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Product manual (part 2 of 2), reference information
IRB 7600 - 500/2.3
IRB 7600 - 400/2.55
IRB 7600 - 340/2.8
IRB 7600 - 150/3.5
M2000
M2000A
M2004
Document ID: 3HAC 022033-001

Revision: B
The information in this manual is subject to change without notice and should not be
construed as a commitment by ABB. ABB assumes no responsibility for any errors that
may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to persons
or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's written
permission, and contents thereof must not be imparted to a third party nor be used for
any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
© Copyright 2004 ABB All right reserved.

ABB Automation Technologies AB
Robotics
SE-721 68 Västerås
Sweden
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Reference information 11
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Applicable Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.6 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.7 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.8 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.9 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 Part list 25
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2 Rebuilding parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.3 Part List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3.1 Part list, overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3.2 Mechanical stop ax 1, 3HAC 12812-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3.3 Base incl frame ax 1, 3HAC 12304-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3.4 Axis 3-4 400kg, 3HAC 13063-1 (IRB 7600 - 400/2.55, -340/2.8, 150/3.5) . . . . . . . . . . . . . . . . . 31
2.3.5 Axis 3-4 500kg, 3HAC 13063-2 (IRB 7600 - 500/2.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.3.6 Axis 3-4 400kg Foundry, 3HAC 13063-4 (IRB 7600 - 400/2.55, -340/2.8, 150/3.5) . . . . . . . . . . 33
2.3.7 Axis 3-4 500kg Foundry, 3HAC 13063-5 (IRB 7600 - 500/2.3) . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.3.8 Wrist, 3HAC 10503-1 (Std) / 3HAC 15992-1 (Foundry) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.3.9 Material set manipulator, 3HAC 13079-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.3.10 Material set ax 1-2, 3HAC 13077-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.3.11 Mtrl.set balancing device, 3HAC 13082-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.3.12 Arm extension set, 956 mm, 3HAC 12311-1 (IRB 7600 - 150/3.5) . . . . . . . . . . . . . . . . . . . . . . 49
2.3.13 Arm extension set, 250 mm, 3HAC 12311-2 (IRB 7600 - 340/2.8) . . . . . . . . . . . . . . . . . . . . . . 50
3 Exploded views 51
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.2 Base incl. Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.3 Frame-Lower arm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.4 Frame-Lower arm 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.5 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.6 Wrist complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4 Circuit Diagram 57
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3HAC 022033-001 Revision: B 3

Table of Contents
4 3HAC 022033-001 Revision: B

Overview
Overview
About this manual

This manual contains reference information for all procedures described in the Product
manual, procedures .
Usage
This manual should be used during
• installation
• maintenance work
• repair work.
Who should read this manual?

This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
The reader should...
• be a trained maintenance/repair craftsman
• have the required knowledge of mechanical and electrical installation/repair/
maintenance work.

Overview
Organization of chapters
The manual is organized in the following chapters:
Chapter Contents
Reference information Useful information when performing installation, maintenance
or repair work (lists of necessary tools, reference documents,
safety standards).
Part list Complete list of manipulator parts, shown in the exploded
views or foldouts.
Exploded views / Foldouts Detailed illustrations of the manipulator with reference
numbers to the part list.
Circuit Diagram Circuit Diagram of the manipulator.
Revisions
Revision Description
- First edition.
Replaces previous manuals:
• Installation and Commssioning Manual
• Maintenance Manual
• Repair Manual, part 1
• Repair Manual, part 2.
Changes made in the material from the previous manuals:
• Model M2004 implemented.
• Various corrections due to technical revisions, changes in the
toolkits etc.
A Following updates are made:
• Section Document references is completed with article numbers
for calibration manuals.
• Section Part list is completed with the spare part number for a
variant of the cable harness/brake release unit.
B New lubricating oil in the gearboxes. Changes are made in the section
Part list.

Product documentation, M2000/M2000A
Product documentation, M2000/M2000A
General
The complete product documentation kit for the M2000 robot system, including controller,
robot and any hardware option, consists of the manuals listed below:
Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
is divided into two parts:
Product manual, procedures
• Safety information
• Installation and commissioning (descriptions of mechanical installation, electrical
connections and loading system software)
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
• Repair (descriptions of all recommended repair procedures including spare parts)
• Additional procedures, if any (calibration, decommissioning)
Product manual, reference information
• Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
• Part list
• Foldouts or exploded views
• Circuit diagrams
Software manuals
The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during
operation.
A complete listing of all available software manuals is available from ABB.
Controller hardware option manual

Each hardware option for the controller is supplied with its own documentation. Each
document set contains the types of information specified below:
• Installation information
• Repair information
• Maintenance information
In addition, spare part information is supplied for the entire option.

Product documentation, M2004
General
The robot documentation may be divided into a number of categories. This listing is based on
the type of information contained within the documents, regardless of whether the products
are standard or optional. This means that any given delivery of robot products will not contain
all documents listed, only the ones pertaining to the equipment delivered.
However, all documents listed may be ordered from ABB. The documents listed are valid for
M2004 robot systems.
Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
is divided into two parts:
Product manual, procedures
• Safety information
• Installation and commissioning (descriptions of mechanical installation, electrical
connections and loading system software)
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
• Repair (descriptions of all recommended repair procedures including spare parts)
• Additional procedures, if any (calibration, decommissioning)
Product manual, reference information
• Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
• Part list
• Foldouts or exploded views
• Circuit diagrams
RobotWare manuals
The following manuals describe the robot software in general and contain relevant reference
information:
• RAPID Overview: An overview of the RAPID programming language.
• RAPID reference manual part 1: Description of all RAPID instructions.
• RAPID reference manual part 2: Description of all RAPID functions and data types.
• Technical reference manual - System parameters: Description of system
parameters and configuration workflows.

Application manuals
Specific applications (e.g. software or hardware options) are described in Application
manuals. An application manual can describe one or several applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful)
• What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)
• How to use the application
• Examples of how to use the application
Operator's manuals
This group of manuals is aimed at those having first hand operational contact with the robot,
i.e. production cell operators, programmers and trouble shooters. The group of manuals
include:
• Operator's manual - IRC5 with FlexPendant
• Operator's manual - RobotStudio Online
• Trouble shooting manual for the controller and robot
Miscellaneous
A number of manuals provide generic descriptions of the robot and robot system. These
include:
• Robot fundamentals (describing the fundamental aspects, functions, concept and
similar, of a robot system to provide a basic understanding of the robot system)


1 Reference information
1.1. Introduction
1.1. Introduction
General
This chapter includes general information, complementing the more specific information in
the Product manual (part 1 of 2), procedures.

1.2. Applicable Safety Standards
1.2. Applicable Safety Standards
Standards, general
The robot is designed in accordance with the requirements of:
• EN 775 - Robot safety.
• EN 292-1 - Basic terminology.
• EN 292-2 - Technical principles.
• EN 418 - Emergency stop.
• EN 563 - Temperatures of surfaces.
• EN 954-1 - Safety related parts of control systems.
• EN 60204-1 - Electrical equipment of machines.
• EN 1050 - Principles for risk assessment.
• ANSI/RIA 15.06-1999 - Industrial robots, safety requirements.
• DIN 19258 - Interbus-S, International Standard
Standards, robot cell

The following standards are applicable when the robot is part of a robot cell:
• EN 953 - Fixed and moveable guards
• EN 811 - Safety distances to prevent danger zones being reached by the lower limbs.
• EN 349 - Minimum gaps to avoid crushing of parts of the human body.
• EN 294 - Safety distances to prevent danger zones being reached by the upper limbs.
• EN 1088 - Interlocking devices
• EN 999 - The positioning of protective equipment in respect of approach speeds of the
human body.
• ISO 11 161 - Industrial automation systems - Safety of intergrated manufacturing
systems.

1.3. Unit conversion
1.3. Unit conversion
Converter table
Use the table below to convert units used in this manual.
Quantity Units
Length 1m 3.28 ft 39.37 in
Weight 1 kg 2.21 lb
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.738 lbf
Moment 1 Nm 0.738 lbf-tn
Volume 1L 0.264 US gal

1.4. Screw joints
1.4. Screw joints
General
This section details how to tighten the various types of screw joints on the robot and the
controller.
The instructions and torque values are valid for screw joints comprised of metallic materials
and do not apply to soft or brittle materials.
UNBRAKO screws
UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It
features special surface treatment (Gleitmo as described below), and is extremely resistant to
fatigue.
Whenever used, this is specified in the instructions, and in such cases, no other type of
replacement screw is allowed! Using other types of screws will void any warranty and may
potentially cause serious damage or injury!
Gleitmo treated screws

Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.
Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this
the screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should
be used.
Screws lubricated in other ways

Screws lubricated with Molycote 1000 should only be used when specified in the repair,
maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1. Apply lubricant to the screw thread.
2. Apply lubricant between the plain washer and screw head.
3. Tighten to the torque specified in section Tightening torque below. Screw dimensions
of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or
smaller may be tightened without a torque wrench if this is done by trained and
qualified personnel.
Lubricant Art. no.

Molycote 1000 (molybdenum disulphide grease) 1171 2016-618

1.4. Screw joints
Tightening torque
Before tightening any screw, note the following:
• Determine whether a standard tightening torque or special torque is to be applied. The
standard torques are specified in the tables below. Any special torques are specified in
the Repair, Maintenance or Installation procedure description. Any special torque
specified overrides the standard value.
• Use the correct tightening torque for each type of screw joint.
• Only use correctly calibrated torque keys.
• Always tighten the joint by hand, and never use pneumatical tools.
• Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a slow,
flowing motion.
• Maximum allowed total deviation from the specified value is 10%!
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with slotted or cross-recess head screws.
Tightening torque (Nm)

Dimension
Class 4.8, oil-lubricated
M2.5 0.25
M3 0.5
M4 1.2
M5 2.5
M6 5.0
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with Allen head screws.
Tightening torque Tightening torque Tightening torque

(Nm) (Nm) (Nm)
Dimension
Class 8.8, oil- Class 10.9, oil- Class 12.9, oil-
lubricated lubricated lubricated
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340
The table below specifies the recommended standard tightening torque for Molycote-
lubricated screws with Allen head screws.
Tightening torque (Nm) Tightening torque (Nm)

Dimension
Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M8 28 34

1.4. Screw joints
Tightening torque (Nm) Tightening torque (Nm)

Dimension
Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M10 55 66
M12 96 115
M16 235 280
The table below specifies the recommended standard tightening torque for water and air
connectors when one or both connectors are made of brass.
Tightening torque Tightening torque Tightening torque

Dimension
Nm - Nominal Nm - Min. Nm - Max.
1/8 12 8 15
1/4 15 10 20
3/8 20 15 25
1/2 40 30 50
3/4 70 55 90

1.5. Weight specifications
1.5. Weight specifications
Definition
In all repair and maintenance procedures, weights of the components handled are sometimes
specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.
To avoid injury, ABB recommends the use of lifting equipment when handling components
with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each
manipulator model.
Example
Below is an example of how a weight specification is presented:
CAUTION!
Caution!
The motor weighs 32 kg! All lifting equipment used must be sized accordingly!

1.6. Standard toolkit
1.6. Standard toolkit
General
All service (repairs, maintenance and installation) instructions contain lists of tools required
to perform the specified activity.
All special tools required are listed directly in the instructions while all the tools that are
considered standard are gathered in the Standard toolkit and defined in the table below.
In this way, the tools required are the sum of the Standard Toolkit and any tools listed in the
instruction.
Contents, standard toolkit, 3HAC 15571-1
Qty Art. no. Tool Rem.

1 - Ring-open-end spanner 8-19mm
1 - Socket head cap 5-17mm
1 - Torx socket no:20-60
1 - Box spanner set
1 - Torque wrench 10-100Nm
1 - Torque wrench 75-400Nm
1 - Ratchet head for torque wrench 1/2
2 - Hexagon-headed screw M10x100
1 - Socket head cap no:14, socket 40mm bit L 100mm
1 - Socket head cap no:14, socket 40mm bit L 20mm To be shorted to 12mm

1.7. Special tools
1.7. Special tools
General
All service instructions contain lists of tools required to perform the specified activity. The
required tools are a sum of standard tools, defined in section Standard toolkit on page 18, and
of special tools, listed directly in the instructions and also gathered in this section.
Basic tools
The table below specifies the tools in the basic toolkit (3HAC 15571-3) that are used for the
current robot model. This toolkit is necessary primarly when removing and refitting the
motors.
The tools are also listed directly in the instructions.
Description Qty Art. no.

Bolts (M16 x 80) for Mech stop ax 3 2 3HAB 3409-89
Extension 300mm for bits 1/2" 1 3HAC 12342-1
Guide pins M10 x 100 2 3HAC 15521-1
Lifting tool, wrist unit 1 3HAC 12734-1
Lifting tool, motor ax 1, 4, 5 1 3HAC 14459-1
Lifting tool, motor ax 2, 3, 4 1 3HAC 15534-1
Mech stop ax 3 2 3HAC 12708-2
Removal tool, motor M12x 1 3HAC 14973-1
Fits motors, axes 1, 2, 3, 4 and 5.
Rotation tool 1 3HAC 17105-1
Standard toolkit (content described in 1 3HAC 15571-1
section Standard toolkit on page 18)
Washers for mech stop axis 3 2 3HAA 1001-186
Special tools
The table below specifies the special tools required during several of the service procedures.
The tools may be ordered separately and are also specified directly in concerned instructions
in the Product manual, procedures.

Fixture lower arm 1 3HAC 13660-1
Guide pins M12 x 130 2 3HAC 022637-001
Guide pins, sealing ax 2/3, 100mm 1 3HAC 14627-3
Guide pins, sealing ax 2/3, 80mm 1 3HAC 14627-2
Hydraulic cylinder 1 3HAC 11731-1
Hydraulic pump, 80 MPa 1 3HAC 13086-1

1.7. Special tools

Hydraulic pump, 150 MPa (Glycerin) 1 3HAC 021563-012
Lifting device, base 1 3HAC 15560-1
Lifting device, manipulator 1 3HAC 15607-1
Lifting device, upper arm 1 3HAC 15536-1
Lifting eye VLBG M12 1 3HAC 16131-1
Lifting eye M12 2 3HAC 14457-3
Lifting eye M16 2 3HAC 14457-4
Lifting tool (chain) 1 3HAC 15556-1
Lifting tool, gearbox axis 2 1 3HAC 12731-1
Measuring tool 1 6896 134-GN
Motor press pinion 1 3HAC 021883-001
Oil injector / max 500 MPa 1 3HAC 021590-001
Press tool, axis 2 bearing 1 3HAC 13453-1
Puller device, axis 2 shaft 1 3HAC 021563-001
Press device, axis 2 shaft 1 3HAC 021600-001
Press tool, balancing device 1 3HAC 020902-001
Press tool, balancing device shaft 1 3HAC 17129-1
Puller tool, balancing device shaft 1 3HAC 12475-1
Removal tool, wheel unit 1 3HAC 15814-1
Support, base 1 3HAC 15535-1
Tool set balancing device 1 3HAC 15943-1
Tools that may be rented

The table below specifies the tools that may be rented from ABB in order to perform certain
service procedures as described in the Product manual.
The special tools are also listed directly in the instructions.
Description Art. no. Note

Lifting tool, lower arm 3HAC 14691-1 Includes
• guidings, 3HAC 14445-1

1.7. Special tools
Calibration equipment, Wyler

The table below specifies the calibration equipment required when calibrating the robot with
the Wyler method, using the Levelmeter 2000.

Angel bracket 68080011-LP
Calibration bracket 3HAC 13908-9
Calibration tool ax1 3HAC 13908-4
Levelmeter 2000 kit 6369901-347 Includes one sensor.
Measuring pin 3HAC 13908-5
Sensor fixture 68080011-GM
Sensor plate 3HAC 0392-1
Sync. adapter 3HAC 13908-1
Turn disk fixture 3HAC 68080011-GU
Calibration equipment, Pendulum

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

CalPen (Calibration 3HAC 15716-1 Complete kit that also includes user
Pendulum) instructions.
Oil exchange equipment

The table below specifies the recommended equipment for oil exhange.

Oil exchange equipment 3HAC 021745-001 Includes
• vacuum pump with
regulator, hose and coupling
• couplings and adapters
• pump (manual) with hose
and coupling
• graduated measuring glass
• oil gun
• user instructions.

1.8. Document references
General
The contents of this manual may include references to additional documentation necessary to
perform certain procedures. This section specifies the article numbers for the referenced
documentation.
Product specification, robot

The product specification includes generic technical data. The specification listed below is
the English version.
Document name Document ID

Product specification 3HAC 13491-1
Product manuals, controller

The product manuals include information about installation and service activities. The table
below specifies the article numbers of the product manuals for all controller models. The part
number -001 is the English version.
Document name Document ID

Product manual, S4Cplus M2000 3HAC 021333-001
Product manual, S4Cplus M2000A 3HAC 021128-001
Product manual, IRC5 M2004 3HAC 021313-001
Operators manual
The operators manual contains instructions for daily operation of robot systems. The table
below specifies the article numbers of the operators manuals for different robot systems.
Document name Document ID Note

User's guide (S4Cplus) 3HAC 7793-1 Contains instructions for daily operation
of S4Cplus based robot systems.
Operator's manual (IRC5) 3HAC 16590-1
Calibration manuals

Calibration Pendulum 3HAC 16578-1 Enclosed with the Calibration
Instruction Pendulum Toolkit.
Instructions for Levelmeter 3HAC 022907-001 Enclosed with the Levelmeter 2000.
calibration (alternative method)
CalibWare 2.0 Users Guide 3HAC 16090-1 Manual for Absolute Accuracy
calibration.

Additional documentation

External axes 3HAC 9299-1

1.9. Lifting equipment and lifting instructions
1.9. Lifting equipment and lifting instructions
General
Many repair and maintenance activities require different pieces of lifting equipment, which
are specified in each procedure.
The use of each piece of lifting equipment is not detailed in the activity procedure, but in the
instruction delivered with each piece of lifting equipment.
This implies that the instructions delivered with the lifting equipment should be stored for
later reference.

2 Part list
2.1. Introduction
2 Part list
2.1. Introduction
Overview
This section specifies all the replacement articles of the robot. The parts are shown in
exploded views or in foldouts, either in this or in a separate chapter.
Specific spare parts are listed separately in a Spare part list.

2 Part list
2.2.1. Overview
2.2 Rebuilding parts
2.2.1. Overview
General
The IRB 7600 have some rebuilding parts that differ from eachother, depending on the
version of the manipulator. The table below is a general overview of which parts belongs to
which versions.
Art. no. Part 500/2.3 400/2.55 340/2.8 150/3.5

3HAC 13063-1 Axis 3-4 400kg (Std) X X X
3HAC 13063-4 Axis 3-4 400kg (Foundry) X X X
3HAC 13063-2 Axis 3-4 500kg (Std) X
3HAC 13063-5 Axis 3-4 500kg (Foundry) X
3HAC 10509-1 Tube shaft 2.55 (Std) X X X
3HAC 15932-1 Tube shaft 2.55 (Foundry) X X X
3HAC 10509-5 Tube shaft 2.3 (Std) X
3HAC 15932-2 Tube shaft 2.3 (Foundry) X
3HAC 9760-5 Arm extender 250mm (Std) X
3HAC 15932-3 Arm extender 250mm (Foundry) X
3HAC 9760-5 Arm extender 956mm (Std) X
3HAC 15932-4 Arm extender 956mm (Foundry) X
3HAC 11755-1 Friction washer X X
3HAB 7700-69 Screw M12x50 20X 20X
3HAA 1001-134 Washer 13x19x1,5 20X 20X
9ABA 107-56 Parallel pin 10x20 X X
3HAC 14207-1 Motor axis 1 X X X X
3HAC 16628-1 Wrist 400-500kg X X X X

2 Part list
2.3.1. Part list, overview
2.3 Part List
Overview
Item Qty Art. number Description Note/Dimension

5 1 3HAC 12812-2 Mechanical stop axis 1, See
assembly Mechanical stop ax 1, 3HAC
12812-2 on page 29
6 1 3HAC 10499-7 Cover sheet
7 1 3HAB 7700-89 Hex socket head cap M16x90
screw
8 1 3HAC 14222-1 Plate T=4
9 4 9ADA 618-56 Torx pan head screw M6x16
10 2 3HAC 10509-11 Cover
101 1 3HAC 12304-1 Base incl frame ax 1 See
Base incl frame ax 1, 3HAC
12304-1 on page 30
102 1 3HAC 13063-1 Axis 3-4 400kg (IRB See
7600 - 400/2.55, -340/ Axis 3-4 400kg, 3HAC
2.8, -150/3.5) 13063-1 (IRB 7600 - 400/
2.55, -340/2.8, 150/3.5) on
page 31
102 1 3HAC 13063-2 Axis 3-4 500kg (IRB See
7600 - 500/2.3) Axis 3-4 500kg, 3HAC
13063-2 (IRB 7600 - 500/
2.3) on page 32
102 1 3HAC 13063-4 Axis 3-4 400 kg Foundry
(IRB 7600 - 400/2.55, -
340/2.8, -150/3.5)
102 1 3HAC 13063-5 Axis 3-4 500 kg Foundry
(IRB 7600 - 500/2.3)
103 1 3HAC 10503-1 Wrist See
Wrist, 3HAC 10503-1 (Std) /
3HAC 15992-1 (Foundry) on
page 38
103 1 3HAC 15992-1 Wrist Foundry See
Wrist, 3HAC 10503-1 (Std) /
3HAC 15992-1 (Foundry) on
page 38
104 1 3HAC 14675-1 Balancing Device
105 1 3HAC 10523-1 Lower arm
106 1 3HAC 14940-1 Cable harness, man. Brake release in frame.
ax1-4
106 1 3HAC 12782-1 Cable harness, man. Brake release at base.
ax1-4

2 Part list

108 1 3HAC 13079-1 Material set manipulator See
Material set manipulator,
3HAC 13079-1 on page 44
109 1 3HAC 13077-1 Material set ax 1-2 See
Material set ax 1-2, 3HAC
13077-1 on page 45
110 1 3HAC 13082-1 Mtrl.set balancing device See
Mtrl.set balancing device,
3HAC 13082-1 on page 48
111 1 3HAC 12311-1 Arm extension set See
956mm ((IRB 7600 -150/ Arm extension set, 956 mm,
3.5) 3HAC 12311-1 (IRB 7600 -
150/3.5) on page 49
111 1 3HAC 12311-2 Arm extension set See
250mm ((IRB 7600 -340/ Arm extension set, 250 mm,
2.8) 3HAC 12311-2 (IRB 7600 -
340/2.8) on page 50
112 1 3HAC 12129-1 Cover plate
112 2 3HAC 12129-1 Cover plate
113 4 9ADA 618-56 Torx pan head screw M6x16
113 8 9ADA 618-56 Torx pan head screw
114 1 3HAC 13416-1 Protection cover

2 Part list
2.3.2. Mechanical stop ax 1, 3HAC 12812-2
2.3.2. Mechanical stop ax 1, 3HAC 12812-2
Overview
Item Qty Art. number Description Dimension

5.1 1 3HAC 12812-1 Mechanical stop
5.2 1 9ABA 142-92 Spring pin, slotted 10x30

2 Part list
2.3.3 Base incl frame ax 1, 3HAC 12304-1
2.3.3 Base incl frame ax 1, 3HAC 12304-1
Overview

101.1 1 3HAC 10044-1 Base, machining See
Base, machining, 3HAC
10044-1 on page 30
101.2 1 3HAC 12303-1 Frame incl ax 1 gearbox See
Frame incl ax 1 gearbox,
3HAC 12303-1 on page 30
101.3 3 3HAC 11732-1 Washer T=3
101.4 18 3HAB 7700-89 Hex socket head cap M16x90
screw
101.5 1 3HAC 11529-1 Rubber lined clip D=28
101.6 1 3HAC 14453-1 Hose with flange
101.7 1 3HAC 14453-2 Plug
101.8 1 3HAC 4428-2 Hose Clip
101.9 1 9ADA 618-56 Torx pan head screw M6x16
Base, machining, 3HAC 10044-1
Item Qty Art. number Description Note

101.1.1 1 3HAC 10044-2 Base, casting
101.1.2 5 3HAC 4836-7 Protection plug
101.1.3 1 3HAC 1383-2 Protection Cover compl.
101.1.4 1 3HAC 14024-1 Protection screw
Frame incl ax 1 gearbox, 3HAC 12303-1

101.2.1 1 3HAC 15865-1 Frame machining
101.2.2 1 3HAC 10828-1 RV 500C-219,95 assembly
101.2.3 24 3HAB 7700-77 Hex socket head cap screw M12x110
101.2.4 24 3HAA 1001-134 Washer 13x19x1,5

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

102.1 1 3HAC 13076-1 Material set ax 4 See
Material set ax 4, 3HAC
13076-1 on page 34
102.2 1 3HAC 10509-1 Tube shaft 2,55 See
Tube shaft 2,55, 3HAC
10509-1 on page 36
102.3 1 3HAC 13062-1 Axis 3 See
Axis 3, 3HAC 13062-1 on
page 36

2 Part list
2.3.5 Axis 3-4 500kg, 3HAC 13063-2 (IRB 7600 - 500/2.3)
2.3.5 Axis 3-4 500kg, 3HAC 13063-2 (IRB 7600 - 500/2.3)
Overview

Material set ax 4, 3HAC 13076-1 on
page 34
102.2 1 3HAC 10509-5 Tube shaft 2,3 See
Tube shaft 2,3, 3HAC 10509-5 on
page 36
102.3 1 3HAC 13062-1 Axis 3 See
Axis 3, 3HAC 13062-1 on page 36

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

13076-1 on page 34
102.2 1 3HAC 15932-1 Tube shaft 2,55 foundry
102.3 1 3HAC 13062-1 Axis 3 See
Axis 3, 3HAC 13062-1 on
page 36

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

13076-1 on page 34
102.2 1 3HAC 15932-2 Tube shaft 2,3 foundry
102.3 1 3HAC 13062-1 Axis 3 See
Axis 3, 3HAC 13062-1 on
page 36
Material set ax 4, 3HAC 13076-1

102.1.1 1 3HAC 11523-1 Gear Z4 / 4
102.1.2 1 3HAC 14725-1 Rot ac motor incl pinion See
Rot ac motor incl pinion,
3HAC 14725-1 on page 35
102.1.3 4 3HAB 3409-50 Hex socket head cap M10x40
screw
102.1.4 4 3HAB 4233-1 Washer
102.1.5 1 3HAC 11499-1 Motor flange, machin.
screw
102.1.7 2 3HAC 10122-12 Washer, RV 125 F, T=3
axis4,5
102.1.8 1 3HAC 12642-1 RV 125F incl. gear See
RV 125F incl. gear, 3HAC
12642-1 on page 35
102.1.9 1 3HAC 12640-1 Cover ax 4 incl. sealing See
Cover ax 4 incl. sealing,
3HAC 12640-1 on page 36
102.1.10 10 3HAC 11409-6 Shoulder Screw M6x8x8
102.1.12 2 3HAC 13564-1 Damper axis 4
102.1.13 2 3HAA 1001-17 Stop, Axis 4, Casting
102.1.14 2 3HAC 11925-1 Mechanical stop head
screw
102.1.16 2 3HAA 1001-98 Gasket T=1
102.1.17 8 9ADA 183-37 Hex socket head cap M8x25
screw
102.1.18 8 9ADA 312-7 Plain washer 8,4x16x1,6
102.1.19 2 3HAA 2103-21 Taper roller bearing 170x230x38
102.1.20 1 2216 261-18 Sealing 170x200x15

2 Part list
102.1.21 1 3HAB 3772-27 O-ring 170x5

102.1.22 1 3HAC 3774-7 Spacer ring
102.1.23 1 3HAC 11461-1 Sealing
102.1.24 1 3HAC 17219-1 Thrust washer
102.1.25 1 9ABA 135-45 Retaining ring, shaft 170
102.1.26 1 3HAC 11928-1 Protective ring housing
102.1.27 1 3HAC 17218-1 Set of shims
102.1.28 2 2522 122-1 Magnetic plug R1/4"
102.1.29 2 3HAC 16721-1 Magnetic plug R1/2"
102.1.30 900 ml 3HAC 021469- Lubricating oil, Shell
001 Tivela S 150
102.1.31 3850 ml 1171 2016-604/ Lubricating oil, X320 Do not mix the oils!
3HAC 021469- Lubricating oil, Shell
001 Tivela S 150
102.1.32 1 9ABA 107-56 Parallel pin 10x20
102.1.33 2 3HAC 10122-27 Friction washer T=0,5
102.1.34 1 ml 3HAB 7116-1 Locking liquid
102.1.35 30 g 3HAB 3537-1 Bearing grease
Rot ac motor incl pinion, 3HAC 14725-1

102.1.2.1 1 3HAC 17484-2 Rotational ac motor M2
102.1.2.2 1 3HAC 10122-17 Pinion RV 125F-97,909
102.1.2.3 0 2152 2012-430 O-ring 89,5x3
RV 125F incl. gear, 3HAC 12642-1

102.1.8.1 1 3HAC 17273-1 RV 125F-97,909 assembly See
RV 125F-97,909
assembly, 3HAC
17273-1 on page 35
102.1.8.2 1 3HAC 11488-1 Gear Z3 / 4, 5
102.1.8.3 9 3HAB 7700-69 Hex socket head cap screw M12x50
102.1.8.4 6 3HAB 3409-86 Hex socket head cap screw M16x60
RV 125F-97,909 assembly, 3HAC 17273-1

102.1.8.1.1 1 3HAC 11384-1 RV 125F, i=97,909
102.1.8.1.2 1 3HAB 3772-50 O-ring 196,52x2,62
102.1.8.1.3 1 3HAB 3772-49 O-ring 189,3x3,1

2 Part list
Cover ax 4 incl. sealing, 3HAC 12640-1

102.1.9.1 1 3HAC 11423-4 Cover axis 4 See
Cover axis 4, 3HAC 11423-4 on
page 36
102.1.9.2 1 3HAA 1001-628 Sealing
Cover axis 4, 3HAC 11423-4

102.1.9.1.1 1 3HAC 11423-1 Cover axis 4, machined
102.1.9.1.2 1 3HAC 11423-3 Gasket cover axis 4
Tube shaft 2,55, 3HAC 10509-1

102.2.1 1 3HAC 10509-2 Tube shaft 2,55, cast
Tube shaft 2,3, 3HAC 10509-5

102.2.1 1 3HAC 10509-6 Tube shaft 2,3, cast
Axis 3, 3HAC 13062-1

102.3.1 1 3HAC 10502-3 Axis 4 housing, mach.
102.3.2 1 3HAC 12641-1 RV 700F incl. gear See
RV 700F incl. gear, 3HAC
12641-1 on page 46
screw
102.3.4 20 3HAC 10264-1 Washer 17x30x3
3HAC 14725-1 on page 35
screw
102.3.7 4 3HAB 4233-1 Washer

2 Part list
102.3.8 1 3HAC 11719-1 Plug R1/4”

102.3.8 1 3HAC 16721-1 Magnetic plug R1/2”
102.3.9 4200 3HAC 16843-1/ Lubricating oil, RMO Do not mix the oils!
ml 3HAC 021469- 150/
001 Lubricating oil, Shell
Tivela S 150
102.3.10 1 9ABA 142-92 Spring pin, slotted 10x30

102.3.2.1 1 3HAC 17272-1 RV 700F-269,21 See
assembly RV 700F-269,21 assembly,
3HAC 17272-1 on page 46
102.3.2.2 1 3HAC 11636-1 Gear Z2 /2.3
RV 700F-269,21 assembly, 3HAC 17272-1

102.3.2.1.1 1 3HAC 10122-21 RV 700F, i=269,21
102.3.2.1.2 1 3HAB 3772-51 O-ring 369,3x5,7

102.3.5.2 1 3HAC 11632-1 Pinion Z1 /2.3
102.3.5.3 0 2152 2012-430 O-ring 89,5x3

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

103.1 1 3HAC 11409-7 Cover, right See
Cover, right, 3HAC
11409-7 on page 39
103.2 14 3HAC 11409-6 Shoulder Screw M6x8x8
103.5 2 3HAC 16721-1 Magnetic plug R1/2”
103.6 1 3HAC 12642-1 RV 125F incl. gear See
RV 125F incl. gear,
3HAC 12642-1 on
page 39
103.7 18 3HAB 3409-50 Hex socket head cap screw M10x40
103.8 2 3HAC 10122-12 Washer, RV 125 F, axis4,5 T=3
103.9 1 3HAC 10503-3 Wrist housing, machining
103.10 2 2522 122-1 Magnetic plug R1/4"
103.11 4 9ADA 183-35 Hex socket head cap screw
103.12 2 3HAC 10503-8 Damper ax 5
103.13 2 3HAC 10122-27 Friction washer
103.15 4 3HAB 4233-1 Washer
103.16 1 3HAC 14725-1 Rot ac motor incl pinion See
Rot ac motor incl
pinion, 3HAC 14725-1
on page 35
103.18 1 3HAC 11409-3 Cover, left machining
103.22 7 3HAB 4233-1 Washer
103.24 1 3HAC 10503-14 Support shaft inc bearing See
Support shaft inc
bearing, 3HAC 10503-
14 on page 40
103.25 1 3HAC 9953-1 Sync plate with vernier
103.28 1 3HAC 12707-1 Axis 6 complete See
Axis 6 complete, 3HAC
12707-1 on page 40
103.28 1 3HAC 12707-2 Axis 6 complete Foundry See
Axis 6 complete
Foundry, 3HAC 12707-
2 on page 42
103.31 1 3HAA 2166-24 VK-Cover

2 Part list
103.33 1 3HAC 10503-13 Wheel Unit See

Wheel Unit, 3HAC
10503-13 on page 43
103.34 1 3HAA 1001-628 Sealing
103.35 7 9ADA 624-56 Torx counters. head screw M6x16
103.37 1 3HAB 7116-1 Locking liquid
103.38 1 3HAC 11440-5 Heat protection plate
103.39 3 2166 2055-3 Cable straps, outdoors
103.40 1 3HAC 11440-1 Cable harness, manip ax5-6
103.41 3800 ml 1171 2016-604/ Lubricating oil, X320/ Do not mix the oils!
3HAC 021469- Lubricating oil, Shell Tivela S
001 150
103.42 750 ml 3HAC 021469- Lubricating oil, Shell Tivela S
001 150
103.43 1 3HAC 5984-1 Label
103.43 1 3HAC 17260-1 Spårbarhetsetikett
103.43 1 3HAC 17260-2 Spårbarhetsetikett Wrist,
Foundry
Cover, right, 3HAC 11409-7

103.1.1 1 3HAC 11409-1 Cover, right machining
103.1.2 1 3HAC 11409-5 Gasket, right

103.6.1 1 3HAC 17273-1 RV 125F-97,909 assembly See
RV 125F-97,909 assembly,
3HAC 17273-1 on page 35
103.6.2 1 3HAC 11488-1 Gear Z3 / 4, 5
RV 125F-97,909 assembly, 3HAC 17273-1

103.6.1.1 1 3HAC 11384-1 RV 125F, i=97,909
103.6.1.2 1 3HAB 3772-50 O-ring 196,52x2,62
103.6.1.3 1 3HAB 3772-49 O-ring 189,3x3,1

2 Part list

103.16.1 1 3HAC 17484-2 Rotational ac motor M2
103.16.2 1 3HAC 10122-17 Pinion RV 125F-97,909
103.16 3 2152 2012-430 O-ring 89,5x3
Support shaft inc bearing, 3HAC 10503-14

103.24.1 1 3HAC 11470-1 Support Shaft
103.24.2 1 3HAA 2325-12 Ball bearing W.two seal. 130x200x33
103.24.3 3 9ADA 618-56 Torx pan head screw M6x16
Axis 6 complete, 3HAC 12707-1

103.28.1 1 3HAC 10436-1 Tilt house RV125F
103.28.2 1 3HAC 17274-1 RV 125F-178,41 See
assembly RV 125F-178,41
assembly, 3HAC 17274-
1 on page 42
103.28.3 2 3HAC 10122-13 Washer, RV 125 F T=3
screw
103.28.5 1 3HAC 13193-1 Turning disc, dia. 250
screw
103.28.7 2 2522 122-1 Magnetic plug R1/4"
103.28.8 1 3HAC 11471-1 Sync. Plate
103.28.9 1 2152 2012-433 O-ring 104,5x3
103.28.12 850 ml 3HAC 021469- Lubricating oil, Shell
001 Tivela S 150
3HAC 14725-1 on page
35
screw
103.28.16 1 3HAC 14263-1 Protection cover

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

2 Part list
Axis 6 complete Foundry, 3HAC 12707-2

103.28.1 1 3HAC 16010-1 Tilt house RV125F,
foundry
103.28.2 1 3HAC 17274-1 RV 125F-178,41 See
assembly RV 125F-178,41
1 on page 42
103.28.3 2 3HAC 10122-13 Washer, RV 125 F T=3
screw
103.28.5 1 3HAC 13193-1 Turning disc, dia. 250
screw
103.28.7 2 2522 122-1 Magnetic plug R1/4"
103.28.8 1 3HAC 11471-1 Sync. Plate
103.28.9 1 2152 2012-433 O-ring 104,5x3
103.28.12 850 ml 3HAC 021469- Lubricating oil, Shell Tivela
001 S 150
35
screw
103.28.16 1 3HAC 14263-1 Protection cover
103.28.17 1 9ADA 624-69 Torx counters, head screw M8x20
RV 125F-178,41 assembly, 3HAC 17274-1

103.28.2.1 1 3HAC 10122-1 RV 125F, i=178,41
103.28.2.2 1 3HAB 3772-49 O-ring 189,3x3,1

103.28.13.2 1 3HAC 10122-19 Pinion RV 125F-178,41
103.28.13.3 0 2152 2012-430 O-ring 89,5x3

2 Part list
103.28.13.4 1 3HAC 12877-1 Gasket
Wheel Unit, 3HAC 10503-13

103.33.1 1 3HAC 11524-1 Gear Z4 / 5
103.33.2 1 3HAC 10503-12 Bearing Washer
103.33.3 1 3HAB 3710-19 Groove ball bearing 160x220x28
103.33.4 1 3HAC 10503-15 Support Ring

2 Part list
2.3.9. Material set manipulator, 3HAC 13079-1
2.3.9. Material set manipulator, 3HAC 13079-1
Overview

108.201 2 3HAC 17213-1 Sealing axis 2/3
108.203 3 3HAC 11828-1 Washer axis 3
108.204 30 3HAA 1001-186 Washer 17x25x3
108.205 1 3HAC 11755-1 Friction Washer
108.207 20 3HAA 1001-134 Washer 13x19x1,5
108.210 1 3HAC 14300-1 Cable protector
108.212 1 3HAC 11771-1 Cable guide, end part
108.213 1 3HAC 13960-1 Connection plate, ax3
108.214 2 3HAC 11750-1 Damper axis 3
108.215 2 3HAC 12990-1 Damper axis 2
108.216 2 9ADA 624-65 Torx counters, head screw M6x60
108.217 2 9ADA 334-7 Spring washer, conical 8,4x18x2
108.220 2 3HAC 9953-1 Sync plate with nonie
108.222 1 3HAC 14658-1 Sync plate with nonie axis 3
108.223 2 9ADA 183-48 Hex socket head cap screw M10x16
108.228 1 3HAC 3261-1 Cover upperarmcovers
108.229 1 3HAC 15431-1 Cable protection
108.230 1 3HAC 14880-1 Cable fixing bracket
108.231 1 2166 2055-3 Cable straps, outdoors
108.232 5 3HAC 16721-1 Magnetic plug R1/2”
108.233 1 2522 122-1 Magnetic plug R1/4"

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

109.301 1 3HAC 12641-1 RV 700F incl. gear See
RV 700F incl. gear,
46
109.302 1 3HAC 11198-1 Cover, machining
109.303 1 3HAC 14698-1 Friction washer 381x438x1,0
109.305 20 3HAA 1001-186 Washer 17x25x3
35
35
109.309 8 3HAB 4233-1 Washer
109.310 1 3HAC 12252-1 Bottom plate
109.311 1 3HAC 14131-1 Connection plate, base
109.312 1 3HAC 11774-3 Adapter, machined
109.313 1 3HAC 11769-1 Cable guide, ax.1
109.320 1 3HAC 12671-5 Profile with sync scale
109.321 1 3HAC 12671-6 Block for calibration
109.322 1 3HAC 14024-1 Protection screw
109.326 1 3HAC 16014-1 Serial measurement unit
109.327 1 3HAC 14788-3 Cover SMB and BRU See
Cover SMB and BRU,
47
109.328 1 3HAC 16831-1 Battery pack
109.329 1 3HAC 13151-1 Cable battery/SMB
109.330 2 3HAC 11526-1 Stud screw M6x150
109.331 1 3HAC 13152-1 Bracket SMB
109.332 1 3HAC 14791-3 Cover battery box See
Cover battery box, 3HAC
14791-3 on page 47
!

2 Part list
109.335 1 3HAA 2166-23 VK-Cover

109.336 1 3HAC 13914-1 Attachment plate
109.337 2 3HAC 12625-1 Strap, Velcro
109.338 1 3HAC 14793-1 Bracket
109.339 1 3HAC 15619-1 Cable, FB7-SMB7
109.341 7600 ml 3HAC 16843-1/ Lubricating oil, RMO 150 Do not mix the oils!
3HAC 021469- Lubricating oil, Shell Tivela
001 S 150
109.342 4800 ml 3HAC 16843-1/ Lubricating oil, RMO 150 Do not mix the oils!
3HAC 021469- Lubricating oil, Shell Tivela
001 S 150
109.344 1 ml 3HAB 7116-1 Locking liquid
109.345 2 9ADA 298-4 Prev. torque nut, non-met. M6
109.346 1 3HAC 16036-1 BU w. buttons DSQC 561
1 3HAC 14219-1 BU at the base See section Refitting of
brake release unit.
1 3HAC 12989-1 BU at the base See section Refitting of
brake release unit.
109.347 1 3HAC 2744-1 Push button guard
109.348 4 9ADA 629-56 Torx pan head roll. screw M6x16
109.350 1 3HAC 4813-1 Cover, push button guard
109.352 1 3HAC 14024-1 Protection screw
109.353 1 3HAC 17423-1 Washer
109.354 1 9ADA 269-4 Hexagon nut M8

109.301.1 1 3HAC 17272-1 RV 700F-269,21 assembly See
RV 700F-269,21
1 on page 46
109.301.2 1 3HAC 11636-1 Gear Z2 /2.3
RV 700F-269,21 assembly, 3HAC 17272-1

109.301.1.1 1 3HAC 10122-21 RV 700F, i=269,21
109.301.1.2 1 3HAB 3772-51 O-ring 369,3x5,7

2 Part list

109.306.2 1 3HAC 11350-1 Pinion RV 500C & RV 320C
109.306.3 0 2152 2012-430 O-ring 89,5x3

109.307.2 1 3HAC 11632-1 Pinion Z1 /2.3
109.307.3 0 2152 2012-430 O-ring 89,5x3
Cover SMB and BRU, 3HAC 14788-3

109.327.1 1 3HAC 14788-1 Cover, casting
109.327.2 1 3HAC 14788-2 Gasket
109.327.3 1 3HAC 14692-4 Rubber cloth
Cover battery box, 3HAC 14791-3

109.332.1 1 3HAC 14791-1 Cover
109.332.2 1 3HAC 14791-2 Gasket
109.332.2 1 3HAC 16977-1 Warning label battery

2 Part list
2.3.11. Mtrl.set balancing device, 3HAC 13082-1
2.3.11. Mtrl.set balancing device, 3HAC 13082-1
Overview

110.401 1 3HAC 4310-1 Sealed spherical bearing
110.402 1 3HAC 13124-1 Thrust washer
110.403 1 3HAC 13122-1 Bushing
110.404 1 9ABA 135-32 Retaining ring, shaft
110.405 1 3HAC 13123-1 Shaft
110.406 1 3HAC 4836-7 Protection plug 16x12,3x9x7
110.408 2 9ABA 107-56 Parallel pin 10x20
110.409 1 3HAC 12548-2 Protection washer
110.410 1 3HAC 11427-1 Shaft, Balancing device
110.411 4 3HAA 1001-186 Washer 17x25x3
110.412 120 ml 3HAA 1001-294 Grease
110.413 2 3HAC 4836-1 Protection plug 20x14,6x7,5x5,5
110.414 1 9ADA 183-490 Hex socket head cap screw M16x180

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

111.501 1 3HAC 9760-5 Arm extender 956mm
111.501 1 3HAC 15932-4 Arm extender 956mm, Foundry
111.504 20 3HAA 1001-134 Washer 13x19x1,5

2 Part list
Overview

111.501 1 3HAC 9760-1 Arm extender 250mm
111.501 1 3HAC 15932-3 Arm extender 250mm, Foundry
111.504 20 3HAA 1001-134 Washer 13x19x1,5

3 Exploded views
3.1. Introduction
3 Exploded views
3.1. Introduction
Definitions
This chapter contains detailed views of the components on the manipulator.
The numbered details are specified with item numbers in the Part List.
The exploded views are divided into:
• Base, incl. frame
• Frame-Lower arm 1
• Frame-Lower arm 2
• Upper arm
• Wrist complete

3 Exploded views
3.2. Base incl. Frame
3.2. Base incl. Frame
xx0200000329

3 Exploded views
3.3. Frame-Lower arm 1
xx0200000330

3 Exploded views
xx0200000331

3 Exploded views
3.5. Upper arm
3.5. Upper arm
xx0200000333

3 Exploded views
3.6. Wrist complete
3.6. Wrist complete
xx0200000332

4 Circuit Diagram
4.1. Introduction
4 Circuit Diagram
4.1. Introduction
Overview
This chapter includes the circuit diagram of the robot.

Circuit Diagram 3HAC 13347-1 / Rev. 02
CONTENTS
Sheet
Contents ........................................................................................................................101
Connection Point Location ...........................................................................................102
Legend ..........................................................................................................................103
Brake Release Unit .......................................................................................................104
Serial Measurement Board ...........................................................................................105
Axis 1............................................................................................................................106
Axis 2............................................................................................................................107
Axis 3............................................................................................................................108
Axis 4............................................................................................................................109
Axis 5 (IRB 7600) ........................................................................................................110
Axis 6............................................................................................................................111
Switches axis 1 .............................................................................................................113
Switches/Fan axis 2 ......................................................................................................114
Switches/Fan axis 3 ......................................................................................................115
Axis 5 (IRB 6600) ........................................................................................................901
Design changes, note 1.1 ..............................................................................................905
Design changes, note 2.1-2.7 ........................................................................................906
Circuit Diagram 3HAC 13347-1
Revision
02
sheet
101 Contents
sheet Revision
Connection Point Location 102 02
Revision
103 02
sheet
Legend
sheet Revision
Brake Release Unit 104 02
sheet Revision
Serial Measurement Board 105 02
Revision
02
sheet
106
Axis 1
Revision
02
sheet
107 Axis 2
Revision
02
sheet
108
Axis 3
Revision
02
sheet
109
Axis 4
sheet Revision
Axis 5 (IRB 7600) 110 02
Revision
02
sheet
111
Axis 6
sheet Revision
Switches axis 1 113 02
sheet Revision
Switches/Fan axis 2 114 02
sheet Revision
Switches/Fan axis 3 115 02
sheet Revision
Axis 5 (IRB 6600) 901 02
sheet Revision
Design changes, note 1.1 905 02
sheet Revision
Design changes, note 2.1-2.7 906 02

IRC5-IRB7600 Prod Man Part2 3HAC022033-001 - References - Revb - en PDF

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Document ID: 3HAC 022033-001

© Copyright 2004 ABB All right reserved.

3HAC 022033-001 Revision: B 3

4 3HAC 022033-001 Revision: B

About this manual

Who should read this manual?

3HAC 022033-001 Revision: B 5

6 3HAC 022033-001 Revision: B

Product documentation, M2000/M2000A

Controller hardware option manual

3HAC 022033-001 Revision: B 7

Product documentation, M2004

8 3HAC 022033-001 Revision: B

3HAC 022033-001 Revision: B 9

10 3HAC 022033-001 Revision: B

3HAC 022033-001 Revision: B 11

1.2. Applicable Safety Standards

Standards, robot cell

12 3HAC 022033-001 Revision: B

1.3. Unit conversion

3HAC 022033-001 Revision: B 13

1.4. Screw joints

Gleitmo treated screws

Screws lubricated in other ways

Lubricant Art. no.

14 3HAC 022033-001 Revision: B

Tightening torque (Nm)

Tightening torque Tightening torque Tightening torque

Tightening torque (Nm) Tightening torque (Nm)

3HAC 022033-001 Revision: B 15

Tightening torque (Nm) Tightening torque (Nm)

Tightening torque Tightening torque Tightening torque

16 3HAC 022033-001 Revision: B

1.5. Weight specifications

3HAC 022033-001 Revision: B 17

1.6. Standard toolkit

Contents, standard toolkit, 3HAC 15571-1

Qty Art. no. Tool Rem.

18 3HAC 022033-001 Revision: B

1.7. Special tools

Description Qty Art. no.

Description Qty Art. no.

3HAC 022033-001 Revision: B 19

Description Qty Art. no.

Tools that may be rented

Description Art. no. Note

20 3HAC 022033-001 Revision: B

Calibration equipment, Wyler

Description Art. no. Note

Calibration equipment, Pendulum

Description Art. no. Note

Oil exchange equipment

Description Art. no. Note

3HAC 022033-001 Revision: B 21

1.8. Document references

Product specification, robot

Document name Document ID

Product manuals, controller

Document name Document ID

Document name Document ID Note

Document name Document ID Note

22 3HAC 022033-001 Revision: B

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