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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 Vsters
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
Table of Contents
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.
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.
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)
10
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.
11
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:
12
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
Weight
1 kg
2.21 lb
Pressure
1 bar
100 kPa
Force
1N
0.738 lbf
Moment
1 Nm
0.738 lbf-tn
Volume
1L
0.264 US gal
39.37 in
14.5 psi
13
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.
14
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.
Dimension
Tightening torque (Nm)

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.
Dimension
Tightening torque
(Nm)
Class 8.8, oillubricated
Tightening torque
(Nm)
Tightening torque
(Nm)
M5
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 Molycotelubricated screws with Allen head screws.
Dimension

Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M8
28
34
15
1.4. Screw joints
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.
16
Dimension
Tightening torque
Nm - Nominal
Tightening torque
Nm - Min.
Tightening torque
Nm - Max.
1/8
12
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!
17
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
18
Rem.
Ring-open-end spanner 8-19mm
Socket head cap 5-17mm
Torx socket no:20-60
Box spanner set
Torque wrench 10-100Nm
Torque wrench 75-400Nm
Ratchet head for torque wrench 1/2
Hexagon-headed screw M10x100
Socket head cap no:14, socket 40mm bit L 100mm
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
3HAB 3409-89
Extension 300mm for bits 1/2"
3HAC 12342-1
Guide pins M10 x 100
3HAC 15521-1
3HAC 15521-2
Lifting tool, wrist unit
3HAC 12734-1
Lifting tool, motor ax 1, 4, 5
3HAC 14459-1
Lifting tool, motor ax 2, 3, 4
3HAC 15534-1
Mech stop ax 3
3HAC 12708-2
Removal tool, motor M12x
3HAC 14973-1
Fits motors, axes 1, 2, 3, 4 and 5.
Rotation tool
3HAC 17105-1
Standard toolkit (content described in

section Standard toolkit on page 18)
3HAC 15571-1
Washers for mech stop axis 3
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.
Description
Qty
Art. no.
Fixture lower arm
3HAC 13660-1
3HAC 022637-001
3HAC 13120-2
3HAC 13120-3
3HAC 13120-4
3HAC 13120-5
Guide pins, sealing ax 2/3, 100mm
3HAC 14627-3
Guide pins, sealing ax 2/3, 80mm
3HAC 14627-2
Hydraulic cylinder
3HAC 11731-1
Hydraulic pump, 80 MPa
3HAC 13086-1
19
1.7. Special tools
Description
Qty
Art. no.
Hydraulic pump, 150 MPa (Glycerin)
3HAC 021563-012
Lifting device, base
3HAC 15560-1
Lifting device, manipulator
3HAC 15607-1
Lifting device, upper arm
3HAC 15536-1
Lifting eye VLBG M12
3HAC 16131-1
Lifting eye M12
3HAC 14457-3
Lifting eye M16
3HAC 14457-4
Lifting tool (chain)
3HAC 15556-1
Lifting tool, gearbox axis 2
3HAC 12731-1
Measuring tool
6896 134-GN
Motor press pinion
3HAC 021883-001
Oil injector / max 500 MPa
3HAC 021590-001
Press tool, axis 2 bearing
3HAC 13453-1
Puller device, axis 2 shaft
3HAC 021563-001
Press device, axis 2 shaft
3HAC 021600-001
Press tool, balancing device
3HAC 020902-001
Press tool, balancing device shaft
3HAC 17129-1
Puller tool, balancing device shaft
3HAC 12475-1
Removal tool, wheel unit
3HAC 15814-1
Support, base
3HAC 15535-1
Tool set balancing device
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.
20
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.
Description
Art. no.
Angel bracket
68080011-LP
Calibration bracket
3HAC 13908-9
Calibration tool ax1
3HAC 13908-4
Levelmeter 2000 kit
6369901-347
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
Note
Includes one sensor.
Calibration equipment, Pendulum

The table below specifies the calibration equipment needed when calibrating the robot with
the Pendulum method.
Description
Art. no.
Note
CalPen (Calibration
Pendulum)
3HAC 15716-1
Complete kit that also includes user

instructions.
Oil exchange equipment

The table below specifies the recommended equipment for oil exhange.
Description
Art. no.
Note
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.
21
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
22
Document name
Document ID
Note
Calibration Pendulum
Instruction
3HAC 16578-1
Enclosed with the Calibration

Pendulum Toolkit.
Instructions for Levelmeter

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

calibration.
Additional documentation
Document name
Document ID
External axes
3HAC 9299-1
Note
23
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.
24
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.
25
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.
26
Art. no.
Part
500/2.3 400/2.55 340/2.8 150/3.5
3HAC 13063-1
Axis 3-4 400kg (Std)
3HAC 13063-4
Axis 3-4 400kg (Foundry)
3HAC 13063-2
Axis 3-4 500kg (Std)
3HAC 13063-5
Axis 3-4 500kg (Foundry)
3HAC 10509-1
Tube shaft 2.55 (Std)
3HAC 15932-1
Tube shaft 2.55 (Foundry)
3HAC 10509-5
Tube shaft 2.3 (Std)
3HAC 15932-2
Tube shaft 2.3 (Foundry)
3HAC 9760-5
Arm extender 250mm (Std)
3HAC 15932-3
Arm extender 250mm (Foundry)
3HAC 9760-5
Arm extender 956mm (Std)
3HAC 15932-4
Arm extender 956mm (Foundry)
3HAC 11755-1
Friction washer
3HAB 7700-69
Screw M12x50
20X
20X
3HAA 1001-134 Washer 13x19x1,5
20X
20X
9ABA 107-56
Parallel pin 10x20
3HAC 14207-1
Motor axis 1
3HAC 14209-1
Motor axis 2
3HAC 14209-1
Motor axis 3
3HAC 14210-1
Motor axis 4
3HAC 16628-1
Wrist 400-500kg
2 Part list
2.3.1. Part list, overview
2.3 Part List

Overview
Item
Qty
Art. number
Description
Note/Dimension
3HAC 12812-2
Mechanical stop axis 1,

assembly
See
Mechanical stop ax 1, 3HAC
12812-2 on page 29
3HAC 10499-7
Cover sheet
3HAB 7700-89
Hex socket head cap

screw
M16x90
3HAC 14222-1
Plate
T=4
9ADA 618-56
Torx pan head screw
M6x16
10
3HAC 10509-11
Cover
101
3HAC 12304-1
Base incl frame ax 1
See
Base incl frame ax 1, 3HAC
12304-1 on page 30
102
3HAC 13063-1
Axis 3-4 400kg (IRB

7600 - 400/2.55, -340/
2.8, -150/3.5)
See
Axis 3-4 400kg, 3HAC
13063-1 (IRB 7600 - 400/
2.55, -340/2.8, 150/3.5) on
page 31
102
3HAC 13063-2
Axis 3-4 500kg (IRB

7600 - 500/2.3)
See
Axis 3-4 500kg, 3HAC
13063-2 (IRB 7600 - 500/
2.3) on page 32
102
3HAC 13063-4
Axis 3-4 400 kg Foundry

(IRB 7600 - 400/2.55, 340/2.8, -150/3.5)
102
3HAC 13063-5
Axis 3-4 500 kg Foundry

(IRB 7600 - 500/2.3)
103
3HAC 10503-1
Wrist
See
Wrist, 3HAC 10503-1 (Std) /
3HAC 15992-1 (Foundry) on
page 38
103
3HAC 15992-1
Wrist Foundry
See
Wrist, 3HAC 10503-1 (Std) /
3HAC 15992-1 (Foundry) on
page 38
104
3HAC 14675-1
Balancing Device
105
3HAC 10523-1
Lower arm
106
3HAC 14940-1
Cable harness, man.

ax1-4
Brake release in frame.
106
3HAC 12782-1
Cable harness, man.

ax1-4
Brake release at base.
27
2 Part list
28
Item
Qty
Art. number
Description
Note/Dimension
108
3HAC 13079-1
Material set manipulator
See
Material set manipulator,
3HAC 13079-1 on page 44
109
3HAC 13077-1
Material set ax 1-2
See
Material set ax 1-2, 3HAC
13077-1 on page 45
110
3HAC 13082-1
Mtrl.set balancing device See

Mtrl.set balancing device,
3HAC 13082-1 on page 48
111
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
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
3HAC 12129-1
Cover plate
112
3HAC 12129-1
Cover plate
113
9ADA 618-56
Torx pan head screw
113
9ADA 618-56
Torx pan head screw
114
3HAC 13416-1
Protection cover
M6x16
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
5.1
3HAC 12812-1
Mechanical stop
5.2
9ABA 142-92
Spring pin, slotted
Dimension
10x30
29
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
Item
Qty
Art. number
Description
Note/Dimension
101.1
3HAC 10044-1
Base, machining
See
Base, machining, 3HAC
10044-1 on page 30
101.2
3HAC 12303-1
Frame incl ax 1 gearbox
See
Frame incl ax 1 gearbox,
3HAC 12303-1 on page 30
101.3
3HAC 11732-1
Washer
T=3
101.4
18
3HAB 7700-89
Hex socket head cap

screw
M16x90
101.5
3HAC 11529-1
Rubber lined clip D=28
101.6
3HAC 14453-1
Hose with flange
101.7
3HAC 14453-2
Plug
101.8
3HAC 4428-2
Hose Clip
101.9
9ADA 618-56
Torx pan head screw
M6x16
Base, machining, 3HAC 10044-1
Item
Qty
Art. number
Description
Note
101.1.1
3HAC 10044-2
Base, casting
101.1.2
3HAC 4836-7
Protection plug
101.1.3
3HAC 1383-2
Protection Cover compl.
101.1.4
3HAC 14024-1
Protection screw
Frame incl ax 1 gearbox, 3HAC 12303-1
Item
30
Qty
Art. number
Description
Note
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
Item
Art. number
Description
Note
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
Qty
31
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
Item
32
Qty
Art. number
Description
Note
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 10509-5
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
Item
Art. number
Description
Note
102.1 1
3HAC 13076-1
Material set ax 4
See
13076-1 on page 34
102.2 1
3HAC 15932-1
Tube shaft 2,55 foundry
102.3 1
3HAC 13062-1
Axis 3
Qty
See
Axis 3, 3HAC 13062-1 on
page 36
33
2 Part list
2.3.7. Axis 3-4 500kg Foundry, 3HAC 13063-5 (IRB 7600 - 500/2.3)
Overview
Item
Qty
Art. number
Description
Note
102.1
3HAC 13076-1
Material set ax 4
See
13076-1 on page 34
102.2
3HAC 15932-2
Tube shaft 2,3 foundry
102.3
3HAC 13062-1
Axis 3
See
Axis 3, 3HAC 13062-1 on
page 36
Material set ax 4, 3HAC 13076-1
34
Item
Qty
Art. number
Description
Note/Dimension
102.1.1
3HAC 11523-1
Gear Z4 / 4
102.1.2
3HAC 14725-1
Rot ac motor incl pinion See

Rot ac motor incl pinion,
3HAC 14725-1 on page 35
102.1.3
3HAB 3409-50
Hex socket head cap

screw
102.1.4
3HAB 4233-1
Washer
102.1.5
3HAC 11499-1
Motor flange, machin.
102.1.6
18
3HAB 3409-60
Hex socket head cap

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

axis4,5
T=3
102.1.8
3HAC 12642-1
RV 125F incl. gear
See
RV 125F incl. gear, 3HAC
12642-1 on page 35
102.1.9
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
102.1.12
3HAC 13564-1
Damper axis 4
102.1.13
3HAA 1001-17
Stop, Axis 4, Casting
102.1.14
3HAC 11925-1
Mechanical stop head
102.1.15
3HAB 3409-81
Hex socket head cap

screw
M16x35
102.1.16
3HAA 1001-98
Gasket
T=1
102.1.17
9ADA 183-37
Hex socket head cap

screw
M8x25
102.1.18
9ADA 312-7
Plain washer
8,4x16x1,6
102.1.19
3HAA 2103-21
Taper roller bearing
170x230x38
102.1.20
2216 261-18
Sealing
170x200x15
M10x40
M10x80
M6x8x8
2 Part list
102.1.21
3HAB 3772-27
O-ring
170x5
102.1.22
3HAC 3774-7
Spacer ring
102.1.23
3HAC 11461-1
Sealing
102.1.24
3HAC 17219-1
Thrust washer
102.1.25
9ABA 135-45
Retaining ring, shaft
102.1.26
3HAC 11928-1
Protective ring housing
102.1.27
3HAC 17218-1
Set of shims
102.1.28
2522 122-1
Magnetic plug
R1/4"
102.1.29
3HAC 16721-1
Magnetic plug
R1/2"
102.1.30
900 ml
3HAC 021469001
Lubricating oil, Shell

Tivela S 150
102.1.31
3850 ml 1171 2016-604/

3HAC 021469001
Lubricating oil, X320

Tivela S 150
Do not mix the oils!
102.1.32
9ABA 107-56
Parallel pin
10x20
102.1.33
3HAC 10122-27 Friction washer
102.1.34
1 ml
3HAB 7116-1
Locking liquid
102.1.35
30 g
3HAB 3537-1
Bearing grease
170
T=0,5
Rot ac motor incl pinion, 3HAC 14725-1
Item
Qty
Art. number
Description
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
Dimension
89,5x3
RV 125F incl. gear, 3HAC 12642-1
Item
Qty
Art. number
Description
Note/Dimension
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
RV 125F-97,909 assembly, 3HAC 17273-1
Item
Art. number
Description
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
Qty
Dimension
35
2 Part list
Cover ax 4 incl. sealing, 3HAC 12640-1
Item
Qty
Art. number
Description
Note
102.1.9.1
3HAC 11423-4
Cover axis 4
See
Cover axis 4, 3HAC 11423-4 on
page 36
102.1.9.2
3HAA 1001-628
Sealing
Cover axis 4, 3HAC 11423-4
Item
Qty
Art. number
Description
Note
102.1.9.1.1
3HAC 11423-1
Cover axis 4, machined
102.1.9.1.2
3HAC 11423-3
Gasket cover axis 4
Description
Tube shaft 2,55, 3HAC 10509-1
Item
Qty
Art. number
102.2.1
3HAC 10509-2 Tube shaft 2,55, cast
Note
102.2.2
3HAC 1383-2
Item
Qty
Art. number
Description
102.2.1
3HAC 10509-6 Tube shaft 2,3, cast
102.2.2
3HAC 1383-2
Item
Qty
Art. number
Description
102.3.1
3HAC 10502-3
Axis 4 housing, mach.
102.3.2
3HAC 12641-1
RV 700F incl. gear
See
RV 700F incl. gear, 3HAC
12641-1 on page 46
102.3.3
20
3HAB 7700-89
Hex socket head cap

screw
M16x90
102.3.4
20
3HAC 10264-1
Washer
17x30x3
102.3.5
3HAC 14724-1
Rot ac motor incl pinion See

3HAC 14725-1 on page 35
102.3.6
3HAB 3409-50
Hex socket head cap

screw
102.3.7
3HAB 4233-1
Washer
Tube shaft 2,3, 3HAC 10509-5
Note
Axis 3, 3HAC 13062-1
36
Note/Dimension
M10x40
2 Part list
102.3.8
3HAC 11719-1
Plug
R1/4
102.3.8
3HAC 16721-1
Magnetic plug
R1/2
102.3.9
4200
ml
3HAC 16843-1/
3HAC 021469001
Lubricating oil, RMO

150/
Tivela S 150
102.3.10
9ABA 142-92
Spring pin, slotted
10x30
Item
Qty
Art. number
Description
Note
102.3.2.1
3HAC 17272-1
RV 700F-269,21
assembly
See
RV 700F-269,21 assembly,
3HAC 17272-1 on page 46
102.3.2.2
3HAC 11636-1
Gear Z2 /2.3
RV 700F-269,21 assembly, 3HAC 17272-1
Item
Qty
Art. number
Description
102.3.2.1.1
3HAC 10122-21
RV 700F, i=269,21
102.3.2.1.2
3HAB 3772-51
O-ring
Dimension
369,3x5,7
Item
Qty
Art. number
Description
102.3.5.1
3HAC 17484-1
102.3.5.2
3HAC 11632-1
Pinion Z1 /2.3
102.3.5.3
2152 2012-430
O-ring
Dimension
89,5x3
37
2 Part list
2.3.8 Wrist, 3HAC 10503-1 (Std) / 3HAC 15992-1 (Foundry)
38
Item
Qty
Art. number
Description
Note/Dimension
103.1
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
3HAC 16721-1
Magnetic plug
R1/2
103.6
3HAC 12642-1
RV 125F incl. gear
See
RV 125F incl. gear,
3HAC 12642-1 on
page 39
103.7
18
3HAB 3409-50
M10x40
103.8
3HAC 10122-12
Washer, RV 125 F, axis4,5
T=3
103.9
3HAC 10503-3
Wrist housing, machining
103.10 2
2522 122-1
Magnetic plug
103.11 4
9ADA 183-35
103.12 2
3HAC 10503-8
Damper ax 5
103.13 2
3HAC 10122-27
Friction washer
103.14 4
3HAB 3409-50
103.15 4
3HAB 4233-1
Washer
103.16 1
3HAC 14725-1
Rot ac motor incl pinion
103.18 1
3HAC 11409-3
Cover, left machining
103.19 4
9ADA 618-56
Torx pan head screw
M6x16
103.21 7
3HAB 3409-50
M10x40
103.22 7
3HAB 4233-1
Washer
103.24 1
3HAC 10503-14
Support shaft inc bearing
103.25 1
3HAC 9953-1
Sync plate with vernier
103.26 2
9ADA 618-56
Torx pan head screw
M6x16
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 127072 on page 42
103.31 1
3HAA 2166-24
VK-Cover
103.32 21
3HAB 7700-89
R1/4"
M10x40
See
Rot ac motor incl
pinion, 3HAC 14725-1
on page 35
See
Support shaft inc
bearing, 3HAC 1050314 on page 40
M16x90
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
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
M6x16
103.41 3800 ml 1171 2016-604/

3HAC 021469001
Lubricating oil, X320/

Lubricating oil, Shell Tivela S
150
103.42 750 ml
3HAC 021469001
Lubricating oil, Shell Tivela S

150
103.43 1
3HAC 5984-1
Label
103.43 1
3HAC 17260-1
Sprbarhetsetikett
103.43 1
3HAC 17260-2
Sprbarhetsetikett Wrist,
Foundry
Cover, right, 3HAC 11409-7
Item
Qty
Art. number
Description
Note
103.1.1 1
3HAC 11409-1
Cover, right machining
103.1.2 1
3HAC 11409-5
Gasket, right
Art. number
Description
Note/Dimension
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
103.6.3 9
3HAB 7700-69
103.6.4 6
3HAB 3409-86
Item
Qty
RV 125F-97,909 assembly, 3HAC 17273-1
Item
Art. number
Description
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
Qty
Dimension
39
2 Part list
Item
Qty
Art. number
Description
103.16.1 1
3HAC 17484-2
103.16.2 1
3HAC 10122-17
Pinion RV 125F-97,909
103.16
2152 2012-430
O-ring
89,5x3
Description
Dimension
Dimension
Support shaft inc bearing, 3HAC 10503-14
Item
Qty
Art. number
103.24.1 1
3HAC 11470-1 Support Shaft
103.24.2 1
3HAA 2325-12 Ball bearing W.two seal.
130x200x33
103.24.3 3
9ADA 618-56
Torx pan head screw
M6x16
103.24.4 1 ml
3HAB 7116-1
Locking liquid
Axis 6 complete, 3HAC 12707-1
40
Item
Qty
Art. number
Description
Note/Dimension
103.28.1
3HAC 10436-1
Tilt house RV125F
103.28.2
3HAC 17274-1
RV 125F-178,41
assembly
See
RV 125F-178,41
assembly, 3HAC 172741 on page 42
103.28.3
3HAC 10122-13
Washer, RV 125 F
T=3
103.28.4
18
3HAB 7700-8
Hex socket head cap

screw
M10x50
103.28.5
3HAC 13193-1
Turning disc, dia. 250
103.28.6
33
3HAB 7700-3
Hex socket head cap

screw
M10x25
103.28.7
2522 122-1
Magnetic plug
R1/4"
103.28.8
3HAC 11471-1
Sync. Plate
103.28.9
2152 2012-433
O-ring
104,5x3
103.28.10 2
9ADA 618-32
Torx pan head screw
M4x8
103.28.11 6 ml
3HAB 7116-1
Locking liquid
103.28.12 850 ml 3HAC 021469001

Tivela S 150
103.28.13 1
3HAC 14726-1
See
3HAC 14725-1 on page
35
103.28.14 4
9ADA 312-7
Plain washer
8,4x16x1,6
103.28.15 4
9ADA 183-37
Hex socket head cap

screw
M8x25
103.28.16 1
3HAC 14263-1
Protection cover
2 Part list
103.28.17 1
9ADA 624-69
Torx counters, head screw M8x20
41
2 Part list
Axis 6 complete Foundry, 3HAC 12707-2
Item
Qty
Art. number
Description
Note
103.28.1
3HAC 16010-1
Tilt house RV125F,

foundry
103.28.2
3HAC 17274-1
RV 125F-178,41
assembly
See
RV 125F-178,41
103.28.3
3HAC 10122-13
Washer, RV 125 F
T=3
103.28.4
18
3HAB 7700-8
Hex socket head cap

screw
M10x50
103.28.5
3HAC 13193-1
Turning disc, dia. 250
103.28.6
33
3HAB 7700-3
Hex socket head cap

screw
M10x25
103.28.7
2522 122-1
Magnetic plug
R1/4"
103.28.8
3HAC 11471-1
Sync. Plate
103.28.9
2152 2012-433
O-ring
104,5x3
103.28.10 2
9ADA 618-32
Torx pan head screw
M4x8
103.28.11 6 ml
3HAB 7116-1
Locking liquid
103.28.12 850 ml 3HAC 021469001
Lubricating oil, Shell Tivela

S 150
103.28.13 1
3HAC 14726-1
See
35
103.28.14 4
9ADA 312-7
Plain washer
8,4x16x1,6
103.28.15 4
9ADA 183-37
Hex socket head cap

screw
M8x25
103.28.16 1
3HAC 14263-1
Protection cover
103.28.17 1
9ADA 624-69
Torx counters, head screw M8x20
RV 125F-178,41 assembly, 3HAC 17274-1
Item
Qty
Art. number
Description
103.28.2.1 1
3HAC 10122-1
RV 125F, i=178,41
103.28.2.2 1
3HAB 3772-49
O-ring
Dimension
189,3x3,1
Item
42
Qty
Art. number
Description
Dimension
103.28.13.1 1
3HAC 17484-3
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
Item
Art. number
Description
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
103.33.4 1
3HAC 10503-15
Support Ring
103.33.5 1 ml
3HAB 7116-2
Locking liquid
Qty
Dimension
160x220x28
43
2 Part list
2.3.9. Material set manipulator, 3HAC 13079-1
2.3.9. Material set manipulator, 3HAC 13079-1

Overview
44
Item
Qty
Art. number
Description
Note/Dimension
108.201
3HAC 17213-1
Sealing axis 2/3
108.202
60
3HAB 3409-84
108.203
3HAC 11828-1
Washer axis 3
108.204
30
3HAA 1001-186
Washer
108.205
3HAC 11755-1
Friction Washer
108.206
20
3HAB 7700-69
M12x50
108.207
20
3HAA 1001-134
Washer
13x19x1,5
108.210
3HAC 14300-1
Cable protector
108.212
3HAC 11771-1
Cable guide, end part
108.213
3HAC 13960-1
Connection plate, ax3
108.214
3HAC 11750-1
Damper axis 3
108.215
3HAC 12990-1
Damper axis 2
108.216
9ADA 624-65
Torx counters, head screw
M6x60
108.217
9ADA 334-7
Spring washer, conical
8,4x18x2
108.218
9ADA 618-57
Torx pan head screw
M6x20
108.220
3HAC 9953-1
Sync plate with nonie
108.222
3HAC 14658-1
Sync plate with nonie axis 3
108.223
9ADA 183-48
M10x16
108.225
13
9ADA 618-56
Torx pan head screw
M6x16
108.228
3HAC 3261-1
Cover upperarmcovers
108.229
3HAC 15431-1
Cable protection
108.230
3HAC 14880-1
Cable fixing bracket
108.231
2166 2055-3
Cable straps, outdoors
108.232
3HAC 16721-1
Magnetic plug
R1/2
108.233
2522 122-1
Magnetic plug
R1/4"
M16x50
17x25x3
2 Part list
2.3.10. Material set ax 1-2, 3HAC 13077-1

Overview
Item
Art. number
Description
Note/Dimension
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
109.304 20
3HAB 3409-92
109.305 20
3HAA 1001-186 Washer
17x25x3
109.306 1
3HAC 14723-1
See
35
109.307 1
3HAC 14724-1
See
35
109.308 8
3HAB 3409-50
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
109.324 24
9ADA 618-56
Torx pan head screw
M6x16
109.325 3
9ADA 618-57
Torx pan head screw
M6x20
109.326 1
3HAC 16014-1
Serial measurement unit
109.327 1
3HAC 14788-3
Cover SMB and BRU
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
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
!
109.334 6
9ADA 618-53
Torx pan head screw
M6x8
Qty
381x438x1,0
See
Cover SMB and BRU,
47
M6x150
45
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

3HAC 021469- Lubricating oil, Shell Tivela
001
S 150
109.342 4800 ml
3HAC 16843-1/ Lubricating oil, RMO 150

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.
109.346 1
3HAC 16036-1
BU w. buttons DSQC 561
3HAC 14219-1
BU at the base
See section Refitting of

brake release unit.
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
109.349 2
9ADA 618-58
Torx pan head screw
M6x25
109.350 1
3HAC 4813-1
Cover, push button guard
109.351 10
9ADA 618-44
Torx pan head screw
109.352 1
3HAC 14024-1
Protection screw
109.353 1
3HAC 17423-1
Washer
109.354 1
9ADA 269-4
Hexagon nut
M6
M5x12
M8
Item
Qty
Art. number
Description
Note
109.301.1 1
3HAC 17272-1
RV 700F-269,21 assembly
See
RV 700F-269,21
109.301.2 1
3HAC 11636-1
Gear Z2 /2.3
RV 700F-269,21 assembly, 3HAC 17272-1
Item
Art. number
Description
109.301.1.1 1
Qty
3HAC 10122-21
RV 700F, i=269,21
109.301.1.2 1
3HAB 3772-51
O-ring
Dimension
369,3x5,7
46
2 Part list
Item
Qty
Art. number
Description
109.306.1 1
3HAC 17484-1
109.306.2 1
3HAC 11350-1
Pinion RV 500C & RV 320C
109.306.3 0
2152 2012-430
O-ring
Dimension
89,5x3
Item
Qty
Art. number
Description
Dimension
109.307.1
3HAC 17484-1
109.307.2
3HAC 11632-1
Pinion Z1 /2.3
109.307.3
2152 2012-430
O-ring
89,5x3
Note
Cover SMB and BRU, 3HAC 14788-3
Item
Qty
Art. number
Description
109.327.1
3HAC 14788-1
Cover, casting
109.327.2
3HAC 14788-2
Gasket
109.327.3
3HAC 14692-4
Rubber cloth
Cover battery box, 3HAC 14791-3
Item
Art. number
Description
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
Qty
Note
47
2 Part list
2.3.11. Mtrl.set balancing device, 3HAC 13082-1
2.3.11. Mtrl.set balancing device, 3HAC 13082-1

Overview
Item
48
Qty
Art. number
Description
Dimension
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
110.407 4
3HAB 7700-89
M16x90
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
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
M16x180
17x25x3
2 Part list
2.3.12. Arm extension set, 956 mm, 3HAC 12311-1 (IRB 7600 - 150/3.5)
Overview
Item
Art. number
Description
111.501 1
3HAC 9760-5
Arm extender 956mm
111.501 1
3HAC 15932-4
Arm extender 956mm, Foundry
111.502 1
3HAC 11755-1
Friction Washer
111.503 20
3HAB 7700-69
M12x50
111.504 20
3HAA 1001-134
Washer
13x19x1,5
111.505 1
9ABA 107-56
Parallel pin
10x20
Qty
Dimension
49
2 Part list
Overview
Item
50
Qty
Art. number
Description
Dimension
111.501 1
3HAC 9760-1
Arm extender 250mm
111.501 1
3HAC 15932-3
Arm extender 250mm, Foundry
111.502 1
3HAC 11755-1
Friction Washer
111.503 20
3HAB 7700-69
M12x50
111.504 20
3HAA 1001-134
Washer
13x19x1,5
111.505 1
9ABA 107-56
Parallel pin
10x20
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
51
3 Exploded views
3.2. Base incl. Frame
3.2. Base incl. Frame
xx0200000329
52
3 Exploded views
3.3. Frame-Lower arm 1
xx0200000330
53
3 Exploded views
xx0200000331
54
3 Exploded views
3.5. Upper arm
3.5. Upper arm
xx0200000333
55
3 Exploded views
3.6. Wrist complete
3.6. Wrist complete
xx0200000332
56
4 Circuit Diagram
4.1. Introduction
4 Circuit Diagram
4.1. Introduction
Overview
This chapter includes the circuit diagram of the robot.
57
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
Contents
101
02
Circuit Diagram 3HAC 13347-1
Revision
sheet
Connection Point Location
102
Revision
02
sheet
02
Legend
103
Revision
sheet
sheet
104
Revision
02
Brake Release Unit
Serial Measurement Board
105
Revision
02
sheet
Axis 1
106
02
Revision
sheet
Axis 2
107
02
Revision
sheet
Axis 3
108
02
Revision
sheet
109
02
Revision
sheet
Axis 4
sheet
110
Revision
02
Axis 5 (IRB 7600)
Axis 6
111
02
Revision
sheet
Switches axis 1
113
Revision
02
sheet
Switches/Fan axis 2
114
Revision
02
sheet
Switches/Fan axis 3
115
Revision
02
sheet
sheet
Revision
901
02
Axis 5 (IRB 6600)
Revision
905
02
Design changes, note 1.1
sheet
Revision
906
02
Design changes, note 2.1-2.7
sheet

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3URGXFWPDQXDO SDUWRI UHIHUHQFHLQIRUPDWLRQ

Product manual (part 2 of 2), reference information

Copyright 2004 ABB All right reserved.

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

3HAC 022033-001 Revision: B

3HAC 022033-001 Revision: B

Who should read this manual?

be a trained maintenance/repair craftsman

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

3HAC 022033-001 Revision: B

Useful information when performing installation, maintenance

Complete list of manipulator parts, shown in the exploded

Exploded views / Foldouts

Detailed illustrations of the manipulator with reference

Circuit Diagram of the manipulator.

Following updates are made:

3HAC 022033-001 Revision: B

Product documentation, M2000/M2000A

Product documentation, M2000/M2000A

Installation and commissioning (descriptions of mechanical installation, electrical

Maintenance (descriptions of all required preventive maintenance procedures

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

Foldouts or exploded views

In addition, spare part information is supplied for the entire option.

3HAC 022033-001 Revision: B

Product documentation, M2004

Product documentation, M2004

Installation and commissioning (descriptions of mechanical installation, electrical

Maintenance (descriptions of all required preventive maintenance procedures

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

Foldouts or exploded views

RAPID Overview: An overview of the RAPID programming language.

RAPID reference manual part 1: Description of all RAPID instructions.

Technical reference manual - System parameters: Description of system

3HAC 022033-001 Revision: B

Product documentation, M2004

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

How to use the application

Examples of how to use the application

Operator's manual - IRC5 with FlexPendant

Operator's manual - RobotStudio Online

Trouble shooting manual for the controller and robot

3HAC 022033-001 Revision: B

Robot fundamentals (describing the fundamental aspects, functions, concept and

Product documentation, M2004

3HAC 022033-001 Revision: B

3HAC 022033-001 Revision: B

1.2. Applicable Safety Standards

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.

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