
Run the lifting chain from the rear lifting point
through the overhead crane hook, through the
hoisting block to the lifting eye in the front.
6
Continues on next page
Product manual - IRB 7600
243
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.3 Replacement of complete upper arm
Continued
Note/Illustration
Action
Use the hoisting block to adjust the tension in the
chain in order to lift the upper arm completely level.
7
Lift the upper arm and move it to its mounting posi-
tion.
8
Make sure the washers are not
scarred or pitted in the surface
facing the screw heads. If both
washer sides are damaged, re-
place the washer. Art. no. is spe-
cified in Required equipment on
page 241 .
Fit the three washers to be placed beneath the at-
tachment screws.
9
In some cases, removing the
plastic mechanical stops may be
required before fitting the upper
arm.
Insert the attachment screws.
Do not remove the guide pins until the attachment
screws are tightened as detailed below!
10
If guide pins are removed before
the screws are tightened, the
sealing can be involuntarily
moved into wrong position.
30 pcs: M16 x 50. Tightening
torque: 300 Nm.
Secure the lower arm to gearbox axis 3 with the
upper arm attachment screws .
11
Shown in the figure Location of
upper arm on page 240 .
Remove the guide pins and fit the two remaining
attachment screws. Tighten them as detailed above!
12
Refit any cabling removed during the removal pro-
cess.
13
Reconnect all connectors inside motors 3 and 4.
14
Reconnect connector R2.M5/6 gently at the rear
cable division point.
15
Be careful not to bend the attachment plate when
fastening the screws!
Detailed in section Filling, oil on
page 172 .
Refill the gearbox with oil.
16
Pendulum Calibration is described
in Operating manual - Calibration
Pendulum , enclosed with the cal-
ibration tools.
Re-calibrate the robot.
17
Axis Calibration is described in
Calibrating 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.
18
244
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
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
https://search.abb.com/library/Download.aspx?DocumentID=3HAC022033-001&LanguageCode=en&DocumentPartId=&Action=Launch&DocumentRevisionId=AF
| 244
|
Note
Action
Remove the sealing from the lower arm.
16
Refitting, upper arm
The procedure below details how to refit the upper arm to the robot.
Note/Illustration
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
Always use a new sealing when
reassembling!
Fit the new sealing, axis 2/3 onto the axis-3 gearbox
and keep it in place by also fitting the two guide
pins, sealing axis 2/3 in two of the attachment screw
holes on the gearbox, see figure to the right.
2
Art. no. is specified in Required
equipment on page 241 .
xx0200000125
Holes for guide pins in the
gearbox.
CAUTION
The complete upper arm weighs 450 kg without any
additional equipment fitted! Use a suitable lifting
device to avoid injury to personnel!
3
Shown in the figure Location of
upper arm on page 240 .
Fit the lifting eye to the attachment hole in the wrist
unit.
4
Art. no. is specified in Required
equipment on page 241 .
Shown in the figure Location of
upper arm on page 240 .
Fit one of the pieces included in the lifting device,
upper arm to the attachment holes for lifting device,
upper arm using the included attachment screws.
5
Art. no. is specified in Required
equipment on page 241 .
Art. no. is specified in Required
equipment on page 241 .
Run the lifting chain from the rear lifting point
through the overhead crane hook, through the
hoisting block to the lifting eye in the front.
6
Continues on next page
Product manual - IRB 7600
243
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.3 Replacement of complete upper arm
Continued
Note/Illustration
Action
Use the hoisting block to adjust the tension in the
chain in order to lift the upper arm completely level.
7
Lift the upper arm and move it to its mounting posi-
tion.
8
Make sure the washers are not
scarred or pitted in the surface
facing the screw heads. If both
washer sides are damaged, re-
place the washer. Art. no. is spe-
cified in Required equipment on
page 241 .
Fit the three washers to be placed beneath the at-
tachment screws.
9
In some cases, removing the
plastic mechanical stops may be
required before fitting the upper
arm.
Insert the attachment screws.
Do not remove the guide pins until the attachment
screws are tightened as detailed below!
10
If guide pins are removed before
the screws are tightened, the
sealing can be involuntarily
moved into wrong position.
30 pcs: M16 x 50. Tightening
torque: 300 Nm.
Secure the lower arm to gearbox axis 3 with the
upper arm attachment screws .
11
Shown in the figure Location of
upper arm on page 240 .
Remove the guide pins and fit the two remaining
attachment screws. Tighten them as detailed above!
12
Refit any cabling removed during the removal pro-
cess.
13
Reconnect all connectors inside motors 3 and 4.
14
Reconnect connector R2.M5/6 gently at the rear
cable division point.
15
Be careful not to bend the attachment plate when
fastening the screws!
Detailed in section Filling, oil on
page 172 .
Refill the gearbox with oil.
16
Pendulum Calibration is described
in Operating manual - Calibration
Pendulum , enclosed with the cal-
ibration tools.
Re-calibrate the robot.
17
Axis Calibration is described in
Calibrating 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.
18
244
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
Continued
4.4.4 Replacement of complete lower arm
Location of lower arm
The lower arm is located as shown in the figure below.
xx0100000149
Lower arm
A
Pivot point, axis 2
B
Front shaft, balancing device, including securing screw
C
Attachment for lifting eye, M12, balancing device
D
Attachment points, lower arm
The lower arm attachment points are located as shown in the figure below:
•
The figure (1) shows gearbox 3, but the location of sealing axis 2/3 in relation
to the gearbox is identical for axis 3.
•
The figure (2) shows a cut view through the lower arm pivot point in axis 2
(item B in the figure above!), valid for robots with protection Standard.
Continues on next page
Product manual - IRB 7600
245
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
|
ABB_IRB7600_Product_Manual.pdf
|
https://search.abb.com/library/Download.aspx?DocumentID=3HAC022033-001&LanguageCode=en&DocumentPartId=&Action=Launch&DocumentRevisionId=AF
| 245
|
Note/Illustration
Action
Use the hoisting block to adjust the tension in the
chain in order to lift the upper arm completely level.
7
Lift the upper arm and move it to its mounting posi-
tion.
8
Make sure the washers are not
scarred or pitted in the surface
facing the screw heads. If both
washer sides are damaged, re-
place the washer. Art. no. is spe-
cified in Required equipment on
page 241 .
Fit the three washers to be placed beneath the at-
tachment screws.
9
In some cases, removing the
plastic mechanical stops may be
required before fitting the upper
arm.
Insert the attachment screws.
Do not remove the guide pins until the attachment
screws are tightened as detailed below!
10
If guide pins are removed before
the screws are tightened, the
sealing can be involuntarily
moved into wrong position.
30 pcs: M16 x 50. Tightening
torque: 300 Nm.
Secure the lower arm to gearbox axis 3 with the
upper arm attachment screws .
11
Shown in the figure Location of
upper arm on page 240 .
Remove the guide pins and fit the two remaining
attachment screws. Tighten them as detailed above!
12
Refit any cabling removed during the removal pro-
cess.
13
Reconnect all connectors inside motors 3 and 4.
14
Reconnect connector R2.M5/6 gently at the rear
cable division point.
15
Be careful not to bend the attachment plate when
fastening the screws!
Detailed in section Filling, oil on
page 172 .
Refill the gearbox with oil.
16
Pendulum Calibration is described
in Operating manual - Calibration
Pendulum , enclosed with the cal-
ibration tools.
Re-calibrate the robot.
17
Axis Calibration is described in
Calibrating 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.
18
244
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
Continued
4.4.4 Replacement of complete lower arm
Location of lower arm
The lower arm is located as shown in the figure below.
xx0100000149
Lower arm
A
Pivot point, axis 2
B
Front shaft, balancing device, including securing screw
C
Attachment for lifting eye, M12, balancing device
D
Attachment points, lower arm
The lower arm attachment points are located as shown in the figure below:
•
The figure (1) shows gearbox 3, but the location of sealing axis 2/3 in relation
to the gearbox is identical for axis 3.
•
The figure (2) shows a cut view through the lower arm pivot point in axis 2
(item B in the figure above!), valid for robots with protection Standard.
Continues on next page
Product manual - IRB 7600
245
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
xx0200000031
Gearbox
A
Lower arm
B
Balancing device piston rod ear
C
Frame
D
Shaft hole
E
Sealing, axis 2/3
201
Attachment screw
202
Washer
204
Bearing
401
Thrust washer
402
Bushing
403
Retaining ring
404
Shaft
405
Protection plug
406
Protection washer
409
Continues on next page
246
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
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|
4.4.4 Replacement of complete lower arm
Location of lower arm
The lower arm is located as shown in the figure below.
xx0100000149
Lower arm
A
Pivot point, axis 2
B
Front shaft, balancing device, including securing screw
C
Attachment for lifting eye, M12, balancing device
D
Attachment points, lower arm
The lower arm attachment points are located as shown in the figure below:
•
The figure (1) shows gearbox 3, but the location of sealing axis 2/3 in relation
to the gearbox is identical for axis 3.
•
The figure (2) shows a cut view through the lower arm pivot point in axis 2
(item B in the figure above!), valid for robots with protection Standard.
Continues on next page
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245
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© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
xx0200000031
Gearbox
A
Lower arm
B
Balancing device piston rod ear
C
Frame
D
Shaft hole
E
Sealing, axis 2/3
201
Attachment screw
202
Washer
204
Bearing
401
Thrust washer
402
Bushing
403
Retaining ring
404
Shaft
405
Protection plug
406
Protection washer
409
Continues on next page
246
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
Components, lower arm shaft for robots with protection Foundry Plus and Foundry Prime
The figure shows components fitted to the lower arm shaft when the robot has
protection Foundry Plus and Foundry Prime.
![Image]
xx1100000954
Bearing
A
Thrust washer
B
Bushing
C
Shaft for the lower arm
D
Set screw with cup point, M4x6 (2 pcs)
E
Hexagon bolt M8x190
F
Conical spring washer 8.4x16x1.6
G
Shaft tap
H
Shaft for the sealing cover
J
O-ring
K
Sealing cover
L
Radial sealing with dust lip
M
Required equipment
Note
Article number
Equipment, etc.
Always use a new bearing.
3HAC4310-1
Bearing
Always use a new sealing.
3HAC17213-1
Sealing, axis 2/3
Replace if damaged.
3HAA2166-23
VK cover
Only used on lower arms with a hole
in the upper end (axis 3).
Continues on next page
Product manual - IRB 7600
247
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
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| 247
|
xx0200000031
Gearbox
A
Lower arm
B
Balancing device piston rod ear
C
Frame
D
Shaft hole
E
Sealing, axis 2/3
201
Attachment screw
202
Washer
204
Bearing
401
Thrust washer
402
Bushing
403
Retaining ring
404
Shaft
405
Protection plug
406
Protection washer
409
Continues on next page
246
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
Components, lower arm shaft for robots with protection Foundry Plus and Foundry Prime
The figure shows components fitted to the lower arm shaft when the robot has
protection Foundry Plus and Foundry Prime.
![Image]
xx1100000954
Bearing
A
Thrust washer
B
Bushing
C
Shaft for the lower arm
D
Set screw with cup point, M4x6 (2 pcs)
E
Hexagon bolt M8x190
F
Conical spring washer 8.4x16x1.6
G
Shaft tap
H
Shaft for the sealing cover
J
O-ring
K
Sealing cover
L
Radial sealing with dust lip
M
Required equipment
Note
Article number
Equipment, etc.
Always use a new bearing.
3HAC4310-1
Bearing
Always use a new sealing.
3HAC17213-1
Sealing, axis 2/3
Replace if damaged.
3HAA2166-23
VK cover
Only used on lower arms with a hole
in the upper end (axis 3).
Continues on next page
Product manual - IRB 7600
247
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
Note
Article number
Equipment, etc.
Tool that may be rented from ABB.
3HAC14691-1
Lifting tool, lower arm
Includes
•
Guidances, 3HAC14445-1
The guidings are used for guiding the
sealing, axis 2/3.
3HAC17105-1
Rotation tool
Used to lift the balancing device.
3HAC14457-3
Lifting eye M12
For replacing the balancing device
shaft.
3HAC076202-001
Press equipment, balan-
cing device shaft
User instructions are enclosed with
the tool.
To be used with the press and puller
tools.
3HAC13086-1
Hydraulic pump, 80 MPa
See technical specifications in the user
instructions for the press equipment.
To be used with the press and puller
tools.
3HAC021563-012
Hydraulic pump, 150 MPa
(Glycerin)
See technical specifications in the user
instructions for the press equipment.
Hydraulic pressing accessory.
3HAC076203-001
Press device, axis 2 shaft
User instructions are enclosed with
the tool.
3HAC13453-1
Press tool, axis 2 bearing
24 VDC, 1.5 A.
-
Power supply
For releasing the brakes.
-
Retaining ring pliers
Content is defined in section Standard
tools on page 419 .
-
Standard toolkit
Complete kit that also includes operat-
ing 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
Calibration
Required if Axis Calibration is the valid
calibration method for the robot.
These procedures include references
to the tools required.
Other tools and proced-
ures may be required. See
references to these proced-
ures in the step-by-step
instructions below.
Continues on next page
248
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
|
ABB_IRB7600_Product_Manual.pdf
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| 248
|
Components, lower arm shaft for robots with protection Foundry Plus and Foundry Prime
The figure shows components fitted to the lower arm shaft when the robot has
protection Foundry Plus and Foundry Prime.
![Image]
xx1100000954
Bearing
A
Thrust washer
B
Bushing
C
Shaft for the lower arm
D
Set screw with cup point, M4x6 (2 pcs)
E
Hexagon bolt M8x190
F
Conical spring washer 8.4x16x1.6
G
Shaft tap
H
Shaft for the sealing cover
J
O-ring
K
Sealing cover
L
Radial sealing with dust lip
M
Required equipment
Note
Article number
Equipment, etc.
Always use a new bearing.
3HAC4310-1
Bearing
Always use a new sealing.
3HAC17213-1
Sealing, axis 2/3
Replace if damaged.
3HAA2166-23
VK cover
Only used on lower arms with a hole
in the upper end (axis 3).
Continues on next page
Product manual - IRB 7600
247
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
Note
Article number
Equipment, etc.
Tool that may be rented from ABB.
3HAC14691-1
Lifting tool, lower arm
Includes
•
Guidances, 3HAC14445-1
The guidings are used for guiding the
sealing, axis 2/3.
3HAC17105-1
Rotation tool
Used to lift the balancing device.
3HAC14457-3
Lifting eye M12
For replacing the balancing device
shaft.
3HAC076202-001
Press equipment, balan-
cing device shaft
User instructions are enclosed with
the tool.
To be used with the press and puller
tools.
3HAC13086-1
Hydraulic pump, 80 MPa
See technical specifications in the user
instructions for the press equipment.
To be used with the press and puller
tools.
3HAC021563-012
Hydraulic pump, 150 MPa
(Glycerin)
See technical specifications in the user
instructions for the press equipment.
Hydraulic pressing accessory.
3HAC076203-001
Press device, axis 2 shaft
User instructions are enclosed with
the tool.
3HAC13453-1
Press tool, axis 2 bearing
24 VDC, 1.5 A.
-
Power supply
For releasing the brakes.
-
Retaining ring pliers
Content is defined in section Standard
tools on page 419 .
-
Standard toolkit
Complete kit that also includes operat-
ing 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
Calibration
Required if Axis Calibration is the valid
calibration method for the robot.
These procedures include references
to the tools required.
Other tools and proced-
ures may be required. See
references to these proced-
ures in the step-by-step
instructions below.
Continues on next page
248
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
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, lower arm
The procedure below details how to remove the complete lower arm.
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
Detailed in section Replacement of
complete upper arm on page 240 .
Remove the upper arm.
3
Detailed in section Replacement of
cable harness, axes 1-4 on page 214 .
Disconnect and remove the cables from inside
the lower arm.
Release any cable attachments.
4
Art. no. is specified in Required equip-
ment on page 247 .
Apply the lifting eye to the balancing device
and raise to unload the device.
5
Attachment is shown in the figure Loc-
ation of lower arm on page 245 .
Continues on next page
Product manual - IRB 7600
249
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 249
|
Note
Article number
Equipment, etc.
Tool that may be rented from ABB.
3HAC14691-1
Lifting tool, lower arm
Includes
•
Guidances, 3HAC14445-1
The guidings are used for guiding the
sealing, axis 2/3.
3HAC17105-1
Rotation tool
Used to lift the balancing device.
3HAC14457-3
Lifting eye M12
For replacing the balancing device
shaft.
3HAC076202-001
Press equipment, balan-
cing device shaft
User instructions are enclosed with
the tool.
To be used with the press and puller
tools.
3HAC13086-1
Hydraulic pump, 80 MPa
See technical specifications in the user
instructions for the press equipment.
To be used with the press and puller
tools.
3HAC021563-012
Hydraulic pump, 150 MPa
(Glycerin)
See technical specifications in the user
instructions for the press equipment.
Hydraulic pressing accessory.
3HAC076203-001
Press device, axis 2 shaft
User instructions are enclosed with
the tool.
3HAC13453-1
Press tool, axis 2 bearing
24 VDC, 1.5 A.
-
Power supply
For releasing the brakes.
-
Retaining ring pliers
Content is defined in section Standard
tools on page 419 .
-
Standard toolkit
Complete kit that also includes operat-
ing 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
Calibration
Required if Axis Calibration is the valid
calibration method for the robot.
These procedures include references
to the tools required.
Other tools and proced-
ures may be required. See
references to these proced-
ures in the step-by-step
instructions below.
Continues on next page
248
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
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, lower arm
The procedure below details how to remove the complete lower arm.
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
Detailed in section Replacement of
complete upper arm on page 240 .
Remove the upper arm.
3
Detailed in section Replacement of
cable harness, axes 1-4 on page 214 .
Disconnect and remove the cables from inside
the lower arm.
Release any cable attachments.
4
Art. no. is specified in Required equip-
ment on page 247 .
Apply the lifting eye to the balancing device
and raise to unload the device.
5
Attachment is shown in the figure Loc-
ation of lower arm on page 245 .
Continues on next page
Product manual - IRB 7600
249
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
Note
Action
Detailed in section Unloading the bal-
ancing device on page 283 .
Unload the balancing device in order to make
the piston rod and front ear adjustable when
pulling the front shaft out.
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions
for the tool.
The power for brake release is only applied
for 180 seconds after activation.
6
Shown in the figure Location of lower
arm on page 245 .
Remove the securing screw from the balancing
device front shaft.
7
Art. no. is specified in Required equip-
ment on page 247 .
Pull the shaft out using the press equipment,
balancing device shaft , according to user in-
structions enclosed with the equipment.
xx0900000813
8
User instructions are enclosed with the
tool.
Go to the user instructions enclosed with the
press tool.
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions
for the tool.
The power for brake release is only applied
for 180 seconds after activation.
Lower the balancing device until it rests safely
against the bottom of the frame, out of reach
from the lower arm.
9
xx0300000015
Move the lower arm backwards to the lowest
position possible.
10
Continues on next page
250
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 250
|
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, lower arm
The procedure below details how to remove the complete lower arm.
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
Detailed in section Replacement of
complete upper arm on page 240 .
Remove the upper arm.
3
Detailed in section Replacement of
cable harness, axes 1-4 on page 214 .
Disconnect and remove the cables from inside
the lower arm.
Release any cable attachments.
4
Art. no. is specified in Required equip-
ment on page 247 .
Apply the lifting eye to the balancing device
and raise to unload the device.
5
Attachment is shown in the figure Loc-
ation of lower arm on page 245 .
Continues on next page
Product manual - IRB 7600
249
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
Note
Action
Detailed in section Unloading the bal-
ancing device on page 283 .
Unload the balancing device in order to make
the piston rod and front ear adjustable when
pulling the front shaft out.
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions
for the tool.
The power for brake release is only applied
for 180 seconds after activation.
6
Shown in the figure Location of lower
arm on page 245 .
Remove the securing screw from the balancing
device front shaft.
7
Art. no. is specified in Required equip-
ment on page 247 .
Pull the shaft out using the press equipment,
balancing device shaft , according to user in-
structions enclosed with the equipment.
xx0900000813
8
User instructions are enclosed with the
tool.
Go to the user instructions enclosed with the
press tool.
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions
for the tool.
The power for brake release is only applied
for 180 seconds after activation.
Lower the balancing device until it rests safely
against the bottom of the frame, out of reach
from the lower arm.
9
xx0300000015
Move the lower arm backwards to the lowest
position possible.
10
Continues on next page
250
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
Note
Action
CAUTION
The lower arm weighs 225 kg! All lifting
equipment used must be sized accordingly!
11
Article number is specified in Required
equipment on page 247 !
Apply the lifting tool to the lower arm.
12
Detailed in section Changing oil, axis-
2 gearbox on page 167 .
Drain the oil from gearbox 2.
13
Raise the tool to unload the lower arm.
14
Remove the lower arm shaft and all additional
components, as detailed in section Replace-
ment of lower arm shaft on page 255 .
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions
for the tool.
The power for brake release is only applied
for 180 seconds after activation.
15
Shown in the figure Attachment points,
lower arm on page 245 .
Remove the lower arm attachment screws and
washers that attaches the lower arm to the
gearbox 2.
16
Lift the lower arm down and place it on a se-
cure surface.
17
Shown in the figure Attachment points,
lower arm on page 245 .
Remove the bearing and thrust washer from
the shaft hole in the lower arm.
18
On reassembly a new bearing must be
used!
Shown in the figure Attachment points,
lower arm on page 245 .
Remove the sealing from the lower arm.
19
On reassembly a new sealing must be
used!
Refitting, lower arm
The procedure below details how to refit the lower arm to the robot.
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
Continues on next page
Product manual - IRB 7600
251
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 251
|
Note
Action
Detailed in section Unloading the bal-
ancing device on page 283 .
Unload the balancing device in order to make
the piston rod and front ear adjustable when
pulling the front shaft out.
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions
for the tool.
The power for brake release is only applied
for 180 seconds after activation.
6
Shown in the figure Location of lower
arm on page 245 .
Remove the securing screw from the balancing
device front shaft.
7
Art. no. is specified in Required equip-
ment on page 247 .
Pull the shaft out using the press equipment,
balancing device shaft , according to user in-
structions enclosed with the equipment.
xx0900000813
8
User instructions are enclosed with the
tool.
Go to the user instructions enclosed with the
press tool.
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions
for the tool.
The power for brake release is only applied
for 180 seconds after activation.
Lower the balancing device until it rests safely
against the bottom of the frame, out of reach
from the lower arm.
9
xx0300000015
Move the lower arm backwards to the lowest
position possible.
10
Continues on next page
250
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
Note
Action
CAUTION
The lower arm weighs 225 kg! All lifting
equipment used must be sized accordingly!
11
Article number is specified in Required
equipment on page 247 !
Apply the lifting tool to the lower arm.
12
Detailed in section Changing oil, axis-
2 gearbox on page 167 .
Drain the oil from gearbox 2.
13
Raise the tool to unload the lower arm.
14
Remove the lower arm shaft and all additional
components, as detailed in section Replace-
ment of lower arm shaft on page 255 .
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions
for the tool.
The power for brake release is only applied
for 180 seconds after activation.
15
Shown in the figure Attachment points,
lower arm on page 245 .
Remove the lower arm attachment screws and
washers that attaches the lower arm to the
gearbox 2.
16
Lift the lower arm down and place it on a se-
cure surface.
17
Shown in the figure Attachment points,
lower arm on page 245 .
Remove the bearing and thrust washer from
the shaft hole in the lower arm.
18
On reassembly a new bearing must be
used!
Shown in the figure Attachment points,
lower arm on page 245 .
Remove the sealing from the lower arm.
19
On reassembly a new sealing must be
used!
Refitting, lower arm
The procedure below details how to refit the lower arm to the robot.
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
Continues on next page
Product manual - IRB 7600
251
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
Note
Action
Spare part number is specified in Re-
quired equipment on page 247 .
![Image]
xx1700000917
If the lower arm is designed with a hole, fit a
new VK-cover on a new lower arm or replace
existing if damaged.
2
Included in the lifting tool, lower arm,
article number is specified in Re-
quired equipment on page 247 .
xx0200000262
Fit the two guidings in the attachment holes of
the lower arm.
3
A
Attachment holes for the two
guidings.
Always use a new sealing when reas-
sembling!
Fit the new sealing, axis 2/3 on the guidings.
4
Article number is specified in Re-
quired equipment on page 247 .
CAUTION
The lower arm weighs 225 kg! All lifting equip-
ment used must be sized accordingly!
5
Article number is specified in Re-
quired equipment on page 247 .
Apply the lifting tool to the lower arm.
6
Lift the lower arm and move it to its mounting
position.
7
Continues on next page
252
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 252
|
Note
Action
CAUTION
The lower arm weighs 225 kg! All lifting
equipment used must be sized accordingly!
11
Article number is specified in Required
equipment on page 247 !
Apply the lifting tool to the lower arm.
12
Detailed in section Changing oil, axis-
2 gearbox on page 167 .
Drain the oil from gearbox 2.
13
Raise the tool to unload the lower arm.
14
Remove the lower arm shaft and all additional
components, as detailed in section Replace-
ment of lower arm shaft on page 255 .
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions
for the tool.
The power for brake release is only applied
for 180 seconds after activation.
15
Shown in the figure Attachment points,
lower arm on page 245 .
Remove the lower arm attachment screws and
washers that attaches the lower arm to the
gearbox 2.
16
Lift the lower arm down and place it on a se-
cure surface.
17
Shown in the figure Attachment points,
lower arm on page 245 .
Remove the bearing and thrust washer from
the shaft hole in the lower arm.
18
On reassembly a new bearing must be
used!
Shown in the figure Attachment points,
lower arm on page 245 .
Remove the sealing from the lower arm.
19
On reassembly a new sealing must be
used!
Refitting, lower arm
The procedure below details how to refit the lower arm to the robot.
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
Continues on next page
Product manual - IRB 7600
251
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
Note
Action
Spare part number is specified in Re-
quired equipment on page 247 .
![Image]
xx1700000917
If the lower arm is designed with a hole, fit a
new VK-cover on a new lower arm or replace
existing if damaged.
2
Included in the lifting tool, lower arm,
article number is specified in Re-
quired equipment on page 247 .
xx0200000262
Fit the two guidings in the attachment holes of
the lower arm.
3
A
Attachment holes for the two
guidings.
Always use a new sealing when reas-
sembling!
Fit the new sealing, axis 2/3 on the guidings.
4
Article number is specified in Re-
quired equipment on page 247 .
CAUTION
The lower arm weighs 225 kg! All lifting equip-
ment used must be sized accordingly!
5
Article number is specified in Re-
quired equipment on page 247 .
Apply the lifting tool to the lower arm.
6
Lift the lower arm and move it to its mounting
position.
7
Continues on next page
252
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
Note
Action
Connect power supply to connector
R2.MP2:
•
+ : pin 2
•
-: pin 5
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
xx0200000165
In case the holes of the lower arm and the ones
of the gearbox axis 2 doesn´t match, use power
supply to release the motor axis 2 brakes and
rotate the pinion and gear with the rotation tool.
8
The rotation tool (A) is used beneath
the motor cover, directly on the motor
shaft as shown in the figure above!
Article number is specified in Re-
quired equipment on page 247 .
30 pcs: M16 x 50; tightening torque:
300 Nm.
Secure the lower arm with 28 of the 30 attach-
ment screws and washers in gearbox 2.
9
Shown in the figure Attachment
points, lower arm on page 245 .
Remove the guidings and secure the two remain-
ing attachment screws as detailed above!
10
Refit the lower arm shaft and all additional
components, as detailed in section Replacement
of lower arm shaft on page 255 .
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions for
the tool.
The power for brake release is only applied for
180 seconds after activation.
11
Detailed in section Refitting, balan-
cing device on page 286 .
Refit and restore the balancing device.
12
Detailed in section Refitting, upper
arm on page 243 .
Refit the upper arm.
13
Detailed in section Performing a leak-
down test on page 206 .
Perform a leak-down test.
14
Detailed in section Filling, oil on
page 168 .
Refill the axis 2 gearbox with oil.
15
Detailed in section Refitting, cable
harness, axes 1-4 on page 218 .
Refit and reconnect all cables inside the lower
arm.
Refit removed cable attachments.
16
Continues on next page
Product manual - IRB 7600
253
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
|
ABB_IRB7600_Product_Manual.pdf
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| 253
|
Note
Action
Spare part number is specified in Re-
quired equipment on page 247 .
![Image]
xx1700000917
If the lower arm is designed with a hole, fit a
new VK-cover on a new lower arm or replace
existing if damaged.
2
Included in the lifting tool, lower arm,
article number is specified in Re-
quired equipment on page 247 .
xx0200000262
Fit the two guidings in the attachment holes of
the lower arm.
3
A
Attachment holes for the two
guidings.
Always use a new sealing when reas-
sembling!
Fit the new sealing, axis 2/3 on the guidings.
4
Article number is specified in Re-
quired equipment on page 247 .
CAUTION
The lower arm weighs 225 kg! All lifting equip-
ment used must be sized accordingly!
5
Article number is specified in Re-
quired equipment on page 247 .
Apply the lifting tool to the lower arm.
6
Lift the lower arm and move it to its mounting
position.
7
Continues on next page
252
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
Note
Action
Connect power supply to connector
R2.MP2:
•
+ : pin 2
•
-: pin 5
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
xx0200000165
In case the holes of the lower arm and the ones
of the gearbox axis 2 doesn´t match, use power
supply to release the motor axis 2 brakes and
rotate the pinion and gear with the rotation tool.
8
The rotation tool (A) is used beneath
the motor cover, directly on the motor
shaft as shown in the figure above!
Article number is specified in Re-
quired equipment on page 247 .
30 pcs: M16 x 50; tightening torque:
300 Nm.
Secure the lower arm with 28 of the 30 attach-
ment screws and washers in gearbox 2.
9
Shown in the figure Attachment
points, lower arm on page 245 .
Remove the guidings and secure the two remain-
ing attachment screws as detailed above!
10
Refit the lower arm shaft and all additional
components, as detailed in section Replacement
of lower arm shaft on page 255 .
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions for
the tool.
The power for brake release is only applied for
180 seconds after activation.
11
Detailed in section Refitting, balan-
cing device on page 286 .
Refit and restore the balancing device.
12
Detailed in section Refitting, upper
arm on page 243 .
Refit the upper arm.
13
Detailed in section Performing a leak-
down test on page 206 .
Perform a leak-down test.
14
Detailed in section Filling, oil on
page 168 .
Refill the axis 2 gearbox with oil.
15
Detailed in section Refitting, cable
harness, axes 1-4 on page 218 .
Refit and reconnect all cables inside the lower
arm.
Refit removed cable attachments.
16
Continues on next page
Product manual - IRB 7600
253
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
Note
Action
Pendulum Calibration is described in
Operating manual - Calibration Pendu-
lum , enclosed with the calibration
tools.
Recalibrate the robot.
17
Axis Calibration is described in Calib-
rating with Axis Calibration method
on page 383 .
General calibration information is in-
cluded in section Calibration on
page 371 .
DANGER
Make sure all safety requirements are met when
performing the first test run.
18
254
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 254
|
Note
Action
Connect power supply to connector
R2.MP2:
•
+ : pin 2
•
-: pin 5
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
xx0200000165
In case the holes of the lower arm and the ones
of the gearbox axis 2 doesn´t match, use power
supply to release the motor axis 2 brakes and
rotate the pinion and gear with the rotation tool.
8
The rotation tool (A) is used beneath
the motor cover, directly on the motor
shaft as shown in the figure above!
Article number is specified in Re-
quired equipment on page 247 .
30 pcs: M16 x 50; tightening torque:
300 Nm.
Secure the lower arm with 28 of the 30 attach-
ment screws and washers in gearbox 2.
9
Shown in the figure Attachment
points, lower arm on page 245 .
Remove the guidings and secure the two remain-
ing attachment screws as detailed above!
10
Refit the lower arm shaft and all additional
components, as detailed in section Replacement
of lower arm shaft on page 255 .
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions for
the tool.
The power for brake release is only applied for
180 seconds after activation.
11
Detailed in section Refitting, balan-
cing device on page 286 .
Refit and restore the balancing device.
12
Detailed in section Refitting, upper
arm on page 243 .
Refit the upper arm.
13
Detailed in section Performing a leak-
down test on page 206 .
Perform a leak-down test.
14
Detailed in section Filling, oil on
page 168 .
Refill the axis 2 gearbox with oil.
15
Detailed in section Refitting, cable
harness, axes 1-4 on page 218 .
Refit and reconnect all cables inside the lower
arm.
Refit removed cable attachments.
16
Continues on next page
Product manual - IRB 7600
253
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
Note
Action
Pendulum Calibration is described in
Operating manual - Calibration Pendu-
lum , enclosed with the calibration
tools.
Recalibrate the robot.
17
Axis Calibration is described in Calib-
rating with Axis Calibration method
on page 383 .
General calibration information is in-
cluded in section Calibration on
page 371 .
DANGER
Make sure all safety requirements are met when
performing the first test run.
18
254
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
4.4.5 Replacement of lower arm shaft
Prerequisites
This section details how to remove and refit the lower arm shaft as a step in the
procedure of removing/refitting the complete lower arm. To perform the procedure
described in this section, it is required that the preceding instructions in section
Replacement of complete lower arm on page 245 are followed! These include:
•
removing the upper arm
•
removing the cabling in the lower arm
•
unloading the balancing device and removing the front eye shaft
•
draining the oil in gearbox axis 2
•
unloading the lower arm with specific lifting equipment.
Components, lower arm shaft for robots with protection Standard
The figure shows components fitted to the lower arm shaft when the robot has
protection Standard.
xx0300000487
Protection plug
A
Lower arm shaft (axis 2 shaft)
B
Thrust washer
C
Bearing
D
Protection washer
E
Retaining ring
F
Continues on next page
Product manual - IRB 7600
255
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
|
ABB_IRB7600_Product_Manual.pdf
|
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| 255
|
Note
Action
Pendulum Calibration is described in
Operating manual - Calibration Pendu-
lum , enclosed with the calibration
tools.
Recalibrate the robot.
17
Axis Calibration is described in Calib-
rating with Axis Calibration method
on page 383 .
General calibration information is in-
cluded in section Calibration on
page 371 .
DANGER
Make sure all safety requirements are met when
performing the first test run.
18
254
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.4 Replacement of complete lower arm
Continued
4.4.5 Replacement of lower arm shaft
Prerequisites
This section details how to remove and refit the lower arm shaft as a step in the
procedure of removing/refitting the complete lower arm. To perform the procedure
described in this section, it is required that the preceding instructions in section
Replacement of complete lower arm on page 245 are followed! These include:
•
removing the upper arm
•
removing the cabling in the lower arm
•
unloading the balancing device and removing the front eye shaft
•
draining the oil in gearbox axis 2
•
unloading the lower arm with specific lifting equipment.
Components, lower arm shaft for robots with protection Standard
The figure shows components fitted to the lower arm shaft when the robot has
protection Standard.
xx0300000487
Protection plug
A
Lower arm shaft (axis 2 shaft)
B
Thrust washer
C
Bearing
D
Protection washer
E
Retaining ring
F
Continues on next page
Product manual - IRB 7600
255
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
Components, lower arm shaft for robots with protection Foundry Plus
The figure shows components fitted to the lower arm shaft when the robot has
protection Foundry Plus.
![Image]
xx1100000954
Bearing
A
Thrust washer
B
Bushing
C
Shaft for the lower arm
D
Set screw with cup point, M4x6 (2 pcs)
E
Hexagon bolt M8x190
F
Conical spring washer 8.4x16x1.6
G
Shaft tap
H
Shaft for the sealing cover
J
O-ring
K
Sealing cover
L
Radial sealing with dust lip
M
Required equipment
Note
Article number
Equipment
Always use a new bearing
when reassembling!
For spare part number
see:
•
Spare part lists
on page 425 .
Bearing
Hydraulic pressing accessory.
3HAC075427-001
Puller device, axis 2 shaft
User instructions are enclosed
with the tool.
Continues on next page
256
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 256
|
4.4.5 Replacement of lower arm shaft
Prerequisites
This section details how to remove and refit the lower arm shaft as a step in the
procedure of removing/refitting the complete lower arm. To perform the procedure
described in this section, it is required that the preceding instructions in section
Replacement of complete lower arm on page 245 are followed! These include:
•
removing the upper arm
•
removing the cabling in the lower arm
•
unloading the balancing device and removing the front eye shaft
•
draining the oil in gearbox axis 2
•
unloading the lower arm with specific lifting equipment.
Components, lower arm shaft for robots with protection Standard
The figure shows components fitted to the lower arm shaft when the robot has
protection Standard.
xx0300000487
Protection plug
A
Lower arm shaft (axis 2 shaft)
B
Thrust washer
C
Bearing
D
Protection washer
E
Retaining ring
F
Continues on next page
Product manual - IRB 7600
255
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
Components, lower arm shaft for robots with protection Foundry Plus
The figure shows components fitted to the lower arm shaft when the robot has
protection Foundry Plus.
![Image]
xx1100000954
Bearing
A
Thrust washer
B
Bushing
C
Shaft for the lower arm
D
Set screw with cup point, M4x6 (2 pcs)
E
Hexagon bolt M8x190
F
Conical spring washer 8.4x16x1.6
G
Shaft tap
H
Shaft for the sealing cover
J
O-ring
K
Sealing cover
L
Radial sealing with dust lip
M
Required equipment
Note
Article number
Equipment
Always use a new bearing
when reassembling!
For spare part number
see:
•
Spare part lists
on page 425 .
Bearing
Hydraulic pressing accessory.
3HAC075427-001
Puller device, axis 2 shaft
User instructions are enclosed
with the tool.
Continues on next page
256
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
Continued
Note
Article number
Equipment
Hydraulic pressing accessory.
3HAC076203-001
Press device, axis 2 shaft and
bearing
User instructions are enclosed
with the tool.
To be used with the press and
puller tools.
3HAC13086-1
Hydraulic pump, 80 MPa
See technical specifications in
the user instructions for the
press equipment.
3HAC021563-012
Hydraulic pump, 150 MPa (Glycer-
in)
-
Retaining ring plier
For cleaning the shaft.
11771012-208
Isopropanol
For lubrication of the bearing.
3HAB3537-1
Grease
For lubrication of the shaft.
Equivalent:
•
Mercasol 3106
3HAC026621-001
Rust preventive
Loctite 243
3HAB7116-1
Locking liquid (only for robots with
protection Foundry Plus and
Foundry Prime)
Removal, lower arm shaft from robot with protection Standard
Use this procedure to remove the lower arm shaft if the robot has protection
Standard.
If encountering any problems when removing the shaft, contact ABB Robotics!
Note/Illustration
Action
WARNING
This procedure is a step in the complete
procedure of removing the lower arm! Make
sure all the preceding steps specified in Re-
placement of lower arm shaft on page255 are
made before removing the lower arm shaft!
1
Shown in the figure Components, lower
arm shaft for robots with protection
Standard on page 255 !
Remove the protection plug.
2
Shown in the figure Components, lower
arm shaft for robots with protection
Standard on page 255 !
Remove the protection washer and the retain-
ing ring.
3
Use a plier for the retaining ring.
Continues on next page
Product manual - IRB 7600
257
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
https://search.abb.com/library/Download.aspx?DocumentID=3HAC022033-001&LanguageCode=en&DocumentPartId=&Action=Launch&DocumentRevisionId=AF
| 257
|
Components, lower arm shaft for robots with protection Foundry Plus
The figure shows components fitted to the lower arm shaft when the robot has
protection Foundry Plus.
![Image]
xx1100000954
Bearing
A
Thrust washer
B
Bushing
C
Shaft for the lower arm
D
Set screw with cup point, M4x6 (2 pcs)
E
Hexagon bolt M8x190
F
Conical spring washer 8.4x16x1.6
G
Shaft tap
H
Shaft for the sealing cover
J
O-ring
K
Sealing cover
L
Radial sealing with dust lip
M
Required equipment
Note
Article number
Equipment
Always use a new bearing
when reassembling!
For spare part number
see:
•
Spare part lists
on page 425 .
Bearing
Hydraulic pressing accessory.
3HAC075427-001
Puller device, axis 2 shaft
User instructions are enclosed
with the tool.
Continues on next page
256
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
Continued
Note
Article number
Equipment
Hydraulic pressing accessory.
3HAC076203-001
Press device, axis 2 shaft and
bearing
User instructions are enclosed
with the tool.
To be used with the press and
puller tools.
3HAC13086-1
Hydraulic pump, 80 MPa
See technical specifications in
the user instructions for the
press equipment.
3HAC021563-012
Hydraulic pump, 150 MPa (Glycer-
in)
-
Retaining ring plier
For cleaning the shaft.
11771012-208
Isopropanol
For lubrication of the bearing.
3HAB3537-1
Grease
For lubrication of the shaft.
Equivalent:
•
Mercasol 3106
3HAC026621-001
Rust preventive
Loctite 243
3HAB7116-1
Locking liquid (only for robots with
protection Foundry Plus and
Foundry Prime)
Removal, lower arm shaft from robot with protection Standard
Use this procedure to remove the lower arm shaft if the robot has protection
Standard.
If encountering any problems when removing the shaft, contact ABB Robotics!
Note/Illustration
Action
WARNING
This procedure is a step in the complete
procedure of removing the lower arm! Make
sure all the preceding steps specified in Re-
placement of lower arm shaft on page255 are
made before removing the lower arm shaft!
1
Shown in the figure Components, lower
arm shaft for robots with protection
Standard on page 255 !
Remove the protection plug.
2
Shown in the figure Components, lower
arm shaft for robots with protection
Standard on page 255 !
Remove the protection washer and the retain-
ing ring.
3
Use a plier for the retaining ring.
Continues on next page
Product manual - IRB 7600
257
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
Continued
Note/Illustration
Action
Art. no. is specified in Required equip-
ment on page 256 !
Pull out the axis-2 shaft with the puller device
according to user instructions enclosed with
the equipment.
xx0900000813
4
User instructions are enclosed with the
tool.
Go to the user instructions enclosed with the
press tool.
DANGER
Handling the tool incorrectly will cause seri-
ous injury.
Read and follow enclosed user instructions
for the tool.
The power for brake release is only applied
for 180 seconds after activation.
Remove the bearing and thrust washer from
the shaft hole in the lower arm, recommend-
able after removing the complete lower arm
as detailed in section Replacement of com-
plete lower arm on page 245 .
5
Removal, lower arm shaft on robot with protection Foundry Plus
Use this procedure to remove the lower arm shaft if the robot has protection Foundry
Plus.
If encountering any problems when removing the shaft, contact ABB Robotics!
Note
Action
WARNING
This procedure is a step in the complete procedure
of removing the lower arm! Make sure all the preced-
ing steps specified in Replacement of lower arm
shaft on page 255 are made before removing the
lower arm shaft!
1
Shown in the figure Components,
lower arm shaft for robots with
protection Foundry Plus on
page 256 .
Remove the two set screws .
2
Remove the shaft sealing cover .
3
Remove the sealing cover .
4
Remove the radial sealing , if the lower arm is to be
replaced with a new one.
5
If the same lower arm is refitted, the radial sealing
can be left in the lower arm.
Remove the hexagon bolt with the washer and shaft
tap .
6
Continues on next page
258
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
Continued
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ABB_IRB7600_Product_Manual.pdf
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| 258
|
Note
Article number
Equipment
Hydraulic pressing accessory.
3HAC076203-001
Press device, axis 2 shaft and
bearing
User instructions are enclosed
with the tool.
To be used with the press and
puller tools.
3HAC13086-1
Hydraulic pump, 80 MPa
See technical specifications in
the user instructions for the
press equipment.
3HAC021563-012
Hydraulic pump, 150 MPa (Glycer-
in)
-
Retaining ring plier
For cleaning the shaft.
11771012-208
Isopropanol
For lubrication of the bearing.
3HAB3537-1
Grease
For lubrication of the shaft.
Equivalent:
•
Mercasol 3106
3HAC026621-001
Rust preventive
Loctite 243
3HAB7116-1
Locking liquid (only for robots with
protection Foundry Plus and
Foundry Prime)
Removal, lower arm shaft from robot with protection Standard
Use this procedure to remove the lower arm shaft if the robot has protection
Standard.
If encountering any problems when removing the shaft, contact ABB Robotics!
Note/Illustration
Action
WARNING
This procedure is a step in the complete
procedure of removing the lower arm! Make
sure all the preceding steps specified in Re-
placement of lower arm shaft on page255 are
made before removing the lower arm shaft!
1
Shown in the figure Components, lower
arm shaft for robots with protection
Standard on page 255 !
Remove the protection plug.
2
Shown in the figure Components, lower
arm shaft for robots with protection
Standard on page 255 !
Remove the protection washer and the retain-
ing ring.
3
Use a plier for the retaining ring.
Continues on next page
Product manual - IRB 7600
257
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
Continued
Note/Illustration
Action
Art. no. is specified in Required equip-
ment on page 256 !
Pull out the axis-2 shaft with the puller device
according to user instructions enclosed with
the equipment.
xx0900000813
4
User instructions are enclosed with the
tool.
Go to the user instructions enclosed with the
press tool.
DANGER
Handling the tool incorrectly will cause seri-
ous injury.
Read and follow enclosed user instructions
for the tool.
The power for brake release is only applied
for 180 seconds after activation.
Remove the bearing and thrust washer from
the shaft hole in the lower arm, recommend-
able after removing the complete lower arm
as detailed in section Replacement of com-
plete lower arm on page 245 .
5
Removal, lower arm shaft on robot with protection Foundry Plus
Use this procedure to remove the lower arm shaft if the robot has protection Foundry
Plus.
If encountering any problems when removing the shaft, contact ABB Robotics!
Note
Action
WARNING
This procedure is a step in the complete procedure
of removing the lower arm! Make sure all the preced-
ing steps specified in Replacement of lower arm
shaft on page 255 are made before removing the
lower arm shaft!
1
Shown in the figure Components,
lower arm shaft for robots with
protection Foundry Plus on
page 256 .
Remove the two set screws .
2
Remove the shaft sealing cover .
3
Remove the sealing cover .
4
Remove the radial sealing , if the lower arm is to be
replaced with a new one.
5
If the same lower arm is refitted, the radial sealing
can be left in the lower arm.
Remove the hexagon bolt with the washer and shaft
tap .
6
Continues on next page
258
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
Continued
Note
Action
Art. no. is specified in Required
equipment on page 256 !
Pull out the axis-2 shaft with the puller device accord-
ing to user instructions enclosed with the equipment.
xx0900000813
7
User instructions are enclosed
with the tool.
Go to the user instructions enclosed with the press
tool.
DANGER
Handling the tool incorrectly will cause serious in-
jury.
Read and follow enclosed user instructions for the
tool.
The power for brake release is only applied for 180
seconds after activation.
Remove the bearing and thrust washer from the
shaft hole in the lower arm, recommendable after
removing the complete lower arm as detailed in
section Replacement of complete lower arm on
page 245 .
8
Refitting, lower arm shaft on robot with protection Standard
Use this procedure to refit the lower arm shaft if the robot has protection Standard.
Note/Illustration
Action
Art. no. is specified in Required
equipment on page 256 !
Clean the shaft with isopropanol and lubricate it
with grease .
1
![Image]
A
A
Apply mercas
If the robot is going to work in a water jet applica-
tion cell:
Apply Mercasol 3106 on the Support shaft axis 2.
•
Apply Mercasol 3106 on both sides of the
thrust washer, all around the bearing and on
surface on the shaft.
2
•
A: Mercasol on marked
areas.
Continues on next page
Product manual - IRB 7600
259
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
https://search.abb.com/library/Download.aspx?DocumentID=3HAC022033-001&LanguageCode=en&DocumentPartId=&Action=Launch&DocumentRevisionId=AF
| 259
|
Note/Illustration
Action
Art. no. is specified in Required equip-
ment on page 256 !
Pull out the axis-2 shaft with the puller device
according to user instructions enclosed with
the equipment.
xx0900000813
4
User instructions are enclosed with the
tool.
Go to the user instructions enclosed with the
press tool.
DANGER
Handling the tool incorrectly will cause seri-
ous injury.
Read and follow enclosed user instructions
for the tool.
The power for brake release is only applied
for 180 seconds after activation.
Remove the bearing and thrust washer from
the shaft hole in the lower arm, recommend-
able after removing the complete lower arm
as detailed in section Replacement of com-
plete lower arm on page 245 .
5
Removal, lower arm shaft on robot with protection Foundry Plus
Use this procedure to remove the lower arm shaft if the robot has protection Foundry
Plus.
If encountering any problems when removing the shaft, contact ABB Robotics!
Note
Action
WARNING
This procedure is a step in the complete procedure
of removing the lower arm! Make sure all the preced-
ing steps specified in Replacement of lower arm
shaft on page 255 are made before removing the
lower arm shaft!
1
Shown in the figure Components,
lower arm shaft for robots with
protection Foundry Plus on
page 256 .
Remove the two set screws .
2
Remove the shaft sealing cover .
3
Remove the sealing cover .
4
Remove the radial sealing , if the lower arm is to be
replaced with a new one.
5
If the same lower arm is refitted, the radial sealing
can be left in the lower arm.
Remove the hexagon bolt with the washer and shaft
tap .
6
Continues on next page
258
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
Continued
Note
Action
Art. no. is specified in Required
equipment on page 256 !
Pull out the axis-2 shaft with the puller device accord-
ing to user instructions enclosed with the equipment.
xx0900000813
7
User instructions are enclosed
with the tool.
Go to the user instructions enclosed with the press
tool.
DANGER
Handling the tool incorrectly will cause serious in-
jury.
Read and follow enclosed user instructions for the
tool.
The power for brake release is only applied for 180
seconds after activation.
Remove the bearing and thrust washer from the
shaft hole in the lower arm, recommendable after
removing the complete lower arm as detailed in
section Replacement of complete lower arm on
page 245 .
8
Refitting, lower arm shaft on robot with protection Standard
Use this procedure to refit the lower arm shaft if the robot has protection Standard.
Note/Illustration
Action
Art. no. is specified in Required
equipment on page 256 !
Clean the shaft with isopropanol and lubricate it
with grease .
1
![Image]
A
A
Apply mercas
If the robot is going to work in a water jet applica-
tion cell:
Apply Mercasol 3106 on the Support shaft axis 2.
•
Apply Mercasol 3106 on both sides of the
thrust washer, all around the bearing and on
surface on the shaft.
2
•
A: Mercasol on marked
areas.
Continues on next page
Product manual - IRB 7600
259
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
Continued
Note/Illustration
Action
Push the shaft in by hand.
3
Also shown in the figure Compon-
ents, lower arm shaft for robots
with protection Standard on
page 255 !
Refit the thrust washer to the shaft.
4
Art. no. is specified in Required
equipment on page 256 !
Fit the axis-2 shaft with the press device, axis 2
shaft according to user instructions enclosed with
the equipment.
xx0900000813
5
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the press
tool.
DANGER
Handling the tool incorrectly will cause serious in-
jury.
Read and follow enclosed user instructions for the
tool.
The power for brake release is only applied for 180
seconds after activation.
Remove the press device, axis 2 shaft.
6
Art. no. is specified in Required
equipment on page 256
Apply grease to the location of the shaft where the
bearing is to be mounted.
7
Note
Always use a new bearing when
reassembling!
Press in the new bearing with the press tool, axis
2 bearing according to user instructions enclosed
with the equipment..
xx0900000813
8
Art. no. is specified in Required
equipment on page 256 .
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the press
tool.
DANGER
Handling the tool incorrectly will cause serious in-
jury.
Read and follow enclosed user instructions for the
tool.
The power for brake release is only applied for 180
seconds after activation.
Shown in the figure Components,
lower arm shaft for robots with
protection Standard on page 255 .
Refit the protection washer and the retaining ring .
9
Refit the protection plug .
10
Continues on next page
260
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 260
|
Note
Action
Art. no. is specified in Required
equipment on page 256 !
Pull out the axis-2 shaft with the puller device accord-
ing to user instructions enclosed with the equipment.
xx0900000813
7
User instructions are enclosed
with the tool.
Go to the user instructions enclosed with the press
tool.
DANGER
Handling the tool incorrectly will cause serious in-
jury.
Read and follow enclosed user instructions for the
tool.
The power for brake release is only applied for 180
seconds after activation.
Remove the bearing and thrust washer from the
shaft hole in the lower arm, recommendable after
removing the complete lower arm as detailed in
section Replacement of complete lower arm on
page 245 .
8
Refitting, lower arm shaft on robot with protection Standard
Use this procedure to refit the lower arm shaft if the robot has protection Standard.
Note/Illustration
Action
Art. no. is specified in Required
equipment on page 256 !
Clean the shaft with isopropanol and lubricate it
with grease .
1
![Image]
A
A
Apply mercas
If the robot is going to work in a water jet applica-
tion cell:
Apply Mercasol 3106 on the Support shaft axis 2.
•
Apply Mercasol 3106 on both sides of the
thrust washer, all around the bearing and on
surface on the shaft.
2
•
A: Mercasol on marked
areas.
Continues on next page
Product manual - IRB 7600
259
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
Continued
Note/Illustration
Action
Push the shaft in by hand.
3
Also shown in the figure Compon-
ents, lower arm shaft for robots
with protection Standard on
page 255 !
Refit the thrust washer to the shaft.
4
Art. no. is specified in Required
equipment on page 256 !
Fit the axis-2 shaft with the press device, axis 2
shaft according to user instructions enclosed with
the equipment.
xx0900000813
5
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the press
tool.
DANGER
Handling the tool incorrectly will cause serious in-
jury.
Read and follow enclosed user instructions for the
tool.
The power for brake release is only applied for 180
seconds after activation.
Remove the press device, axis 2 shaft.
6
Art. no. is specified in Required
equipment on page 256
Apply grease to the location of the shaft where the
bearing is to be mounted.
7
Note
Always use a new bearing when
reassembling!
Press in the new bearing with the press tool, axis
2 bearing according to user instructions enclosed
with the equipment..
xx0900000813
8
Art. no. is specified in Required
equipment on page 256 .
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the press
tool.
DANGER
Handling the tool incorrectly will cause serious in-
jury.
Read and follow enclosed user instructions for the
tool.
The power for brake release is only applied for 180
seconds after activation.
Shown in the figure Components,
lower arm shaft for robots with
protection Standard on page 255 .
Refit the protection washer and the retaining ring .
9
Refit the protection plug .
10
Continues on next page
260
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
Continued
Note/Illustration
Action
Proceed with the refitting procedure of the lower
arm, detailed in section Replacement of complete
lower arm on page 245 .
11
Refitting, lower arm shaft on robot with protection Foundry Plus
Use this procedure to refit the lower arm shaft if the robot has protection Foundry
Plus.
Note/Illustration
Action
Art. no. is specified in Required
equipment on page 256 !
Clean the shaft with isopropanol and lubricate it
with grease .
1
![Image]
A
A
Apply mercas
If the robot is going to work in a water jet applica-
tion cell:
Apply Mercasol 3106 on the support shaft axis 2.
•
Apply Mercasol 3106 on both sides of the
thrust washer, all around the bearing and on
surface on the shaft.
2
A
Mercasol on marked areas.
Push the shaft in by hand.
3
Also shown in the figure Compon-
ents, lower arm shaft for robots
with protection Foundry Plus on
page 256 !
Refit the thrust washer to the shaft.
4
Continues on next page
Product manual - IRB 7600
261
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
Continued
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ABB_IRB7600_Product_Manual.pdf
|
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| 261
|
Note/Illustration
Action
Push the shaft in by hand.
3
Also shown in the figure Compon-
ents, lower arm shaft for robots
with protection Standard on
page 255 !
Refit the thrust washer to the shaft.
4
Art. no. is specified in Required
equipment on page 256 !
Fit the axis-2 shaft with the press device, axis 2
shaft according to user instructions enclosed with
the equipment.
xx0900000813
5
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the press
tool.
DANGER
Handling the tool incorrectly will cause serious in-
jury.
Read and follow enclosed user instructions for the
tool.
The power for brake release is only applied for 180
seconds after activation.
Remove the press device, axis 2 shaft.
6
Art. no. is specified in Required
equipment on page 256
Apply grease to the location of the shaft where the
bearing is to be mounted.
7
Note
Always use a new bearing when
reassembling!
Press in the new bearing with the press tool, axis
2 bearing according to user instructions enclosed
with the equipment..
xx0900000813
8
Art. no. is specified in Required
equipment on page 256 .
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the press
tool.
DANGER
Handling the tool incorrectly will cause serious in-
jury.
Read and follow enclosed user instructions for the
tool.
The power for brake release is only applied for 180
seconds after activation.
Shown in the figure Components,
lower arm shaft for robots with
protection Standard on page 255 .
Refit the protection washer and the retaining ring .
9
Refit the protection plug .
10
Continues on next page
260
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
Continued
Note/Illustration
Action
Proceed with the refitting procedure of the lower
arm, detailed in section Replacement of complete
lower arm on page 245 .
11
Refitting, lower arm shaft on robot with protection Foundry Plus
Use this procedure to refit the lower arm shaft if the robot has protection Foundry
Plus.
Note/Illustration
Action
Art. no. is specified in Required
equipment on page 256 !
Clean the shaft with isopropanol and lubricate it
with grease .
1
![Image]
A
A
Apply mercas
If the robot is going to work in a water jet applica-
tion cell:
Apply Mercasol 3106 on the support shaft axis 2.
•
Apply Mercasol 3106 on both sides of the
thrust washer, all around the bearing and on
surface on the shaft.
2
A
Mercasol on marked areas.
Push the shaft in by hand.
3
Also shown in the figure Compon-
ents, lower arm shaft for robots
with protection Foundry Plus on
page 256 !
Refit the thrust washer to the shaft.
4
Continues on next page
Product manual - IRB 7600
261
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
Continued
Note/Illustration
Action
Art. no. is specified in Required
equipment on page 256 !
Fit the axis-2 shaft with the press device, axis 2
shaft according to user instructions enclosed with
the equipment.
xx0900000813
5
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the press
tool.
DANGER
Handling the tool incorrectly will cause serious in-
jury.
Read and follow enclosed user instructions for the
tool.
The power for brake release is only applied for 180
seconds after activation.
Remove the press device, axis 2 shaft.
6
Art. no. is specified in Required
equipment on page 256
Apply grease to the location of the shaft where the
bearing is to be mounted.
7
Note
Always use a new bearing when
reassembling!
Press in the new bearing with the press tool, axis
2 bearing according to user instructions enclosed
with the equipment.
xx0900000813
8
Art. no. is specified in Required
equipment on page 256 .
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the press
tool.
DANGER
Handling the tool incorrectly will cause serious in-
jury.
Read and follow enclosed user instructions for the
tool.
The power for brake release is only applied for 180
seconds after activation.
Continues on next page
262
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
https://search.abb.com/library/Download.aspx?DocumentID=3HAC022033-001&LanguageCode=en&DocumentPartId=&Action=Launch&DocumentRevisionId=AF
| 262
|
Note/Illustration
Action
Proceed with the refitting procedure of the lower
arm, detailed in section Replacement of complete
lower arm on page 245 .
11
Refitting, lower arm shaft on robot with protection Foundry Plus
Use this procedure to refit the lower arm shaft if the robot has protection Foundry
Plus.
Note/Illustration
Action
Art. no. is specified in Required
equipment on page 256 !
Clean the shaft with isopropanol and lubricate it
with grease .
1
![Image]
A
A
Apply mercas
If the robot is going to work in a water jet applica-
tion cell:
Apply Mercasol 3106 on the support shaft axis 2.
•
Apply Mercasol 3106 on both sides of the
thrust washer, all around the bearing and on
surface on the shaft.
2
A
Mercasol on marked areas.
Push the shaft in by hand.
3
Also shown in the figure Compon-
ents, lower arm shaft for robots
with protection Foundry Plus on
page 256 !
Refit the thrust washer to the shaft.
4
Continues on next page
Product manual - IRB 7600
261
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
Continued
Note/Illustration
Action
Art. no. is specified in Required
equipment on page 256 !
Fit the axis-2 shaft with the press device, axis 2
shaft according to user instructions enclosed with
the equipment.
xx0900000813
5
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the press
tool.
DANGER
Handling the tool incorrectly will cause serious in-
jury.
Read and follow enclosed user instructions for the
tool.
The power for brake release is only applied for 180
seconds after activation.
Remove the press device, axis 2 shaft.
6
Art. no. is specified in Required
equipment on page 256
Apply grease to the location of the shaft where the
bearing is to be mounted.
7
Note
Always use a new bearing when
reassembling!
Press in the new bearing with the press tool, axis
2 bearing according to user instructions enclosed
with the equipment.
xx0900000813
8
Art. no. is specified in Required
equipment on page 256 .
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the press
tool.
DANGER
Handling the tool incorrectly will cause serious in-
jury.
Read and follow enclosed user instructions for the
tool.
The power for brake release is only applied for 180
seconds after activation.
Continues on next page
262
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
Continued
Note/Illustration
Action
Shown in the figure Components,
lower arm shaft for robots with
protection Foundry Plus on
page 256 .
Fit a radial sealing to the lower arm, if there is none
left during removal of the arm.
9
Refit the hexagon bolt with a spring washer and a
shaft tap through the hole in the lower arm shaft.
10
Fit the shaft for the sealing cover onto the hexagon
bolt and tighten the bolt with torque: 24 Nm.
11
Check the o-ring in the sealing cover. Replace if
damaged.
12
Refit the sealing cover onto the shaft. Press it
tightly against the radial sealing while tightening
the set screws. Use locking liquid.
13
Proceed with the refitting procedure of the lower
arm, detailed in section Replacement of complete
lower arm on page 245 .
14
Product manual - IRB 7600
263
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
https://search.abb.com/library/Download.aspx?DocumentID=3HAC022033-001&LanguageCode=en&DocumentPartId=&Action=Launch&DocumentRevisionId=AF
| 263
|
Note/Illustration
Action
Art. no. is specified in Required
equipment on page 256 !
Fit the axis-2 shaft with the press device, axis 2
shaft according to user instructions enclosed with
the equipment.
xx0900000813
5
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the press
tool.
DANGER
Handling the tool incorrectly will cause serious in-
jury.
Read and follow enclosed user instructions for the
tool.
The power for brake release is only applied for 180
seconds after activation.
Remove the press device, axis 2 shaft.
6
Art. no. is specified in Required
equipment on page 256
Apply grease to the location of the shaft where the
bearing is to be mounted.
7
Note
Always use a new bearing when
reassembling!
Press in the new bearing with the press tool, axis
2 bearing according to user instructions enclosed
with the equipment.
xx0900000813
8
Art. no. is specified in Required
equipment on page 256 .
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the press
tool.
DANGER
Handling the tool incorrectly will cause serious in-
jury.
Read and follow enclosed user instructions for the
tool.
The power for brake release is only applied for 180
seconds after activation.
Continues on next page
262
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
Continued
Note/Illustration
Action
Shown in the figure Components,
lower arm shaft for robots with
protection Foundry Plus on
page 256 .
Fit a radial sealing to the lower arm, if there is none
left during removal of the arm.
9
Refit the hexagon bolt with a spring washer and a
shaft tap through the hole in the lower arm shaft.
10
Fit the shaft for the sealing cover onto the hexagon
bolt and tighten the bolt with torque: 24 Nm.
11
Check the o-ring in the sealing cover. Replace if
damaged.
12
Refit the sealing cover onto the shaft. Press it
tightly against the radial sealing while tightening
the set screws. Use locking liquid.
13
Proceed with the refitting procedure of the lower
arm, detailed in section Replacement of complete
lower arm on page 245 .
14
Product manual - IRB 7600
263
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.4.5 Replacement of lower arm shaft
Continued
4.5 Frame and base
4.5.1 Replacing the SMB unit
Location of SMB unit
The SMB unit (SMB = serial measurement board) is located on the left hand side
of the frame as shown in the figure.
A
B C
D
E
G
F
H
J
xx0200000203
Brake release unit
A
Brake unit cover
B
Hexagon nut
C
Pins
D
Battery unit
E
SMB cover
F
Attachment screw, (2 pcs)
G
Attachment screw, brake unit cover (2 pcs)
H
Pins
J
Required equipment
Note
There are different variants of SMB units and batteries. 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 replace the battery contact!
Continues on next page
264
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© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.1 Replacing the SMB unit
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Note/Illustration
Action
Shown in the figure Components,
lower arm shaft for robots with
protection Foundry Plus on
page 256 .
Fit a radial sealing to the lower arm, if there is none
left during removal of the arm.
9
Refit the hexagon bolt with a spring washer and a
shaft tap through the hole in the lower arm shaft.
10
Fit the shaft for the sealing cover onto the hexagon
bolt and tighten the bolt with torque: 24 Nm.
11
Check the o-ring in the sealing cover. Replace if
damaged.
12
Refit the sealing cover onto the shaft. Press it
tightly against the radial sealing while tightening
the set screws. Use locking liquid.
13
Proceed with the refitting procedure of the lower
arm, detailed in section Replacement of complete
lower arm on page 245 .
14
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263
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4 Repair
4.4.5 Replacement of lower arm shaft
Continued
4.5 Frame and base
4.5.1 Replacing the SMB unit
Location of SMB unit
The SMB unit (SMB = serial measurement board) is located on the left hand side
of the frame as shown in the figure.
A
B C
D
E
G
F
H
J
xx0200000203
Brake release unit
A
Brake unit cover
B
Hexagon nut
C
Pins
D
Battery unit
E
SMB cover
F
Attachment screw, (2 pcs)
G
Attachment screw, brake unit cover (2 pcs)
H
Pins
J
Required equipment
Note
There are different variants of SMB units and batteries. 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 replace the battery contact!
Continues on next page
264
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3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.1 Replacing the SMB unit
Note
Article number
Equipment, etc.
For spare part number,
see: Spare part lists on
page 425 .
SMB unit
Content is defined in section Standard
tools on page 419 .
-
Standard toolkit
See chapter Circuit diagram on
page 427 .
-
Circuit diagram
Removing, SMB unit
Use this procedure to remove the SMB unit.
Note
Action
Move the robot to the calibration position.
1
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working area.
2
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the unit
read the safety information in section The unit is
sensitive to ESD on page 61 .
3
Shown in the figure Location of
SMB unit on page 264 .
Remove the SMB cover by unscrewing its 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
Use caution and remove the connectors X8, X9 and
X10 from the brake release board, if need of more
space.
5
Shown in the figure Location of
SMB unit on page 264 .
Remove the nuts and washers from the guide pins
that secure the board.
6
Connectors R1.SMB1-3,
R1.SMB4-6 and R2.SMB
Use caution and disconnect the connectors from the
SMB unit when pulling the board out.
7
Continues on next page
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265
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© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.1 Replacing the SMB unit
Continued
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| 265
|
4.5 Frame and base
4.5.1 Replacing the SMB unit
Location of SMB unit
The SMB unit (SMB = serial measurement board) is located on the left hand side
of the frame as shown in the figure.
A
B C
D
E
G
F
H
J
xx0200000203
Brake release unit
A
Brake unit cover
B
Hexagon nut
C
Pins
D
Battery unit
E
SMB cover
F
Attachment screw, (2 pcs)
G
Attachment screw, brake unit cover (2 pcs)
H
Pins
J
Required equipment
Note
There are different variants of SMB units and batteries. 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 replace the battery contact!
Continues on next page
264
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.1 Replacing the SMB unit
Note
Article number
Equipment, etc.
For spare part number,
see: Spare part lists on
page 425 .
SMB unit
Content is defined in section Standard
tools on page 419 .
-
Standard toolkit
See chapter Circuit diagram on
page 427 .
-
Circuit diagram
Removing, SMB unit
Use this procedure to remove the SMB unit.
Note
Action
Move the robot to the calibration position.
1
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working area.
2
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the unit
read the safety information in section The unit is
sensitive to ESD on page 61 .
3
Shown in the figure Location of
SMB unit on page 264 .
Remove the SMB cover by unscrewing its 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
Use caution and remove the connectors X8, X9 and
X10 from the brake release board, if need of more
space.
5
Shown in the figure Location of
SMB unit on page 264 .
Remove the nuts and washers from the guide pins
that secure the board.
6
Connectors R1.SMB1-3,
R1.SMB4-6 and R2.SMB
Use caution and disconnect the connectors from the
SMB unit when pulling the board out.
7
Continues on next page
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265
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.1 Replacing the SMB unit
Continued
Note
Action
![Image]
xx1700000993
Disconnect the battery cable by pressing down the
upper lip of the R2.G connector to release the lock
while pulling the connector upwards.
8
Refitting, SMB unit
Use this procedure to refit the SMB unit.
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
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the
unit read the safety information in section The
unit is sensitive to ESD on page 61 .
2
Shown in the figure Location of SMB
unit on page 264 .
Connect the battery cable to the SMB unit.
Make sure the lock on the battery cable connect-
or R2.G snaps into place during refitting.
3
Art. no. is specified in Required
equipment on page 264 .
Connect all connectors to the SMB board:
R1.SMB1-3, R1.SMB4-6 and R2.SMB
4
Shown in the figure Location of SMB
unit on page 264 .
Fit the SMB unit onto the guide pins .
5
Secure the SMB unit to the pins with the nuts
and washers.
6
Continues on next page
266
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3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.1 Replacing the SMB unit
Continued
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| 266
|
Note
Article number
Equipment, etc.
For spare part number,
see: Spare part lists on
page 425 .
SMB unit
Content is defined in section Standard
tools on page 419 .
-
Standard toolkit
See chapter Circuit diagram on
page 427 .
-
Circuit diagram
Removing, SMB unit
Use this procedure to remove the SMB unit.
Note
Action
Move the robot to the calibration position.
1
DANGER
Turn off all:
•
electric power supply
•
hydraulic pressure supply
•
air pressure supply
to the robot, before entering the robot working area.
2
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the unit
read the safety information in section The unit is
sensitive to ESD on page 61 .
3
Shown in the figure Location of
SMB unit on page 264 .
Remove the SMB cover by unscrewing its 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
Use caution and remove the connectors X8, X9 and
X10 from the brake release board, if need of more
space.
5
Shown in the figure Location of
SMB unit on page 264 .
Remove the nuts and washers from the guide pins
that secure the board.
6
Connectors R1.SMB1-3,
R1.SMB4-6 and R2.SMB
Use caution and disconnect the connectors from the
SMB unit when pulling the board out.
7
Continues on next page
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265
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.1 Replacing the SMB unit
Continued
Note
Action
![Image]
xx1700000993
Disconnect the battery cable by pressing down the
upper lip of the R2.G connector to release the lock
while pulling the connector upwards.
8
Refitting, SMB unit
Use this procedure to refit the SMB unit.
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
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the
unit read the safety information in section The
unit is sensitive to ESD on page 61 .
2
Shown in the figure Location of SMB
unit on page 264 .
Connect the battery cable to the SMB unit.
Make sure the lock on the battery cable connect-
or R2.G snaps into place during refitting.
3
Art. no. is specified in Required
equipment on page 264 .
Connect all connectors to the SMB board:
R1.SMB1-3, R1.SMB4-6 and R2.SMB
4
Shown in the figure Location of SMB
unit on page 264 .
Fit the SMB unit onto the guide pins .
5
Secure the SMB unit to the pins with the nuts
and washers.
6
Continues on next page
266
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3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.1 Replacing the SMB unit
Continued
Note
Action
![Image]
X9
X8
X10
xx1700000978
If disconnected, reconnect the connectors X8,
X9 and X10 to the brake release board.
Be careful not to damage the sockets or pins.
Make sure the connector and its locking arms
are snapped down properly.
7
Shown in the figure Location of SMB
unit on page 264 .
Secure the SMB cover with its attachment
screws.
If cabling is used for 7th axis (option), refit the
7th axis connector to the SMB cover and tighten
with 6 Nm.
8
See Updating revolution counters on
IRC5 robots on page 378 .
Update the revolution counters.
9
DANGER
Make sure all safety requirements are met when
performing the first test run.
10
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267
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4 Repair
4.5.1 Replacing the SMB unit
Continued
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| 267
|
Note
Action
![Image]
xx1700000993
Disconnect the battery cable by pressing down the
upper lip of the R2.G connector to release the lock
while pulling the connector upwards.
8
Refitting, SMB unit
Use this procedure to refit the SMB unit.
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
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the
unit read the safety information in section The
unit is sensitive to ESD on page 61 .
2
Shown in the figure Location of SMB
unit on page 264 .
Connect the battery cable to the SMB unit.
Make sure the lock on the battery cable connect-
or R2.G snaps into place during refitting.
3
Art. no. is specified in Required
equipment on page 264 .
Connect all connectors to the SMB board:
R1.SMB1-3, R1.SMB4-6 and R2.SMB
4
Shown in the figure Location of SMB
unit on page 264 .
Fit the SMB unit onto the guide pins .
5
Secure the SMB unit to the pins with the nuts
and washers.
6
Continues on next page
266
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.1 Replacing the SMB unit
Continued
Note
Action
![Image]
X9
X8
X10
xx1700000978
If disconnected, reconnect the connectors X8,
X9 and X10 to the brake release board.
Be careful not to damage the sockets or pins.
Make sure the connector and its locking arms
are snapped down properly.
7
Shown in the figure Location of SMB
unit on page 264 .
Secure the SMB cover with its attachment
screws.
If cabling is used for 7th axis (option), refit the
7th axis connector to the SMB cover and tighten
with 6 Nm.
8
See Updating revolution counters on
IRC5 robots on page 378 .
Update the revolution counters.
9
DANGER
Make sure all safety requirements are met when
performing the first test run.
10
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267
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© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.1 Replacing the SMB unit
Continued
4.5.2 Replacement of brake release board
Different designs
Depending on the robot version, the brake release board may be located either at
the base or at the frame. The following two figures show the different locations.
The early design includes a brake release board with or without push buttons,
located at the base. The later design instead includes a brake release board with
push buttons, placed together with the SMB unit on the left hand side of the frame.
The different designs are not compatible.
Location of brake release board, base
The early design includes a brake release board with or without push buttons,
located at the base as shown in the figure below.
xx0200000127
Brake release circuit (brake release unit inside)
A
Attachment screws, brake release circuit, 4 pcs
B
Continues on next page
268
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.2 Replacement of brake release board
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| 268
|
Note
Action
![Image]
X9
X8
X10
xx1700000978
If disconnected, reconnect the connectors X8,
X9 and X10 to the brake release board.
Be careful not to damage the sockets or pins.
Make sure the connector and its locking arms
are snapped down properly.
7
Shown in the figure Location of SMB
unit on page 264 .
Secure the SMB cover with its attachment
screws.
If cabling is used for 7th axis (option), refit the
7th axis connector to the SMB cover and tighten
with 6 Nm.
8
See Updating revolution counters on
IRC5 robots on page 378 .
Update the revolution counters.
9
DANGER
Make sure all safety requirements are met when
performing the first test run.
10
Product manual - IRB 7600
267
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.1 Replacing the SMB unit
Continued
4.5.2 Replacement of brake release board
Different designs
Depending on the robot version, the brake release board may be located either at
the base or at the frame. The following two figures show the different locations.
The early design includes a brake release board with or without push buttons,
located at the base. The later design instead includes a brake release board with
push buttons, placed together with the SMB unit on the left hand side of the frame.
The different designs are not compatible.
Location of brake release board, base
The early design includes a brake release board with or without push buttons,
located at the base as shown in the figure below.
xx0200000127
Brake release circuit (brake release unit inside)
A
Attachment screws, brake release circuit, 4 pcs
B
Continues on next page
268
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.2 Replacement of brake release board
Location of brake release board, frame
The later design includes a brake release board with push buttons, placed together
with the SMB unit on the left hand side of the frame as shown in the figure below.
A
B C
D
E
G
F
H
J
xx0200000203
Break release unit
A
Break unit cover
B
Hexagon nut
C
Pins
D
Battery unit
E
SMB cover
F
Attachment screw, (2 pcs)
G
Attachment screw, brake unit cover (2 pcs)
H
Pins
J
Required equipment
Note
Spare part number
Equipment, etc.
Brake release at the base, according to fig-
ure Location of brake release board, base
on page 268 .
3HAC14219-1
Brake release circuit
without buttons, at base
Includes brake release unit 3HAC14228-1.
Brake release at the base, according to fig-
ure Location of brake release board, base
on page 268 .
3HAC12989-1
Brake release circuit with
buttons, at base
Includes brake release board 3HAC16036-
1.
Brake release unit at the frame, according
to figure Location of brake release board,
frame on page 269 .
3HAC065021-001
Brake release unit with
harness, at frame
DSQC1052
Continues on next page
Product manual - IRB 7600
269
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.2 Replacement of brake release board
Continued
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| 269
|
4.5.2 Replacement of brake release board
Different designs
Depending on the robot version, the brake release board may be located either at
the base or at the frame. The following two figures show the different locations.
The early design includes a brake release board with or without push buttons,
located at the base. The later design instead includes a brake release board with
push buttons, placed together with the SMB unit on the left hand side of the frame.
The different designs are not compatible.
Location of brake release board, base
The early design includes a brake release board with or without push buttons,
located at the base as shown in the figure below.
xx0200000127
Brake release circuit (brake release unit inside)
A
Attachment screws, brake release circuit, 4 pcs
B
Continues on next page
268
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.2 Replacement of brake release board
Location of brake release board, frame
The later design includes a brake release board with push buttons, placed together
with the SMB unit on the left hand side of the frame as shown in the figure below.
A
B C
D
E
G
F
H
J
xx0200000203
Break release unit
A
Break unit cover
B
Hexagon nut
C
Pins
D
Battery unit
E
SMB cover
F
Attachment screw, (2 pcs)
G
Attachment screw, brake unit cover (2 pcs)
H
Pins
J
Required equipment
Note
Spare part number
Equipment, etc.
Brake release at the base, according to fig-
ure Location of brake release board, base
on page 268 .
3HAC14219-1
Brake release circuit
without buttons, at base
Includes brake release unit 3HAC14228-1.
Brake release at the base, according to fig-
ure Location of brake release board, base
on page 268 .
3HAC12989-1
Brake release circuit with
buttons, at base
Includes brake release board 3HAC16036-
1.
Brake release unit at the frame, according
to figure Location of brake release board,
frame on page 269 .
3HAC065021-001
Brake release unit with
harness, at frame
DSQC1052
Continues on next page
Product manual - IRB 7600
269
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.2 Replacement of brake release board
Continued
Note
Spare part number
Equipment, etc.
3HAC2744-1
Push button guard
Content is defined in section Standard tools
on page 419 .
-
Standard toolkit
These procedures include references 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.
Removal of brake release circuit, located at base
The procedure below details how to remove the brake release board, located at
the rear of the base. See the figure Location of brake release board, base on
page 268 .
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
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the unit
read the safety information in section The unit is
sensitive to ESD on page 61 .
2
Remove the cover at the rear of the base.
3
Shown in the figure Location of
brake release board, base on
page 268 .
Unscrew the four attachment screws, brake release
circuit on the outside of the base.
4
Disconnect the cable from the brake release circuit
and remove the circuit from the base.
5
Continues on next page
270
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.2 Replacement of brake release board
Continued
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| 270
|
Location of brake release board, frame
The later design includes a brake release board with push buttons, placed together
with the SMB unit on the left hand side of the frame as shown in the figure below.
A
B C
D
E
G
F
H
J
xx0200000203
Break release unit
A
Break unit cover
B
Hexagon nut
C
Pins
D
Battery unit
E
SMB cover
F
Attachment screw, (2 pcs)
G
Attachment screw, brake unit cover (2 pcs)
H
Pins
J
Required equipment
Note
Spare part number
Equipment, etc.
Brake release at the base, according to fig-
ure Location of brake release board, base
on page 268 .
3HAC14219-1
Brake release circuit
without buttons, at base
Includes brake release unit 3HAC14228-1.
Brake release at the base, according to fig-
ure Location of brake release board, base
on page 268 .
3HAC12989-1
Brake release circuit with
buttons, at base
Includes brake release board 3HAC16036-
1.
Brake release unit at the frame, according
to figure Location of brake release board,
frame on page 269 .
3HAC065021-001
Brake release unit with
harness, at frame
DSQC1052
Continues on next page
Product manual - IRB 7600
269
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.2 Replacement of brake release board
Continued
Note
Spare part number
Equipment, etc.
3HAC2744-1
Push button guard
Content is defined in section Standard tools
on page 419 .
-
Standard toolkit
These procedures include references 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.
Removal of brake release circuit, located at base
The procedure below details how to remove the brake release board, located at
the rear of the base. See the figure Location of brake release board, base on
page 268 .
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
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the unit
read the safety information in section The unit is
sensitive to ESD on page 61 .
2
Remove the cover at the rear of the base.
3
Shown in the figure Location of
brake release board, base on
page 268 .
Unscrew the four attachment screws, brake release
circuit on the outside of the base.
4
Disconnect the cable from the brake release circuit
and remove the circuit from the base.
5
Continues on next page
270
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.2 Replacement of brake release board
Continued
Removal of brake release board, located on frame
The procedure below details how to remove the brake release board, located on
the side of the frame. See the figure Location of brake release board, frame on
page 269 .
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
ELECTROSTATIC DISCHARGE
(ESD)
The unit is sensitive to ESD. Before handling
the unit read the safety information in sec-
tion The unit is sensitive to ESD on page61 .
2
Shown in the figure Location of brake re-
lease board, frame on page 269 .
Remove the push button guard from the
SMB cover.
3
The guard must be removed to ensure a
correct refitting of the brake release unit.
Shown in the figure Location of brake re-
lease board, frame on page 269 .
Remove the SMB cover by unscrewing the
attachment screws.
Let the battery stay connected, to avoid the
need of synchronization of the robot!
4
Take a picture or make notes of how the
robot cabling is positioned in regard to the
brake release board.
5
![Image]
X9
X8
X10
xx1700000978
Disconnect the connectors X8, X9 and X10
from the brake release board.
6
Shown in the figure Location of brake re-
lease board, frame on page 269 !
Unscrew the two attachment screws, brake
release unit.
7
Shown in the figure Location of brake re-
lease board, frame on page 269 !
Unscrew the two attachment screws and
nuts, brake unit cover , and remove the brake
unit cover .
8
Shown in the figure Location of brake re-
lease board, frame on page 269 !
Remove the brake release board from the
plate.
9
Continues on next page
Product manual - IRB 7600
271
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.2 Replacement of brake release board
Continued
|
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|
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| 271
|
Note
Spare part number
Equipment, etc.
3HAC2744-1
Push button guard
Content is defined in section Standard tools
on page 419 .
-
Standard toolkit
These procedures include references 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.
Removal of brake release circuit, located at base
The procedure below details how to remove the brake release board, located at
the rear of the base. See the figure Location of brake release board, base on
page 268 .
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
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the unit
read the safety information in section The unit is
sensitive to ESD on page 61 .
2
Remove the cover at the rear of the base.
3
Shown in the figure Location of
brake release board, base on
page 268 .
Unscrew the four attachment screws, brake release
circuit on the outside of the base.
4
Disconnect the cable from the brake release circuit
and remove the circuit from the base.
5
Continues on next page
270
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.2 Replacement of brake release board
Continued
Removal of brake release board, located on frame
The procedure below details how to remove the brake release board, located on
the side of the frame. See the figure Location of brake release board, frame on
page 269 .
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
ELECTROSTATIC DISCHARGE
(ESD)
The unit is sensitive to ESD. Before handling
the unit read the safety information in sec-
tion The unit is sensitive to ESD on page61 .
2
Shown in the figure Location of brake re-
lease board, frame on page 269 .
Remove the push button guard from the
SMB cover.
3
The guard must be removed to ensure a
correct refitting of the brake release unit.
Shown in the figure Location of brake re-
lease board, frame on page 269 .
Remove the SMB cover by unscrewing the
attachment screws.
Let the battery stay connected, to avoid the
need of synchronization of the robot!
4
Take a picture or make notes of how the
robot cabling is positioned in regard to the
brake release board.
5
![Image]
X9
X8
X10
xx1700000978
Disconnect the connectors X8, X9 and X10
from the brake release board.
6
Shown in the figure Location of brake re-
lease board, frame on page 269 !
Unscrew the two attachment screws, brake
release unit.
7
Shown in the figure Location of brake re-
lease board, frame on page 269 !
Unscrew the two attachment screws and
nuts, brake unit cover , and remove the brake
unit cover .
8
Shown in the figure Location of brake re-
lease board, frame on page 269 !
Remove the brake release board from the
plate.
9
Continues on next page
Product manual - IRB 7600
271
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.2 Replacement of brake release board
Continued
Refitting of brake release circuit, located at base
The procedure below details how to refit the brake release circuit, located at the
rear of the base. See the figure Location of brake release board, base on page268 .
Note
Action
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the
unit read the safety information in section The unit
is sensitive to ESD on page 61 .
1
Spare part no. is specified in Re-
quired equipment on page 269 .
Place the brake release unit in the base of the ro-
bot.
2
Shown in the figure Location of
brake release board, base on
page 268 .
Reconnect the cable to the brake release unit.
3
Shown in the figure Location of
brake release board, base on
page 268 .
Secure the SMB cover with its attachment screws.
4
Refit the cover of the rear of the base.
5
Refitting of brake release board, located on frame
The procedure below details how to refit the brake release board, located on the
side of the frame. See the figure Location of brake release board, frame on page269 .
Note
Action
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling
the unit read the safety information in section
The unit is sensitive to ESD on page 61 .
1
Maximum tightening torque: 5 Nm.
Fit the brake release board on the plate with
the attachment screws.
2
Shown in the figure Location of brake
release board, frame on page 269 .
Make sure the board is positioned as straight
as possible on the plate! The push buttons can
otherwise get jammed when the SMB-cover is
refitted.
Spare part no. is specified in Required
equipment on page 269 .
Place the brake unit cover on the brake release
unit .
3
Secure the brake unit cover with the two attach-
ment screws and nuts, brake unit cover .
4
Continues on next page
272
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.2 Replacement of brake release board
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 272
|
Removal of brake release board, located on frame
The procedure below details how to remove the brake release board, located on
the side of the frame. See the figure Location of brake release board, frame on
page 269 .
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
ELECTROSTATIC DISCHARGE
(ESD)
The unit is sensitive to ESD. Before handling
the unit read the safety information in sec-
tion The unit is sensitive to ESD on page61 .
2
Shown in the figure Location of brake re-
lease board, frame on page 269 .
Remove the push button guard from the
SMB cover.
3
The guard must be removed to ensure a
correct refitting of the brake release unit.
Shown in the figure Location of brake re-
lease board, frame on page 269 .
Remove the SMB cover by unscrewing the
attachment screws.
Let the battery stay connected, to avoid the
need of synchronization of the robot!
4
Take a picture or make notes of how the
robot cabling is positioned in regard to the
brake release board.
5
![Image]
X9
X8
X10
xx1700000978
Disconnect the connectors X8, X9 and X10
from the brake release board.
6
Shown in the figure Location of brake re-
lease board, frame on page 269 !
Unscrew the two attachment screws, brake
release unit.
7
Shown in the figure Location of brake re-
lease board, frame on page 269 !
Unscrew the two attachment screws and
nuts, brake unit cover , and remove the brake
unit cover .
8
Shown in the figure Location of brake re-
lease board, frame on page 269 !
Remove the brake release board from the
plate.
9
Continues on next page
Product manual - IRB 7600
271
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.2 Replacement of brake release board
Continued
Refitting of brake release circuit, located at base
The procedure below details how to refit the brake release circuit, located at the
rear of the base. See the figure Location of brake release board, base on page268 .
Note
Action
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the
unit read the safety information in section The unit
is sensitive to ESD on page 61 .
1
Spare part no. is specified in Re-
quired equipment on page 269 .
Place the brake release unit in the base of the ro-
bot.
2
Shown in the figure Location of
brake release board, base on
page 268 .
Reconnect the cable to the brake release unit.
3
Shown in the figure Location of
brake release board, base on
page 268 .
Secure the SMB cover with its attachment screws.
4
Refit the cover of the rear of the base.
5
Refitting of brake release board, located on frame
The procedure below details how to refit the brake release board, located on the
side of the frame. See the figure Location of brake release board, frame on page269 .
Note
Action
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling
the unit read the safety information in section
The unit is sensitive to ESD on page 61 .
1
Maximum tightening torque: 5 Nm.
Fit the brake release board on the plate with
the attachment screws.
2
Shown in the figure Location of brake
release board, frame on page 269 .
Make sure the board is positioned as straight
as possible on the plate! The push buttons can
otherwise get jammed when the SMB-cover is
refitted.
Spare part no. is specified in Required
equipment on page 269 .
Place the brake unit cover on the brake release
unit .
3
Secure the brake unit cover with the two attach-
ment screws and nuts, brake unit cover .
4
Continues on next page
272
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.2 Replacement of brake release board
Continued
Note
Action
![Image]
X9
X8
X10
xx1700000978
Connect the connectors X8, X9 and X10 to the
brake release board.
Be careful not to damage the sockets or pins.
Make sure the connector and its locking arms
are snapped down properly.
5
Make sure that the white cables run
like shown in the figure.
![Image]
xx1700001155
Verify that the robot cabling is positioned cor-
rectly, according to previously taken pic-
ture/notes.
WARNING
Screened cables must not get in contact with
the brake release board after installation.
Eliminate all risks of contact between screened
cables and the brake release board.
6
Shown in the figure Location of brake
release board, frame on page 269 .
Refit the SMB cover with its attachment screws.
7
WARNING
Before continuing any service work, follow the
safety procedure in section The brake release
buttons may be jammed after service work on
page 213 !
8
Shown in the figure Location of brake
release board, frame on page 269 .
Refit the push button guard on the SMB cover.
9
Press the push buttons 1 to 6, one at a time,
to make sure that the buttons are moving freely
and do not stay in any locked position.
10
Detailed in section Updating revolution
counters on IRC5 robots on page 378 .
If the battery has been disconnected the revolu-
tion counters must be updated.
11
DANGER
Make sure all safety requirements are met
when performing the first test run.
12
Product manual - IRB 7600
273
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.2 Replacement of brake release board
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 273
|
Refitting of brake release circuit, located at base
The procedure below details how to refit the brake release circuit, located at the
rear of the base. See the figure Location of brake release board, base on page268 .
Note
Action
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the
unit read the safety information in section The unit
is sensitive to ESD on page 61 .
1
Spare part no. is specified in Re-
quired equipment on page 269 .
Place the brake release unit in the base of the ro-
bot.
2
Shown in the figure Location of
brake release board, base on
page 268 .
Reconnect the cable to the brake release unit.
3
Shown in the figure Location of
brake release board, base on
page 268 .
Secure the SMB cover with its attachment screws.
4
Refit the cover of the rear of the base.
5
Refitting of brake release board, located on frame
The procedure below details how to refit the brake release board, located on the
side of the frame. See the figure Location of brake release board, frame on page269 .
Note
Action
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling
the unit read the safety information in section
The unit is sensitive to ESD on page 61 .
1
Maximum tightening torque: 5 Nm.
Fit the brake release board on the plate with
the attachment screws.
2
Shown in the figure Location of brake
release board, frame on page 269 .
Make sure the board is positioned as straight
as possible on the plate! The push buttons can
otherwise get jammed when the SMB-cover is
refitted.
Spare part no. is specified in Required
equipment on page 269 .
Place the brake unit cover on the brake release
unit .
3
Secure the brake unit cover with the two attach-
ment screws and nuts, brake unit cover .
4
Continues on next page
272
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.2 Replacement of brake release board
Continued
Note
Action
![Image]
X9
X8
X10
xx1700000978
Connect the connectors X8, X9 and X10 to the
brake release board.
Be careful not to damage the sockets or pins.
Make sure the connector and its locking arms
are snapped down properly.
5
Make sure that the white cables run
like shown in the figure.
![Image]
xx1700001155
Verify that the robot cabling is positioned cor-
rectly, according to previously taken pic-
ture/notes.
WARNING
Screened cables must not get in contact with
the brake release board after installation.
Eliminate all risks of contact between screened
cables and the brake release board.
6
Shown in the figure Location of brake
release board, frame on page 269 .
Refit the SMB cover with its attachment screws.
7
WARNING
Before continuing any service work, follow the
safety procedure in section The brake release
buttons may be jammed after service work on
page 213 !
8
Shown in the figure Location of brake
release board, frame on page 269 .
Refit the push button guard on the SMB cover.
9
Press the push buttons 1 to 6, one at a time,
to make sure that the buttons are moving freely
and do not stay in any locked position.
10
Detailed in section Updating revolution
counters on IRC5 robots on page 378 .
If the battery has been disconnected the revolu-
tion counters must be updated.
11
DANGER
Make sure all safety requirements are met
when performing the first test run.
12
Product manual - IRB 7600
273
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.2 Replacement of brake release board
Continued
4.5.3 Replacement of spherical roller bearing, balancing device
Location of bearing
The bearing is located at the front ear of the balancing device, as shown in the
figure below.
xx0500002249
Spherical roller bearing
A
Sealing ring
B
O-ring
C
Sealing spacer
D
Front ear of balancing device
E
Required equipment
Note
Art. no.
Spare part no.
Equipment
3HAA2167-17
Spherical roller bear-
ing
2 pcs required.
3HAC12988-1
Sealing spacer
2 pcs required.
3HAB3772-76
O-ring
2 pcs required.
3HAC11581-6
Sealing ring
For lubrication of the com-
ponents.
3HAC042536-001
Grease
Continues on next page
274
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.3 Replacement of spherical roller bearing, balancing device
|
ABB_IRB7600_Product_Manual.pdf
|
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| 274
|
Note
Action
![Image]
X9
X8
X10
xx1700000978
Connect the connectors X8, X9 and X10 to the
brake release board.
Be careful not to damage the sockets or pins.
Make sure the connector and its locking arms
are snapped down properly.
5
Make sure that the white cables run
like shown in the figure.
![Image]
xx1700001155
Verify that the robot cabling is positioned cor-
rectly, according to previously taken pic-
ture/notes.
WARNING
Screened cables must not get in contact with
the brake release board after installation.
Eliminate all risks of contact between screened
cables and the brake release board.
6
Shown in the figure Location of brake
release board, frame on page 269 .
Refit the SMB cover with its attachment screws.
7
WARNING
Before continuing any service work, follow the
safety procedure in section The brake release
buttons may be jammed after service work on
page 213 !
8
Shown in the figure Location of brake
release board, frame on page 269 .
Refit the push button guard on the SMB cover.
9
Press the push buttons 1 to 6, one at a time,
to make sure that the buttons are moving freely
and do not stay in any locked position.
10
Detailed in section Updating revolution
counters on IRC5 robots on page 378 .
If the battery has been disconnected the revolu-
tion counters must be updated.
11
DANGER
Make sure all safety requirements are met
when performing the first test run.
12
Product manual - IRB 7600
273
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.2 Replacement of brake release board
Continued
4.5.3 Replacement of spherical roller bearing, balancing device
Location of bearing
The bearing is located at the front ear of the balancing device, as shown in the
figure below.
xx0500002249
Spherical roller bearing
A
Sealing ring
B
O-ring
C
Sealing spacer
D
Front ear of balancing device
E
Required equipment
Note
Art. no.
Spare part no.
Equipment
3HAA2167-17
Spherical roller bear-
ing
2 pcs required.
3HAC12988-1
Sealing spacer
2 pcs required.
3HAB3772-76
O-ring
2 pcs required.
3HAC11581-6
Sealing ring
For lubrication of the com-
ponents.
3HAC042536-001
Grease
Continues on next page
274
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.3 Replacement of spherical roller bearing, balancing device
Note
Art. no.
Spare part no.
Equipment
The tools in the set are
shown in the section Tool
set.
3HAC15943-1
Toolkit
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.
Tool set
The parts of the tool set for replacing the spherical roller bearing are shown in the
figure.
xx0500002259
Threaded bar
A
Dolly
B
Press tool for removal of bearing
C
Press tool for refitting of bearing
D
Hexagon nut M12 (2pcs)
E
Plain washer 13x24x2,5 (2pcs)
F
Removal, spherical roller bearing
Use this procedure to remove the spherical roller bearing from the balancing device
front ear.
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
Continues on next page
Product manual - IRB 7600
275
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.3 Replacement of spherical roller bearing, 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
| 275
|
4.5.3 Replacement of spherical roller bearing, balancing device
Location of bearing
The bearing is located at the front ear of the balancing device, as shown in the
figure below.
xx0500002249
Spherical roller bearing
A
Sealing ring
B
O-ring
C
Sealing spacer
D
Front ear of balancing device
E
Required equipment
Note
Art. no.
Spare part no.
Equipment
3HAA2167-17
Spherical roller bear-
ing
2 pcs required.
3HAC12988-1
Sealing spacer
2 pcs required.
3HAB3772-76
O-ring
2 pcs required.
3HAC11581-6
Sealing ring
For lubrication of the com-
ponents.
3HAC042536-001
Grease
Continues on next page
274
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.3 Replacement of spherical roller bearing, balancing device
Note
Art. no.
Spare part no.
Equipment
The tools in the set are
shown in the section Tool
set.
3HAC15943-1
Toolkit
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.
Tool set
The parts of the tool set for replacing the spherical roller bearing are shown in the
figure.
xx0500002259
Threaded bar
A
Dolly
B
Press tool for removal of bearing
C
Press tool for refitting of bearing
D
Hexagon nut M12 (2pcs)
E
Plain washer 13x24x2,5 (2pcs)
F
Removal, spherical roller bearing
Use this procedure to remove the spherical roller bearing from the balancing device
front ear.
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
Continues on next page
Product manual - IRB 7600
275
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.3 Replacement of spherical roller bearing, balancing device
Continued
Note
Action
Detailed in section Replacing the balan-
cing device on page 279 .
Remove the balancing device from the ro-
bot.
2
Shown in the figure Location of bearing
on page 274 .
Remove the both sealing spacers with a
screwdriver or any equal tool.
3
Insert the threaded bar through the bearing.
4
xx0500002255
Fit the press tool and dolly to the threaded
bar.
Secure with the nut and washer at each end.
5
A
Threaded bar 3HAC15945-1
B
Dolly 3HAC15948-1
C
Press tool 3HAC15941-1
Press out the bearing from the front ear.
6
Refitting, spherical roller bearing
Use this procedure to refit the spherical roller bearing to the balancing device front
ear.
Note
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
Grease the inside walls of the front ear.
2
Continues on next page
276
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.3 Replacement of spherical roller bearing, 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
| 276
|
Note
Art. no.
Spare part no.
Equipment
The tools in the set are
shown in the section Tool
set.
3HAC15943-1
Toolkit
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.
Tool set
The parts of the tool set for replacing the spherical roller bearing are shown in the
figure.
xx0500002259
Threaded bar
A
Dolly
B
Press tool for removal of bearing
C
Press tool for refitting of bearing
D
Hexagon nut M12 (2pcs)
E
Plain washer 13x24x2,5 (2pcs)
F
Removal, spherical roller bearing
Use this procedure to remove the spherical roller bearing from the balancing device
front ear.
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
Continues on next page
Product manual - IRB 7600
275
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.3 Replacement of spherical roller bearing, balancing device
Continued
Note
Action
Detailed in section Replacing the balan-
cing device on page 279 .
Remove the balancing device from the ro-
bot.
2
Shown in the figure Location of bearing
on page 274 .
Remove the both sealing spacers with a
screwdriver or any equal tool.
3
Insert the threaded bar through the bearing.
4
xx0500002255
Fit the press tool and dolly to the threaded
bar.
Secure with the nut and washer at each end.
5
A
Threaded bar 3HAC15945-1
B
Dolly 3HAC15948-1
C
Press tool 3HAC15941-1
Press out the bearing from the front ear.
6
Refitting, spherical roller bearing
Use this procedure to refit the spherical roller bearing to the balancing device front
ear.
Note
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
Grease the inside walls of the front ear.
2
Continues on next page
276
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3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.3 Replacement of spherical roller bearing, balancing device
Continued
Note
Action
Spare part no. is specified in Required
equipment on page 274 .
xx0500002257
Insert the threaded bar through the new
bearing and place it at the front ear. Fit also
the press tool and the dolly to the bar as
shown in the figure to the right.
Secure with the nut and washer at each end.
3
A
Threaded bar 3HAC15945-1
B
Dolly 3HAC15948-1
C
Press tool 3HAC15846-1
Press in the bearing properly inside the ear.
4
Spare part no:s are specified in Required
equipment on page 274 .
Apply grease to the new sealing rings and
o-rings and fit one of each to the new seal-
ing spacers . Also, grease the sealing
spacers.
5
xx0500002258
Press in the sealing spacers with the press
tools, as shown in the figure to the right.
Secure the press tool and dolly with nuts
and washers.
Note
Fit the sealing spacers one at a time!
6
A
Threaded bar 3HAC15945-1
B
Dolly 3HAC15948-1
C
Press tool 3HAC15846-1
Detailed in section Refitting, balancing
device on page 286 .
Refit the balancing device to the robot.
7
Detailed in section Lubrication of spherical
roller bearing, balancing device on
page 188
Lubricate the spherical roller bearing in the
ear.
Note
The balancing device must be mounted on
the robot when lubrication is performed!
8
This is detailed in section Check for leak-
age on page 145 .
Make sure no incorrect leakage occurs. It
could indicate damaged o-rings.
9
Continues on next page
Product manual - IRB 7600
277
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.3 Replacement of spherical roller bearing, balancing device
Continued
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| 277
|
Note
Action
Detailed in section Replacing the balan-
cing device on page 279 .
Remove the balancing device from the ro-
bot.
2
Shown in the figure Location of bearing
on page 274 .
Remove the both sealing spacers with a
screwdriver or any equal tool.
3
Insert the threaded bar through the bearing.
4
xx0500002255
Fit the press tool and dolly to the threaded
bar.
Secure with the nut and washer at each end.
5
A
Threaded bar 3HAC15945-1
B
Dolly 3HAC15948-1
C
Press tool 3HAC15941-1
Press out the bearing from the front ear.
6
Refitting, spherical roller bearing
Use this procedure to refit the spherical roller bearing to the balancing device front
ear.
Note
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
Grease the inside walls of the front ear.
2
Continues on next page
276
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.3 Replacement of spherical roller bearing, balancing device
Continued
Note
Action
Spare part no. is specified in Required
equipment on page 274 .
xx0500002257
Insert the threaded bar through the new
bearing and place it at the front ear. Fit also
the press tool and the dolly to the bar as
shown in the figure to the right.
Secure with the nut and washer at each end.
3
A
Threaded bar 3HAC15945-1
B
Dolly 3HAC15948-1
C
Press tool 3HAC15846-1
Press in the bearing properly inside the ear.
4
Spare part no:s are specified in Required
equipment on page 274 .
Apply grease to the new sealing rings and
o-rings and fit one of each to the new seal-
ing spacers . Also, grease the sealing
spacers.
5
xx0500002258
Press in the sealing spacers with the press
tools, as shown in the figure to the right.
Secure the press tool and dolly with nuts
and washers.
Note
Fit the sealing spacers one at a time!
6
A
Threaded bar 3HAC15945-1
B
Dolly 3HAC15948-1
C
Press tool 3HAC15846-1
Detailed in section Refitting, balancing
device on page 286 .
Refit the balancing device to the robot.
7
Detailed in section Lubrication of spherical
roller bearing, balancing device on
page 188
Lubricate the spherical roller bearing in the
ear.
Note
The balancing device must be mounted on
the robot when lubrication is performed!
8
This is detailed in section Check for leak-
age on page 145 .
Make sure no incorrect leakage occurs. It
could indicate damaged o-rings.
9
Continues on next page
Product manual - IRB 7600
277
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.3 Replacement of spherical roller bearing, balancing device
Continued
Note
Action
DANGER
Make sure all safety requirements are met
when performing the first test run.
10
278
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.3 Replacement of spherical roller bearing, balancing device
Continued
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| 278
|
Note
Action
Spare part no. is specified in Required
equipment on page 274 .
xx0500002257
Insert the threaded bar through the new
bearing and place it at the front ear. Fit also
the press tool and the dolly to the bar as
shown in the figure to the right.
Secure with the nut and washer at each end.
3
A
Threaded bar 3HAC15945-1
B
Dolly 3HAC15948-1
C
Press tool 3HAC15846-1
Press in the bearing properly inside the ear.
4
Spare part no:s are specified in Required
equipment on page 274 .
Apply grease to the new sealing rings and
o-rings and fit one of each to the new seal-
ing spacers . Also, grease the sealing
spacers.
5
xx0500002258
Press in the sealing spacers with the press
tools, as shown in the figure to the right.
Secure the press tool and dolly with nuts
and washers.
Note
Fit the sealing spacers one at a time!
6
A
Threaded bar 3HAC15945-1
B
Dolly 3HAC15948-1
C
Press tool 3HAC15846-1
Detailed in section Refitting, balancing
device on page 286 .
Refit the balancing device to the robot.
7
Detailed in section Lubrication of spherical
roller bearing, balancing device on
page 188
Lubricate the spherical roller bearing in the
ear.
Note
The balancing device must be mounted on
the robot when lubrication is performed!
8
This is detailed in section Check for leak-
age on page 145 .
Make sure no incorrect leakage occurs. It
could indicate damaged o-rings.
9
Continues on next page
Product manual - IRB 7600
277
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.3 Replacement of spherical roller bearing, balancing device
Continued
Note
Action
DANGER
Make sure all safety requirements are met
when performing the first test run.
10
278
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.3 Replacement of spherical roller bearing, balancing device
Continued
4.5.4 Replacement of balancing device
4.5.4.1 Replacing the balancing device
Location of balancing device
The balancing device is located on rear top of the frame as shown in the figure
below.
xx0100000139
Balancing device
A
Rear cover
B
Support shaft inside (included in balancing device 3HAC14675-1)
C
Attachment screws, rear cover
D
Balancing device shaft, including screw and washer
E
Bearing attachment
F
Parallel pin (inside bearing attachment)
G
Attachment screws, bearing attachment
H
Continues on next page
Product manual - IRB 7600
279
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
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ABB_IRB7600_Product_Manual.pdf
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| 279
|
Note
Action
DANGER
Make sure all safety requirements are met
when performing the first test run.
10
278
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.3 Replacement of spherical roller bearing, balancing device
Continued
4.5.4 Replacement of balancing device
4.5.4.1 Replacing the balancing device
Location of balancing device
The balancing device is located on rear top of the frame as shown in the figure
below.
xx0100000139
Balancing device
A
Rear cover
B
Support shaft inside (included in balancing device 3HAC14675-1)
C
Attachment screws, rear cover
D
Balancing device shaft, including screw and washer
E
Bearing attachment
F
Parallel pin (inside bearing attachment)
G
Attachment screws, bearing attachment
H
Continues on next page
Product manual - IRB 7600
279
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Attachment points, balancing device
The attachment points for the lifting tools etc. are located as shown in the figure
below.
xx0600002653
Attachment hole for lifting eye, M12
A
Attachment hole for securing screw that secures the bearing attachment to the
balancing device (protection plug fitted normally)
B
Hole in frame to access the balancing device front eye shaft with the puller/press
tool
C
Attachment hole for locking screw that secures the lower arm to the frame
D
Continues on next page
280
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
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ABB_IRB7600_Product_Manual.pdf
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| 280
|
4.5.4 Replacement of balancing device
4.5.4.1 Replacing the balancing device
Location of balancing device
The balancing device is located on rear top of the frame as shown in the figure
below.
xx0100000139
Balancing device
A
Rear cover
B
Support shaft inside (included in balancing device 3HAC14675-1)
C
Attachment screws, rear cover
D
Balancing device shaft, including screw and washer
E
Bearing attachment
F
Parallel pin (inside bearing attachment)
G
Attachment screws, bearing attachment
H
Continues on next page
Product manual - IRB 7600
279
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Attachment points, balancing device
The attachment points for the lifting tools etc. are located as shown in the figure
below.
xx0600002653
Attachment hole for lifting eye, M12
A
Attachment hole for securing screw that secures the bearing attachment to the
balancing device (protection plug fitted normally)
B
Hole in frame to access the balancing device front eye shaft with the puller/press
tool
C
Attachment hole for locking screw that secures the lower arm to the frame
D
Continues on next page
280
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
Required equipment
Note
Art. no.
Spare part no.
Equipment
Includes:
•
balancing device
3HAC14675-1 or
3HAC023018-001
•
o-ring 3HAB3772-44
(2 pcs)
See Spare part
lists on page 425 .
Balancing device
2 pcs , to be replaced if
damaged! (included with
the new balancing device)
3HAB3772-44
O-ring
M16 x 90
3HAB3409-90
Locking screw
For securing the lower arm.
M12 x 35, 2 pcs required
9ADA183-66
Securing screw
For securing the bearing
attachments to the balan-
cing device when lifting.
For lubricating the o-rings
and the shaft.
3HAC042536-001
Bearing grease
150 ml, Tribol GR 100-0-PD
3HAA1001-294
Grease
For lubrication of spherical
roller bearing in ear, in case
of new balancing device.
Loctite 243
-
Locking liquid
To apply to the securing
screw in the shaft.
Loctite 577
-
Locking liquid
Used to secure the attach-
ment screws of the rear
cover at the end of the bal-
ancing device.
To lubricate spherical roller
bearing.
-
Grease pump
Always use guide pins in
pairs!
3HAC13120-5
Guide pins M16 x 300
3HAC14457-3
Lifting eye M12
3HAC15556-1
Lifting tool (chain)
For unloading the balancing
device.
3HAC074411-001
Press equipment, bal-
ancing device
User instructions are en-
closed with the tool.
To be used with
3HAC074411-001 for balan-
cing devices from 2002 and
older.
3HAC078221-001
Adapter for Press
equipment, balancing
device
For replacing the balancing
device shaft.
3HAC076202-001
Press equipment, bal-
ancing device shaft
User instructions are en-
closed with the tool.
Continues on next page
Product manual - IRB 7600
281
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 281
|
Attachment points, balancing device
The attachment points for the lifting tools etc. are located as shown in the figure
below.
xx0600002653
Attachment hole for lifting eye, M12
A
Attachment hole for securing screw that secures the bearing attachment to the
balancing device (protection plug fitted normally)
B
Hole in frame to access the balancing device front eye shaft with the puller/press
tool
C
Attachment hole for locking screw that secures the lower arm to the frame
D
Continues on next page
280
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
Required equipment
Note
Art. no.
Spare part no.
Equipment
Includes:
•
balancing device
3HAC14675-1 or
3HAC023018-001
•
o-ring 3HAB3772-44
(2 pcs)
See Spare part
lists on page 425 .
Balancing device
2 pcs , to be replaced if
damaged! (included with
the new balancing device)
3HAB3772-44
O-ring
M16 x 90
3HAB3409-90
Locking screw
For securing the lower arm.
M12 x 35, 2 pcs required
9ADA183-66
Securing screw
For securing the bearing
attachments to the balan-
cing device when lifting.
For lubricating the o-rings
and the shaft.
3HAC042536-001
Bearing grease
150 ml, Tribol GR 100-0-PD
3HAA1001-294
Grease
For lubrication of spherical
roller bearing in ear, in case
of new balancing device.
Loctite 243
-
Locking liquid
To apply to the securing
screw in the shaft.
Loctite 577
-
Locking liquid
Used to secure the attach-
ment screws of the rear
cover at the end of the bal-
ancing device.
To lubricate spherical roller
bearing.
-
Grease pump
Always use guide pins in
pairs!
3HAC13120-5
Guide pins M16 x 300
3HAC14457-3
Lifting eye M12
3HAC15556-1
Lifting tool (chain)
For unloading the balancing
device.
3HAC074411-001
Press equipment, bal-
ancing device
User instructions are en-
closed with the tool.
To be used with
3HAC074411-001 for balan-
cing devices from 2002 and
older.
3HAC078221-001
Adapter for Press
equipment, balancing
device
For replacing the balancing
device shaft.
3HAC076202-001
Press equipment, bal-
ancing device shaft
User instructions are en-
closed with the tool.
Continues on next page
Product manual - IRB 7600
281
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
Note
Art. no.
Spare part no.
Equipment
To be used with the press
and puller tools.
3HAC11731-1
Hydraulic cylinder
See technical specifications
in the user instructions for
the press equipment.
To be used with the hydraul-
ic cylinder.
3HAC13086-1
Hydraulic pump 80
MPa
See technical specifications
in the user instructions for
the press equipment.
Content is defined in sec-
tion Standard tools on
page 419 .
-
Standard toolkit
These procedures include
references to the tools re-
quired.
Other tools and pro-
cedures may be re-
quired. See refer-
ences to these proced-
ures in the step-by-
step instructions be-
low.
Removal, balancing device
The procedures below detail how to remove the balancing device.
Preparations before removing the balancing device
Note
Action
Move the lower arm to a position close to the
calibration position.
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
Attachment hole for the locking screw
is shown in the figure Attachment
points, balancing device on page280 .
Secure the lower arm to the frame by inserting
the locking screw into the attachment hole in
the frame.
3
Art. no. is specified in Required
equipment on page 281 !
CAUTION
The balancing device weighs 300 kg! All lifting
equipment used must be sized accordingly!
4
Art. no. is specified in Required
equipment on page 281 !
Fit the lifting eye, M12 to the balancing device
and raise to unload the weight.
5
Attachments are shown in the figure
Attachment points, balancing device
on page 280 .
Continues on next page
282
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 282
|
Required equipment
Note
Art. no.
Spare part no.
Equipment
Includes:
•
balancing device
3HAC14675-1 or
3HAC023018-001
•
o-ring 3HAB3772-44
(2 pcs)
See Spare part
lists on page 425 .
Balancing device
2 pcs , to be replaced if
damaged! (included with
the new balancing device)
3HAB3772-44
O-ring
M16 x 90
3HAB3409-90
Locking screw
For securing the lower arm.
M12 x 35, 2 pcs required
9ADA183-66
Securing screw
For securing the bearing
attachments to the balan-
cing device when lifting.
For lubricating the o-rings
and the shaft.
3HAC042536-001
Bearing grease
150 ml, Tribol GR 100-0-PD
3HAA1001-294
Grease
For lubrication of spherical
roller bearing in ear, in case
of new balancing device.
Loctite 243
-
Locking liquid
To apply to the securing
screw in the shaft.
Loctite 577
-
Locking liquid
Used to secure the attach-
ment screws of the rear
cover at the end of the bal-
ancing device.
To lubricate spherical roller
bearing.
-
Grease pump
Always use guide pins in
pairs!
3HAC13120-5
Guide pins M16 x 300
3HAC14457-3
Lifting eye M12
3HAC15556-1
Lifting tool (chain)
For unloading the balancing
device.
3HAC074411-001
Press equipment, bal-
ancing device
User instructions are en-
closed with the tool.
To be used with
3HAC074411-001 for balan-
cing devices from 2002 and
older.
3HAC078221-001
Adapter for Press
equipment, balancing
device
For replacing the balancing
device shaft.
3HAC076202-001
Press equipment, bal-
ancing device shaft
User instructions are en-
closed with the tool.
Continues on next page
Product manual - IRB 7600
281
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
Note
Art. no.
Spare part no.
Equipment
To be used with the press
and puller tools.
3HAC11731-1
Hydraulic cylinder
See technical specifications
in the user instructions for
the press equipment.
To be used with the hydraul-
ic cylinder.
3HAC13086-1
Hydraulic pump 80
MPa
See technical specifications
in the user instructions for
the press equipment.
Content is defined in sec-
tion Standard tools on
page 419 .
-
Standard toolkit
These procedures include
references to the tools re-
quired.
Other tools and pro-
cedures may be re-
quired. See refer-
ences to these proced-
ures in the step-by-
step instructions be-
low.
Removal, balancing device
The procedures below detail how to remove the balancing device.
Preparations before removing the balancing device
Note
Action
Move the lower arm to a position close to the
calibration position.
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
Attachment hole for the locking screw
is shown in the figure Attachment
points, balancing device on page280 .
Secure the lower arm to the frame by inserting
the locking screw into the attachment hole in
the frame.
3
Art. no. is specified in Required
equipment on page 281 !
CAUTION
The balancing device weighs 300 kg! All lifting
equipment used must be sized accordingly!
4
Art. no. is specified in Required
equipment on page 281 !
Fit the lifting eye, M12 to the balancing device
and raise to unload the weight.
5
Attachments are shown in the figure
Attachment points, balancing device
on page 280 .
Continues on next page
282
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
Unloading the balancing device
Note
Action
xx0200000175
Remove the rear cover of the balancing device,
by unscrewing the attachment screws .
DANGER
DO NOT! remove any other screws then the
rear cover attachment screws.
1
•
E: Rear cover attachment
screws, 4 pcs
Remove the o-ring from the balancing device
end.
2
Remove the support shaft.
3
Art. no. is specified in Required
equipment on page 281 !
Unload the balancing device with the press
equipment in order to make the piston rod and
front ear adjustable when pulling the shaft out.
xx0900000813
4
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the
press tool.
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions for
the tool.
The power for brake release is only applied for
180 seconds after activation.
Removing the balancing device shaft
Note
Action
Shown in the figure Location of balan-
cing device on page 279 !
Remove the securing screw and washer from
the balancing device shaft.
1
Continues on next page
Product manual - IRB 7600
283
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 283
|
Note
Art. no.
Spare part no.
Equipment
To be used with the press
and puller tools.
3HAC11731-1
Hydraulic cylinder
See technical specifications
in the user instructions for
the press equipment.
To be used with the hydraul-
ic cylinder.
3HAC13086-1
Hydraulic pump 80
MPa
See technical specifications
in the user instructions for
the press equipment.
Content is defined in sec-
tion Standard tools on
page 419 .
-
Standard toolkit
These procedures include
references to the tools re-
quired.
Other tools and pro-
cedures may be re-
quired. See refer-
ences to these proced-
ures in the step-by-
step instructions be-
low.
Removal, balancing device
The procedures below detail how to remove the balancing device.
Preparations before removing the balancing device
Note
Action
Move the lower arm to a position close to the
calibration position.
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
Attachment hole for the locking screw
is shown in the figure Attachment
points, balancing device on page280 .
Secure the lower arm to the frame by inserting
the locking screw into the attachment hole in
the frame.
3
Art. no. is specified in Required
equipment on page 281 !
CAUTION
The balancing device weighs 300 kg! All lifting
equipment used must be sized accordingly!
4
Art. no. is specified in Required
equipment on page 281 !
Fit the lifting eye, M12 to the balancing device
and raise to unload the weight.
5
Attachments are shown in the figure
Attachment points, balancing device
on page 280 .
Continues on next page
282
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
Unloading the balancing device
Note
Action
xx0200000175
Remove the rear cover of the balancing device,
by unscrewing the attachment screws .
DANGER
DO NOT! remove any other screws then the
rear cover attachment screws.
1
•
E: Rear cover attachment
screws, 4 pcs
Remove the o-ring from the balancing device
end.
2
Remove the support shaft.
3
Art. no. is specified in Required
equipment on page 281 !
Unload the balancing device with the press
equipment in order to make the piston rod and
front ear adjustable when pulling the shaft out.
xx0900000813
4
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the
press tool.
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions for
the tool.
The power for brake release is only applied for
180 seconds after activation.
Removing the balancing device shaft
Note
Action
Shown in the figure Location of balan-
cing device on page 279 !
Remove the securing screw and washer from
the balancing device shaft.
1
Continues on next page
Product manual - IRB 7600
283
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
Note
Action
Art. no. is specified in Required
equipment on page 281 !
Pull the shaft out using the press equipment,
balancing device shaft , according to user in-
structions enclosed with the equipment.
xx0900000813
2
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the
press tool.
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions for
the tool.
The power for brake release is only applied for
180 seconds after activation.
Restoring the balancing device
Note
Action
Art. no. is specified in Required
equipment on page 281 !
Restore the balancing device according to in-
structions for the press equipment .
xx0900000813
1
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the
press tool.
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions for
the tool.
The power for brake release is only applied for
180 seconds after activation.
Make sure the o-ring is seated prop-
erly! Replace if damaged.
Lubricate and refit the o-ring at the end of the
balancing device.
2
Refit the support shaft to the balancing device.
3
Make sure the o-ring is seated prop-
erly! Replace if damaged.
Lubricate and refit the o-ring on the support
shaft.
4
Continues on next page
284
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 284
|
Unloading the balancing device
Note
Action
xx0200000175
Remove the rear cover of the balancing device,
by unscrewing the attachment screws .
DANGER
DO NOT! remove any other screws then the
rear cover attachment screws.
1
•
E: Rear cover attachment
screws, 4 pcs
Remove the o-ring from the balancing device
end.
2
Remove the support shaft.
3
Art. no. is specified in Required
equipment on page 281 !
Unload the balancing device with the press
equipment in order to make the piston rod and
front ear adjustable when pulling the shaft out.
xx0900000813
4
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the
press tool.
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions for
the tool.
The power for brake release is only applied for
180 seconds after activation.
Removing the balancing device shaft
Note
Action
Shown in the figure Location of balan-
cing device on page 279 !
Remove the securing screw and washer from
the balancing device shaft.
1
Continues on next page
Product manual - IRB 7600
283
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
Note
Action
Art. no. is specified in Required
equipment on page 281 !
Pull the shaft out using the press equipment,
balancing device shaft , according to user in-
structions enclosed with the equipment.
xx0900000813
2
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the
press tool.
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions for
the tool.
The power for brake release is only applied for
180 seconds after activation.
Restoring the balancing device
Note
Action
Art. no. is specified in Required
equipment on page 281 !
Restore the balancing device according to in-
structions for the press equipment .
xx0900000813
1
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the
press tool.
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions for
the tool.
The power for brake release is only applied for
180 seconds after activation.
Make sure the o-ring is seated prop-
erly! Replace if damaged.
Lubricate and refit the o-ring at the end of the
balancing device.
2
Refit the support shaft to the balancing device.
3
Make sure the o-ring is seated prop-
erly! Replace if damaged.
Lubricate and refit the o-ring on the support
shaft.
4
Continues on next page
284
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
Note
Action
xx0200000175
Refit the rear cover to the balancing device with
its attachment screws, using locking liquid.
Apply sikaflex 521FX on the cover.
5
•
E: 4 pcs: M10x30, tightening
torque: 50 Nm.
Locking liquid is specified in Required
equipment on page 281 .
DANGER
The rear cover of the balancing device is a
safety device for the piston rod during opera-
tion! Make sure the cover is properly secured
before commissioning of the robot!
6
Removing the balancing device
Note
Action
Shown in the figure Attachment points,
balancing device on page 280 !
Secure the two bearing attachments to the bal-
ancing device by replacing the protection plug
on the outside of each attachment, with secur-
ing screws.
The protection plugs must be refitted after refit-
ting the balancing device, do not loose them!
1
Dimensions for the securing screws
are specified in Required equipment
on page 281 .
Shown in the figure Location of balan-
cing device on page 279 !
Remove the two bearing attachments from the
frame by unscrewing their four attachment
screws.
2
Make sure the parallel pins inside are
not lost!
Art. no. is specified in Required
equipment on page 281 !
Fit two guide pins through the upper holes of
the bearing attachments, to the frame.
3
Note
Make sure not to burden the guide
pins with the weight of the balancing
device!
Lift the balancing device gently backwards to
a secure area, allowing the bearing attachments
to slide on the guide pins.
4
Continues on next page
Product manual - IRB 7600
285
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 285
|
Note
Action
Art. no. is specified in Required
equipment on page 281 !
Pull the shaft out using the press equipment,
balancing device shaft , according to user in-
structions enclosed with the equipment.
xx0900000813
2
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the
press tool.
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions for
the tool.
The power for brake release is only applied for
180 seconds after activation.
Restoring the balancing device
Note
Action
Art. no. is specified in Required
equipment on page 281 !
Restore the balancing device according to in-
structions for the press equipment .
xx0900000813
1
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the
press tool.
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions for
the tool.
The power for brake release is only applied for
180 seconds after activation.
Make sure the o-ring is seated prop-
erly! Replace if damaged.
Lubricate and refit the o-ring at the end of the
balancing device.
2
Refit the support shaft to the balancing device.
3
Make sure the o-ring is seated prop-
erly! Replace if damaged.
Lubricate and refit the o-ring on the support
shaft.
4
Continues on next page
284
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
Note
Action
xx0200000175
Refit the rear cover to the balancing device with
its attachment screws, using locking liquid.
Apply sikaflex 521FX on the cover.
5
•
E: 4 pcs: M10x30, tightening
torque: 50 Nm.
Locking liquid is specified in Required
equipment on page 281 .
DANGER
The rear cover of the balancing device is a
safety device for the piston rod during opera-
tion! Make sure the cover is properly secured
before commissioning of the robot!
6
Removing the balancing device
Note
Action
Shown in the figure Attachment points,
balancing device on page 280 !
Secure the two bearing attachments to the bal-
ancing device by replacing the protection plug
on the outside of each attachment, with secur-
ing screws.
The protection plugs must be refitted after refit-
ting the balancing device, do not loose them!
1
Dimensions for the securing screws
are specified in Required equipment
on page 281 .
Shown in the figure Location of balan-
cing device on page 279 !
Remove the two bearing attachments from the
frame by unscrewing their four attachment
screws.
2
Make sure the parallel pins inside are
not lost!
Art. no. is specified in Required
equipment on page 281 !
Fit two guide pins through the upper holes of
the bearing attachments, to the frame.
3
Note
Make sure not to burden the guide
pins with the weight of the balancing
device!
Lift the balancing device gently backwards to
a secure area, allowing the bearing attachments
to slide on the guide pins.
4
Continues on next page
Product manual - IRB 7600
285
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
Refitting, balancing device
The procedures below detail how to refit the balancing device.
Refitting the balancing device
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
Art. no. is specified in Required
equipment on page 281 !
Secure the lower arm to the frame by inserting
the locking screw into the attachment hole in
the frame.
2
Attachment hole is shown in the fig-
ure Attachment points, balancing
device on page 280 .
Shown in the figure Attachment
points, balancing device on page280 !
Secure the bearing attachments to the balan-
cing device with securing screws .
3
Dimension of the securing screws is
specified in Required equipment on
page 281 .
Shown in the figure Location of bal-
ancing device on page 279 !
Refit the two parallel pins in the frame.
4
Fit two guide pins to the upper holes in the
frame, where the bearing attachments are to
be attached.
5
Art. no. is specified in Required
equipment on page 281 !
Fit the lifting eye to the balancing device.
6
Attachments are shown in the fig-
ure Attachment points, balancing
device on page 280 .
CAUTION
The balancing device weighs 300 kg! All lifting
equipment used must be sized accordingly!
7
Note
Make sure not to burden the guide
pins with the weight of the balancing
device!
Lift the balancing device and bring it forward,
gliding the bearing attachments on to the guide
pins.
8
Remove the guide pins.
9
Continues on next page
286
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing 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
| 286
|
Note
Action
xx0200000175
Refit the rear cover to the balancing device with
its attachment screws, using locking liquid.
Apply sikaflex 521FX on the cover.
5
•
E: 4 pcs: M10x30, tightening
torque: 50 Nm.
Locking liquid is specified in Required
equipment on page 281 .
DANGER
The rear cover of the balancing device is a
safety device for the piston rod during opera-
tion! Make sure the cover is properly secured
before commissioning of the robot!
6
Removing the balancing device
Note
Action
Shown in the figure Attachment points,
balancing device on page 280 !
Secure the two bearing attachments to the bal-
ancing device by replacing the protection plug
on the outside of each attachment, with secur-
ing screws.
The protection plugs must be refitted after refit-
ting the balancing device, do not loose them!
1
Dimensions for the securing screws
are specified in Required equipment
on page 281 .
Shown in the figure Location of balan-
cing device on page 279 !
Remove the two bearing attachments from the
frame by unscrewing their four attachment
screws.
2
Make sure the parallel pins inside are
not lost!
Art. no. is specified in Required
equipment on page 281 !
Fit two guide pins through the upper holes of
the bearing attachments, to the frame.
3
Note
Make sure not to burden the guide
pins with the weight of the balancing
device!
Lift the balancing device gently backwards to
a secure area, allowing the bearing attachments
to slide on the guide pins.
4
Continues on next page
Product manual - IRB 7600
285
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
Refitting, balancing device
The procedures below detail how to refit the balancing device.
Refitting the balancing device
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
Art. no. is specified in Required
equipment on page 281 !
Secure the lower arm to the frame by inserting
the locking screw into the attachment hole in
the frame.
2
Attachment hole is shown in the fig-
ure Attachment points, balancing
device on page 280 .
Shown in the figure Attachment
points, balancing device on page280 !
Secure the bearing attachments to the balan-
cing device with securing screws .
3
Dimension of the securing screws is
specified in Required equipment on
page 281 .
Shown in the figure Location of bal-
ancing device on page 279 !
Refit the two parallel pins in the frame.
4
Fit two guide pins to the upper holes in the
frame, where the bearing attachments are to
be attached.
5
Art. no. is specified in Required
equipment on page 281 !
Fit the lifting eye to the balancing device.
6
Attachments are shown in the fig-
ure Attachment points, balancing
device on page 280 .
CAUTION
The balancing device weighs 300 kg! All lifting
equipment used must be sized accordingly!
7
Note
Make sure not to burden the guide
pins with the weight of the balancing
device!
Lift the balancing device and bring it forward,
gliding the bearing attachments on to the guide
pins.
8
Remove the guide pins.
9
Continues on next page
286
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
Note
Action
Shown in the figure Location of bal-
ancing device on page 279 !
Secure the rear of the balancing device by
fastening the two bearing attachments to the
frame with their four attachment screws.
10
4 pcs, M16x90, 12.9 quality UN-
BRAKO, tightening torque: 300 Nm.
Reused screws may be used,
providing they are lubricated as de-
tailed in section Screw joints on
page 415 before fitting.
Remove the screws from outside of the bearing
attachments and refit the protection plugs.
11
Raise the balancing device to a position where
the balancing device shaft may be inserted
through the piston shaft front eye.
12
Unloading the balancing device
Note
Action
xx0200000175
Remove the rear cover of the balancing device,
by unscrewing the attachment screws .
DANGER
DO NOT! remove any other screws then the
rear cover attachment screws.
1
•
E: Rear cover attachment
screws, 4 pcs
Remove the o-ring from the balancing device
end.
2
Remove the support shaft.
3
Art. no. is specified in Required
equipment on page 281 !
Unload the balancing device with the press
equipment in order to make the piston rod and
front ear adjustable when pulling the shaft out.
xx0900000813
4
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the
press tool.
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions for
the tool.
The power for brake release is only applied for
180 seconds after activation.
Continues on next page
Product manual - IRB 7600
287
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing 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
| 287
|
Refitting, balancing device
The procedures below detail how to refit the balancing device.
Refitting the balancing device
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
Art. no. is specified in Required
equipment on page 281 !
Secure the lower arm to the frame by inserting
the locking screw into the attachment hole in
the frame.
2
Attachment hole is shown in the fig-
ure Attachment points, balancing
device on page 280 .
Shown in the figure Attachment
points, balancing device on page280 !
Secure the bearing attachments to the balan-
cing device with securing screws .
3
Dimension of the securing screws is
specified in Required equipment on
page 281 .
Shown in the figure Location of bal-
ancing device on page 279 !
Refit the two parallel pins in the frame.
4
Fit two guide pins to the upper holes in the
frame, where the bearing attachments are to
be attached.
5
Art. no. is specified in Required
equipment on page 281 !
Fit the lifting eye to the balancing device.
6
Attachments are shown in the fig-
ure Attachment points, balancing
device on page 280 .
CAUTION
The balancing device weighs 300 kg! All lifting
equipment used must be sized accordingly!
7
Note
Make sure not to burden the guide
pins with the weight of the balancing
device!
Lift the balancing device and bring it forward,
gliding the bearing attachments on to the guide
pins.
8
Remove the guide pins.
9
Continues on next page
286
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
Note
Action
Shown in the figure Location of bal-
ancing device on page 279 !
Secure the rear of the balancing device by
fastening the two bearing attachments to the
frame with their four attachment screws.
10
4 pcs, M16x90, 12.9 quality UN-
BRAKO, tightening torque: 300 Nm.
Reused screws may be used,
providing they are lubricated as de-
tailed in section Screw joints on
page 415 before fitting.
Remove the screws from outside of the bearing
attachments and refit the protection plugs.
11
Raise the balancing device to a position where
the balancing device shaft may be inserted
through the piston shaft front eye.
12
Unloading the balancing device
Note
Action
xx0200000175
Remove the rear cover of the balancing device,
by unscrewing the attachment screws .
DANGER
DO NOT! remove any other screws then the
rear cover attachment screws.
1
•
E: Rear cover attachment
screws, 4 pcs
Remove the o-ring from the balancing device
end.
2
Remove the support shaft.
3
Art. no. is specified in Required
equipment on page 281 !
Unload the balancing device with the press
equipment in order to make the piston rod and
front ear adjustable when pulling the shaft out.
xx0900000813
4
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the
press tool.
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions for
the tool.
The power for brake release is only applied for
180 seconds after activation.
Continues on next page
Product manual - IRB 7600
287
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
Refitting the balancing device shaft
Note
Action
Art. no. is specified in Required
equipment on page 281 !
Lubricate the shaft with grease.
1
Art. no. is specified in Required
equipment on page 281 !
Fit the shaft to the piston shaft front eye
through the hole in the frame, using the press
equipment, balancing device shaft , according
to user instructions enclosed with the equip-
ment.
xx0900000813
2
User instructions are enclosed with
the tool.
Note
Make sure the shaft is pressed all
the way to the bottom.
Go to the user instructions enclosed with the
press tool.
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions for
the tool.
The power for brake release is only applied for
180 seconds after activation.
M16 x 180, tightening torque: 120
Nm.
Refit the securing screw and washer into the
shaft using locking liquid.
3
Locking liquid is specified in Re-
quired equipment on page 281 !
Art. no. and amount are specified in
Required equipment on page 281 !
Lubricate the bearing in the ear with grease
through the lubricating nipple, with a grease
pump.
Fill until excessive grease pierces between the
shaft and the sealing spacer.
4
Lubrication is further detailed in
section Lubrication of spherical roller
bearing, balancing device on
page 188 .
Continues on next page
288
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing 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
| 288
|
Note
Action
Shown in the figure Location of bal-
ancing device on page 279 !
Secure the rear of the balancing device by
fastening the two bearing attachments to the
frame with their four attachment screws.
10
4 pcs, M16x90, 12.9 quality UN-
BRAKO, tightening torque: 300 Nm.
Reused screws may be used,
providing they are lubricated as de-
tailed in section Screw joints on
page 415 before fitting.
Remove the screws from outside of the bearing
attachments and refit the protection plugs.
11
Raise the balancing device to a position where
the balancing device shaft may be inserted
through the piston shaft front eye.
12
Unloading the balancing device
Note
Action
xx0200000175
Remove the rear cover of the balancing device,
by unscrewing the attachment screws .
DANGER
DO NOT! remove any other screws then the
rear cover attachment screws.
1
•
E: Rear cover attachment
screws, 4 pcs
Remove the o-ring from the balancing device
end.
2
Remove the support shaft.
3
Art. no. is specified in Required
equipment on page 281 !
Unload the balancing device with the press
equipment in order to make the piston rod and
front ear adjustable when pulling the shaft out.
xx0900000813
4
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the
press tool.
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions for
the tool.
The power for brake release is only applied for
180 seconds after activation.
Continues on next page
Product manual - IRB 7600
287
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
Refitting the balancing device shaft
Note
Action
Art. no. is specified in Required
equipment on page 281 !
Lubricate the shaft with grease.
1
Art. no. is specified in Required
equipment on page 281 !
Fit the shaft to the piston shaft front eye
through the hole in the frame, using the press
equipment, balancing device shaft , according
to user instructions enclosed with the equip-
ment.
xx0900000813
2
User instructions are enclosed with
the tool.
Note
Make sure the shaft is pressed all
the way to the bottom.
Go to the user instructions enclosed with the
press tool.
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions for
the tool.
The power for brake release is only applied for
180 seconds after activation.
M16 x 180, tightening torque: 120
Nm.
Refit the securing screw and washer into the
shaft using locking liquid.
3
Locking liquid is specified in Re-
quired equipment on page 281 !
Art. no. and amount are specified in
Required equipment on page 281 !
Lubricate the bearing in the ear with grease
through the lubricating nipple, with a grease
pump.
Fill until excessive grease pierces between the
shaft and the sealing spacer.
4
Lubrication is further detailed in
section Lubrication of spherical roller
bearing, balancing device on
page 188 .
Continues on next page
288
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
Restoring the balancing device
Note
Action
Art. no. is specified in Required
equipment on page 281 !
Restore the balancing device according to in-
structions for the press equipment .
xx0900000813
1
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the
press tool.
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions for
the tool.
The power for brake release is only applied for
180 seconds after activation.
Make sure the o-ring is seated prop-
erly! Replace if damaged.
Lubricate and refit the o-ring at the end of the
balancing device.
2
Refit the support shaft to the balancing device.
3
Make sure the o-ring is seated prop-
erly! Replace if damaged.
Lubricate and refit the o-ring on the support
shaft.
4
xx0200000175
Refit the rear cover to the balancing device with
its attachment screws, using locking liquid.
Apply sikaflex 521FX on the cover.
5
•
E: 4 pcs: M10x30, tightening
torque: 50 Nm.
Locking liquid is specified in Required
equipment on page 281 .
DANGER
The rear cover of the balancing device is a
safety device for the piston rod during opera-
tion! Make sure the cover is properly secured
before commissioning of the robot!
6
Continues on next page
Product manual - IRB 7600
289
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
|
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| 289
|
Refitting the balancing device shaft
Note
Action
Art. no. is specified in Required
equipment on page 281 !
Lubricate the shaft with grease.
1
Art. no. is specified in Required
equipment on page 281 !
Fit the shaft to the piston shaft front eye
through the hole in the frame, using the press
equipment, balancing device shaft , according
to user instructions enclosed with the equip-
ment.
xx0900000813
2
User instructions are enclosed with
the tool.
Note
Make sure the shaft is pressed all
the way to the bottom.
Go to the user instructions enclosed with the
press tool.
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions for
the tool.
The power for brake release is only applied for
180 seconds after activation.
M16 x 180, tightening torque: 120
Nm.
Refit the securing screw and washer into the
shaft using locking liquid.
3
Locking liquid is specified in Re-
quired equipment on page 281 !
Art. no. and amount are specified in
Required equipment on page 281 !
Lubricate the bearing in the ear with grease
through the lubricating nipple, with a grease
pump.
Fill until excessive grease pierces between the
shaft and the sealing spacer.
4
Lubrication is further detailed in
section Lubrication of spherical roller
bearing, balancing device on
page 188 .
Continues on next page
288
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
Restoring the balancing device
Note
Action
Art. no. is specified in Required
equipment on page 281 !
Restore the balancing device according to in-
structions for the press equipment .
xx0900000813
1
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the
press tool.
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions for
the tool.
The power for brake release is only applied for
180 seconds after activation.
Make sure the o-ring is seated prop-
erly! Replace if damaged.
Lubricate and refit the o-ring at the end of the
balancing device.
2
Refit the support shaft to the balancing device.
3
Make sure the o-ring is seated prop-
erly! Replace if damaged.
Lubricate and refit the o-ring on the support
shaft.
4
xx0200000175
Refit the rear cover to the balancing device with
its attachment screws, using locking liquid.
Apply sikaflex 521FX on the cover.
5
•
E: 4 pcs: M10x30, tightening
torque: 50 Nm.
Locking liquid is specified in Required
equipment on page 281 .
DANGER
The rear cover of the balancing device is a
safety device for the piston rod during opera-
tion! Make sure the cover is properly secured
before commissioning of the robot!
6
Continues on next page
Product manual - IRB 7600
289
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
Concluding procedure
Note
Action
xx0200000454
Remove the locking screw that secures the
lower arm to the frame.
1
1
Attachment hole for the secur-
ing screw.
DANGER
Make sure all safety requirements are met
when performing the first test run.
2
290
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 290
|
Restoring the balancing device
Note
Action
Art. no. is specified in Required
equipment on page 281 !
Restore the balancing device according to in-
structions for the press equipment .
xx0900000813
1
User instructions are enclosed with
the tool.
Go to the user instructions enclosed with the
press tool.
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions for
the tool.
The power for brake release is only applied for
180 seconds after activation.
Make sure the o-ring is seated prop-
erly! Replace if damaged.
Lubricate and refit the o-ring at the end of the
balancing device.
2
Refit the support shaft to the balancing device.
3
Make sure the o-ring is seated prop-
erly! Replace if damaged.
Lubricate and refit the o-ring on the support
shaft.
4
xx0200000175
Refit the rear cover to the balancing device with
its attachment screws, using locking liquid.
Apply sikaflex 521FX on the cover.
5
•
E: 4 pcs: M10x30, tightening
torque: 50 Nm.
Locking liquid is specified in Required
equipment on page 281 .
DANGER
The rear cover of the balancing device is a
safety device for the piston rod during opera-
tion! Make sure the cover is properly secured
before commissioning of the robot!
6
Continues on next page
Product manual - IRB 7600
289
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
Concluding procedure
Note
Action
xx0200000454
Remove the locking screw that secures the
lower arm to the frame.
1
1
Attachment hole for the secur-
ing screw.
DANGER
Make sure all safety requirements are met
when performing the first test run.
2
290
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
4.6 Motors
4.6.1 Replacement of motor, axis 1
Note
This procedure requires calibration of the robot.
The robot is calibrated by either Calibration Pendulum or Axis Calibration at
factory. Always use the same calibration method as used at the factory.
Information about valid calibration method is found on the calibration label or in
the calibration menu on the FlexPendant.
Location of motor
The motor axis 1 is located on the left hand side of the robot as shown in the figure
below.
xx0100000123
Motor, axis 1
A
Cable gland cover, motor axis
B
Cover for connector access
C
Motor attachment screws
D
Continues on next page
Product manual - IRB 7600
291
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.1 Replacement of motor, axis 1
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ABB_IRB7600_Product_Manual.pdf
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| 291
|
Concluding procedure
Note
Action
xx0200000454
Remove the locking screw that secures the
lower arm to the frame.
1
1
Attachment hole for the secur-
ing screw.
DANGER
Make sure all safety requirements are met
when performing the first test run.
2
290
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.5.4.1 Replacing the balancing device
Continued
4.6 Motors
4.6.1 Replacement of motor, axis 1
Note
This procedure requires calibration of the robot.
The robot is calibrated by either Calibration Pendulum or Axis Calibration at
factory. Always use the same calibration method as used at the factory.
Information about valid calibration method is found on the calibration label or in
the calibration menu on the FlexPendant.
Location of motor
The motor axis 1 is located on the left hand side of the robot as shown in the figure
below.
xx0100000123
Motor, axis 1
A
Cable gland cover, motor axis
B
Cover for connector access
C
Motor attachment screws
D
Continues on next page
Product manual - IRB 7600
291
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.1 Replacement of motor, axis 1
Required equipment
Note
Art. no.
Spare part no.
Equipment, etc.
Includes
•
motor
•
pinion
•
o-ring 21522012-
430.
See Spare part lists
on page 425 .
Motor including pinion
Must be replaced when
reassemling the motor.
21522012-430
O-ring
Used to lubricate the mo-
tor clutch.
-
-
Mobilux EP 2
Used to lubricate the o-
ring.
3HAC042536-001
Grease
Always use the removal
tools in pairs!
3HAC14973-1
Removal tool, motor
M12x
3HAC14459-1
Lifting tool, motor ax
1, 4, 5
3HAC12342-1
Extension 300mm for
bits 1/2"
24 VDC, max. 1,5 A
-
Power supply
For releasing the brakes.
Content is defined in sec-
tion Standard tools on
page 419 .
-
Standard toolkit
Complete kit that also in-
cludes operating manual.
3HAC15716-1
Calibration Pendulum
toolkit
Required if Calibration
Pendulum is the valid cal-
ibration method for the
robot.
Delivered as a set of calib-
ration tools.
3HAC055412-001
Calibration tool box,
Axis Calibration
Required if Axis Calibra-
tion is the valid calibration
method for the robot.
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.
See chapter Circuit dia-
gram on page 427 .
Circuit diagram
Continues on next page
292
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.1 Replacement of motor, axis 1
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 292
|
4.6 Motors
4.6.1 Replacement of motor, axis 1
Note
This procedure requires calibration of the robot.
The robot is calibrated by either Calibration Pendulum or Axis Calibration at
factory. Always use the same calibration method as used at the factory.
Information about valid calibration method is found on the calibration label or in
the calibration menu on the FlexPendant.
Location of motor
The motor axis 1 is located on the left hand side of the robot as shown in the figure
below.
xx0100000123
Motor, axis 1
A
Cable gland cover, motor axis
B
Cover for connector access
C
Motor attachment screws
D
Continues on next page
Product manual - IRB 7600
291
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.1 Replacement of motor, axis 1
Required equipment
Note
Art. no.
Spare part no.
Equipment, etc.
Includes
•
motor
•
pinion
•
o-ring 21522012-
430.
See Spare part lists
on page 425 .
Motor including pinion
Must be replaced when
reassemling the motor.
21522012-430
O-ring
Used to lubricate the mo-
tor clutch.
-
-
Mobilux EP 2
Used to lubricate the o-
ring.
3HAC042536-001
Grease
Always use the removal
tools in pairs!
3HAC14973-1
Removal tool, motor
M12x
3HAC14459-1
Lifting tool, motor ax
1, 4, 5
3HAC12342-1
Extension 300mm for
bits 1/2"
24 VDC, max. 1,5 A
-
Power supply
For releasing the brakes.
Content is defined in sec-
tion Standard tools on
page 419 .
-
Standard toolkit
Complete kit that also in-
cludes operating manual.
3HAC15716-1
Calibration Pendulum
toolkit
Required if Calibration
Pendulum is the valid cal-
ibration method for the
robot.
Delivered as a set of calib-
ration tools.
3HAC055412-001
Calibration tool box,
Axis Calibration
Required if Axis Calibra-
tion is the valid calibration
method for the robot.
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.
See chapter Circuit dia-
gram on page 427 .
Circuit diagram
Continues on next page
292
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.1 Replacement of motor, axis 1
Continued
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, motor axis 1
The procedure below details how to remove motor, axis 1.
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 the cover for connector access on top of
the motor by unscrewing its four attachment screws.
3
Continues on next page
Product manual - IRB 7600
293
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.1 Replacement of motor, axis 1
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 293
|
Required equipment
Note
Art. no.
Spare part no.
Equipment, etc.
Includes
•
motor
•
pinion
•
o-ring 21522012-
430.
See Spare part lists
on page 425 .
Motor including pinion
Must be replaced when
reassemling the motor.
21522012-430
O-ring
Used to lubricate the mo-
tor clutch.
-
-
Mobilux EP 2
Used to lubricate the o-
ring.
3HAC042536-001
Grease
Always use the removal
tools in pairs!
3HAC14973-1
Removal tool, motor
M12x
3HAC14459-1
Lifting tool, motor ax
1, 4, 5
3HAC12342-1
Extension 300mm for
bits 1/2"
24 VDC, max. 1,5 A
-
Power supply
For releasing the brakes.
Content is defined in sec-
tion Standard tools on
page 419 .
-
Standard toolkit
Complete kit that also in-
cludes operating manual.
3HAC15716-1
Calibration Pendulum
toolkit
Required if Calibration
Pendulum is the valid cal-
ibration method for the
robot.
Delivered as a set of calib-
ration tools.
3HAC055412-001
Calibration tool box,
Axis Calibration
Required if Axis Calibra-
tion is the valid calibration
method for the robot.
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.
See chapter Circuit dia-
gram on page 427 .
Circuit diagram
Continues on next page
292
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.1 Replacement of motor, axis 1
Continued
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, motor axis 1
The procedure below details how to remove motor, axis 1.
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 the cover for connector access on top of
the motor by unscrewing its four attachment screws.
3
Continues on next page
Product manual - IRB 7600
293
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.1 Replacement of motor, axis 1
Continued
Note
Action
xx0200000199
Remove the cable gland cover at the cable exit by
unscrewing its two attachment screws.
Note
Make sure the gasket is not damaged!
4
•
A: Cable gland cover
Disconnect all connectors beneath the motor cover.
5
Art. no. is specified in Required
equipment on page 292 .
Apply lifting tool, motor axis 1, 4, 5 to the motor.
6
Connect to connector R2.MP1
•
+: pin 2
•
-: pin 5
In order to release the brakes, connect the 24 VDC
power supply.
7
Shown in the figure Location of
motor on page 291 .
Remove the motor by unscrewing its four attach-
ment screws and plain washers.
If required, use the extension 300mm for bits 1/2" .
8
Art. no. is specified in Required
equipment on page 292 .
CAUTION
The motor weighs 32 kg! All lifting equipment used
must be sized accordingly!
9
Lift the motor to get the pinion away from the gear
and disconnect the brake release voltage.
10
Remove the motor by gently lifting it straight up.
11
Refitting, motor axis 1
The procedure below details how to refit motor, axis 1.
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
Art no. is specified in Required
equipment on page 292 .
Make sure the o-ring on the circumference of the
motor is seated properly. Lightly lubricate the o-
ring with grease.
2
Continues on next page
294
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.1 Replacement of motor, axis 1
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 294
|
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, motor axis 1
The procedure below details how to remove motor, axis 1.
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 the cover for connector access on top of
the motor by unscrewing its four attachment screws.
3
Continues on next page
Product manual - IRB 7600
293
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.1 Replacement of motor, axis 1
Continued
Note
Action
xx0200000199
Remove the cable gland cover at the cable exit by
unscrewing its two attachment screws.
Note
Make sure the gasket is not damaged!
4
•
A: Cable gland cover
Disconnect all connectors beneath the motor cover.
5
Art. no. is specified in Required
equipment on page 292 .
Apply lifting tool, motor axis 1, 4, 5 to the motor.
6
Connect to connector R2.MP1
•
+: pin 2
•
-: pin 5
In order to release the brakes, connect the 24 VDC
power supply.
7
Shown in the figure Location of
motor on page 291 .
Remove the motor by unscrewing its four attach-
ment screws and plain washers.
If required, use the extension 300mm for bits 1/2" .
8
Art. no. is specified in Required
equipment on page 292 .
CAUTION
The motor weighs 32 kg! All lifting equipment used
must be sized accordingly!
9
Lift the motor to get the pinion away from the gear
and disconnect the brake release voltage.
10
Remove the motor by gently lifting it straight up.
11
Refitting, motor axis 1
The procedure below details how to refit motor, axis 1.
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
Art no. is specified in Required
equipment on page 292 .
Make sure the o-ring on the circumference of the
motor is seated properly. Lightly lubricate the o-
ring with grease.
2
Continues on next page
294
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.1 Replacement of motor, axis 1
Continued
Note
Action
CAUTION
The motor weighs 32 kg! All lifting equipment used
must be sized accordingly!
3
Art no. is specified in Required
equipment on page 292 .
Apply the lifting tool, motor axis 1, 4, 5 to the motor.
4
Connect to connector R2.MP1
•
+: pin 2
•
-: pin 5
In order to release the brake, connect the 24 VDC
power supply.
5
Make sure the motor is turned the
correct way, that is connection of
motorcable forwards. .
Fit the motor, making sure the motor pinion is
properly mated to gearbox of axis 1.
6
Make sure the motor pinion does
not get damaged!
Fit the clutch on the pinion on the motor.
7
M10 x 40, tightening torque: 50
Nm.
Secure the motor with its four attachment screws
and plain washers.
8
Disconnect the brake release voltage.
9
Reconnect all connectors beneath the motor cover.
10
Make sure the cover is tightly
sealed!
Refit the cable gland cover at the cable exit with its
two attachment screws.
11
Make sure the cover is tightly
sealed!
Refit the motor cover with its four attachment
screws.
12
Pendulum Calibration is described
in Operating manual - Calibration
Pendulum , enclosed with the calib-
ration tools.
Recalibrate the robot!
13
Axis Calibration is described in
Calibrating 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
295
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.1 Replacement of motor, axis 1
Continued
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|
Note
Action
xx0200000199
Remove the cable gland cover at the cable exit by
unscrewing its two attachment screws.
Note
Make sure the gasket is not damaged!
4
•
A: Cable gland cover
Disconnect all connectors beneath the motor cover.
5
Art. no. is specified in Required
equipment on page 292 .
Apply lifting tool, motor axis 1, 4, 5 to the motor.
6
Connect to connector R2.MP1
•
+: pin 2
•
-: pin 5
In order to release the brakes, connect the 24 VDC
power supply.
7
Shown in the figure Location of
motor on page 291 .
Remove the motor by unscrewing its four attach-
ment screws and plain washers.
If required, use the extension 300mm for bits 1/2" .
8
Art. no. is specified in Required
equipment on page 292 .
CAUTION
The motor weighs 32 kg! All lifting equipment used
must be sized accordingly!
9
Lift the motor to get the pinion away from the gear
and disconnect the brake release voltage.
10
Remove the motor by gently lifting it straight up.
11
Refitting, motor axis 1
The procedure below details how to refit motor, axis 1.
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
Art no. is specified in Required
equipment on page 292 .
Make sure the o-ring on the circumference of the
motor is seated properly. Lightly lubricate the o-
ring with grease.
2
Continues on next page
294
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.1 Replacement of motor, axis 1
Continued
Note
Action
CAUTION
The motor weighs 32 kg! All lifting equipment used
must be sized accordingly!
3
Art no. is specified in Required
equipment on page 292 .
Apply the lifting tool, motor axis 1, 4, 5 to the motor.
4
Connect to connector R2.MP1
•
+: pin 2
•
-: pin 5
In order to release the brake, connect the 24 VDC
power supply.
5
Make sure the motor is turned the
correct way, that is connection of
motorcable forwards. .
Fit the motor, making sure the motor pinion is
properly mated to gearbox of axis 1.
6
Make sure the motor pinion does
not get damaged!
Fit the clutch on the pinion on the motor.
7
M10 x 40, tightening torque: 50
Nm.
Secure the motor with its four attachment screws
and plain washers.
8
Disconnect the brake release voltage.
9
Reconnect all connectors beneath the motor cover.
10
Make sure the cover is tightly
sealed!
Refit the cable gland cover at the cable exit with its
two attachment screws.
11
Make sure the cover is tightly
sealed!
Refit the motor cover with its four attachment
screws.
12
Pendulum Calibration is described
in Operating manual - Calibration
Pendulum , enclosed with the calib-
ration tools.
Recalibrate the robot!
13
Axis Calibration is described in
Calibrating 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
295
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.1 Replacement of motor, axis 1
Continued
4.6.2 Replacement of motor axis 2
Location of motor
The motor, axis 2, is located on the left-hand side of the robot as shown in the
figure below.
xx0100000124
Motor, axis 2
A
Cable gland cover, motor axis 2
B
Hole for lock screw
C
Required equipment
Note
Art. no.
Spare part no.
Equipment, etc.
Includes:
•
motor
•
pinion
•
o-ring 2152 2012-430
See Spare part
lists on page 425 .
Motor axis 2
Must be replaced when re-
assembling motor!
21522012-430
O-ring
For lubricating the o-ring.
3HAC042536-001
Grease
M16 x 60
3HAA1001-266
Locking screw
For securing the lower arm.
Always use the removal
tools in pairs!
3HAC14973-1
Removal tool, motor
M12x
For guiding the motor.
Guides are to be used in
pairs!
3HAC15521-1
Guide pins M10 x 100
Continues on next page
296
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.2 Replacement of motor axis 2
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| 296
|
Note
Action
CAUTION
The motor weighs 32 kg! All lifting equipment used
must be sized accordingly!
3
Art no. is specified in Required
equipment on page 292 .
Apply the lifting tool, motor axis 1, 4, 5 to the motor.
4
Connect to connector R2.MP1
•
+: pin 2
•
-: pin 5
In order to release the brake, connect the 24 VDC
power supply.
5
Make sure the motor is turned the
correct way, that is connection of
motorcable forwards. .
Fit the motor, making sure the motor pinion is
properly mated to gearbox of axis 1.
6
Make sure the motor pinion does
not get damaged!
Fit the clutch on the pinion on the motor.
7
M10 x 40, tightening torque: 50
Nm.
Secure the motor with its four attachment screws
and plain washers.
8
Disconnect the brake release voltage.
9
Reconnect all connectors beneath the motor cover.
10
Make sure the cover is tightly
sealed!
Refit the cable gland cover at the cable exit with its
two attachment screws.
11
Make sure the cover is tightly
sealed!
Refit the motor cover with its four attachment
screws.
12
Pendulum Calibration is described
in Operating manual - Calibration
Pendulum , enclosed with the calib-
ration tools.
Recalibrate the robot!
13
Axis Calibration is described in
Calibrating 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
295
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.1 Replacement of motor, axis 1
Continued
4.6.2 Replacement of motor axis 2
Location of motor
The motor, axis 2, is located on the left-hand side of the robot as shown in the
figure below.
xx0100000124
Motor, axis 2
A
Cable gland cover, motor axis 2
B
Hole for lock screw
C
Required equipment
Note
Art. no.
Spare part no.
Equipment, etc.
Includes:
•
motor
•
pinion
•
o-ring 2152 2012-430
See Spare part
lists on page 425 .
Motor axis 2
Must be replaced when re-
assembling motor!
21522012-430
O-ring
For lubricating the o-ring.
3HAC042536-001
Grease
M16 x 60
3HAA1001-266
Locking screw
For securing the lower arm.
Always use the removal
tools in pairs!
3HAC14973-1
Removal tool, motor
M12x
For guiding the motor.
Guides are to be used in
pairs!
3HAC15521-1
Guide pins M10 x 100
Continues on next page
296
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.2 Replacement of motor axis 2
Note
Art. no.
Spare part no.
Equipment, etc.
For guiding the motor.
Guides are to be used in
pairs!
3HAC15521-2
Guide pins M10 x 150
3HAC15534-1
Lifting tool, motor ax
2, 3, 4
3HAC12342-1
Extension 300mm for
bits 1/2"
3HAC12342-1
Extension bar, 300
mm for bits 1/2"
24 VDC, 1.5 A
-
Power supply
For releasing the brakes.
Used to rotate the motor
pinion when mating it to the
gear when brakes are re-
leased with 24VDC power
supply.
3HAC17105-1
Rotation tool
Content is defined in sec-
tion Standard tools on
page 419 .
-
Standard toolkit
Complete kit that also in-
cludes operating manual.
3HAC15716-1
Calibration Pendulum
toolkit
Required if Calibration Pen-
dulum is the valid calibra-
tion method for the robot.
Delivered as a set of calibra-
tion tools.
3HAC055412-001
Calibration tool box,
Axis Calibration
Required if Axis Calibration
is the valid calibration
method for the robot.
These procedures include
references to the tools re-
quired.
Other tools and pro-
cedures may be re-
quired. See refer-
ences to these pro-
cedures 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
Continues on next page
Product manual - IRB 7600
297
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.2 Replacement of motor axis 2
Continued
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| 297
|
4.6.2 Replacement of motor axis 2
Location of motor
The motor, axis 2, is located on the left-hand side of the robot as shown in the
figure below.
xx0100000124
Motor, axis 2
A
Cable gland cover, motor axis 2
B
Hole for lock screw
C
Required equipment
Note
Art. no.
Spare part no.
Equipment, etc.
Includes:
•
motor
•
pinion
•
o-ring 2152 2012-430
See Spare part
lists on page 425 .
Motor axis 2
Must be replaced when re-
assembling motor!
21522012-430
O-ring
For lubricating the o-ring.
3HAC042536-001
Grease
M16 x 60
3HAA1001-266
Locking screw
For securing the lower arm.
Always use the removal
tools in pairs!
3HAC14973-1
Removal tool, motor
M12x
For guiding the motor.
Guides are to be used in
pairs!
3HAC15521-1
Guide pins M10 x 100
Continues on next page
296
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.2 Replacement of motor axis 2
Note
Art. no.
Spare part no.
Equipment, etc.
For guiding the motor.
Guides are to be used in
pairs!
3HAC15521-2
Guide pins M10 x 150
3HAC15534-1
Lifting tool, motor ax
2, 3, 4
3HAC12342-1
Extension 300mm for
bits 1/2"
3HAC12342-1
Extension bar, 300
mm for bits 1/2"
24 VDC, 1.5 A
-
Power supply
For releasing the brakes.
Used to rotate the motor
pinion when mating it to the
gear when brakes are re-
leased with 24VDC power
supply.
3HAC17105-1
Rotation tool
Content is defined in sec-
tion Standard tools on
page 419 .
-
Standard toolkit
Complete kit that also in-
cludes operating manual.
3HAC15716-1
Calibration Pendulum
toolkit
Required if Calibration Pen-
dulum is the valid calibra-
tion method for the robot.
Delivered as a set of calibra-
tion tools.
3HAC055412-001
Calibration tool box,
Axis Calibration
Required if Axis Calibration
is the valid calibration
method for the robot.
These procedures include
references to the tools re-
quired.
Other tools and pro-
cedures may be re-
quired. See refer-
ences to these pro-
cedures 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
Continues on next page
Product manual - IRB 7600
297
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.2 Replacement of motor axis 2
Continued
Note
Action
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, motor
The procedure below details how to remove the motor, axis 2.
Note
Action
Decide which calibration routine to
use, and take actions accordingly
prior to beginning the repair proced-
ure.
1
Shown in the figure Location of motor on page296 .
Move the robot to a position close
enough to its calibration position, to
allow the lock screw to be inserted
into the hole for lock screw .
2
DANGER
Turn off all:
•
electric power supply to the
robot
•
hydraulic pressure supply to
the robot
•
air pressure supply to the ro-
bot
Before entering the robot working
area.
3
Art. no. and dimension is specified in Required
equipment on page 296 .
Lock the lower arm by inserting the
lock screw into the hole.
4
Detailed in the section Changing oil, axis-2 gear-
box on page 167 .
Drain the oil from gearbox, axis 2.
5
Remove the cover on top of the mo-
tor by unscrewing its four attach-
ment screws.
6
Shown in the figure Location of motor on page296 .
Remove the cable gland cover at the
cable exit by unscrewing its two at-
tachment screws.
7
Make sure the gasket is not damaged!
Disconnect all connectors beneath
the motor cover.
8
Continues on next page
298
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.2 Replacement of motor axis 2
Continued
|
ABB_IRB7600_Product_Manual.pdf
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| 298
|
Note
Art. no.
Spare part no.
Equipment, etc.
For guiding the motor.
Guides are to be used in
pairs!
3HAC15521-2
Guide pins M10 x 150
3HAC15534-1
Lifting tool, motor ax
2, 3, 4
3HAC12342-1
Extension 300mm for
bits 1/2"
3HAC12342-1
Extension bar, 300
mm for bits 1/2"
24 VDC, 1.5 A
-
Power supply
For releasing the brakes.
Used to rotate the motor
pinion when mating it to the
gear when brakes are re-
leased with 24VDC power
supply.
3HAC17105-1
Rotation tool
Content is defined in sec-
tion Standard tools on
page 419 .
-
Standard toolkit
Complete kit that also in-
cludes operating manual.
3HAC15716-1
Calibration Pendulum
toolkit
Required if Calibration Pen-
dulum is the valid calibra-
tion method for the robot.
Delivered as a set of calibra-
tion tools.
3HAC055412-001
Calibration tool box,
Axis Calibration
Required if Axis Calibration
is the valid calibration
method for the robot.
These procedures include
references to the tools re-
quired.
Other tools and pro-
cedures may be re-
quired. See refer-
ences to these pro-
cedures 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
Continues on next page
Product manual - IRB 7600
297
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.2 Replacement of motor axis 2
Continued
Note
Action
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, motor
The procedure below details how to remove the motor, axis 2.
Note
Action
Decide which calibration routine to
use, and take actions accordingly
prior to beginning the repair proced-
ure.
1
Shown in the figure Location of motor on page296 .
Move the robot to a position close
enough to its calibration position, to
allow the lock screw to be inserted
into the hole for lock screw .
2
DANGER
Turn off all:
•
electric power supply to the
robot
•
hydraulic pressure supply to
the robot
•
air pressure supply to the ro-
bot
Before entering the robot working
area.
3
Art. no. and dimension is specified in Required
equipment on page 296 .
Lock the lower arm by inserting the
lock screw into the hole.
4
Detailed in the section Changing oil, axis-2 gear-
box on page 167 .
Drain the oil from gearbox, axis 2.
5
Remove the cover on top of the mo-
tor by unscrewing its four attach-
ment screws.
6
Shown in the figure Location of motor on page296 .
Remove the cable gland cover at the
cable exit by unscrewing its two at-
tachment screws.
7
Make sure the gasket is not damaged!
Disconnect all connectors beneath
the motor cover.
8
Continues on next page
298
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.2 Replacement of motor axis 2
Continued
Note
Action
Use the lock screw to lock the lower arm, as de-
tailed above!
DANGER
Secure the weight of the lower arm
properly before releasing the brakes
of motor, axis 2!
When releasing the holding brakes
of the motor, the lower arm will be
movable and may fall down!
9
Connect to connector R2.MP2
•
+: pin 2
•
-: pin 5
In order to release the brake, con-
nect the 24 VDC power supply.
10
Remove the motor by unscrewing
its four attachment screws and plain
washers.
11
Art. no. is specified in Required equipment on
page 296 .
Fit the two guide pins in two of the
motor attachment holes.
12
Shown in the figure Location of motor on page296 .
Art. no. is specified in Required equipment on
page 296 .
If required, press the motor out of
position by fitting the removal tool,
motor to the remaining motor attach-
ment holes.
13
Shown in the figure Location of motor on page296 .
Always use the removal tools in pairs!
Art. no. is specified in Required equipment on
page 296 .
Remove the removal tools and fit the
lifting tool, motor axis 2, 3, 4 to the
motor.
14
CAUTION
The motor weighs 32 kg! All lifting
equipment used must be sized ac-
cordingly!
15
Make sure the motor pinion does not get dam-
aged!
Lift the motor to get the pinion away
from the gear.
16
Remove the motor by gently lifting
it straight out and place it on a se-
cure surface. Disconnect the brake
release voltage.
17
Refitting, motor
The procedure below details how to refit the motor axis 2.
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
Continues on next page
Product manual - IRB 7600
299
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.2 Replacement of motor axis 2
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
https://search.abb.com/library/Download.aspx?DocumentID=3HAC022033-001&LanguageCode=en&DocumentPartId=&Action=Launch&DocumentRevisionId=AF
| 299
|
Note
Action
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, motor
The procedure below details how to remove the motor, axis 2.
Note
Action
Decide which calibration routine to
use, and take actions accordingly
prior to beginning the repair proced-
ure.
1
Shown in the figure Location of motor on page296 .
Move the robot to a position close
enough to its calibration position, to
allow the lock screw to be inserted
into the hole for lock screw .
2
DANGER
Turn off all:
•
electric power supply to the
robot
•
hydraulic pressure supply to
the robot
•
air pressure supply to the ro-
bot
Before entering the robot working
area.
3
Art. no. and dimension is specified in Required
equipment on page 296 .
Lock the lower arm by inserting the
lock screw into the hole.
4
Detailed in the section Changing oil, axis-2 gear-
box on page 167 .
Drain the oil from gearbox, axis 2.
5
Remove the cover on top of the mo-
tor by unscrewing its four attach-
ment screws.
6
Shown in the figure Location of motor on page296 .
Remove the cable gland cover at the
cable exit by unscrewing its two at-
tachment screws.
7
Make sure the gasket is not damaged!
Disconnect all connectors beneath
the motor cover.
8
Continues on next page
298
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.2 Replacement of motor axis 2
Continued
Note
Action
Use the lock screw to lock the lower arm, as de-
tailed above!
DANGER
Secure the weight of the lower arm
properly before releasing the brakes
of motor, axis 2!
When releasing the holding brakes
of the motor, the lower arm will be
movable and may fall down!
9
Connect to connector R2.MP2
•
+: pin 2
•
-: pin 5
In order to release the brake, con-
nect the 24 VDC power supply.
10
Remove the motor by unscrewing
its four attachment screws and plain
washers.
11
Art. no. is specified in Required equipment on
page 296 .
Fit the two guide pins in two of the
motor attachment holes.
12
Shown in the figure Location of motor on page296 .
Art. no. is specified in Required equipment on
page 296 .
If required, press the motor out of
position by fitting the removal tool,
motor to the remaining motor attach-
ment holes.
13
Shown in the figure Location of motor on page296 .
Always use the removal tools in pairs!
Art. no. is specified in Required equipment on
page 296 .
Remove the removal tools and fit the
lifting tool, motor axis 2, 3, 4 to the
motor.
14
CAUTION
The motor weighs 32 kg! All lifting
equipment used must be sized ac-
cordingly!
15
Make sure the motor pinion does not get dam-
aged!
Lift the motor to get the pinion away
from the gear.
16
Remove the motor by gently lifting
it straight out and place it on a se-
cure surface. Disconnect the brake
release voltage.
17
Refitting, motor
The procedure below details how to refit the motor axis 2.
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
Continues on next page
Product manual - IRB 7600
299
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.2 Replacement of motor axis 2
Continued
Note
Action
Art. no. is specified in Required equip-
ment on page 296 .
Make sure the o-ring on the circumference
of the motor is seated properly. Lightly lubric-
ate the o-ring with grease.
2
Tightening torque, transparent plug: 25
Nm ±10%.
Foundry Plus :
If the motor is a new spare part, the evacu-
ation hole protection filter must be replaced
with a transparent plug/sight glass (enclosed
with the spare part delivery). Remove the
protection filter and install the transparent
plug/sight glass.
![Image]
xx1800000102
Transparent plug
(Foundry Plus).
![Image]
xx1800000101
Protection filter
(Standard).
3
Tightening torque, protection filter: 10
Nm ±10%.
![Image]
xx1600000576
Connect to connector R2.MP2
•
+: pin 2
•
-: pin 5
In order to release the brake, remove the
cover on top of the motor and connect the 24
VDC power supply.
4
Art. no. is specified in Required equip-
ment on page 296 .
Fit the lifting tool, motor axis 2, 3, 4 to the
motor.
5
Art. no. is specified in Required equip-
ment on page 296 .
Fit the two guide pins in the two lower motor
attachment holes.
6
Shown in the figure Location of motor
on page 296 .
CAUTION
The motor weighs 32 kg! All lifting equipment
used must be sized accordingly!
7
Lift the motor and guide it onto the guide pins,
as close to the correct position as possible
without pushing the motor pinion into the
gear.
8
Make sure that the motor is turned the right
direction, that is the cables facing downwards.
Remove the lifting tool and allow the motor
to rest on the guide pins.
9
Continues on next page
300
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.2 Replacement of motor axis 2
Continued
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ABB_IRB7600_Product_Manual.pdf
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| 300
|
Note
Action
Use the lock screw to lock the lower arm, as de-
tailed above!
DANGER
Secure the weight of the lower arm
properly before releasing the brakes
of motor, axis 2!
When releasing the holding brakes
of the motor, the lower arm will be
movable and may fall down!
9
Connect to connector R2.MP2
•
+: pin 2
•
-: pin 5
In order to release the brake, con-
nect the 24 VDC power supply.
10
Remove the motor by unscrewing
its four attachment screws and plain
washers.
11
Art. no. is specified in Required equipment on
page 296 .
Fit the two guide pins in two of the
motor attachment holes.
12
Shown in the figure Location of motor on page296 .
Art. no. is specified in Required equipment on
page 296 .
If required, press the motor out of
position by fitting the removal tool,
motor to the remaining motor attach-
ment holes.
13
Shown in the figure Location of motor on page296 .
Always use the removal tools in pairs!
Art. no. is specified in Required equipment on
page 296 .
Remove the removal tools and fit the
lifting tool, motor axis 2, 3, 4 to the
motor.
14
CAUTION
The motor weighs 32 kg! All lifting
equipment used must be sized ac-
cordingly!
15
Make sure the motor pinion does not get dam-
aged!
Lift the motor to get the pinion away
from the gear.
16
Remove the motor by gently lifting
it straight out and place it on a se-
cure surface. Disconnect the brake
release voltage.
17
Refitting, motor
The procedure below details how to refit the motor axis 2.
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
Continues on next page
Product manual - IRB 7600
299
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.2 Replacement of motor axis 2
Continued
Note
Action
Art. no. is specified in Required equip-
ment on page 296 .
Make sure the o-ring on the circumference
of the motor is seated properly. Lightly lubric-
ate the o-ring with grease.
2
Tightening torque, transparent plug: 25
Nm ±10%.
Foundry Plus :
If the motor is a new spare part, the evacu-
ation hole protection filter must be replaced
with a transparent plug/sight glass (enclosed
with the spare part delivery). Remove the
protection filter and install the transparent
plug/sight glass.
![Image]
xx1800000102
Transparent plug
(Foundry Plus).
![Image]
xx1800000101
Protection filter
(Standard).
3
Tightening torque, protection filter: 10
Nm ±10%.
![Image]
xx1600000576
Connect to connector R2.MP2
•
+: pin 2
•
-: pin 5
In order to release the brake, remove the
cover on top of the motor and connect the 24
VDC power supply.
4
Art. no. is specified in Required equip-
ment on page 296 .
Fit the lifting tool, motor axis 2, 3, 4 to the
motor.
5
Art. no. is specified in Required equip-
ment on page 296 .
Fit the two guide pins in the two lower motor
attachment holes.
6
Shown in the figure Location of motor
on page 296 .
CAUTION
The motor weighs 32 kg! All lifting equipment
used must be sized accordingly!
7
Lift the motor and guide it onto the guide pins,
as close to the correct position as possible
without pushing the motor pinion into the
gear.
8
Make sure that the motor is turned the right
direction, that is the cables facing downwards.
Remove the lifting tool and allow the motor
to rest on the guide pins.
9
Continues on next page
300
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.2 Replacement of motor axis 2
Continued
Note
Action
Art. no. is specified in Required equip-
ment on page 296 .
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
xx0200000165
Use the rotation tool in order to rotate the
motor pinion when mating it to the gear (see
the figure to the right). Fit the motor, making
sure the motor pinion is properly mated to
the gear of gearbox axis 2 and that it does
not get damaged.
10
The rotation tool is used beneath the
motor cover, directly on the motor shaft
as shown in the figure above.
•
A: Rotation tool
Remove the guide pins.
11
M10 x 40, tightening torque: 50 Nm.
Secure the motor with four attachment screws
and plain washers.
12
Reused screws may be used, providing
they are lubricated as detailed in section
Screw joints on page 415 before fitting.
If required, use the extension 300mm for bits
1/2" .
Disconnect the brake release voltage.
13
Connect in accordance with markings
on connectors.
Reconnect all connectors beneath the motor
cover.
14
Shown in the figure Location of motor
on page 296 .
Refit the cable gland cover at the cable exit
with its two attachment screws.
15
Make sure the cover is tightly sealed!
Refit the cover on top of the motor with its
four attachment screws.
16
Shown in the figure Location of motor
on page 296 .
Remove the lock screw from the hole for lock
screw.
17
Detailed in Performing a leak-down test
on page 206 .
Perform a leak down test.
18
Detailed in the section Changing oil,
axis-2 gearbox on page 167 .
Refill the gearbox with oil.
19
Pendulum Calibration is described in
Operating manual - Calibration Pendu-
lum , enclosed with the calibration tools.
Recalibrate the robot.
20
Axis Calibration is described in Calibrat-
ing with Axis Calibration method on
page 383 .
General calibration information is in-
cluded in section Calibration on
page 371 .
DANGER
Make sure all safety requirements are met
when performing the first test run.
21
Product manual - IRB 7600
301
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.2 Replacement of motor axis 2
Continued
|
ABB_IRB7600_Product_Manual.pdf
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| 301
|
Note
Action
Art. no. is specified in Required equip-
ment on page 296 .
Make sure the o-ring on the circumference
of the motor is seated properly. Lightly lubric-
ate the o-ring with grease.
2
Tightening torque, transparent plug: 25
Nm ±10%.
Foundry Plus :
If the motor is a new spare part, the evacu-
ation hole protection filter must be replaced
with a transparent plug/sight glass (enclosed
with the spare part delivery). Remove the
protection filter and install the transparent
plug/sight glass.
![Image]
xx1800000102
Transparent plug
(Foundry Plus).
![Image]
xx1800000101
Protection filter
(Standard).
3
Tightening torque, protection filter: 10
Nm ±10%.
![Image]
xx1600000576
Connect to connector R2.MP2
•
+: pin 2
•
-: pin 5
In order to release the brake, remove the
cover on top of the motor and connect the 24
VDC power supply.
4
Art. no. is specified in Required equip-
ment on page 296 .
Fit the lifting tool, motor axis 2, 3, 4 to the
motor.
5
Art. no. is specified in Required equip-
ment on page 296 .
Fit the two guide pins in the two lower motor
attachment holes.
6
Shown in the figure Location of motor
on page 296 .
CAUTION
The motor weighs 32 kg! All lifting equipment
used must be sized accordingly!
7
Lift the motor and guide it onto the guide pins,
as close to the correct position as possible
without pushing the motor pinion into the
gear.
8
Make sure that the motor is turned the right
direction, that is the cables facing downwards.
Remove the lifting tool and allow the motor
to rest on the guide pins.
9
Continues on next page
300
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.2 Replacement of motor axis 2
Continued
Note
Action
Art. no. is specified in Required equip-
ment on page 296 .
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
xx0200000165
Use the rotation tool in order to rotate the
motor pinion when mating it to the gear (see
the figure to the right). Fit the motor, making
sure the motor pinion is properly mated to
the gear of gearbox axis 2 and that it does
not get damaged.
10
The rotation tool is used beneath the
motor cover, directly on the motor shaft
as shown in the figure above.
•
A: Rotation tool
Remove the guide pins.
11
M10 x 40, tightening torque: 50 Nm.
Secure the motor with four attachment screws
and plain washers.
12
Reused screws may be used, providing
they are lubricated as detailed in section
Screw joints on page 415 before fitting.
If required, use the extension 300mm for bits
1/2" .
Disconnect the brake release voltage.
13
Connect in accordance with markings
on connectors.
Reconnect all connectors beneath the motor
cover.
14
Shown in the figure Location of motor
on page 296 .
Refit the cable gland cover at the cable exit
with its two attachment screws.
15
Make sure the cover is tightly sealed!
Refit the cover on top of the motor with its
four attachment screws.
16
Shown in the figure Location of motor
on page 296 .
Remove the lock screw from the hole for lock
screw.
17
Detailed in Performing a leak-down test
on page 206 .
Perform a leak down test.
18
Detailed in the section Changing oil,
axis-2 gearbox on page 167 .
Refill the gearbox with oil.
19
Pendulum Calibration is described in
Operating manual - Calibration Pendu-
lum , enclosed with the calibration tools.
Recalibrate the robot.
20
Axis Calibration is described in Calibrat-
ing with Axis Calibration method on
page 383 .
General calibration information is in-
cluded in section Calibration on
page 371 .
DANGER
Make sure all safety requirements are met
when performing the first test run.
21
Product manual - IRB 7600
301
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.2 Replacement of motor axis 2
Continued
4.6.3 Replacement of motor, axis 3
Location of motor
The motor axis 3 is located on the left hand side of the robot as shown in the figure
below.
xx0200000186
Motor axis 3
A
Cable gland cover, motor axis 3
B
Motor attachment holes (4 pcs)
C
Required equipment
Note
Art. no.
Spare part no.
Equipment, etc.
Includes:
•
motor
•
pinion
•
o-ring 21522012-430.
See Spare part lists
on page 425 .
Motor, axis 3
Must be replaced when reas-
sembling motor!
21522012-430
O-ring
May be used to fix axis 3.
3HAC12708-2
Mechanical stop
axis 3
Use attachment screws 3HAB
3409-86 (M16 x 60).
For lubricating the o-ring.
3HAC042536-001
Grease
Always use the removal tools
in pairs!
3HAC14973-1
Removal tool, mo-
tor M12x
Continues on next page
302
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.3 Replacement of motor, axis 3
|
ABB_IRB7600_Product_Manual.pdf
|
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| 302
|
Note
Action
Art. no. is specified in Required equip-
ment on page 296 .
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
xx0200000165
Use the rotation tool in order to rotate the
motor pinion when mating it to the gear (see
the figure to the right). Fit the motor, making
sure the motor pinion is properly mated to
the gear of gearbox axis 2 and that it does
not get damaged.
10
The rotation tool is used beneath the
motor cover, directly on the motor shaft
as shown in the figure above.
•
A: Rotation tool
Remove the guide pins.
11
M10 x 40, tightening torque: 50 Nm.
Secure the motor with four attachment screws
and plain washers.
12
Reused screws may be used, providing
they are lubricated as detailed in section
Screw joints on page 415 before fitting.
If required, use the extension 300mm for bits
1/2" .
Disconnect the brake release voltage.
13
Connect in accordance with markings
on connectors.
Reconnect all connectors beneath the motor
cover.
14
Shown in the figure Location of motor
on page 296 .
Refit the cable gland cover at the cable exit
with its two attachment screws.
15
Make sure the cover is tightly sealed!
Refit the cover on top of the motor with its
four attachment screws.
16
Shown in the figure Location of motor
on page 296 .
Remove the lock screw from the hole for lock
screw.
17
Detailed in Performing a leak-down test
on page 206 .
Perform a leak down test.
18
Detailed in the section Changing oil,
axis-2 gearbox on page 167 .
Refill the gearbox with oil.
19
Pendulum Calibration is described in
Operating manual - Calibration Pendu-
lum , enclosed with the calibration tools.
Recalibrate the robot.
20
Axis Calibration is described in Calibrat-
ing with Axis Calibration method on
page 383 .
General calibration information is in-
cluded in section Calibration on
page 371 .
DANGER
Make sure all safety requirements are met
when performing the first test run.
21
Product manual - IRB 7600
301
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.2 Replacement of motor axis 2
Continued
4.6.3 Replacement of motor, axis 3
Location of motor
The motor axis 3 is located on the left hand side of the robot as shown in the figure
below.
xx0200000186
Motor axis 3
A
Cable gland cover, motor axis 3
B
Motor attachment holes (4 pcs)
C
Required equipment
Note
Art. no.
Spare part no.
Equipment, etc.
Includes:
•
motor
•
pinion
•
o-ring 21522012-430.
See Spare part lists
on page 425 .
Motor, axis 3
Must be replaced when reas-
sembling motor!
21522012-430
O-ring
May be used to fix axis 3.
3HAC12708-2
Mechanical stop
axis 3
Use attachment screws 3HAB
3409-86 (M16 x 60).
For lubricating the o-ring.
3HAC042536-001
Grease
Always use the removal tools
in pairs!
3HAC14973-1
Removal tool, mo-
tor M12x
Continues on next page
302
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.3 Replacement of motor, axis 3
Note
Art. no.
Spare part no.
Equipment, etc.
3HAC15534-1
Lifting tool, motor
ax 2, 3, 4
3HAB3409-86
Bolts M16x60
(for mechanical
stop axis 3)
3HAA1001-186
Washers (for
mechanical stop
axis 3)
For guiding the motor.
3HAC15521-1
Guide pins M10 x
100
For guiding the motor.
3HAC15521-2
Guide pins M10 x
150
3HAC12342-1
Extension 300mm
for bits 1/2"
Used to rotate the motor pin-
ion when mating it to the gear
when brakes are released with
24 VDC power supply.
3HAC17105-1
Rotation tool
24 VDC, max. 1.5 A
-
Power supply
For releasing the brakes.
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Complete kit that also includes
operating manual.
3HAC15716-1
Calibration Pendu-
lum toolkit
Required if Calibration Pendu-
lum is the valid calibration
method for the robot.
Delivered as a set of calibra-
tion tools.
3HAC055412-001
Calibration tool
box, Axis Calibra-
tion
Required if Axis Calibration is
the valid calibration method
for the robot.
These procedures include ref-
erences to the tools required.
Other tools and
procedures may be
required. See refer-
ences to these pro-
cedures in the
step-by-step in-
structions below.
See chapter Circuit diagram
on page 427 .
Circuit diagram
Continues on next page
Product manual - IRB 7600
303
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.3 Replacement of motor, axis 3
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 303
|
4.6.3 Replacement of motor, axis 3
Location of motor
The motor axis 3 is located on the left hand side of the robot as shown in the figure
below.
xx0200000186
Motor axis 3
A
Cable gland cover, motor axis 3
B
Motor attachment holes (4 pcs)
C
Required equipment
Note
Art. no.
Spare part no.
Equipment, etc.
Includes:
•
motor
•
pinion
•
o-ring 21522012-430.
See Spare part lists
on page 425 .
Motor, axis 3
Must be replaced when reas-
sembling motor!
21522012-430
O-ring
May be used to fix axis 3.
3HAC12708-2
Mechanical stop
axis 3
Use attachment screws 3HAB
3409-86 (M16 x 60).
For lubricating the o-ring.
3HAC042536-001
Grease
Always use the removal tools
in pairs!
3HAC14973-1
Removal tool, mo-
tor M12x
Continues on next page
302
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.3 Replacement of motor, axis 3
Note
Art. no.
Spare part no.
Equipment, etc.
3HAC15534-1
Lifting tool, motor
ax 2, 3, 4
3HAB3409-86
Bolts M16x60
(for mechanical
stop axis 3)
3HAA1001-186
Washers (for
mechanical stop
axis 3)
For guiding the motor.
3HAC15521-1
Guide pins M10 x
100
For guiding the motor.
3HAC15521-2
Guide pins M10 x
150
3HAC12342-1
Extension 300mm
for bits 1/2"
Used to rotate the motor pin-
ion when mating it to the gear
when brakes are released with
24 VDC power supply.
3HAC17105-1
Rotation tool
24 VDC, max. 1.5 A
-
Power supply
For releasing the brakes.
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Complete kit that also includes
operating manual.
3HAC15716-1
Calibration Pendu-
lum toolkit
Required if Calibration Pendu-
lum is the valid calibration
method for the robot.
Delivered as a set of calibra-
tion tools.
3HAC055412-001
Calibration tool
box, Axis Calibra-
tion
Required if Axis Calibration is
the valid calibration method
for the robot.
These procedures include ref-
erences to the tools required.
Other tools and
procedures may be
required. See refer-
ences to these pro-
cedures in the
step-by-step in-
structions below.
See chapter Circuit diagram
on page 427 .
Circuit diagram
Continues on next page
Product manual - IRB 7600
303
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.3 Replacement of motor, axis 3
Continued
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, motor
The procedure below details how to remove motor, axis 3.
Note
Action
Decide which calibration routine to
use, and take actions accordingly
prior to beginning the repair proced-
ure.
1
xx0300000051
Unload the upper arm of the robot
by either:
•
Move the robot to a position
where the turning disk rests
against the foundation (re-
commended).
•
Use a fork lift to rest the up-
per arm onto.
•
Use lifting slings and an
overhead crane to rest the
upper arm.
•
Use a mechanical stop to rest
the upper arm. Fit the mech-
anical stop in the attachment
hole (A) with tightening
torque: 115 Nm.
2
Fit the mechanical stop to the third and final attach-
ment hole (A), below the fixed stop (B) in the upper
arm. See the figure above!
Continues on next page
304
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.3 Replacement of motor, axis 3
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
https://search.abb.com/library/Download.aspx?DocumentID=3HAC022033-001&LanguageCode=en&DocumentPartId=&Action=Launch&DocumentRevisionId=AF
| 304
|
Note
Art. no.
Spare part no.
Equipment, etc.
3HAC15534-1
Lifting tool, motor
ax 2, 3, 4
3HAB3409-86
Bolts M16x60
(for mechanical
stop axis 3)
3HAA1001-186
Washers (for
mechanical stop
axis 3)
For guiding the motor.
3HAC15521-1
Guide pins M10 x
100
For guiding the motor.
3HAC15521-2
Guide pins M10 x
150
3HAC12342-1
Extension 300mm
for bits 1/2"
Used to rotate the motor pin-
ion when mating it to the gear
when brakes are released with
24 VDC power supply.
3HAC17105-1
Rotation tool
24 VDC, max. 1.5 A
-
Power supply
For releasing the brakes.
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Complete kit that also includes
operating manual.
3HAC15716-1
Calibration Pendu-
lum toolkit
Required if Calibration Pendu-
lum is the valid calibration
method for the robot.
Delivered as a set of calibra-
tion tools.
3HAC055412-001
Calibration tool
box, Axis Calibra-
tion
Required if Axis Calibration is
the valid calibration method
for the robot.
These procedures include ref-
erences to the tools required.
Other tools and
procedures may be
required. See refer-
ences to these pro-
cedures in the
step-by-step in-
structions below.
See chapter Circuit diagram
on page 427 .
Circuit diagram
Continues on next page
Product manual - IRB 7600
303
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.3 Replacement of motor, axis 3
Continued
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, motor
The procedure below details how to remove motor, axis 3.
Note
Action
Decide which calibration routine to
use, and take actions accordingly
prior to beginning the repair proced-
ure.
1
xx0300000051
Unload the upper arm of the robot
by either:
•
Move the robot to a position
where the turning disk rests
against the foundation (re-
commended).
•
Use a fork lift to rest the up-
per arm onto.
•
Use lifting slings and an
overhead crane to rest the
upper arm.
•
Use a mechanical stop to rest
the upper arm. Fit the mech-
anical stop in the attachment
hole (A) with tightening
torque: 115 Nm.
2
Fit the mechanical stop to the third and final attach-
ment hole (A), below the fixed stop (B) in the upper
arm. See the figure above!
Continues on next page
304
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.3 Replacement of motor, axis 3
Continued
Note
Action
DANGER
Turn off all:
•
electric power supply to the
robot
•
hydraulic pressure supply to
the robot
•
air pressure supply to the ro-
bot
Before entering the robot working
area.
3
Detailed in section Changing oil, axis-3 gearbox
on page 170 .
Drain the oil from gearbox axis 3.
4
Remove any equipment hindering
access to motor axis 3.
5
Remove the cover on top of the
motor by unscrewing its four attach-
ment screws.
6
Shown in the figure Location of motor on page302 .
Remove the cable gland cover at
the cable exit by unscrewing its two
securing screws.
7
Make sure the gasket is not damaged!
Disconnect all connectors beneath
the motor cover.
8
Shown in the figure Location of motor on page302 .
Unscrew the motors four attachment
screws and plain washers .
9
Art. no. is specified in Required equipment on
page 302 .
Fit the two guide pins in two of the
motor attachment screw holes.
10
Art. no. is specified in Required equipment on
page 302 .
Press the motor out of position by
fitting removal tool, motor to the re-
maining motor attachment screw
holes.
11
Always use the removal tools in pairs!
Art. no. is specified in Required equipment on
page 302 .
Apply the lifting tool, motor axis 2
,3, 4 to the motor.
12
CAUTION
The motor weighs 32 kg! All lifting
equipment used must be sized ac-
cordingly!
13
Lift the motor to get the pinion away
from the gear.
14
Make sure the motor pinion is not damaged!
Remove the motor by gently lifting
it straight out and disconnect the
brake release voltage.
15
Continues on next page
Product manual - IRB 7600
305
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.3 Replacement of motor, axis 3
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 305
|
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, motor
The procedure below details how to remove motor, axis 3.
Note
Action
Decide which calibration routine to
use, and take actions accordingly
prior to beginning the repair proced-
ure.
1
xx0300000051
Unload the upper arm of the robot
by either:
•
Move the robot to a position
where the turning disk rests
against the foundation (re-
commended).
•
Use a fork lift to rest the up-
per arm onto.
•
Use lifting slings and an
overhead crane to rest the
upper arm.
•
Use a mechanical stop to rest
the upper arm. Fit the mech-
anical stop in the attachment
hole (A) with tightening
torque: 115 Nm.
2
Fit the mechanical stop to the third and final attach-
ment hole (A), below the fixed stop (B) in the upper
arm. See the figure above!
Continues on next page
304
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.3 Replacement of motor, axis 3
Continued
Note
Action
DANGER
Turn off all:
•
electric power supply to the
robot
•
hydraulic pressure supply to
the robot
•
air pressure supply to the ro-
bot
Before entering the robot working
area.
3
Detailed in section Changing oil, axis-3 gearbox
on page 170 .
Drain the oil from gearbox axis 3.
4
Remove any equipment hindering
access to motor axis 3.
5
Remove the cover on top of the
motor by unscrewing its four attach-
ment screws.
6
Shown in the figure Location of motor on page302 .
Remove the cable gland cover at
the cable exit by unscrewing its two
securing screws.
7
Make sure the gasket is not damaged!
Disconnect all connectors beneath
the motor cover.
8
Shown in the figure Location of motor on page302 .
Unscrew the motors four attachment
screws and plain washers .
9
Art. no. is specified in Required equipment on
page 302 .
Fit the two guide pins in two of the
motor attachment screw holes.
10
Art. no. is specified in Required equipment on
page 302 .
Press the motor out of position by
fitting removal tool, motor to the re-
maining motor attachment screw
holes.
11
Always use the removal tools in pairs!
Art. no. is specified in Required equipment on
page 302 .
Apply the lifting tool, motor axis 2
,3, 4 to the motor.
12
CAUTION
The motor weighs 32 kg! All lifting
equipment used must be sized ac-
cordingly!
13
Lift the motor to get the pinion away
from the gear.
14
Make sure the motor pinion is not damaged!
Remove the motor by gently lifting
it straight out and disconnect the
brake release voltage.
15
Continues on next page
Product manual - IRB 7600
305
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.3 Replacement of motor, axis 3
Continued
Refitting, motor
The procedure below details how to refit motor, axis 3.
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
Art no. is specified in Required
equipment on page 302 .
Make sure the o-ring on the circumference of the
motor is seated properly. Lightly lubricate it with
grease .
2
Tightening torque, transparent plug:
25 Nm ±10%.
Foundry Plus :
If the motor is a new spare part, the evacuation
hole protection filter must be replaced with a
transparent plug/sight glass (enclosed with the
spare part delivery). Remove the protection filter
and install the transparent plug/sight glass.
![Image]
xx1800000102
Transparent plug
(Foundry Plus).
![Image]
xx1800000101
Protection filter
(Standard).
3
Tightening torque, protection filter:
10 Nm ±10%.
![Image]
xx1600000576
Art no. is specified in Required
equipment on page 302 .
Fit the lifting tool, motor axis 2, 3, 4 to the motor.
4
Art no. is specified in Required
equipment on page 302 .
Fit the two guide pins in the two lower motor at-
tachment holes.
5
Shown in the figure Location of mo-
tor on page 302
CAUTION
The motor weighs 32 kg! All lifting equipment
used must be sized accordingly!
6
Lift the motor and guide it onto the guide pins, as
close to the correct position as possible without
pushing the motor pinion into the gear.
7
Remove the lifting tool and allow the motor to stay
on the guide pins.
8
Connect to connector R2.MP3
•
+: pin 2
•
-: pin 5
In order to release the brake, connect the 24 VDC
power supply.
9
Continues on next page
306
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.3 Replacement of motor, axis 3
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 306
|
Note
Action
DANGER
Turn off all:
•
electric power supply to the
robot
•
hydraulic pressure supply to
the robot
•
air pressure supply to the ro-
bot
Before entering the robot working
area.
3
Detailed in section Changing oil, axis-3 gearbox
on page 170 .
Drain the oil from gearbox axis 3.
4
Remove any equipment hindering
access to motor axis 3.
5
Remove the cover on top of the
motor by unscrewing its four attach-
ment screws.
6
Shown in the figure Location of motor on page302 .
Remove the cable gland cover at
the cable exit by unscrewing its two
securing screws.
7
Make sure the gasket is not damaged!
Disconnect all connectors beneath
the motor cover.
8
Shown in the figure Location of motor on page302 .
Unscrew the motors four attachment
screws and plain washers .
9
Art. no. is specified in Required equipment on
page 302 .
Fit the two guide pins in two of the
motor attachment screw holes.
10
Art. no. is specified in Required equipment on
page 302 .
Press the motor out of position by
fitting removal tool, motor to the re-
maining motor attachment screw
holes.
11
Always use the removal tools in pairs!
Art. no. is specified in Required equipment on
page 302 .
Apply the lifting tool, motor axis 2
,3, 4 to the motor.
12
CAUTION
The motor weighs 32 kg! All lifting
equipment used must be sized ac-
cordingly!
13
Lift the motor to get the pinion away
from the gear.
14
Make sure the motor pinion is not damaged!
Remove the motor by gently lifting
it straight out and disconnect the
brake release voltage.
15
Continues on next page
Product manual - IRB 7600
305
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.3 Replacement of motor, axis 3
Continued
Refitting, motor
The procedure below details how to refit motor, axis 3.
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
Art no. is specified in Required
equipment on page 302 .
Make sure the o-ring on the circumference of the
motor is seated properly. Lightly lubricate it with
grease .
2
Tightening torque, transparent plug:
25 Nm ±10%.
Foundry Plus :
If the motor is a new spare part, the evacuation
hole protection filter must be replaced with a
transparent plug/sight glass (enclosed with the
spare part delivery). Remove the protection filter
and install the transparent plug/sight glass.
![Image]
xx1800000102
Transparent plug
(Foundry Plus).
![Image]
xx1800000101
Protection filter
(Standard).
3
Tightening torque, protection filter:
10 Nm ±10%.
![Image]
xx1600000576
Art no. is specified in Required
equipment on page 302 .
Fit the lifting tool, motor axis 2, 3, 4 to the motor.
4
Art no. is specified in Required
equipment on page 302 .
Fit the two guide pins in the two lower motor at-
tachment holes.
5
Shown in the figure Location of mo-
tor on page 302
CAUTION
The motor weighs 32 kg! All lifting equipment
used must be sized accordingly!
6
Lift the motor and guide it onto the guide pins, as
close to the correct position as possible without
pushing the motor pinion into the gear.
7
Remove the lifting tool and allow the motor to stay
on the guide pins.
8
Connect to connector R2.MP3
•
+: pin 2
•
-: pin 5
In order to release the brake, connect the 24 VDC
power supply.
9
Continues on next page
306
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.3 Replacement of motor, axis 3
Continued
Note
Action
Art no. is specified in Required
equipment on page 302 .
Use the rotation tool in order to rotate the motor
pinion when mating it to the gear!
Fit the motor, making sure the motor pinion is
properly mated to the gear of gearbox, axis 3.
10
Make sure the motor pinion does
not get damaged!
Make sure the motor is turned the
right direction, that is the cables fa-
cing forwards.
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
xx0200000165
The rotation tool is used beneath
the motor cover, directly on the mo-
tor shaft as shown in figure above.
•
A: Rotation tool.
Remove the guide pins.
11
4 pcs: M10 x 40, tightening torque:
50 Nm.
Secure the motor with four attachment screws
and plain washers.
12
Art. no. is specified in Required
equipment on page 302 .
If required, use the extension 300mm for bits 1/2" .
Disconnect the brake release voltage.
13
Connect in accordance with mark-
ings on connectors.
Reconnect all connectors beneath the motor
cover.
14
Make sure the cover is tightly
sealed!
Refit the cable gland cover at the cable exit with
its two attachment screws.
15
Shown in the figure Location of mo-
tor on page 302 .
Make sure the cover is tightly
sealed!
Refit the cover on top of the motor with its four
attachment screws.
16
Remove the equipment used to unload the upper
arm.
17
Detailed in the section Performing
a leak-down test on page 206 .
Perform a leak-down test.
18
Detailed in the section Changing oil,
axis-3 gearbox on page 170 .
Refill the gearbox with oil.
19
Pendulum Calibration is described
in Operating manual - Calibration
Pendulum , enclosed with the calib-
ration tools.
Recalibrate the robot!
20
Axis Calibration is described in Cal-
ibrating with Axis Calibration meth-
od on page 383 .
General calibration information is
included in section Calibration on
page 371 .
Continues on next page
Product manual - IRB 7600
307
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.3 Replacement of motor, axis 3
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 307
|
Refitting, motor
The procedure below details how to refit motor, axis 3.
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
Art no. is specified in Required
equipment on page 302 .
Make sure the o-ring on the circumference of the
motor is seated properly. Lightly lubricate it with
grease .
2
Tightening torque, transparent plug:
25 Nm ±10%.
Foundry Plus :
If the motor is a new spare part, the evacuation
hole protection filter must be replaced with a
transparent plug/sight glass (enclosed with the
spare part delivery). Remove the protection filter
and install the transparent plug/sight glass.
![Image]
xx1800000102
Transparent plug
(Foundry Plus).
![Image]
xx1800000101
Protection filter
(Standard).
3
Tightening torque, protection filter:
10 Nm ±10%.
![Image]
xx1600000576
Art no. is specified in Required
equipment on page 302 .
Fit the lifting tool, motor axis 2, 3, 4 to the motor.
4
Art no. is specified in Required
equipment on page 302 .
Fit the two guide pins in the two lower motor at-
tachment holes.
5
Shown in the figure Location of mo-
tor on page 302
CAUTION
The motor weighs 32 kg! All lifting equipment
used must be sized accordingly!
6
Lift the motor and guide it onto the guide pins, as
close to the correct position as possible without
pushing the motor pinion into the gear.
7
Remove the lifting tool and allow the motor to stay
on the guide pins.
8
Connect to connector R2.MP3
•
+: pin 2
•
-: pin 5
In order to release the brake, connect the 24 VDC
power supply.
9
Continues on next page
306
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.3 Replacement of motor, axis 3
Continued
Note
Action
Art no. is specified in Required
equipment on page 302 .
Use the rotation tool in order to rotate the motor
pinion when mating it to the gear!
Fit the motor, making sure the motor pinion is
properly mated to the gear of gearbox, axis 3.
10
Make sure the motor pinion does
not get damaged!
Make sure the motor is turned the
right direction, that is the cables fa-
cing forwards.
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
xx0200000165
The rotation tool is used beneath
the motor cover, directly on the mo-
tor shaft as shown in figure above.
•
A: Rotation tool.
Remove the guide pins.
11
4 pcs: M10 x 40, tightening torque:
50 Nm.
Secure the motor with four attachment screws
and plain washers.
12
Art. no. is specified in Required
equipment on page 302 .
If required, use the extension 300mm for bits 1/2" .
Disconnect the brake release voltage.
13
Connect in accordance with mark-
ings on connectors.
Reconnect all connectors beneath the motor
cover.
14
Make sure the cover is tightly
sealed!
Refit the cable gland cover at the cable exit with
its two attachment screws.
15
Shown in the figure Location of mo-
tor on page 302 .
Make sure the cover is tightly
sealed!
Refit the cover on top of the motor with its four
attachment screws.
16
Remove the equipment used to unload the upper
arm.
17
Detailed in the section Performing
a leak-down test on page 206 .
Perform a leak-down test.
18
Detailed in the section Changing oil,
axis-3 gearbox on page 170 .
Refill the gearbox with oil.
19
Pendulum Calibration is described
in Operating manual - Calibration
Pendulum , enclosed with the calib-
ration tools.
Recalibrate the robot!
20
Axis Calibration is described in Cal-
ibrating with Axis Calibration meth-
od on page 383 .
General calibration information is
included in section Calibration on
page 371 .
Continues on next page
Product manual - IRB 7600
307
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.3 Replacement of motor, axis 3
Continued
Note
Action
DANGER
Make sure all safety requirements are met when
performing the first test run.
21
308
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.3 Replacement of motor, axis 3
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 308
|
Note
Action
Art no. is specified in Required
equipment on page 302 .
Use the rotation tool in order to rotate the motor
pinion when mating it to the gear!
Fit the motor, making sure the motor pinion is
properly mated to the gear of gearbox, axis 3.
10
Make sure the motor pinion does
not get damaged!
Make sure the motor is turned the
right direction, that is the cables fa-
cing forwards.
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
xx0200000165
The rotation tool is used beneath
the motor cover, directly on the mo-
tor shaft as shown in figure above.
•
A: Rotation tool.
Remove the guide pins.
11
4 pcs: M10 x 40, tightening torque:
50 Nm.
Secure the motor with four attachment screws
and plain washers.
12
Art. no. is specified in Required
equipment on page 302 .
If required, use the extension 300mm for bits 1/2" .
Disconnect the brake release voltage.
13
Connect in accordance with mark-
ings on connectors.
Reconnect all connectors beneath the motor
cover.
14
Make sure the cover is tightly
sealed!
Refit the cable gland cover at the cable exit with
its two attachment screws.
15
Shown in the figure Location of mo-
tor on page 302 .
Make sure the cover is tightly
sealed!
Refit the cover on top of the motor with its four
attachment screws.
16
Remove the equipment used to unload the upper
arm.
17
Detailed in the section Performing
a leak-down test on page 206 .
Perform a leak-down test.
18
Detailed in the section Changing oil,
axis-3 gearbox on page 170 .
Refill the gearbox with oil.
19
Pendulum Calibration is described
in Operating manual - Calibration
Pendulum , enclosed with the calib-
ration tools.
Recalibrate the robot!
20
Axis Calibration is described in Cal-
ibrating with Axis Calibration meth-
od on page 383 .
General calibration information is
included in section Calibration on
page 371 .
Continues on next page
Product manual - IRB 7600
307
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.3 Replacement of motor, axis 3
Continued
Note
Action
DANGER
Make sure all safety requirements are met when
performing the first test run.
21
308
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.3 Replacement of motor, axis 3
Continued
4.6.4 Replacement of motor, axis 4
Location of motor
The motor axis 4 is located on the left-hand side of the upper arm as shown in the
figure below.
xx0200000202
Motor, axis 4
A
Cable gland cover, motor axis 4
B
Motor attachment holes (4 pcs)
C
Required equipment
Note
Art. no.
Equipment, etc.
Includes:
•
motor
•
pinion
•
o-ring 21522012-430
See spare part number
in Spare part lists on
page 425 .
Motor including pinion
Must be replaced when reas-
sembling motor!
21522012-430
O-ring
3HAC14459-1
Lifting tool, motor ax 1, 4, 5
3HAC15534-1
Lifting tool, motor ax 2, 3, 4
Used to lubricate the o-ring.
3HAC042536-001
Grease
Option Foundry Plus
12340011-116
Loctite 574, Flange sealant
To be used if the upper arm is
positioned vertically.
3HAC14459-1
Lifting tool, motor ax 1, 4, 5
To be used if the upper arm is
positioned horizontally.
3HAC15534-1
Lifting tool, motor ax 2, 3, 4
Continues on next page
Product manual - IRB 7600
309
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.4 Replacement of motor, axis 4
|
ABB_IRB7600_Product_Manual.pdf
|
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| 309
|
Note
Action
DANGER
Make sure all safety requirements are met when
performing the first test run.
21
308
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.3 Replacement of motor, axis 3
Continued
4.6.4 Replacement of motor, axis 4
Location of motor
The motor axis 4 is located on the left-hand side of the upper arm as shown in the
figure below.
xx0200000202
Motor, axis 4
A
Cable gland cover, motor axis 4
B
Motor attachment holes (4 pcs)
C
Required equipment
Note
Art. no.
Equipment, etc.
Includes:
•
motor
•
pinion
•
o-ring 21522012-430
See spare part number
in Spare part lists on
page 425 .
Motor including pinion
Must be replaced when reas-
sembling motor!
21522012-430
O-ring
3HAC14459-1
Lifting tool, motor ax 1, 4, 5
3HAC15534-1
Lifting tool, motor ax 2, 3, 4
Used to lubricate the o-ring.
3HAC042536-001
Grease
Option Foundry Plus
12340011-116
Loctite 574, Flange sealant
To be used if the upper arm is
positioned vertically.
3HAC14459-1
Lifting tool, motor ax 1, 4, 5
To be used if the upper arm is
positioned horizontally.
3HAC15534-1
Lifting tool, motor ax 2, 3, 4
Continues on next page
Product manual - IRB 7600
309
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.4 Replacement of motor, axis 4
Note
Art. no.
Equipment, etc.
Always use the removal tools in
pairs!
3HAC14973-1
Removal tool, motor M12x
For guiding the motor.
3HAC15521-1
Guide pins M10 x 100
For guiding the motor.
3HAC15521-2
Guide pins M10 x 150
3HAC12342-1
Extension 300mm for bits 1/2"
Used to rotate the motor pinion
when mating it to the gear when
brakes are released with 24 VDC
power supply.
3HAC17105-1
Rotation tool
24 VDC, max. 1,5 A
-
Power supply
For releasing the brakes.
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Complete kit that also includes
operating 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
robot.
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
Continues on next page
310
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.4 Replacement of motor, axis 4
Continued
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| 310
|
4.6.4 Replacement of motor, axis 4
Location of motor
The motor axis 4 is located on the left-hand side of the upper arm as shown in the
figure below.
xx0200000202
Motor, axis 4
A
Cable gland cover, motor axis 4
B
Motor attachment holes (4 pcs)
C
Required equipment
Note
Art. no.
Equipment, etc.
Includes:
•
motor
•
pinion
•
o-ring 21522012-430
See spare part number
in Spare part lists on
page 425 .
Motor including pinion
Must be replaced when reas-
sembling motor!
21522012-430
O-ring
3HAC14459-1
Lifting tool, motor ax 1, 4, 5
3HAC15534-1
Lifting tool, motor ax 2, 3, 4
Used to lubricate the o-ring.
3HAC042536-001
Grease
Option Foundry Plus
12340011-116
Loctite 574, Flange sealant
To be used if the upper arm is
positioned vertically.
3HAC14459-1
Lifting tool, motor ax 1, 4, 5
To be used if the upper arm is
positioned horizontally.
3HAC15534-1
Lifting tool, motor ax 2, 3, 4
Continues on next page
Product manual - IRB 7600
309
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.4 Replacement of motor, axis 4
Note
Art. no.
Equipment, etc.
Always use the removal tools in
pairs!
3HAC14973-1
Removal tool, motor M12x
For guiding the motor.
3HAC15521-1
Guide pins M10 x 100
For guiding the motor.
3HAC15521-2
Guide pins M10 x 150
3HAC12342-1
Extension 300mm for bits 1/2"
Used to rotate the motor pinion
when mating it to the gear when
brakes are released with 24 VDC
power supply.
3HAC17105-1
Rotation tool
24 VDC, max. 1,5 A
-
Power supply
For releasing the brakes.
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Complete kit that also includes
operating 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
robot.
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
Continues on next page
310
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.4 Replacement of motor, axis 4
Continued
Note
Action
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, motor axis 4
The procedure below details how to remove the motor, axis 4.
Note
Action
Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.
1
Move the upper arm to one of the basic pos-
itions:
•
upper arm is pointed straight up. This
position enables the motor to be re-
placed without draining the gear oil,
which in turn saves time.
•
upper arm is close to horizontal. This
position is recommended if the gear-
box is also to be replaced, i.e. when
the gearbox oil has to be drained
anyway.
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
In horizontal position: unload the upper arm
to avoid movement of the axis, with one of
the given methods:
•
move the upper arm to a position
where the turning disk rests against
the foundation (recommended)
•
use a fork lift or an overhead crane
and lifting slings to rest the weight of
the upper arm.
4
Detailed in section Draining, oil, gearbox
axis 4 on page 174 .
In horizontal position: drain the gearbox,
axis 4.
5
Continues on next page
Product manual - IRB 7600
311
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.4 Replacement of motor, axis 4
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 311
|
Note
Art. no.
Equipment, etc.
Always use the removal tools in
pairs!
3HAC14973-1
Removal tool, motor M12x
For guiding the motor.
3HAC15521-1
Guide pins M10 x 100
For guiding the motor.
3HAC15521-2
Guide pins M10 x 150
3HAC12342-1
Extension 300mm for bits 1/2"
Used to rotate the motor pinion
when mating it to the gear when
brakes are released with 24 VDC
power supply.
3HAC17105-1
Rotation tool
24 VDC, max. 1,5 A
-
Power supply
For releasing the brakes.
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Complete kit that also includes
operating 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
robot.
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
Continues on next page
310
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.4 Replacement of motor, axis 4
Continued
Note
Action
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, motor axis 4
The procedure below details how to remove the motor, axis 4.
Note
Action
Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.
1
Move the upper arm to one of the basic pos-
itions:
•
upper arm is pointed straight up. This
position enables the motor to be re-
placed without draining the gear oil,
which in turn saves time.
•
upper arm is close to horizontal. This
position is recommended if the gear-
box is also to be replaced, i.e. when
the gearbox oil has to be drained
anyway.
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
In horizontal position: unload the upper arm
to avoid movement of the axis, with one of
the given methods:
•
move the upper arm to a position
where the turning disk rests against
the foundation (recommended)
•
use a fork lift or an overhead crane
and lifting slings to rest the weight of
the upper arm.
4
Detailed in section Draining, oil, gearbox
axis 4 on page 174 .
In horizontal position: drain the gearbox,
axis 4.
5
Continues on next page
Product manual - IRB 7600
311
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.4 Replacement of motor, axis 4
Continued
Note
Action
Shown in the figure Location of motor on
page 309 .
Remove the cable gland cover at the cable
exit of the motor by unscrewing its two at-
tachment screws.
6
Make sure the gasket is not damaged!
Remove the cover on top of the motor by
unscrewing its four attachment screws.
7
Disconnect all connectors beneath the motor
cover.
8
Connect to connector R2.MP4
•
+: pin 2
•
-: pin 5
In order to release the brake, connect the
24 VDC power supply.
9
CAUTION
The motor weighs 22 kg! All lifting equip-
ment used must be sized accordingly!
10
Shown in the figure Location of motor on
page 309 .
Unscrew the motors four attachment screws
and plain washers.
11
Fit the two guide pins in two of the motor
attachment screw holes.
12
Art. no. is specified in Required equipment
on page 309 .
If required, press the motor out of position
by fitting removal tool, motor to the motor
attachment screw holes.
13
Always use the removal tools in pairs!
Choose the correct lifting tool:
•
lifting tool, motor axis 1, 4 and 5, if
the upper arm is positioned vertic-
ally.
•
lifting tool, motor axis 2, 3 and 4, if
the upper arm is positioned hori-
zontally.
Art. no. is specified in Required equipment
on page 309 .
Fit the lifting tool to the motor.
14
Lift the motor to get the pinion away from
the gear and disconnect the brake release
voltage.
15
Make sure the motor pinion is not dam-
aged!
Remove the motor by gently lifting it straight
out.
16
Refitting, motor axis 4
The procedure below details how to refit motor, axis 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
Continues on next page
312
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.4 Replacement of motor, axis 4
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 312
|
Note
Action
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, motor axis 4
The procedure below details how to remove the motor, axis 4.
Note
Action
Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.
1
Move the upper arm to one of the basic pos-
itions:
•
upper arm is pointed straight up. This
position enables the motor to be re-
placed without draining the gear oil,
which in turn saves time.
•
upper arm is close to horizontal. This
position is recommended if the gear-
box is also to be replaced, i.e. when
the gearbox oil has to be drained
anyway.
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
In horizontal position: unload the upper arm
to avoid movement of the axis, with one of
the given methods:
•
move the upper arm to a position
where the turning disk rests against
the foundation (recommended)
•
use a fork lift or an overhead crane
and lifting slings to rest the weight of
the upper arm.
4
Detailed in section Draining, oil, gearbox
axis 4 on page 174 .
In horizontal position: drain the gearbox,
axis 4.
5
Continues on next page
Product manual - IRB 7600
311
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.4 Replacement of motor, axis 4
Continued
Note
Action
Shown in the figure Location of motor on
page 309 .
Remove the cable gland cover at the cable
exit of the motor by unscrewing its two at-
tachment screws.
6
Make sure the gasket is not damaged!
Remove the cover on top of the motor by
unscrewing its four attachment screws.
7
Disconnect all connectors beneath the motor
cover.
8
Connect to connector R2.MP4
•
+: pin 2
•
-: pin 5
In order to release the brake, connect the
24 VDC power supply.
9
CAUTION
The motor weighs 22 kg! All lifting equip-
ment used must be sized accordingly!
10
Shown in the figure Location of motor on
page 309 .
Unscrew the motors four attachment screws
and plain washers.
11
Fit the two guide pins in two of the motor
attachment screw holes.
12
Art. no. is specified in Required equipment
on page 309 .
If required, press the motor out of position
by fitting removal tool, motor to the motor
attachment screw holes.
13
Always use the removal tools in pairs!
Choose the correct lifting tool:
•
lifting tool, motor axis 1, 4 and 5, if
the upper arm is positioned vertic-
ally.
•
lifting tool, motor axis 2, 3 and 4, if
the upper arm is positioned hori-
zontally.
Art. no. is specified in Required equipment
on page 309 .
Fit the lifting tool to the motor.
14
Lift the motor to get the pinion away from
the gear and disconnect the brake release
voltage.
15
Make sure the motor pinion is not dam-
aged!
Remove the motor by gently lifting it straight
out.
16
Refitting, motor axis 4
The procedure below details how to refit motor, axis 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
Continues on next page
312
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.4 Replacement of motor, axis 4
Continued
Note
Action
Art. no. is specified in Required equip-
ment on page 309 .
Make sure the o-ring on the circumference
of the motor is seated properly. Lightly lub-
ricate the o-ring with grease.
2
Tightening torque, transparent plug: 25
Nm ±10%.
Foundry Plus :
If the motor is a new spare part, the evacu-
ation hole protection filter must be replaced
with a transparent plug/sight glass (enclosed
with the spare part delivery). Remove the
protection filter and install the transparent
plug/sight glass.
![Image]
xx1800000102
Transparent plug
(Foundry Plus).
![Image]
xx1800000101
Protection filter
(Standard).
3
Tightening torque, protection filter: 10 Nm
±10%.
![Image]
xx1600000576
CAUTION
The motor weighs 22 kg! All lifting equip-
ment used must be sized accordingly!
4
Choose the correct lifting tool:
•
lifting tool, motor axis 1, 4 and 5, if
the upper arm is positioned vertic-
ally
•
lifting tool, motor axis 2, 3 and 4, if
the upper arm is positioned hori-
zontally.
Art. no. is specified in Required equip-
ment on page 309 .
Fit the lifting tool to the motor.
5
Connect to connector R2.MP4:
•
+: pin 2
•
-: pin 5
In order to release the brakes, connect the
24 VDC power supply.
6
Art. no. is specified in Required equip-
ment on page 309 .
Fit the two guide pins in two of the motor
attachment holes.
7
Shown in the figure Location of motor on
page 309 .
Make sure the motor pinion does not get
damaged!
Fit the motor with guidance of the pins,
making sure the motor pinion is properly
mated to the gear of gearbox 4.
8
Continues on next page
Product manual - IRB 7600
313
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.4 Replacement of motor, axis 4
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 313
|
Note
Action
Shown in the figure Location of motor on
page 309 .
Remove the cable gland cover at the cable
exit of the motor by unscrewing its two at-
tachment screws.
6
Make sure the gasket is not damaged!
Remove the cover on top of the motor by
unscrewing its four attachment screws.
7
Disconnect all connectors beneath the motor
cover.
8
Connect to connector R2.MP4
•
+: pin 2
•
-: pin 5
In order to release the brake, connect the
24 VDC power supply.
9
CAUTION
The motor weighs 22 kg! All lifting equip-
ment used must be sized accordingly!
10
Shown in the figure Location of motor on
page 309 .
Unscrew the motors four attachment screws
and plain washers.
11
Fit the two guide pins in two of the motor
attachment screw holes.
12
Art. no. is specified in Required equipment
on page 309 .
If required, press the motor out of position
by fitting removal tool, motor to the motor
attachment screw holes.
13
Always use the removal tools in pairs!
Choose the correct lifting tool:
•
lifting tool, motor axis 1, 4 and 5, if
the upper arm is positioned vertic-
ally.
•
lifting tool, motor axis 2, 3 and 4, if
the upper arm is positioned hori-
zontally.
Art. no. is specified in Required equipment
on page 309 .
Fit the lifting tool to the motor.
14
Lift the motor to get the pinion away from
the gear and disconnect the brake release
voltage.
15
Make sure the motor pinion is not dam-
aged!
Remove the motor by gently lifting it straight
out.
16
Refitting, motor axis 4
The procedure below details how to refit motor, axis 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
Continues on next page
312
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.4 Replacement of motor, axis 4
Continued
Note
Action
Art. no. is specified in Required equip-
ment on page 309 .
Make sure the o-ring on the circumference
of the motor is seated properly. Lightly lub-
ricate the o-ring with grease.
2
Tightening torque, transparent plug: 25
Nm ±10%.
Foundry Plus :
If the motor is a new spare part, the evacu-
ation hole protection filter must be replaced
with a transparent plug/sight glass (enclosed
with the spare part delivery). Remove the
protection filter and install the transparent
plug/sight glass.
![Image]
xx1800000102
Transparent plug
(Foundry Plus).
![Image]
xx1800000101
Protection filter
(Standard).
3
Tightening torque, protection filter: 10 Nm
±10%.
![Image]
xx1600000576
CAUTION
The motor weighs 22 kg! All lifting equip-
ment used must be sized accordingly!
4
Choose the correct lifting tool:
•
lifting tool, motor axis 1, 4 and 5, if
the upper arm is positioned vertic-
ally
•
lifting tool, motor axis 2, 3 and 4, if
the upper arm is positioned hori-
zontally.
Art. no. is specified in Required equip-
ment on page 309 .
Fit the lifting tool to the motor.
5
Connect to connector R2.MP4:
•
+: pin 2
•
-: pin 5
In order to release the brakes, connect the
24 VDC power supply.
6
Art. no. is specified in Required equip-
ment on page 309 .
Fit the two guide pins in two of the motor
attachment holes.
7
Shown in the figure Location of motor on
page 309 .
Make sure the motor pinion does not get
damaged!
Fit the motor with guidance of the pins,
making sure the motor pinion is properly
mated to the gear of gearbox 4.
8
Continues on next page
Product manual - IRB 7600
313
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.4 Replacement of motor, axis 4
Continued
Note
Action
Art. no. is specified in Required equip-
ment on page 309 .
Use the rotation tool in order to rotate the
motor pinion when mating it to the gear!
Fit the motor, making sure the motor pinion
is properly mated to the gear, axis 4.
9
Make sure the motor pinion does not get
damaged!
Make sure the motor is turned the right
direction, that is the cables facing for-
wards.
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
xx0200000165
The rotation tool is used beneath the mo-
tor cover, directly on the motor shaft as
shown in figure above.
•
A: Rotation tool.
Remove the guide pins.
10
4 pcs: M10 x 80, tightening torque: 50 Nm.
Secure the motor with four attachment
screws and plain washers.
11
Art. no. is specified in Required equip-
ment on page 309 .
If required, use the extension 300mm for
bits 1/2" .
Disconnect the brake release voltage.
12
Reconnect all connectors beneath the motor
cover.
13
Make sure the cover is tightly sealed!
Refit the cover on top of the motor with its
four attachment screws.
14
Shown in the figure Location of motor on
page 309 .
Refit the cable gland cover at the cable exit
with its two attachment screws.
15
Detailed in the section Performing a leak-
down test on page 206 .
Perform a leak-down test if the gearbox has
been drained.
16
Detailed in the section Filling, oil, gearbox
axis 4 on page 175 .
Refill the gearbox with oil if drained.
17
Pendulum Calibration is described in Op-
erating manual - Calibration Pendulum ,
enclosed with the calibration tools.
Recalibrate the robot!
18
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.
19
314
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.4 Replacement of motor, axis 4
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 314
|
Note
Action
Art. no. is specified in Required equip-
ment on page 309 .
Make sure the o-ring on the circumference
of the motor is seated properly. Lightly lub-
ricate the o-ring with grease.
2
Tightening torque, transparent plug: 25
Nm ±10%.
Foundry Plus :
If the motor is a new spare part, the evacu-
ation hole protection filter must be replaced
with a transparent plug/sight glass (enclosed
with the spare part delivery). Remove the
protection filter and install the transparent
plug/sight glass.
![Image]
xx1800000102
Transparent plug
(Foundry Plus).
![Image]
xx1800000101
Protection filter
(Standard).
3
Tightening torque, protection filter: 10 Nm
±10%.
![Image]
xx1600000576
CAUTION
The motor weighs 22 kg! All lifting equip-
ment used must be sized accordingly!
4
Choose the correct lifting tool:
•
lifting tool, motor axis 1, 4 and 5, if
the upper arm is positioned vertic-
ally
•
lifting tool, motor axis 2, 3 and 4, if
the upper arm is positioned hori-
zontally.
Art. no. is specified in Required equip-
ment on page 309 .
Fit the lifting tool to the motor.
5
Connect to connector R2.MP4:
•
+: pin 2
•
-: pin 5
In order to release the brakes, connect the
24 VDC power supply.
6
Art. no. is specified in Required equip-
ment on page 309 .
Fit the two guide pins in two of the motor
attachment holes.
7
Shown in the figure Location of motor on
page 309 .
Make sure the motor pinion does not get
damaged!
Fit the motor with guidance of the pins,
making sure the motor pinion is properly
mated to the gear of gearbox 4.
8
Continues on next page
Product manual - IRB 7600
313
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.4 Replacement of motor, axis 4
Continued
Note
Action
Art. no. is specified in Required equip-
ment on page 309 .
Use the rotation tool in order to rotate the
motor pinion when mating it to the gear!
Fit the motor, making sure the motor pinion
is properly mated to the gear, axis 4.
9
Make sure the motor pinion does not get
damaged!
Make sure the motor is turned the right
direction, that is the cables facing for-
wards.
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
xx0200000165
The rotation tool is used beneath the mo-
tor cover, directly on the motor shaft as
shown in figure above.
•
A: Rotation tool.
Remove the guide pins.
10
4 pcs: M10 x 80, tightening torque: 50 Nm.
Secure the motor with four attachment
screws and plain washers.
11
Art. no. is specified in Required equip-
ment on page 309 .
If required, use the extension 300mm for
bits 1/2" .
Disconnect the brake release voltage.
12
Reconnect all connectors beneath the motor
cover.
13
Make sure the cover is tightly sealed!
Refit the cover on top of the motor with its
four attachment screws.
14
Shown in the figure Location of motor on
page 309 .
Refit the cable gland cover at the cable exit
with its two attachment screws.
15
Detailed in the section Performing a leak-
down test on page 206 .
Perform a leak-down test if the gearbox has
been drained.
16
Detailed in the section Filling, oil, gearbox
axis 4 on page 175 .
Refill the gearbox with oil if drained.
17
Pendulum Calibration is described in Op-
erating manual - Calibration Pendulum ,
enclosed with the calibration tools.
Recalibrate the robot!
18
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.
19
314
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.4 Replacement of motor, axis 4
Continued
4.6.5 Replacement of motor, axis 5
Location of motor
The motor axis 5 is located in the rear of the wrist unit as shown in the figure below.
Notice that the left hand side cover already is removed in the figure!
xx0100000127
Motor, axis 5
A
Cable gland cover, motor axis 5
B
Heat protection plate
C
Required equipment
Note
Art. no.
Equipment, etc.
Includes:
•
motor
•
pinion
•
o-ring 21522012-430
See Spare part lists
on page 425 .
Motor, axis 5
Must be replaced when replacing
motor!
21522012-430
O-ring
For lubricating the o-ring.
3HAC042536-001
Grease
Content is defined in section Stand-
ard tools on page 419 .
-
Standard toolkit
For guiding the motor.
3HAC15521-1
Guide pins M10 x 100
For guiding the motor.
3HAC15521-2
Guide pins M10 x 150
For lifting the motor in a vertical pos-
ition
3HAC14459-1
Lifting tool, motor ax 1, 4, 5
24 VDC, 1.5 A.
Power supply
For releasing the brakes.
3HAC12342-1
Extension 300mm for bits 1/2"
Always use the removal tools in
pairs!
3HAC14973-1
Removal tool, motor M12x
Continues on next page
Product manual - IRB 7600
315
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.5 Replacement of motor, axis 5
|
ABB_IRB7600_Product_Manual.pdf
|
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| 315
|
Note
Action
Art. no. is specified in Required equip-
ment on page 309 .
Use the rotation tool in order to rotate the
motor pinion when mating it to the gear!
Fit the motor, making sure the motor pinion
is properly mated to the gear, axis 4.
9
Make sure the motor pinion does not get
damaged!
Make sure the motor is turned the right
direction, that is the cables facing for-
wards.
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
xx0200000165
The rotation tool is used beneath the mo-
tor cover, directly on the motor shaft as
shown in figure above.
•
A: Rotation tool.
Remove the guide pins.
10
4 pcs: M10 x 80, tightening torque: 50 Nm.
Secure the motor with four attachment
screws and plain washers.
11
Art. no. is specified in Required equip-
ment on page 309 .
If required, use the extension 300mm for
bits 1/2" .
Disconnect the brake release voltage.
12
Reconnect all connectors beneath the motor
cover.
13
Make sure the cover is tightly sealed!
Refit the cover on top of the motor with its
four attachment screws.
14
Shown in the figure Location of motor on
page 309 .
Refit the cable gland cover at the cable exit
with its two attachment screws.
15
Detailed in the section Performing a leak-
down test on page 206 .
Perform a leak-down test if the gearbox has
been drained.
16
Detailed in the section Filling, oil, gearbox
axis 4 on page 175 .
Refill the gearbox with oil if drained.
17
Pendulum Calibration is described in Op-
erating manual - Calibration Pendulum ,
enclosed with the calibration tools.
Recalibrate the robot!
18
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.
19
314
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.4 Replacement of motor, axis 4
Continued
4.6.5 Replacement of motor, axis 5
Location of motor
The motor axis 5 is located in the rear of the wrist unit as shown in the figure below.
Notice that the left hand side cover already is removed in the figure!
xx0100000127
Motor, axis 5
A
Cable gland cover, motor axis 5
B
Heat protection plate
C
Required equipment
Note
Art. no.
Equipment, etc.
Includes:
•
motor
•
pinion
•
o-ring 21522012-430
See Spare part lists
on page 425 .
Motor, axis 5
Must be replaced when replacing
motor!
21522012-430
O-ring
For lubricating the o-ring.
3HAC042536-001
Grease
Content is defined in section Stand-
ard tools on page 419 .
-
Standard toolkit
For guiding the motor.
3HAC15521-1
Guide pins M10 x 100
For guiding the motor.
3HAC15521-2
Guide pins M10 x 150
For lifting the motor in a vertical pos-
ition
3HAC14459-1
Lifting tool, motor ax 1, 4, 5
24 VDC, 1.5 A.
Power supply
For releasing the brakes.
3HAC12342-1
Extension 300mm for bits 1/2"
Always use the removal tools in
pairs!
3HAC14973-1
Removal tool, motor M12x
Continues on next page
Product manual - IRB 7600
315
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.5 Replacement of motor, axis 5
Note
Art. no.
Equipment, etc.
Complete kit that also includes oper-
ating 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 Calib-
ration
Required if Axis Calibration is the
valid calibration method for the robot.
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.
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.
Removal, motor axis 5
The procedure below details how to remove the motor, axis 5.
Note
Action
Decide which calibration routine to use, and take
actions accordingly prior to beginning the repair
procedure.
1
Continues on next page
316
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.5 Replacement of motor, axis 5
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 316
|
4.6.5 Replacement of motor, axis 5
Location of motor
The motor axis 5 is located in the rear of the wrist unit as shown in the figure below.
Notice that the left hand side cover already is removed in the figure!
xx0100000127
Motor, axis 5
A
Cable gland cover, motor axis 5
B
Heat protection plate
C
Required equipment
Note
Art. no.
Equipment, etc.
Includes:
•
motor
•
pinion
•
o-ring 21522012-430
See Spare part lists
on page 425 .
Motor, axis 5
Must be replaced when replacing
motor!
21522012-430
O-ring
For lubricating the o-ring.
3HAC042536-001
Grease
Content is defined in section Stand-
ard tools on page 419 .
-
Standard toolkit
For guiding the motor.
3HAC15521-1
Guide pins M10 x 100
For guiding the motor.
3HAC15521-2
Guide pins M10 x 150
For lifting the motor in a vertical pos-
ition
3HAC14459-1
Lifting tool, motor ax 1, 4, 5
24 VDC, 1.5 A.
Power supply
For releasing the brakes.
3HAC12342-1
Extension 300mm for bits 1/2"
Always use the removal tools in
pairs!
3HAC14973-1
Removal tool, motor M12x
Continues on next page
Product manual - IRB 7600
315
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.5 Replacement of motor, axis 5
Note
Art. no.
Equipment, etc.
Complete kit that also includes oper-
ating 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 Calib-
ration
Required if Axis Calibration is the
valid calibration method for the robot.
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.
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.
Removal, motor axis 5
The procedure below details how to remove the motor, axis 5.
Note
Action
Decide which calibration routine to use, and take
actions accordingly prior to beginning the repair
procedure.
1
Continues on next page
316
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.5 Replacement of motor, axis 5
Continued
Note
Action
Move the robot to a position where the motor in axis
5 is pointed straight up. This position enables the
motor to be replaced without draining the gear oil,
which in turn saves time.
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
The motor is accessible behind
the rear part of the cover.
Remove the left hand side cover of the wrist unit by
unscrewing its six attachment screws.
4
Shown in the figure Location of
motor on page 315 .
Remove the heat protection plate by unscrewing its
two attachment screws.
5
Remove the cover on top of the motor by unscrewing
its four attachment screws.
6
Shown in the figure Location of
motor on page 315 .
Remove the cable gland cover at the cable exit by
unscrewing its two attachment screws.
7
Disconnect all connectors beneath the motor cover.
8
Connect to connector R3.MP5
•
+: pin 2
•
-: pin 5
In order to release the brake, connect the 24 VDC
power supply.
9
CAUTION
The motor weighs 22 kg! All lifting equipment used
must be sized accordingly!
10
Art. no. is specified in Required
equipment on page 315 .
Remove the motor by unscrewing its four attachment
screws and plain washers.
If required, use the extension 300 mm for bits 1/2 .
11
Art. no. is specified in Required
equipment on page 315 .
Fit the lifting tool, motor axis 1, 4, 5 to the motor.
12
Art. no. is specified in Required
equipment on page 315 .
Fit the two guide pins in two of the motor attachment
screw holes.
13
Art. no. is specified in Required
equipment on page 315 .
If required, press the motor out of position by fitting
removal tool, motor to the motor attachment screw
holes.
14
Always use the removal tools in
pairs and diagonally!
Lift the motor to get the pinion away from the gear
and disconnect the brake release voltage.
15
Make sure the motor pinion is
not damaged!
Remove the motor by gently lifting it straight out.
16
Continues on next page
Product manual - IRB 7600
317
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.5 Replacement of motor, axis 5
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 317
|
Note
Art. no.
Equipment, etc.
Complete kit that also includes oper-
ating 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 Calib-
ration
Required if Axis Calibration is the
valid calibration method for the robot.
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.
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.
Removal, motor axis 5
The procedure below details how to remove the motor, axis 5.
Note
Action
Decide which calibration routine to use, and take
actions accordingly prior to beginning the repair
procedure.
1
Continues on next page
316
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.5 Replacement of motor, axis 5
Continued
Note
Action
Move the robot to a position where the motor in axis
5 is pointed straight up. This position enables the
motor to be replaced without draining the gear oil,
which in turn saves time.
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
The motor is accessible behind
the rear part of the cover.
Remove the left hand side cover of the wrist unit by
unscrewing its six attachment screws.
4
Shown in the figure Location of
motor on page 315 .
Remove the heat protection plate by unscrewing its
two attachment screws.
5
Remove the cover on top of the motor by unscrewing
its four attachment screws.
6
Shown in the figure Location of
motor on page 315 .
Remove the cable gland cover at the cable exit by
unscrewing its two attachment screws.
7
Disconnect all connectors beneath the motor cover.
8
Connect to connector R3.MP5
•
+: pin 2
•
-: pin 5
In order to release the brake, connect the 24 VDC
power supply.
9
CAUTION
The motor weighs 22 kg! All lifting equipment used
must be sized accordingly!
10
Art. no. is specified in Required
equipment on page 315 .
Remove the motor by unscrewing its four attachment
screws and plain washers.
If required, use the extension 300 mm for bits 1/2 .
11
Art. no. is specified in Required
equipment on page 315 .
Fit the lifting tool, motor axis 1, 4, 5 to the motor.
12
Art. no. is specified in Required
equipment on page 315 .
Fit the two guide pins in two of the motor attachment
screw holes.
13
Art. no. is specified in Required
equipment on page 315 .
If required, press the motor out of position by fitting
removal tool, motor to the motor attachment screw
holes.
14
Always use the removal tools in
pairs and diagonally!
Lift the motor to get the pinion away from the gear
and disconnect the brake release voltage.
15
Make sure the motor pinion is
not damaged!
Remove the motor by gently lifting it straight out.
16
Continues on next page
Product manual - IRB 7600
317
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.5 Replacement of motor, axis 5
Continued
Refitting, motor axis 5
The procedure below details how to refit the motor, axis 5.
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
Art. no. is specified in Required
equipment on page 315 .
Make sure the o-ring on the circumference of the
motor is seated properly. Lightly lubricate the o-ring
with grease .
2
CAUTION
The motor weighs 22 kg! All lifting equipment used
must be sized accordingly!
3
Fit the lifting tool, motor axis 1, 4, 5 to the motor.
4
Connect to connector R3.MP5
•
+: pin 2
•
-: pin 5
In order to release the brakes, connect the 24 VDC
power supply to the motor.
5
Art. no. is specified in Required
equipment on page 315 .
Fit the two guide pins in two of the motor attach-
ment holes.
6
Make sure the motor pinion does
not get damaged!
Fit the motor, with guidance from the pins, making
sure the motor pinion is properly mated to the gear
of gearbox, axis 5.
7
Make sure the motor is turned the
right direction, that is the cables
facing forward.
Art. no. is specified in Required
equipment on page 315 .
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
xx0200000165
If necessary, use the rotation tool in order to rotate
the motor pinion when mating it to the gear!
8
The rotation tool (A) is used be-
neath the motor cover, directly on
the motor shaft as shown in figure
above.
M10 x 40, 12.9 quality.
Secure the motor with four attachment screws and
plain washers.
9
Tightening torque: 50 Nm.
If required, use the extension 300 mm for bits 1/2" . Art. no. is specified in Required
equipment on page 315 .
Disconnect the brake release voltage.
10
Reconnect all connectors beneath the motor cover.
11
Continues on next page
318
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.5 Replacement of motor, axis 5
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 318
|
Note
Action
Move the robot to a position where the motor in axis
5 is pointed straight up. This position enables the
motor to be replaced without draining the gear oil,
which in turn saves time.
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
The motor is accessible behind
the rear part of the cover.
Remove the left hand side cover of the wrist unit by
unscrewing its six attachment screws.
4
Shown in the figure Location of
motor on page 315 .
Remove the heat protection plate by unscrewing its
two attachment screws.
5
Remove the cover on top of the motor by unscrewing
its four attachment screws.
6
Shown in the figure Location of
motor on page 315 .
Remove the cable gland cover at the cable exit by
unscrewing its two attachment screws.
7
Disconnect all connectors beneath the motor cover.
8
Connect to connector R3.MP5
•
+: pin 2
•
-: pin 5
In order to release the brake, connect the 24 VDC
power supply.
9
CAUTION
The motor weighs 22 kg! All lifting equipment used
must be sized accordingly!
10
Art. no. is specified in Required
equipment on page 315 .
Remove the motor by unscrewing its four attachment
screws and plain washers.
If required, use the extension 300 mm for bits 1/2 .
11
Art. no. is specified in Required
equipment on page 315 .
Fit the lifting tool, motor axis 1, 4, 5 to the motor.
12
Art. no. is specified in Required
equipment on page 315 .
Fit the two guide pins in two of the motor attachment
screw holes.
13
Art. no. is specified in Required
equipment on page 315 .
If required, press the motor out of position by fitting
removal tool, motor to the motor attachment screw
holes.
14
Always use the removal tools in
pairs and diagonally!
Lift the motor to get the pinion away from the gear
and disconnect the brake release voltage.
15
Make sure the motor pinion is
not damaged!
Remove the motor by gently lifting it straight out.
16
Continues on next page
Product manual - IRB 7600
317
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.5 Replacement of motor, axis 5
Continued
Refitting, motor axis 5
The procedure below details how to refit the motor, axis 5.
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
Art. no. is specified in Required
equipment on page 315 .
Make sure the o-ring on the circumference of the
motor is seated properly. Lightly lubricate the o-ring
with grease .
2
CAUTION
The motor weighs 22 kg! All lifting equipment used
must be sized accordingly!
3
Fit the lifting tool, motor axis 1, 4, 5 to the motor.
4
Connect to connector R3.MP5
•
+: pin 2
•
-: pin 5
In order to release the brakes, connect the 24 VDC
power supply to the motor.
5
Art. no. is specified in Required
equipment on page 315 .
Fit the two guide pins in two of the motor attach-
ment holes.
6
Make sure the motor pinion does
not get damaged!
Fit the motor, with guidance from the pins, making
sure the motor pinion is properly mated to the gear
of gearbox, axis 5.
7
Make sure the motor is turned the
right direction, that is the cables
facing forward.
Art. no. is specified in Required
equipment on page 315 .
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
xx0200000165
If necessary, use the rotation tool in order to rotate
the motor pinion when mating it to the gear!
8
The rotation tool (A) is used be-
neath the motor cover, directly on
the motor shaft as shown in figure
above.
M10 x 40, 12.9 quality.
Secure the motor with four attachment screws and
plain washers.
9
Tightening torque: 50 Nm.
If required, use the extension 300 mm for bits 1/2" . Art. no. is specified in Required
equipment on page 315 .
Disconnect the brake release voltage.
10
Reconnect all connectors beneath the motor cover.
11
Continues on next page
318
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.5 Replacement of motor, axis 5
Continued
Note
Action
Shown in the figure Location of
motor on page 315 .
Refit the cable gland cover at the cable exit with its
two attachment screws.
12
Make sure the cover is tightly
sealed!
Refit the cover on top of the motor with its four at-
tachment screws.
13
Shown in the figure Location of
motor on page 315 .
Refit the heat protection plate with its two attach-
ment screws.
14
If cables are loose, place them correctly and tie
them up with cable ties.
15
Refit the left hand side cover of the wrist unit with
its six attachment screws.
16
Pendulum Calibration is described
in Operating manual - Calibration
Pendulum , enclosed with the cal-
ibration tools.
Recalibrate the robot.
17
Axis Calibration is described in
Calibrating 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.
18
Product manual - IRB 7600
319
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.5 Replacement of motor, axis 5
Continued
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| 319
|
Refitting, motor axis 5
The procedure below details how to refit the motor, axis 5.
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
Art. no. is specified in Required
equipment on page 315 .
Make sure the o-ring on the circumference of the
motor is seated properly. Lightly lubricate the o-ring
with grease .
2
CAUTION
The motor weighs 22 kg! All lifting equipment used
must be sized accordingly!
3
Fit the lifting tool, motor axis 1, 4, 5 to the motor.
4
Connect to connector R3.MP5
•
+: pin 2
•
-: pin 5
In order to release the brakes, connect the 24 VDC
power supply to the motor.
5
Art. no. is specified in Required
equipment on page 315 .
Fit the two guide pins in two of the motor attach-
ment holes.
6
Make sure the motor pinion does
not get damaged!
Fit the motor, with guidance from the pins, making
sure the motor pinion is properly mated to the gear
of gearbox, axis 5.
7
Make sure the motor is turned the
right direction, that is the cables
facing forward.
Art. no. is specified in Required
equipment on page 315 .
![Image]
![Image]
![Image]
![Image]
![Image]
![Image]
xx0200000165
If necessary, use the rotation tool in order to rotate
the motor pinion when mating it to the gear!
8
The rotation tool (A) is used be-
neath the motor cover, directly on
the motor shaft as shown in figure
above.
M10 x 40, 12.9 quality.
Secure the motor with four attachment screws and
plain washers.
9
Tightening torque: 50 Nm.
If required, use the extension 300 mm for bits 1/2" . Art. no. is specified in Required
equipment on page 315 .
Disconnect the brake release voltage.
10
Reconnect all connectors beneath the motor cover.
11
Continues on next page
318
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.5 Replacement of motor, axis 5
Continued
Note
Action
Shown in the figure Location of
motor on page 315 .
Refit the cable gland cover at the cable exit with its
two attachment screws.
12
Make sure the cover is tightly
sealed!
Refit the cover on top of the motor with its four at-
tachment screws.
13
Shown in the figure Location of
motor on page 315 .
Refit the heat protection plate with its two attach-
ment screws.
14
If cables are loose, place them correctly and tie
them up with cable ties.
15
Refit the left hand side cover of the wrist unit with
its six attachment screws.
16
Pendulum Calibration is described
in Operating manual - Calibration
Pendulum , enclosed with the cal-
ibration tools.
Recalibrate the robot.
17
Axis Calibration is described in
Calibrating 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.
18
Product manual - IRB 7600
319
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.5 Replacement of motor, axis 5
Continued
4.6.6 Replacement of motor, axis 6
Location of motor
The motor axis 6 is located in the center of the wrist unit as shown in the figure
below.
xx0100000128
Motor, axis 6
A
Required equipment
Note
Art. no.
Spare part no.
Equipment, etc.
Includes:
•
motor
•
pinion
•
o-ring
See spare part
number in Spare
part lists on
page 425 .
Motor, axis 6
Must be replaced when reas-
sembling motor!
21522012-430
O-ring
Must be replaced when repla-
cing motor
3HAC048560-001
i
Gasket
3HAC063071-001
ii
Must be replaced when
opening cover.
3HAC033489-001
Gasket, cover
Always use the removal tools
in pairs!
3HAC14972-1
Removal tool, motor
M10x
3HAC12342-1
Extension 300mm for
bits 1/2"
Continues on next page
320
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.6 Replacement of motor, axis 6
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| 320
|
Note
Action
Shown in the figure Location of
motor on page 315 .
Refit the cable gland cover at the cable exit with its
two attachment screws.
12
Make sure the cover is tightly
sealed!
Refit the cover on top of the motor with its four at-
tachment screws.
13
Shown in the figure Location of
motor on page 315 .
Refit the heat protection plate with its two attach-
ment screws.
14
If cables are loose, place them correctly and tie
them up with cable ties.
15
Refit the left hand side cover of the wrist unit with
its six attachment screws.
16
Pendulum Calibration is described
in Operating manual - Calibration
Pendulum , enclosed with the cal-
ibration tools.
Recalibrate the robot.
17
Axis Calibration is described in
Calibrating 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.
18
Product manual - IRB 7600
319
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.5 Replacement of motor, axis 5
Continued
4.6.6 Replacement of motor, axis 6
Location of motor
The motor axis 6 is located in the center of the wrist unit as shown in the figure
below.
xx0100000128
Motor, axis 6
A
Required equipment
Note
Art. no.
Spare part no.
Equipment, etc.
Includes:
•
motor
•
pinion
•
o-ring
See spare part
number in Spare
part lists on
page 425 .
Motor, axis 6
Must be replaced when reas-
sembling motor!
21522012-430
O-ring
Must be replaced when repla-
cing motor
3HAC048560-001
i
Gasket
3HAC063071-001
ii
Must be replaced when
opening cover.
3HAC033489-001
Gasket, cover
Always use the removal tools
in pairs!
3HAC14972-1
Removal tool, motor
M10x
3HAC12342-1
Extension 300mm for
bits 1/2"
Continues on next page
320
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.6 Replacement of motor, axis 6
Note
Art. no.
Spare part no.
Equipment, etc.
24 VDC, 1.5 A
-
Power supply
For releasing the brakes.
For lubricating the o-ring.
3HAC042536-
001
Grease
Option Foundry Plus
12340011-116
Loctite 574, Flange
sealant
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Complete kit that also in-
cludes operating manual.
3HAC15716-1
Calibration Pendulum
toolkit
Required if Calibration Pendu-
lum is the valid calibration
method for the robot.
Delivered as a set of calibra-
tion tools.
3HAC055412-
001
Calibration tool box,
Axis Calibration
Required if Axis Calibration
is the valid calibration meth-
od for the robot.
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 instructions be-
low.
See chapter Circuit diagram
on page 427 .
-
Circuit diagram
i
Only fits type A motor.
See Type A vs type B motors on page 409 .
ii
Only fits type B motor.
See Type A vs type B motors on page 409 .
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
Continues on next page
Product manual - IRB 7600
321
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.6 Replacement of motor, axis 6
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 321
|
4.6.6 Replacement of motor, axis 6
Location of motor
The motor axis 6 is located in the center of the wrist unit as shown in the figure
below.
xx0100000128
Motor, axis 6
A
Required equipment
Note
Art. no.
Spare part no.
Equipment, etc.
Includes:
•
motor
•
pinion
•
o-ring
See spare part
number in Spare
part lists on
page 425 .
Motor, axis 6
Must be replaced when reas-
sembling motor!
21522012-430
O-ring
Must be replaced when repla-
cing motor
3HAC048560-001
i
Gasket
3HAC063071-001
ii
Must be replaced when
opening cover.
3HAC033489-001
Gasket, cover
Always use the removal tools
in pairs!
3HAC14972-1
Removal tool, motor
M10x
3HAC12342-1
Extension 300mm for
bits 1/2"
Continues on next page
320
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.6 Replacement of motor, axis 6
Note
Art. no.
Spare part no.
Equipment, etc.
24 VDC, 1.5 A
-
Power supply
For releasing the brakes.
For lubricating the o-ring.
3HAC042536-
001
Grease
Option Foundry Plus
12340011-116
Loctite 574, Flange
sealant
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Complete kit that also in-
cludes operating manual.
3HAC15716-1
Calibration Pendulum
toolkit
Required if Calibration Pendu-
lum is the valid calibration
method for the robot.
Delivered as a set of calibra-
tion tools.
3HAC055412-
001
Calibration tool box,
Axis Calibration
Required if Axis Calibration
is the valid calibration meth-
od for the robot.
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 instructions be-
low.
See chapter Circuit diagram
on page 427 .
-
Circuit diagram
i
Only fits type A motor.
See Type A vs type B motors on page 409 .
ii
Only fits type B motor.
See Type A vs type B motors on page 409 .
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
Continues on next page
Product manual - IRB 7600
321
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.6 Replacement of motor, axis 6
Continued
Note
Action
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, motor
The procedure below details how to remove the motor, axis 6.
Note
Robots with protection type Foundry Plus or Foundry Prime require special repair
routines to maintain the tightness level, in addition to the procedure below,
described in Replacement of the motor axis 6 (Foundry Plus) on page 324 .
Note
Action
Decide which calibration routine to use, and take
actions accordingly prior to beginning the repair
procedure.
1
Move the robot to one of the recommended posi-
tions:
•
to a position where the motor in axis 6 is
pointed straight up. This position enables the
motor to be replaced without draining the
gear oil, which in turn saves time.
•
to a position where the motor in axis 6 is
close to horizontal. This position may be se-
lected when the gearbox is to be replaced,
i.e. when the gearbox oil has to be drained
anyway.
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
Detailed in section Draining oil,
gearbox axis 6 on page 181 .
In horizontal position: drain the oil from the axis 6
gearbox.
4
Remove the rear motor cover by unscrewing the
five attachment screws.
5
Disconnect all connectors beneath the cover.
6
Continues on next page
322
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.6 Replacement of motor, axis 6
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 322
|
Note
Art. no.
Spare part no.
Equipment, etc.
24 VDC, 1.5 A
-
Power supply
For releasing the brakes.
For lubricating the o-ring.
3HAC042536-
001
Grease
Option Foundry Plus
12340011-116
Loctite 574, Flange
sealant
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
Complete kit that also in-
cludes operating manual.
3HAC15716-1
Calibration Pendulum
toolkit
Required if Calibration Pendu-
lum is the valid calibration
method for the robot.
Delivered as a set of calibra-
tion tools.
3HAC055412-
001
Calibration tool box,
Axis Calibration
Required if Axis Calibration
is the valid calibration meth-
od for the robot.
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 instructions be-
low.
See chapter Circuit diagram
on page 427 .
-
Circuit diagram
i
Only fits type A motor.
See Type A vs type B motors on page 409 .
ii
Only fits type B motor.
See Type A vs type B motors on page 409 .
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
Continues on next page
Product manual - IRB 7600
321
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.6 Replacement of motor, axis 6
Continued
Note
Action
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, motor
The procedure below details how to remove the motor, axis 6.
Note
Robots with protection type Foundry Plus or Foundry Prime require special repair
routines to maintain the tightness level, in addition to the procedure below,
described in Replacement of the motor axis 6 (Foundry Plus) on page 324 .
Note
Action
Decide which calibration routine to use, and take
actions accordingly prior to beginning the repair
procedure.
1
Move the robot to one of the recommended posi-
tions:
•
to a position where the motor in axis 6 is
pointed straight up. This position enables the
motor to be replaced without draining the
gear oil, which in turn saves time.
•
to a position where the motor in axis 6 is
close to horizontal. This position may be se-
lected when the gearbox is to be replaced,
i.e. when the gearbox oil has to be drained
anyway.
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
Detailed in section Draining oil,
gearbox axis 6 on page 181 .
In horizontal position: drain the oil from the axis 6
gearbox.
4
Remove the rear motor cover by unscrewing the
five attachment screws.
5
Disconnect all connectors beneath the cover.
6
Continues on next page
322
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.6 Replacement of motor, axis 6
Continued
Note
Action
Connect to connector R3.MP6
•
+: pin 2
•
-: pin 5
Connect the 24 VDC power supply to release the
brakes.
7
Art. no. is specified in Required
equipment on page 320 .
Remove the motor by unscrewing its four attach-
ment screws and plain washers.
If required, use the extension 300mm for bits 1/2".
8
Art. no. is specified in Required
equipment on page 320 .
If required, press the motor out of position by fitting
removal tool, motor to the motor attachment screw
holes.
9
Always use the removal tools in
pairs!
Make sure the motor pinion is not
damaged!
Lift the motor carefully to get the pinion away from
the gear and disconnect the brake release voltage.
10
Remove the motor by gently lifting it straight out.
11
Refitting, motor
The procedure below details how to refit motor, axis 6.
Note
Robots with protection type Foundry Plus or Foundry Prime require special repair
routines to maintain the tightness level, in addition to the procedure below,
described in Replacement of the motor axis 6 (Foundry Plus) on page 324 .
Note
Action
Art. no. is specified in Required
equipment on page 320 .
Make sure the o-ring on the circumference of
the motor is seated properly. Lightly lubricate
the o-ring with grease.
1
Connect to connector R3.MP6
•
+: pin 2
•
-: pin 5
In order to release the brake, connect the 24
VDC power supply.
2
Art. no. is specified in Required
equipment on page 320 .
Fit the two guide pins in two of the motor attach-
ment holes.
3
Make sure the pinion on the motor
shaft is not damaged!
Fit the motor, with guidance from the pins,
making sure the motor pinion is properly mated
to the gear of gearbox, axis 6.
4
Remove the guide pins.
5
4 pcs: M8 x 25, tightening torque: 24
Nm.
Secure the motor with its four attachment screws
and plain washers.
6
Art. no. is specified in Required
equipment on page 320 .
If required, use extension 300mm for bits 1/2" .
Disconnect the brake release voltage.
7
Reconnect all connectors beneath the motor
cover.
8
Make sure the cover is tightly sealed!
Refit the cover on top of the motor with its five
attachment screws.
9
Detailed in section Performing a leak-
down test on page 206 .
Perform a leak-down test (if the gearbox has
been drained).
10
Continues on next page
Product manual - IRB 7600
323
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.6 Replacement of motor, axis 6
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 323
|
Note
Action
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, motor
The procedure below details how to remove the motor, axis 6.
Note
Robots with protection type Foundry Plus or Foundry Prime require special repair
routines to maintain the tightness level, in addition to the procedure below,
described in Replacement of the motor axis 6 (Foundry Plus) on page 324 .
Note
Action
Decide which calibration routine to use, and take
actions accordingly prior to beginning the repair
procedure.
1
Move the robot to one of the recommended posi-
tions:
•
to a position where the motor in axis 6 is
pointed straight up. This position enables the
motor to be replaced without draining the
gear oil, which in turn saves time.
•
to a position where the motor in axis 6 is
close to horizontal. This position may be se-
lected when the gearbox is to be replaced,
i.e. when the gearbox oil has to be drained
anyway.
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
Detailed in section Draining oil,
gearbox axis 6 on page 181 .
In horizontal position: drain the oil from the axis 6
gearbox.
4
Remove the rear motor cover by unscrewing the
five attachment screws.
5
Disconnect all connectors beneath the cover.
6
Continues on next page
322
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.6 Replacement of motor, axis 6
Continued
Note
Action
Connect to connector R3.MP6
•
+: pin 2
•
-: pin 5
Connect the 24 VDC power supply to release the
brakes.
7
Art. no. is specified in Required
equipment on page 320 .
Remove the motor by unscrewing its four attach-
ment screws and plain washers.
If required, use the extension 300mm for bits 1/2".
8
Art. no. is specified in Required
equipment on page 320 .
If required, press the motor out of position by fitting
removal tool, motor to the motor attachment screw
holes.
9
Always use the removal tools in
pairs!
Make sure the motor pinion is not
damaged!
Lift the motor carefully to get the pinion away from
the gear and disconnect the brake release voltage.
10
Remove the motor by gently lifting it straight out.
11
Refitting, motor
The procedure below details how to refit motor, axis 6.
Note
Robots with protection type Foundry Plus or Foundry Prime require special repair
routines to maintain the tightness level, in addition to the procedure below,
described in Replacement of the motor axis 6 (Foundry Plus) on page 324 .
Note
Action
Art. no. is specified in Required
equipment on page 320 .
Make sure the o-ring on the circumference of
the motor is seated properly. Lightly lubricate
the o-ring with grease.
1
Connect to connector R3.MP6
•
+: pin 2
•
-: pin 5
In order to release the brake, connect the 24
VDC power supply.
2
Art. no. is specified in Required
equipment on page 320 .
Fit the two guide pins in two of the motor attach-
ment holes.
3
Make sure the pinion on the motor
shaft is not damaged!
Fit the motor, with guidance from the pins,
making sure the motor pinion is properly mated
to the gear of gearbox, axis 6.
4
Remove the guide pins.
5
4 pcs: M8 x 25, tightening torque: 24
Nm.
Secure the motor with its four attachment screws
and plain washers.
6
Art. no. is specified in Required
equipment on page 320 .
If required, use extension 300mm for bits 1/2" .
Disconnect the brake release voltage.
7
Reconnect all connectors beneath the motor
cover.
8
Make sure the cover is tightly sealed!
Refit the cover on top of the motor with its five
attachment screws.
9
Detailed in section Performing a leak-
down test on page 206 .
Perform a leak-down test (if the gearbox has
been drained).
10
Continues on next page
Product manual - IRB 7600
323
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.6 Replacement of motor, axis 6
Continued
Note
Action
Detailed in section Filling oil, gearbox
axis 6 on page 182 .
Refill the gearbox with oil, if it has been drained.
11
Pendulum Calibration is described in
Operating manual - Calibration Pen-
dulum , enclosed with the calibration
tools.
Re-calibrate the robot.
12
Axis Calibration is described in Calib-
rating with Axis Calibration method
on page 383 .
General calibration information is in-
cluded in section Calibration on
page 371 .
DANGER
Make sure all safety requirements are met when
performing the first test run.
13
Replacement of the motor axis 6 (Foundry Plus)
Robots with protection type Foundry Plus require special repair routines to maintain
the tightness level.
The repair must be done according to the previous repair procedure with the
following additions.
Note
Action
Move the robot to one of the recommended
positions:
•
to a position where the motor in axis 6
is pointed straight up. This position en-
ables the motor to be replaced without
draining the gear oil, which in turn saves
time.
•
to a position where the motor in axis 6
is close to horizontal. This position may
be selected when the gearbox is to be
replaced, that is when the gearbox oil
has to be drained anyway.
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
Detailed in section: Draining oil, gear-
box axis 6 on page 181 .
In horizontal position: drain the oil from the
axis 6 gearbox.
3
Continues on next page
324
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.6 Replacement of motor, axis 6
Continued
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ABB_IRB7600_Product_Manual.pdf
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| 324
|
Note
Action
Connect to connector R3.MP6
•
+: pin 2
•
-: pin 5
Connect the 24 VDC power supply to release the
brakes.
7
Art. no. is specified in Required
equipment on page 320 .
Remove the motor by unscrewing its four attach-
ment screws and plain washers.
If required, use the extension 300mm for bits 1/2".
8
Art. no. is specified in Required
equipment on page 320 .
If required, press the motor out of position by fitting
removal tool, motor to the motor attachment screw
holes.
9
Always use the removal tools in
pairs!
Make sure the motor pinion is not
damaged!
Lift the motor carefully to get the pinion away from
the gear and disconnect the brake release voltage.
10
Remove the motor by gently lifting it straight out.
11
Refitting, motor
The procedure below details how to refit motor, axis 6.
Note
Robots with protection type Foundry Plus or Foundry Prime require special repair
routines to maintain the tightness level, in addition to the procedure below,
described in Replacement of the motor axis 6 (Foundry Plus) on page 324 .
Note
Action
Art. no. is specified in Required
equipment on page 320 .
Make sure the o-ring on the circumference of
the motor is seated properly. Lightly lubricate
the o-ring with grease.
1
Connect to connector R3.MP6
•
+: pin 2
•
-: pin 5
In order to release the brake, connect the 24
VDC power supply.
2
Art. no. is specified in Required
equipment on page 320 .
Fit the two guide pins in two of the motor attach-
ment holes.
3
Make sure the pinion on the motor
shaft is not damaged!
Fit the motor, with guidance from the pins,
making sure the motor pinion is properly mated
to the gear of gearbox, axis 6.
4
Remove the guide pins.
5
4 pcs: M8 x 25, tightening torque: 24
Nm.
Secure the motor with its four attachment screws
and plain washers.
6
Art. no. is specified in Required
equipment on page 320 .
If required, use extension 300mm for bits 1/2" .
Disconnect the brake release voltage.
7
Reconnect all connectors beneath the motor
cover.
8
Make sure the cover is tightly sealed!
Refit the cover on top of the motor with its five
attachment screws.
9
Detailed in section Performing a leak-
down test on page 206 .
Perform a leak-down test (if the gearbox has
been drained).
10
Continues on next page
Product manual - IRB 7600
323
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.6 Replacement of motor, axis 6
Continued
Note
Action
Detailed in section Filling oil, gearbox
axis 6 on page 182 .
Refill the gearbox with oil, if it has been drained.
11
Pendulum Calibration is described in
Operating manual - Calibration Pen-
dulum , enclosed with the calibration
tools.
Re-calibrate the robot.
12
Axis Calibration is described in Calib-
rating with Axis Calibration method
on page 383 .
General calibration information is in-
cluded in section Calibration on
page 371 .
DANGER
Make sure all safety requirements are met when
performing the first test run.
13
Replacement of the motor axis 6 (Foundry Plus)
Robots with protection type Foundry Plus require special repair routines to maintain
the tightness level.
The repair must be done according to the previous repair procedure with the
following additions.
Note
Action
Move the robot to one of the recommended
positions:
•
to a position where the motor in axis 6
is pointed straight up. This position en-
ables the motor to be replaced without
draining the gear oil, which in turn saves
time.
•
to a position where the motor in axis 6
is close to horizontal. This position may
be selected when the gearbox is to be
replaced, that is when the gearbox oil
has to be drained anyway.
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
Detailed in section: Draining oil, gear-
box axis 6 on page 181 .
In horizontal position: drain the oil from the
axis 6 gearbox.
3
Continues on next page
324
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.6 Replacement of motor, axis 6
Continued
Note
Action
xx1500002524
Remove the rear motor cover by unscrewing
the five attachment screws.
4
•
A: Motor unit
•
B: Connection box
•
C: Attachment screw (5 pcs)
•
D: Rear motor cover
•
E: Gasket
Continue to remove the motor unit, according
to step 6 and forwards in Removal, motor on
page 322 .
5
Note
Keep the old rear motor cover with the air
nipple.
6
Continues on next page
Product manual - IRB 7600
325
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.6 Replacement of motor, axis 6
Continued
|
ABB_IRB7600_Product_Manual.pdf
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| 325
|
Note
Action
Detailed in section Filling oil, gearbox
axis 6 on page 182 .
Refill the gearbox with oil, if it has been drained.
11
Pendulum Calibration is described in
Operating manual - Calibration Pen-
dulum , enclosed with the calibration
tools.
Re-calibrate the robot.
12
Axis Calibration is described in Calib-
rating with Axis Calibration method
on page 383 .
General calibration information is in-
cluded in section Calibration on
page 371 .
DANGER
Make sure all safety requirements are met when
performing the first test run.
13
Replacement of the motor axis 6 (Foundry Plus)
Robots with protection type Foundry Plus require special repair routines to maintain
the tightness level.
The repair must be done according to the previous repair procedure with the
following additions.
Note
Action
Move the robot to one of the recommended
positions:
•
to a position where the motor in axis 6
is pointed straight up. This position en-
ables the motor to be replaced without
draining the gear oil, which in turn saves
time.
•
to a position where the motor in axis 6
is close to horizontal. This position may
be selected when the gearbox is to be
replaced, that is when the gearbox oil
has to be drained anyway.
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
Detailed in section: Draining oil, gear-
box axis 6 on page 181 .
In horizontal position: drain the oil from the
axis 6 gearbox.
3
Continues on next page
324
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.6 Replacement of motor, axis 6
Continued
Note
Action
xx1500002524
Remove the rear motor cover by unscrewing
the five attachment screws.
4
•
A: Motor unit
•
B: Connection box
•
C: Attachment screw (5 pcs)
•
D: Rear motor cover
•
E: Gasket
Continue to remove the motor unit, according
to step 6 and forwards in Removal, motor on
page 322 .
5
Note
Keep the old rear motor cover with the air
nipple.
6
Continues on next page
Product manual - IRB 7600
325
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.6 Replacement of motor, axis 6
Continued
Note
Action
![Image]
xx1500002425
Remove the protection strip on the gasket and
mount it on the motor .
7
•
A: Attachment screw (4pcs)
Mercasol 3106
•
B: Motor unit
•
C: O-ring
•
D: Sikaflex in screw recesses
•
E: Tilt house
•
F: Washer
•
G: Rear motor cover
•
H: Sealing
•
J: Loctite 574
Apply Mercasol 3106 on the motor end cover .
8
![Image]
xx1400000992
Apply Loctite 574 flange sealant on the contact
surface.
9
Apply grease on the o-ring on the motor .
10
Continue to refit the new motor according to
section, Refitting, motor on page 323 .
11
326
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.6 Replacement of motor, axis 6
Continued
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| 326
|
Note
Action
xx1500002524
Remove the rear motor cover by unscrewing
the five attachment screws.
4
•
A: Motor unit
•
B: Connection box
•
C: Attachment screw (5 pcs)
•
D: Rear motor cover
•
E: Gasket
Continue to remove the motor unit, according
to step 6 and forwards in Removal, motor on
page 322 .
5
Note
Keep the old rear motor cover with the air
nipple.
6
Continues on next page
Product manual - IRB 7600
325
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.6 Replacement of motor, axis 6
Continued
Note
Action
![Image]
xx1500002425
Remove the protection strip on the gasket and
mount it on the motor .
7
•
A: Attachment screw (4pcs)
Mercasol 3106
•
B: Motor unit
•
C: O-ring
•
D: Sikaflex in screw recesses
•
E: Tilt house
•
F: Washer
•
G: Rear motor cover
•
H: Sealing
•
J: Loctite 574
Apply Mercasol 3106 on the motor end cover .
8
![Image]
xx1400000992
Apply Loctite 574 flange sealant on the contact
surface.
9
Apply grease on the o-ring on the motor .
10
Continue to refit the new motor according to
section, Refitting, motor on page 323 .
11
326
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.6 Replacement of motor, axis 6
Continued
4.7 Gearboxes
4.7.1 Replacing the axis 1 gearbox
Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure.
xx0100000133
Gearbox, axis 1
A
Oil plug, filling
B
Attachment screws, gearbox to frame
C
Frame
D
Base
E
Attachment screws, base to gearbox (not shown in figure)
-
Required equipment
Note
Art. no.
Equipment, etc.
Includes:
•
gearbox
•
all o-rings and sealing rings
For spare part no. see:
•
Spare part lists on
page 425 .
Gearbox
Replace if damaged!
3HAB3772-54
O-ring
Replace if damaged!
3HAB3772-55
O-ring
Replace if damaged!
3HAC11581-4
Sealing ring
Continues on next page
Product manual - IRB 7600
327
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
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ABB_IRB7600_Product_Manual.pdf
|
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| 327
|
Note
Action
![Image]
xx1500002425
Remove the protection strip on the gasket and
mount it on the motor .
7
•
A: Attachment screw (4pcs)
Mercasol 3106
•
B: Motor unit
•
C: O-ring
•
D: Sikaflex in screw recesses
•
E: Tilt house
•
F: Washer
•
G: Rear motor cover
•
H: Sealing
•
J: Loctite 574
Apply Mercasol 3106 on the motor end cover .
8
![Image]
xx1400000992
Apply Loctite 574 flange sealant on the contact
surface.
9
Apply grease on the o-ring on the motor .
10
Continue to refit the new motor according to
section, Refitting, motor on page 323 .
11
326
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.6.6 Replacement of motor, axis 6
Continued
4.7 Gearboxes
4.7.1 Replacing the axis 1 gearbox
Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure.
xx0100000133
Gearbox, axis 1
A
Oil plug, filling
B
Attachment screws, gearbox to frame
C
Frame
D
Base
E
Attachment screws, base to gearbox (not shown in figure)
-
Required equipment
Note
Art. no.
Equipment, etc.
Includes:
•
gearbox
•
all o-rings and sealing rings
For spare part no. see:
•
Spare part lists on
page 425 .
Gearbox
Replace if damaged!
3HAB3772-54
O-ring
Replace if damaged!
3HAB3772-55
O-ring
Replace if damaged!
3HAC11581-4
Sealing ring
Continues on next page
Product manual - IRB 7600
327
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Note
Art. no.
Equipment, etc.
Shell Gadus S2
3HAC042536-001
Grease
For lubricating the o-ring.
3HAC15535-1
Support, base and gear 1
3HAC15560-1
Lifting accessory, base
3HAC15556-1
Lifting accessory (chain)
2 pcs, M16x150.
Guide pins
Used for guiding the gearbox into
place in the base.
Always use guide pins in pairs!
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
Calibration
Required if Axis Calibration is the
valid calibration method for the ro-
bot.
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
These procedures include refer-
ences to the tools required.
Other tools and procedures
may be required. See refer-
ences to these procedures
in the step-by-step instruc-
tions 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.
Continues on next page
328
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 328
|
4.7 Gearboxes
4.7.1 Replacing the axis 1 gearbox
Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure.
xx0100000133
Gearbox, axis 1
A
Oil plug, filling
B
Attachment screws, gearbox to frame
C
Frame
D
Base
E
Attachment screws, base to gearbox (not shown in figure)
-
Required equipment
Note
Art. no.
Equipment, etc.
Includes:
•
gearbox
•
all o-rings and sealing rings
For spare part no. see:
•
Spare part lists on
page 425 .
Gearbox
Replace if damaged!
3HAB3772-54
O-ring
Replace if damaged!
3HAB3772-55
O-ring
Replace if damaged!
3HAC11581-4
Sealing ring
Continues on next page
Product manual - IRB 7600
327
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Note
Art. no.
Equipment, etc.
Shell Gadus S2
3HAC042536-001
Grease
For lubricating the o-ring.
3HAC15535-1
Support, base and gear 1
3HAC15560-1
Lifting accessory, base
3HAC15556-1
Lifting accessory (chain)
2 pcs, M16x150.
Guide pins
Used for guiding the gearbox into
place in the base.
Always use guide pins in pairs!
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
Calibration
Required if Axis Calibration is the
valid calibration method for the ro-
bot.
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
These procedures include refer-
ences to the tools required.
Other tools and procedures
may be required. See refer-
ences to these procedures
in the step-by-step instruc-
tions 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.
Continues on next page
328
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
Note
Action
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
Removal, gearbox axis 1
Use this procedure to remove gearbox, axis 1.
Note
Action
Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.
1
xx0300000022
Move the robot to its most stable position,
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
See Changing oil, axis-1 gearbox on
page 163 .
Drain the axis 1 gearbox.
4
Detailed in section Replacement of com-
plete arm system on page 227 .
Remove the complete arm system.
5
Unfasten the robot base from the foundation
by removing the base attachment screws.
6
Continues on next page
Product manual - IRB 7600
329
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 329
|
Note
Art. no.
Equipment, etc.
Shell Gadus S2
3HAC042536-001
Grease
For lubricating the o-ring.
3HAC15535-1
Support, base and gear 1
3HAC15560-1
Lifting accessory, base
3HAC15556-1
Lifting accessory (chain)
2 pcs, M16x150.
Guide pins
Used for guiding the gearbox into
place in the base.
Always use guide pins in pairs!
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
Calibration
Required if Axis Calibration is the
valid calibration method for the ro-
bot.
Content is defined in section
Standard tools on page 419 .
-
Standard toolkit
These procedures include refer-
ences to the tools required.
Other tools and procedures
may be required. See refer-
ences to these procedures
in the step-by-step instruc-
tions 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.
Continues on next page
328
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
Note
Action
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
Removal, gearbox axis 1
Use this procedure to remove gearbox, axis 1.
Note
Action
Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.
1
xx0300000022
Move the robot to its most stable position,
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
See Changing oil, axis-1 gearbox on
page 163 .
Drain the axis 1 gearbox.
4
Detailed in section Replacement of com-
plete arm system on page 227 .
Remove the complete arm system.
5
Unfasten the robot base from the foundation
by removing the base attachment screws.
6
Continues on next page
Product manual - IRB 7600
329
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
Note
Action
![Image]
xx1000001395
Attach the lifting accessory, base and gear
1 and the lifting tool (chain) to the gearbox
and base.
7
Specified in Required equipment on
page 327 .
CAUTION
The base and axis 1 gearbox weighs 310
kg + 200 Kg.
All lifting accessories used must be sized
accordingly!
8
Art. no. is specified in Required equip-
ment on page 327 .
Lift the robot base including the axis 1
gearbox to allow the base and gear 1 sup-
port be fitted on each sides of the base.
9
![Image]
xx1000000364
A
Support base (4 pcs)
Secure the support to the base and to the
foundation.
Make sure the base remains in a stable
position before performing any work under-
neath the base!
10
Continues on next page
330
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
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ABB_IRB7600_Product_Manual.pdf
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| 330
|
Note
Action
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
Removal, gearbox axis 1
Use this procedure to remove gearbox, axis 1.
Note
Action
Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.
1
xx0300000022
Move the robot to its most stable position,
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
See Changing oil, axis-1 gearbox on
page 163 .
Drain the axis 1 gearbox.
4
Detailed in section Replacement of com-
plete arm system on page 227 .
Remove the complete arm system.
5
Unfasten the robot base from the foundation
by removing the base attachment screws.
6
Continues on next page
Product manual - IRB 7600
329
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
Note
Action
![Image]
xx1000001395
Attach the lifting accessory, base and gear
1 and the lifting tool (chain) to the gearbox
and base.
7
Specified in Required equipment on
page 327 .
CAUTION
The base and axis 1 gearbox weighs 310
kg + 200 Kg.
All lifting accessories used must be sized
accordingly!
8
Art. no. is specified in Required equip-
ment on page 327 .
Lift the robot base including the axis 1
gearbox to allow the base and gear 1 sup-
port be fitted on each sides of the base.
9
![Image]
xx1000000364
A
Support base (4 pcs)
Secure the support to the base and to the
foundation.
Make sure the base remains in a stable
position before performing any work under-
neath the base!
10
Continues on next page
330
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
Note
Action
![Image]
xx1000001385
Remove the bottom plate from underneath
the base in order to get access to the attach-
ment screws.
It may be necessary to also remove the rear
connector plate.
11
xx0300000612
A
Bottom plate
B
Rear connector plate
C
Attachment screw
D
Groove
xx0200000227
A view from below:
•
A: Oil drain hose
•
B: Attachment screws, gearbox
axis 1, 18 pcs
•
C: Washers, 3 pcs
Unscrew the attachment screws and re-
move the washers.
12
Continues on next page
Product manual - IRB 7600
331
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
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ABB_IRB7600_Product_Manual.pdf
|
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| 331
|
Note
Action
![Image]
xx1000001395
Attach the lifting accessory, base and gear
1 and the lifting tool (chain) to the gearbox
and base.
7
Specified in Required equipment on
page 327 .
CAUTION
The base and axis 1 gearbox weighs 310
kg + 200 Kg.
All lifting accessories used must be sized
accordingly!
8
Art. no. is specified in Required equip-
ment on page 327 .
Lift the robot base including the axis 1
gearbox to allow the base and gear 1 sup-
port be fitted on each sides of the base.
9
![Image]
xx1000000364
A
Support base (4 pcs)
Secure the support to the base and to the
foundation.
Make sure the base remains in a stable
position before performing any work under-
neath the base!
10
Continues on next page
330
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
Note
Action
![Image]
xx1000001385
Remove the bottom plate from underneath
the base in order to get access to the attach-
ment screws.
It may be necessary to also remove the rear
connector plate.
11
xx0300000612
A
Bottom plate
B
Rear connector plate
C
Attachment screw
D
Groove
xx0200000227
A view from below:
•
A: Oil drain hose
•
B: Attachment screws, gearbox
axis 1, 18 pcs
•
C: Washers, 3 pcs
Unscrew the attachment screws and re-
move the washers.
12
Continues on next page
Product manual - IRB 7600
331
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
Note
Action
![Image]
xx1000001387
Remove the cable guide in the center of
gearbox 1 by unscrewing its attachment
screws.
13
CAUTION
The gearbox weighs 200 Kg.
All lifting accessories used must be sized
accordingly!
14
Lift the gearbox away with the already
mounted lifting tools.
15
![Image]
xx1400000786
Turn the gearbox, and remove the protec-
tion pipe by unscrewing two attachment
screws.
Note
Move the protective pipe over to the new
gearbox.
16
Continues on next page
332
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 332
|
Note
Action
![Image]
xx1000001385
Remove the bottom plate from underneath
the base in order to get access to the attach-
ment screws.
It may be necessary to also remove the rear
connector plate.
11
xx0300000612
A
Bottom plate
B
Rear connector plate
C
Attachment screw
D
Groove
xx0200000227
A view from below:
•
A: Oil drain hose
•
B: Attachment screws, gearbox
axis 1, 18 pcs
•
C: Washers, 3 pcs
Unscrew the attachment screws and re-
move the washers.
12
Continues on next page
Product manual - IRB 7600
331
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
Note
Action
![Image]
xx1000001387
Remove the cable guide in the center of
gearbox 1 by unscrewing its attachment
screws.
13
CAUTION
The gearbox weighs 200 Kg.
All lifting accessories used must be sized
accordingly!
14
Lift the gearbox away with the already
mounted lifting tools.
15
![Image]
xx1400000786
Turn the gearbox, and remove the protec-
tion pipe by unscrewing two attachment
screws.
Note
Move the protective pipe over to the new
gearbox.
16
Continues on next page
332
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
Refitting, gearbox axis 1
Use this procedure to refit gearbox, axis 1.
Note
Action
Mounting of the support, base and gear
1 is detailed in section Removal, gear-
box axis 1 on page 329 .
![Image]
xx1000000364
A
Support base (4 pcs)
Fit the support, base and gear 1 to the base.
1
Art no. is specified in Required equip-
ment on page 327 .
xx0200000055
•
A: Guide pin
•
C: O-ring 3HAB 3772-54
•
D: O-ring 3HAB 3772-55
•
E: Sealing ring 3HAC 11581-4
Make sure the two o-rings on the circumfer-
ence of the gearbox are seated properly in
their respective groove. Lubricate them with
grease .
2
Continues on next page
Product manual - IRB 7600
333
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 333
|
Note
Action
![Image]
xx1000001387
Remove the cable guide in the center of
gearbox 1 by unscrewing its attachment
screws.
13
CAUTION
The gearbox weighs 200 Kg.
All lifting accessories used must be sized
accordingly!
14
Lift the gearbox away with the already
mounted lifting tools.
15
![Image]
xx1400000786
Turn the gearbox, and remove the protec-
tion pipe by unscrewing two attachment
screws.
Note
Move the protective pipe over to the new
gearbox.
16
Continues on next page
332
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
Refitting, gearbox axis 1
Use this procedure to refit gearbox, axis 1.
Note
Action
Mounting of the support, base and gear
1 is detailed in section Removal, gear-
box axis 1 on page 329 .
![Image]
xx1000000364
A
Support base (4 pcs)
Fit the support, base and gear 1 to the base.
1
Art no. is specified in Required equip-
ment on page 327 .
xx0200000055
•
A: Guide pin
•
C: O-ring 3HAB 3772-54
•
D: O-ring 3HAB 3772-55
•
E: Sealing ring 3HAC 11581-4
Make sure the two o-rings on the circumfer-
ence of the gearbox are seated properly in
their respective groove. Lubricate them with
grease .
2
Continues on next page
Product manual - IRB 7600
333
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
Note
Action
![Image]
xx1000001392
Make sure the small o-ring around the oil hole
is fitted properly!
3
Specified in Required equipment on
page 327 .
![Image]
xx1000001395
Attach the lifting accessory, base and gear 1
and the lifting tool (chain) to the gearbox.
4
Specified in Required equipment on
page 327 .
Fit two guide pins in two of the attachment
holes in the gearbox, parallel to each other.
5
CAUTION
The gearbox weighs 200 Kg.
All lifting accessories used must be sized ac-
cordingly!
6
Continues on next page
334
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 334
|
Refitting, gearbox axis 1
Use this procedure to refit gearbox, axis 1.
Note
Action
Mounting of the support, base and gear
1 is detailed in section Removal, gear-
box axis 1 on page 329 .
![Image]
xx1000000364
A
Support base (4 pcs)
Fit the support, base and gear 1 to the base.
1
Art no. is specified in Required equip-
ment on page 327 .
xx0200000055
•
A: Guide pin
•
C: O-ring 3HAB 3772-54
•
D: O-ring 3HAB 3772-55
•
E: Sealing ring 3HAC 11581-4
Make sure the two o-rings on the circumfer-
ence of the gearbox are seated properly in
their respective groove. Lubricate them with
grease .
2
Continues on next page
Product manual - IRB 7600
333
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
Note
Action
![Image]
xx1000001392
Make sure the small o-ring around the oil hole
is fitted properly!
3
Specified in Required equipment on
page 327 .
![Image]
xx1000001395
Attach the lifting accessory, base and gear 1
and the lifting tool (chain) to the gearbox.
4
Specified in Required equipment on
page 327 .
Fit two guide pins in two of the attachment
holes in the gearbox, parallel to each other.
5
CAUTION
The gearbox weighs 200 Kg.
All lifting accessories used must be sized ac-
cordingly!
6
Continues on next page
334
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
Note
Action
![Image]
xx1000001389
Lift the gearbox.
Make sure the guide pin in the bottom face of
the gearbox is properly aligned with the base.
7
![Image]
xx1000001391
Always use guide pins in pairs!
Lift gearbox axis 1 onto the guide pins and
lower it carefully to its mounting position.
8
Continues on next page
Product manual - IRB 7600
335
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 335
|
Note
Action
![Image]
xx1000001392
Make sure the small o-ring around the oil hole
is fitted properly!
3
Specified in Required equipment on
page 327 .
![Image]
xx1000001395
Attach the lifting accessory, base and gear 1
and the lifting tool (chain) to the gearbox.
4
Specified in Required equipment on
page 327 .
Fit two guide pins in two of the attachment
holes in the gearbox, parallel to each other.
5
CAUTION
The gearbox weighs 200 Kg.
All lifting accessories used must be sized ac-
cordingly!
6
Continues on next page
334
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
Note
Action
![Image]
xx1000001389
Lift the gearbox.
Make sure the guide pin in the bottom face of
the gearbox is properly aligned with the base.
7
![Image]
xx1000001391
Always use guide pins in pairs!
Lift gearbox axis 1 onto the guide pins and
lower it carefully to its mounting position.
8
Continues on next page
Product manual - IRB 7600
335
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
Note
Action
18 pcs, M16 x 90, 12.9 quality UN-
BRAKO.
Secure the gearbox with its attachment
screws and washers.
9
Tightening torque: 300 Nm
Reused screws may be used, providing
they are lubricated as detailed in sec-
tion Screw joints on page415 before fit-
ting.
xx0200000227
A view from below:
•
A: Oil drain hose
•
B: Attachment screws, gearbox
axis 1, 18 pcs
•
C: Washers, 3 pcs
![Image]
xx1000001393
Refit the cable guide in the center of gearbox
1 with its attachment screws.
10
Continues on next page
336
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the 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
| 336
|
Note
Action
![Image]
xx1000001389
Lift the gearbox.
Make sure the guide pin in the bottom face of
the gearbox is properly aligned with the base.
7
![Image]
xx1000001391
Always use guide pins in pairs!
Lift gearbox axis 1 onto the guide pins and
lower it carefully to its mounting position.
8
Continues on next page
Product manual - IRB 7600
335
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
Note
Action
18 pcs, M16 x 90, 12.9 quality UN-
BRAKO.
Secure the gearbox with its attachment
screws and washers.
9
Tightening torque: 300 Nm
Reused screws may be used, providing
they are lubricated as detailed in sec-
tion Screw joints on page415 before fit-
ting.
xx0200000227
A view from below:
•
A: Oil drain hose
•
B: Attachment screws, gearbox
axis 1, 18 pcs
•
C: Washers, 3 pcs
![Image]
xx1000001393
Refit the cable guide in the center of gearbox
1 with its attachment screws.
10
Continues on next page
336
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
Note
Action
1 screw: M6 x 8.
xx0300000612
Refit the bottom plate underneath the robot
base by pushing it into the groove and fitting
the attachment screw.
If removed, also refit the rear connector plate.
Note
Direct the bends on the bottom plate down-
wards!
11
•
A: Bottom plate
•
B: Rear connector plate
•
C: Attachment screw
•
D: Groove
CAUTION
The base and axis 1 gearbox weighs 310 kg
+ 200 Kg.
All lifting accessories used must be sized ac-
cordingly!
12
Lift the robot base and gearbox 1 and remove
the base and gear support.
13
See Orienting and securing the robot
on page 80 .
Secure the base to the mounting site.
14
Detailed in section Replacing the axis
1 gearbox on page 327 .
Refit the complete arm system.
CAUTION
This is a complex task to be performed with
utmost care in order to avoid injury or dam-
age!
15
See section Performing a leak-down
test on page 206 .
Perform a leak-down test.
16
See Changing oil, axis-1 gearbox on
page 163 .
Refill the gearbox with oil.
17
Pendulum Calibration is described in
Operating manual - Calibration Pendu-
lum , enclosed with the calibration tools.
Recalibrate the robot.
18
Axis Calibration is described in Calibrat-
ing with Axis Calibration method on
page 383 .
General calibration information is in-
cluded in section Calibration on
page 371 .
DANGER
Make sure all safety requirements are met
when performing the first test run.
19
Product manual - IRB 7600
337
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
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| 337
|
Note
Action
18 pcs, M16 x 90, 12.9 quality UN-
BRAKO.
Secure the gearbox with its attachment
screws and washers.
9
Tightening torque: 300 Nm
Reused screws may be used, providing
they are lubricated as detailed in sec-
tion Screw joints on page415 before fit-
ting.
xx0200000227
A view from below:
•
A: Oil drain hose
•
B: Attachment screws, gearbox
axis 1, 18 pcs
•
C: Washers, 3 pcs
![Image]
xx1000001393
Refit the cable guide in the center of gearbox
1 with its attachment screws.
10
Continues on next page
336
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
Note
Action
1 screw: M6 x 8.
xx0300000612
Refit the bottom plate underneath the robot
base by pushing it into the groove and fitting
the attachment screw.
If removed, also refit the rear connector plate.
Note
Direct the bends on the bottom plate down-
wards!
11
•
A: Bottom plate
•
B: Rear connector plate
•
C: Attachment screw
•
D: Groove
CAUTION
The base and axis 1 gearbox weighs 310 kg
+ 200 Kg.
All lifting accessories used must be sized ac-
cordingly!
12
Lift the robot base and gearbox 1 and remove
the base and gear support.
13
See Orienting and securing the robot
on page 80 .
Secure the base to the mounting site.
14
Detailed in section Replacing the axis
1 gearbox on page 327 .
Refit the complete arm system.
CAUTION
This is a complex task to be performed with
utmost care in order to avoid injury or dam-
age!
15
See section Performing a leak-down
test on page 206 .
Perform a leak-down test.
16
See Changing oil, axis-1 gearbox on
page 163 .
Refill the gearbox with oil.
17
Pendulum Calibration is described in
Operating manual - Calibration Pendu-
lum , enclosed with the calibration tools.
Recalibrate the robot.
18
Axis Calibration is described in Calibrat-
ing with Axis Calibration method on
page 383 .
General calibration information is in-
cluded in section Calibration on
page 371 .
DANGER
Make sure all safety requirements are met
when performing the first test run.
19
Product manual - IRB 7600
337
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
4.7.2 Replacement of gearbox, axis 2
Location of gearbox
The axis 2 gearbox is located in the lower arm rotational center as shown in the
figure below.
A more detailed view of the component and its position may be found in chapter
Exploded views in Product manual, spare parts - IRB 7600 .
xx0100000135
Gearbox, axis 2 (behind motor attachment not shown in figure )
A
Motor, axis 2
B
Oil plug, filling
C
Oil plug, draining
D
Front gearbox attachment screws
E
Attachment holes, fixture lower arm
F
Motor attachment
G
Hole for locking screw, lower arm, M16 x 60
I
Sealing (between gearbox and motor attachment, not shown in figure )
-
Friction washer (between the gearbox and lower arm, not shown in figure )
-
Continues on next page
338
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.2 Replacement of gearbox, axis 2
|
ABB_IRB7600_Product_Manual.pdf
|
https://search.abb.com/library/Download.aspx?DocumentID=3HAC022033-001&LanguageCode=en&DocumentPartId=&Action=Launch&DocumentRevisionId=AF
| 338
|
Note
Action
1 screw: M6 x 8.
xx0300000612
Refit the bottom plate underneath the robot
base by pushing it into the groove and fitting
the attachment screw.
If removed, also refit the rear connector plate.
Note
Direct the bends on the bottom plate down-
wards!
11
•
A: Bottom plate
•
B: Rear connector plate
•
C: Attachment screw
•
D: Groove
CAUTION
The base and axis 1 gearbox weighs 310 kg
+ 200 Kg.
All lifting accessories used must be sized ac-
cordingly!
12
Lift the robot base and gearbox 1 and remove
the base and gear support.
13
See Orienting and securing the robot
on page 80 .
Secure the base to the mounting site.
14
Detailed in section Replacing the axis
1 gearbox on page 327 .
Refit the complete arm system.
CAUTION
This is a complex task to be performed with
utmost care in order to avoid injury or dam-
age!
15
See section Performing a leak-down
test on page 206 .
Perform a leak-down test.
16
See Changing oil, axis-1 gearbox on
page 163 .
Refill the gearbox with oil.
17
Pendulum Calibration is described in
Operating manual - Calibration Pendu-
lum , enclosed with the calibration tools.
Recalibrate the robot.
18
Axis Calibration is described in Calibrat-
ing with Axis Calibration method on
page 383 .
General calibration information is in-
cluded in section Calibration on
page 371 .
DANGER
Make sure all safety requirements are met
when performing the first test run.
19
Product manual - IRB 7600
337
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.1 Replacing the axis 1 gearbox
Continued
4.7.2 Replacement of gearbox, axis 2
Location of gearbox
The axis 2 gearbox is located in the lower arm rotational center as shown in the
figure below.
A more detailed view of the component and its position may be found in chapter
Exploded views in Product manual, spare parts - IRB 7600 .
xx0100000135
Gearbox, axis 2 (behind motor attachment not shown in figure )
A
Motor, axis 2
B
Oil plug, filling
C
Oil plug, draining
D
Front gearbox attachment screws
E
Attachment holes, fixture lower arm
F
Motor attachment
G
Hole for locking screw, lower arm, M16 x 60
I
Sealing (between gearbox and motor attachment, not shown in figure )
-
Friction washer (between the gearbox and lower arm, not shown in figure )
-
Continues on next page
338
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.2 Replacement of gearbox, axis 2
Required equipment
Note
Article number
Spare part num-
ber
Equipment, etc.
Includes gearbox and o-
ring
3HAC12641-1
Gearbox, axis 2
3HAB3772-51
O-ring
A new sealing must be
used on each assembly!
3HAC17213-1
Sealing, axis 2/3
For lubricating the o-ring.
3HAC042536-
001
Grease
Content is defined in sec-
tion Standard tools on
page 419 .
-
Standard toolkit
3HAC032723-
001
Lifting accessory, axis-2 and
axis-3 gear
3HAC13660-1
Fixture lower arm
M16 x 60 8.8.
Locking screw, lower arm
Included in the fixture,
lower arm.
To be used in pairs!
3HAC13120-2
Guide pins M16 x 150
To be used in pairs!
3HAC13120-3
Guide pins M16 x 200
For guiding the gearbox.
3HAC13120-5
Guide pins M16 x 300
Always use the guide pins
in pairs.
For guiding the sealing ax-
is 2/3. Guides are to be
used in pairs!
3HAC14627-2
Guide pins, sealing ax 2/3,
80mm
For guiding the sealing ax-
is 2/3. Guides are to be
used in pairs!
3HAC14627-3
Guide pins, sealing ax 2/3,
100mm
Complete kit that also in-
cludes operating manual.
3HAC15716-1
Calibration Pendulum toolkit
Required if Calibration
Pendulum is the valid calib-
ration method for the robot.
Delivered as a set of calib-
ration tools.
3HAC055412-
001
Calibration tool box, Axis
Calibration
Required if Axis Calibration
is the valid calibration
method for the robot.
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 instruc-
tions below.
Continues on next page
Product manual - IRB 7600
339
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.2 Replacement of gearbox, axis 2
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
https://search.abb.com/library/Download.aspx?DocumentID=3HAC022033-001&LanguageCode=en&DocumentPartId=&Action=Launch&DocumentRevisionId=AF
| 339
|
4.7.2 Replacement of gearbox, axis 2
Location of gearbox
The axis 2 gearbox is located in the lower arm rotational center as shown in the
figure below.
A more detailed view of the component and its position may be found in chapter
Exploded views in Product manual, spare parts - IRB 7600 .
xx0100000135
Gearbox, axis 2 (behind motor attachment not shown in figure )
A
Motor, axis 2
B
Oil plug, filling
C
Oil plug, draining
D
Front gearbox attachment screws
E
Attachment holes, fixture lower arm
F
Motor attachment
G
Hole for locking screw, lower arm, M16 x 60
I
Sealing (between gearbox and motor attachment, not shown in figure )
-
Friction washer (between the gearbox and lower arm, not shown in figure )
-
Continues on next page
338
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.2 Replacement of gearbox, axis 2
Required equipment
Note
Article number
Spare part num-
ber
Equipment, etc.
Includes gearbox and o-
ring
3HAC12641-1
Gearbox, axis 2
3HAB3772-51
O-ring
A new sealing must be
used on each assembly!
3HAC17213-1
Sealing, axis 2/3
For lubricating the o-ring.
3HAC042536-
001
Grease
Content is defined in sec-
tion Standard tools on
page 419 .
-
Standard toolkit
3HAC032723-
001
Lifting accessory, axis-2 and
axis-3 gear
3HAC13660-1
Fixture lower arm
M16 x 60 8.8.
Locking screw, lower arm
Included in the fixture,
lower arm.
To be used in pairs!
3HAC13120-2
Guide pins M16 x 150
To be used in pairs!
3HAC13120-3
Guide pins M16 x 200
For guiding the gearbox.
3HAC13120-5
Guide pins M16 x 300
Always use the guide pins
in pairs.
For guiding the sealing ax-
is 2/3. Guides are to be
used in pairs!
3HAC14627-2
Guide pins, sealing ax 2/3,
80mm
For guiding the sealing ax-
is 2/3. Guides are to be
used in pairs!
3HAC14627-3
Guide pins, sealing ax 2/3,
100mm
Complete kit that also in-
cludes operating manual.
3HAC15716-1
Calibration Pendulum toolkit
Required if Calibration
Pendulum is the valid calib-
ration method for the robot.
Delivered as a set of calib-
ration tools.
3HAC055412-
001
Calibration tool box, Axis
Calibration
Required if Axis Calibration
is the valid calibration
method for the robot.
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 instruc-
tions below.
Continues on next page
Product manual - IRB 7600
339
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.2 Replacement of gearbox, axis 2
Continued
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, gearbox
The procedure below details how to remove gearbox, axis 2.
Note
Action
Decide which calibration routine to use, and take
actions accordingly prior to beginning the repair
procedure.
1
Remove any equipment fitted to the turning disk.
2
xx0200000260
Run the robot to the calibration position. The up-
per arm may be directed in three different ways,
shown in figure to the right.
The lowered position, as in figure A, is recommen-
ded as it gives the least load on the tool.
3
Continues on next page
340
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.2 Replacement of gearbox, axis 2
Continued
|
ABB_IRB7600_Product_Manual.pdf
|
https://search.abb.com/library/Download.aspx?DocumentID=3HAC022033-001&LanguageCode=en&DocumentPartId=&Action=Launch&DocumentRevisionId=AF
| 340
|
Required equipment
Note
Article number
Spare part num-
ber
Equipment, etc.
Includes gearbox and o-
ring
3HAC12641-1
Gearbox, axis 2
3HAB3772-51
O-ring
A new sealing must be
used on each assembly!
3HAC17213-1
Sealing, axis 2/3
For lubricating the o-ring.
3HAC042536-
001
Grease
Content is defined in sec-
tion Standard tools on
page 419 .
-
Standard toolkit
3HAC032723-
001
Lifting accessory, axis-2 and
axis-3 gear
3HAC13660-1
Fixture lower arm
M16 x 60 8.8.
Locking screw, lower arm
Included in the fixture,
lower arm.
To be used in pairs!
3HAC13120-2
Guide pins M16 x 150
To be used in pairs!
3HAC13120-3
Guide pins M16 x 200
For guiding the gearbox.
3HAC13120-5
Guide pins M16 x 300
Always use the guide pins
in pairs.
For guiding the sealing ax-
is 2/3. Guides are to be
used in pairs!
3HAC14627-2
Guide pins, sealing ax 2/3,
80mm
For guiding the sealing ax-
is 2/3. Guides are to be
used in pairs!
3HAC14627-3
Guide pins, sealing ax 2/3,
100mm
Complete kit that also in-
cludes operating manual.
3HAC15716-1
Calibration Pendulum toolkit
Required if Calibration
Pendulum is the valid calib-
ration method for the robot.
Delivered as a set of calib-
ration tools.
3HAC055412-
001
Calibration tool box, Axis
Calibration
Required if Axis Calibration
is the valid calibration
method for the robot.
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 instruc-
tions below.
Continues on next page
Product manual - IRB 7600
339
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.2 Replacement of gearbox, axis 2
Continued
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, gearbox
The procedure below details how to remove gearbox, axis 2.
Note
Action
Decide which calibration routine to use, and take
actions accordingly prior to beginning the repair
procedure.
1
Remove any equipment fitted to the turning disk.
2
xx0200000260
Run the robot to the calibration position. The up-
per arm may be directed in three different ways,
shown in figure to the right.
The lowered position, as in figure A, is recommen-
ded as it gives the least load on the tool.
3
Continues on next page
340
Product manual - IRB 7600
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.2 Replacement of gearbox, axis 2
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.
4
If the robot is fitted with moveable mechanical
stops on axis 2 (not stock equipment), these must
be removed at this point.
The attachment holes of the mechanical stops
are used to attach the fixture, lower arm.
5
Art. no. is specified in Required
equipment on page 339 !
Secure the lower arm to the frame by inserting
the locking screw into the hole.
6
Shown in the figure Location of
gearbox on page 338 !
Art. no. is specified in Required
equipment on page 339 !
Fit the fixture, lower arm to prevent the lower arm
from falling.
•
Make sure that both adjusters (B) on the
fixture are screwed back.
•
Align the fixture with the frame and lower
arm.
•
Tighten the four M16 bolts (C) on the in-
side of the frame, in attachment holes, with
tightening torque: 220 Nm.
•
Screw in the two adjusters (B) until they
rest against the flats on the lower arm.
Tighten by hand.
•
Lock, using the two ring nuts (D).
•
Tighten the two M12 bolts (E) in the attach-
ment holes, fixture lower arm with tighten-
ing torque: 91 Nm.
7
Attachment holes for the fixture are
shown in the figure Location of
gearbox on page 338 !
Make sure the fixture is pressed
tightly against the lower arm before
securing with screws!
xx0200000261
•
A: Locking screw, lower arm
Detailed in section Unloading the
balancing device on page 283 .
Unload the balancing device shaft by using a
specific press tool.
DANGER
Handling the tool incorrectly will cause serious
injury.
Read and follow enclosed user instructions for
the tool.
The power for brake release is only applied for
180 seconds after activation.
8
Detailed in section Draining, oil on
page 168 .
Drain the gearbox, axis 2.
9
Continues on next page
Product manual - IRB 7600
341
3HAC022033-001 Revision: AF
© Copyright 2007 - 2022 ABB. All rights reserved.
4 Repair
4.7.2 Replacement of gearbox, axis 2
Continued
|
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