ABB IRB 7600 User manual

ROBOTICS
Product manual
IRB 7600

Trace back information:
Workspace 23D version a13
Checked in 2023-12-07
Skribenta version 5.5.019

Product manual
IRB 7600 - 500/2.55
IRB 7600 - 500/2.3
IRB 7600 - 400/2.55
IRB 7600 - 340/2.8
IRB 7600 - 325/3.1
IRB 7600 - 150/3.5
IRC5, OmniCore
Document ID: 3HAC022033-001
Revision: AH
© Copyright 2007 - 2023 ABB. All rights reserved.
Specifications subject to change without notice.

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, damage 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.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.
© Copyright 2007 - 2023 ABB. All rights reserved.
Specifications subject to change without notice.

Table of contents
9Overview of this manual ...................................................................................................................
17Product documentation, IRC5, OmniCore .......................................................................................
19How to read the product manual ......................................................................................................
211 Safety
211.1 Safety information .............................................................................................
211.1.1 Limitation of liability .................................................................................
221.1.2 Requirements on personnel ......................................................................
231.2 Safety signals and symbols .................................................................................
231.2.1 Safety signals in the manual ......................................................................
251.2.2 Safety symbols on manipulator labels .........................................................
311.3 Robot stopping functions ....................................................................................
321.4 Safety during installation and commissioning .........................................................
351.5 Safety during operation ......................................................................................
361.6 Safety during maintenance and repair ...................................................................
361.6.1 Safety during maintenance and repair .........................................................
391.6.2 Emergency release of the robot axes ..........................................................
401.6.3 Brake testing ..........................................................................................
411.7 Safety during troubleshooting ..............................................................................
421.8 Safety during decommissioning ...........................................................................
432 Installation and commissioning
432.1 Introduction to installation and commissioning .......................................................
442.2 Robot transportation precautions .........................................................................
482.3 Securing the robot with a transport support ...........................................................
502.4 Unpacking .......................................................................................................
502.4.1 Pre-installation procedure .........................................................................
512.4.2 Technical data ........................................................................................
552.4.3 Working range, IRB 7600 - 150/3.5 ..............................................................
562.4.4 Working range, IRB 7600 - 340/2.8 ..............................................................
572.4.5 Working range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55 ................................
582.4.6 Working range, IRB 7600 - 500/2.3 ..............................................................
592.4.7 Risk of tipping/stability .............................................................................
602.4.8 The unit is sensitive to ESD .......................................................................
612.5 On-site installation ............................................................................................
612.5.1 Lifting robot with fork lift ...........................................................................
672.5.2 Lifting robot with lifting accessory (recommended lifting method) .....................
692.5.3 Lifting robot with roundslings ....................................................................
712.5.4 Manually releasing the brakes ...................................................................
732.5.5 Lifting the base plate ................................................................................
742.5.6 Securing the base plate ............................................................................
792.5.7 Orienting and securing the robot ................................................................
822.5.8 Fitting equipment on robot .......................................................................
872.5.9 Installation of base spacers (option) ...........................................................
892.5.10 Installation of cooling fan for motors (option) ................................................
962.5.11 Installation of Foundry Plus Cable guard (option) ..........................................
972.5.12 Loads fitted to the robot, stopping time and braking distances .........................
982.5.13 Safety lamp (option for IRC5) .....................................................................
992.5.14 Extended working range, axis 1 (option) .....................................................
1012.6 Restricting the working range ..............................................................................
1012.6.1 Axes with restricted working range .............................................................
1022.6.2 Mechanically restricting the working range of axis 1 ......................................
1042.6.3 Mechanically restricting the working range of axis 2 ......................................
1062.6.4 Mechanically restricting the working range of axis 3 ......................................
1092.7 Electrical connections ........................................................................................
1092.7.1 Robot cabling and connection points ..........................................................
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Table of contents

1132.8 Start of robot in cold environments ......................................................................
1142.9 Test run after installation, maintenance, or repair ....................................................
1153 Maintenance
1153.1 Introduction ......................................................................................................
1163.2 Maintenance schedule and expected life ...............................................................
1163.2.1 Specification of maintenance intervals ........................................................
1173.2.2 Maintenance schedule .............................................................................
1213.2.3 Expected component life .........................................................................
1223.3 Inspection activities ...........................................................................................
1223.3.1 Inspecting the motor seal .........................................................................
1253.3.2 Inspecting the oil level in axis-1 gearbox .....................................................
1283.3.3 Inspecting the oil level in axis-2 gearbox .....................................................
1313.3.4 Inspecting the oil level in axis-3 gearbox .....................................................
1343.3.5 Inspecting the oil level in axis-4 gearbox .....................................................
1373.3.6 Inspecting the oil level in axis-5 gearbox .....................................................
1403.3.7 Inspecting the oil level in axis-6 gearbox .....................................................
1433.3.8 Inspecting the balancing device .................................................................
1493.3.9 Inspecting the cable harness .....................................................................
1523.3.10 Inspecting the axis-1 mechanical stop pin ...................................................
1543.3.11 Inspecting the mechanical stops on axes 1, 2, and 3 ......................................
1563.3.12 Inspecting the damper on axes 2 to 5 ..........................................................
1583.3.13 Inspecting the information labels ................................................................
1603.3.14 Inspecting the UL lamp .............................................................................
1623.4 Changing/replacement activities ..........................................................................
1623.4.1 Type of lubrication in gearboxes ................................................................
1643.4.2 Changing oil, axis-1 gearbox .....................................................................
1683.4.3 Changing oil, axis-2 gearbox .....................................................................
1713.4.4 Changing oil, axis-3 gearbox .....................................................................
1743.4.5 Changing oil, axis-4 gearbox .....................................................................
1773.4.6 Changing oil, axis-5 gearbox .....................................................................
1813.4.7 Changing oil, axis-6 gearbox .....................................................................
1843.4.8 Replacing the SMB battery ........................................................................
1893.5 Lubrication activities ..........................................................................................
1893.5.1 Lubrication of spherical roller bearing, balancing device .................................
1913.6 Cleaning activities .............................................................................................
1913.6.1 Flushing a contaminated gearbox ...............................................................
1933.6.2 Cleaning the IRB 7600 ..............................................................................
1973.7 Service Information System, M2000 ......................................................................
1973.7.1 Using the SIS system ...............................................................................
1983.7.2 Description of Service Information System (SIS) ...........................................
2013.7.3 SIS system parameters ............................................................................
2023.7.4 Setting the SIS parameters .......................................................................
2033.7.5 Reading the SIS output logs ......................................................................
2043.7.6 Exporting the SIS data .............................................................................
2054 Repair
2054.1 Introduction ......................................................................................................
2064.2 General procedures ...........................................................................................
2064.2.1 Performing a leak-down test ......................................................................
2074.2.2 Mounting instructions for bearings .............................................................
2094.2.3 Mounting instructions for sealings ..............................................................
2134.2.4 Cut the paint or surface on the robot before replacing parts ............................
2144.2.5 The brake release buttons may be jammed after service work .........................
2154.3 Complete robot .................................................................................................
2154.3.1 Replacement of cable harness, axes 1-4 .....................................................
2254.3.2 Replacement of cable harness, axes 5-6 ......................................................
2284.3.3 Replacement of complete arm system .........................................................
6 Product manual - IRB 7600
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Table of contents

2334.4 Upper and lower arm .........................................................................................
2334.4.1 Replacing turning disk ..............................................................................
2374.4.2 Replacement of complete wrist unit ............................................................
2424.4.3 Replacement of complete upper arm ...........................................................
2474.4.4 Replacement of complete lower arm ...........................................................
2574.4.5 Replacement of lower arm shaft .................................................................
2654.5 Frame and base ................................................................................................
2654.5.1 Replacing the SMB unit ............................................................................
2694.5.2 Replacement of brake release board ...........................................................
2754.5.3 Replacement of spherical roller bearing, balancing device ..............................
2804.5.4 Replacing the balancing device ..................................................................
2924.6 Motors ............................................................................................................
2924.6.1 Replacement of motor, axis 1 ....................................................................
2974.6.2 Replacement of motor axis 2 .....................................................................
3034.6.3 Replacement of motor, axis 3 ....................................................................
3104.6.4 Replacement of motor, axis 4 ....................................................................
3174.6.5 Replacement of motor, axis 5 ....................................................................
3224.6.6 Replacement of motor, axis 6 ....................................................................
3294.7 Gearboxes .......................................................................................................
3294.7.1 Replacing the axis 1 gearbox .....................................................................
3414.7.2 Replacement of gearbox, axis 2 .................................................................
3504.7.3 Replacement of gearbox, axis 3 .................................................................
3574.7.4 Replacement of gearbox, axis 4 .................................................................
3624.7.5 Replacement of gearbox, axis 5 .................................................................
3694.7.6 Replacement of gearbox, axis 6 .................................................................
3755 Calibration
3755.1 Introduction to calibration ...................................................................................
3755.1.1 Introduction and calibration terminology ......................................................
3765.1.2 Calibration methods .................................................................................
3795.1.3 When to calibrate ...................................................................................
3805.2 Synchronization marks and axis movement directions .............................................
3805.2.1 Synchronization marks and synchronization position for axes .........................
3815.2.2 Calibration movement directions for all axes ................................................
3825.3 Updating revolution counters ...............................................................................
3825.3.1 Updating revolution counters on IRC5 robots ...............................................
3875.3.2 Updating revolution counters on OmniCore robots ........................................
3895.4 Calibrating with Axis Calibration method ...............................................................
3895.4.1 Description of Axis Calibration ..................................................................
3925.4.2 Calibration tools for Axis Calibration ...........................................................
3945.4.3 Installation locations for the calibration tools ...............................................
3955.4.4 Axis Calibration - Running the calibration procedure ......................................
3995.4.5 Reference calibration ...............................................................................
4015.5 Calibrating with Calibration Pendulum method .......................................................
4025.6 Calibrating with Wrist Optimization method ...........................................................
4045.7 Verifying the calibration ......................................................................................
4055.8 Checking the synchronization position ..................................................................
4096 Decommissioning
4096.1 Introduction to decommissioning .........................................................................
4106.2 Environmental information ..................................................................................
4126.3 Scrapping of robot .............................................................................................
4136.4 Decommissioning of balancing device ...................................................................
4177 Robot description
4177.1 Type A vs type B motors ....................................................................................
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4198 Reference information
4198.1 Introduction ......................................................................................................
4208.2 Applicable standards .........................................................................................
4218.3 Unit conversion .................................................................................................
4228.4 Screw joints ....................................................................................................
4258.5 Weight specifications .........................................................................................
4268.6 Standard tools ..................................................................................................
4278.7 Special tools ....................................................................................................
4318.8 Lifting accessories and lifting instructions ..............................................................
4339 Spare part lists
4339.1 Spare part lists and illustrations ...........................................................................
43510 Circuit diagram
43510.1 Circuit diagrams ................................................................................................
43710.2 Validity of circuit diagram 3HAC025744-1 ..............................................................
43810.3 Validity of circuit diagram 3HAC13347-1 ................................................................
439Index
8 Product manual - IRB 7600
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Table of contents

Overview of this manual
About this manual
This manual contains instructions for:
• mechanical and electrical installation of the IRB 7600
• maintenance of the IRB 7600
• mechanical and electrical repair of the IRB 7600
The robot described in this manual has the following protection types:
•Standard
•Foundry Plus
This manual describes the manipulator using either the IRC5 or the OmniCore
controller.
Product manual scope
The manual covers all variants and designs of the IRB 7600. Some variants and
designs may have been removed from the business offer and are no longer available
for purchase.
Usage
This manual should be used during:
• installation and commissioning, from lifting the product to its work site and
securing it to the foundation, to making it ready for operation
• maintenance work
• repair work
• decommissioning work
Note
It is the responsibility of the integrator to conduct a risk assessment of the final
application.
It is the responsibility of the integrator to provide safety and user guides for the
robot system.
Who should read this manual?
This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
A maintenance/repair/installation craftsman working with an ABB robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
• be trained to respond to emergencies or abnormal situations.
Continues on next page
Product manual - IRB 7600 9
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Overview of this manual

References
Procedures in this product manual contain references to the following manuals:
General
Document IDDocument name
3HAC049113-001Product manual, spare parts - IRB 7600
3HAC13347-1Circuit diagram - IRB 7600
3HAC025744-001
3HAC031045-001Safety manual for robot - Manipulator and IRC5 or OmniCore
controller i
3HAC16578-1Operating manual - Calibration Pendulum
3HAC042927-001Technical reference manual - Lubrication in gearboxes
iThis manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
OmniCore robots
Document IDDocument name
3HAC087209-001Product specification - IRB 7600
3HAC081697-001Product manual - OmniCore V400XT
3HAC065036-001Operating manual - OmniCore
3HAC065041-001Technical reference manual - System parameters
3HAC082287-001Application manual - Additional axes for OmniCore
IRC5 robots
Document IDDocument name
Document.ID-1Product specification - IRB 7600
3HAC047136-001Product manual - IRC5
IRC5 with main computer DSQC1000 or later.
3HAC050941-001Operating manual - IRC5 with FlexPendant
3HAC16578-1Operating manual - Calibration Pendulum
3HAC050944-001Operating manual - Service Information System
3HAC050948-001Technical reference manual - System parameters
3HAC051016-001Application manual - Additional axes and standalone controller
3HAC030421-001Application manual - CalibWare Field
Revisions
DescriptionRevision
First edition.-
Replaces previous manuals:
• Installation and Commissioning Manual
• Maintenance Manual
• Repair Manual, part 1
• Repair Manual, part 2.
Continues on next page
10 Product manual - IRB 7600
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Overview of this manual
Continued

DescriptionRevision
Changes made in the material from the previous manuals:
• Model M2004 implemented.
• Various corrections due to technical revisions, changes in the toolkits
etc.
Chapter Calibration replaced with chapter Calibration information.A
Following corrections are made:
• In chapter 3: Maintenance in section Exporting the SIS data, the unit
seconds for different SIS parameters is replaced by the unit hours.
The change is only valid for RobotWare release 5.0.
Following updates are made:
• In chapter 4: Repair, the sections Removal of complete lower arm and
Refitting of complete lower arm are completed with more detailed in-
formation about how to use the glycerin pump.
• 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 made in the chapter Mainten-
ance on page 115 and Part list.
B
C• New variant of the robot (IRB 7600 - 500/2.55) implemented throughout
the manual.
• Wrist unit updated, new spare part number is specified in Replacement
of complete wrist unit on page 237 and Spare part list.
• Insulated wrist unit implemented, new spare part number is specified
in Replacement of complete wrist unit on page 237 and Spare part list.
Amount of oil differs from non-insulated wrist unit, changes made in
sections Type of oil in gearboxes and Changing oil, axis-6 gearbox on
page 181.
• New section that describes how to replace the bearing at the front eye
of the balancing device, Replacement of spherical roller bearing, balan-
cing device on page 275.
• Incorrect article numbers for position switches are corrected.
• New section: Installation of cooling fan for motors (option) on page 89.
• New section: Installation of base spacers (option) on page 87
• New section that specifies all the recommended spare parts: Spare
part list.
• Repair sections for removal/refitting are restructured into replacement
sections.
• Various corrections made, due to technical revisions etc.
Foundry Prime option included.D
E• New variant of the robot (IRB 7600 - 325/3.1) implemented throughout
the manual.
• In chapter 3 Maintenance section Oil in gearboxes type of oil and art.
no. in gearbox axes 1 has been added.
• New product name has been implemented throughout the manual:
"Mobilgear 600 XP 320". Replaces "Mobil Gearlube X320".
• Interval for change of Shell Tivela S 150 has been changed in section
Maintenance schedule.
• Section Service Information System has been removed from the
manual. There is a specific manual for SIS. See References.
• Section Chip and dust protection has been removed from the manual.
This option is no longer available.
• Standard tightening torque for M24 Allen head screws has been added
in section Screw joints.
• Prerequisites in section Overview
Continues on next page
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Overview of this manual
Continued

DescriptionRevision
This revision includes the following additions and/or changes:F
• Section "WARNING! - Mixed oils may cause severe damage to gear-
boxes" in chapter Safety, has been integrated in section "Type of oil in
gearboxes" in the Maintenance chapter.
• The oil Shell Tivela S150 in gearboxes 1, 2, 3 and 6 has been replaced
by Kyodo Yushi TMO 150. Changes made in chapters Maintenance and
Spare Parts.
•The section "Type of oil in gearboxes" in chapter Maintenance has been
updated according to changes made in oil types and intervals for oil
change.
• Sections "Robot transportation precaution" and "Securing the robot"
are added to the Installation chapter.
• Modified maintenance intervals for oil change in gearboxes.
• Chapter Maintenance, section "Maintenance Schedule": interval for
replacement of battery pack changed.
• Section "Type of oil" changed.
This revision include the following addition:G
•New WARNING! added in Safety chapter section Work inside the robot´s
working range.
• New WARNING! added in Safety chapter section WARNING! - Safety
risks during work with gearbox oil.
• The text in the introduction to chapters Installation,Maintenance and
Repair has been uppdated concerning the robot being connected to
earth when power connected.
• Section Expected component life in chapter Maintenance: The lifetime
of certain parts has been updated.
• Section Type of oil in chapter Maintenance has been updated.
• Section Foundry Plus,Cable guard added to Installation chapter.
This revision includes the following additions and/or changes:H
• Circuit diagrams are not included in this document but delivered as
separate files. See Circuit diagram on page 435.
• List of standards updated, see Applicable standards on page 420.
• Interval changed for inspection and lubrication of balancing device
(Foundry Prime). See chapter Maintenance section Maintenance
schedule on page 117.
The chapter Safety updated with:
• Updated safety signal graphics for the levels Danger and Warning, see
Safety signals in the manual on page 23.
• New safety labels on the manipulators, see Safety symbols on manipu-
lator labels on page 25.
• Revised terminology: robot replaced with manipulator.
This revision includes the following updates:J
• Maximum deviation changed, see Securing the base plate on page 74.
• Corrected part numbers, see Wrist, 3HAC16628-4.
• Corrected exploded view, see Wrist complete.
• Added inspection of oil level in gearboxes and inspection of surface
treatment in maintenance schedule for Foundry Prime. See section
Activities and intervals, Foundry Prime.
• Text in maintenance schedules concerning lubrication of balancing
device bearing changed into concerning all bearings of the balancing
device, see Maintenance schedule on page 117.
• Replacement of cable harness in Foundry Prime robots added to
maintenance schedule, see Activities and intervals, Foundry Prime.
Continues on next page
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Overview of this manual
Continued

DescriptionRevision
This revision includes the following updates:K
•Removed incorrect article number for fork lift, see Lifting robot with fork
lift on page 61.
• Information about restricting and extending the working range of axis
1 is now separated, see Mechanically restricting the working range of
axis 1 on page 102 and the new section Extended working range, axis
1 (option) on page 99. Also added signal about option 561-1 in section
Inspecting the axis-1 mechanical stop pin on page 152.
This revision includes the following updates:L
• A new block, about general illustrations, added in section How to read
the product manual on page 19.
• Made minor corrections and improvements in the complete instruction
for how to replace the axis 1 gearbox, see Replacing the axis 1 gearbox
on page 329.
• Robot designations are adjusted in sub-headings in section Robot
transportation precautions on page 44.
• Added new mechanical structure of the lower arm attachment point for
robots with protection Foundry Plus and Foundry Prime, see Replace-
ment of complete lower arm on page 247, the new section Replacement
of lower arm shaft on page 257 and the exploded view Frame-Lower arm
2in Product manual, spare parts - IRB 7600.
• Some general tightening torques have been changed/added, see up-
dated values in Screw joints on page 422.
• Added information about batteries.
• The maximum allowed deviation in levelness of the base plate is
changed, see Securing the base plate on page 74.
• Reference to Hilti standard added to the foundation recommendation
for the base plate and class designation for foundation is changed to
european standard C25/C30 (previously Swedish standard K25/K30),
see Securing the base plate on page 74.
•Added attachment plate for axis-2 switch to equipment list for installation
of position switch.
• Friction washer added to the instruction for replacing axis-2 gearbox
and to the exploded view, see Replacement of gearbox, axis 2 on
page 341 and Exploded view.
• Moved all information about Foundry Prime to a separate Product
manual, see References on page 10 for document number.
• Corrected article numbers for the o-rings and removed the removal tool
from the equipment list and from the procedure, see Replacement of
gearbox, axis 6 on page 369.
• Corrected article number for axis-2-3 sealing, see Replacement of
complete lower arm on page 247 and Replacement of complete upper
arm on page 242.
This revision includes the following updates:M
• A new SMB unit and battery is introduced, with longer battery lifetime.
This revision includes the following updates:N
• Instruction for inspection of oil level updated.
• Spare part number, motor axis 2 corrected.
•Added information about risks when scrapping a decommissioned robot,
see Scrapping of robot on page 412.
• Added information in draining instructions and in Safety chapter about
draining oil from gearboxes.
• Information regarding fork lift set 3HAC0604-2 deleted from manual.
• Information regarding oil types added to maintenance schedule.
• New illustrations, and updated repair instructions regarding brake unit
cover.
Continues on next page
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Overview of this manual
Continued

DescriptionRevision
•Spare parts and exploded views are not included in this document but
delivered as a separate document. See Product manual, spare
parts - IRB 7600
This revision includes the following updates:P
• Information about maintenance kit (3HAC15834-1), and upgrade kit
(3HAC14965-1), deleted from manual.
• The maximum allowed deviation in levelness of the base plate and
foundation is changed, see Securing the base plate on page 74.
• Added tightening torque for R1.SMB and 7th axis connector, see Re-
placement of cable harness, axes 1-4 on page 215.
• Minor corrections.
This revision includes the following updates:Q
• The inspection of oil level in gearboxes is removed from the mainten-
ance schedule and moved to the cleaning section.
• The instructions for inspection of oil level in gearboxes are updated,
see Inspection activities on page 122.
• Illustrations of SMB battery RMU improved.
This revision includes the following updates:R
• Article number changed for Fork lift accessory (from 3HAC0604-1 to
3HAC0604-2)
• New standard calibration method introduced (Axis Calibration). See
Calibration on page 375.
• Tightening torque for securing screw in piston shaft front eye changed,
see Replacing the balancing device on page 280.
• External brake release unit section removed from the manual.
• Turning disk fixture is removed from special tools for Levelmeter calib-
ration.
This revision includes the following updates:S
• Oil types in maintenance schedule table removed and a reference to
the Tech. manual added.
• Maintenance table splitted into several tables.
• Edited information regarding deciding calibration routine in each repair
section.
• Added a warning that calibration pin must be inserted in the calibration
bushing until it snaps, see Description of Axis Calibration on page 389.
• Added warning regarding risk of pinching, in Description of Axis Calib-
ration on page 389.
• Added information about inspection of calibration tool prior to usage,
see Examining the calibration tool on page 392.
• Added information about the calibration procedure, see Overview of
the calibration procedure on the FlexPendant on page 395,Restarting
an interrupted calibration procedure on page 397.
• Added information about Axis Calibration when SafeMove is installed,
see Axis Calibration with SafeMove option on page 397.
Published in release R16.2. The following updates are done in this revision:T
• Drawing of base plate is not available for purchase, faulty information
removed in Securing the base plate on page 74.
• Corrections due to updates in terminology.
• Drawing of tool flange for LeanID added.
Published in release R17.2. The following updates are done in this revision:U
• Caution about removing metal residues added in sections about SMB
boards.
• Information about minimum resonance frequency added.
• Bending radius for static floor cables added.
Continues on next page
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Continued

DescriptionRevision
• Note regarding VK cover on axis 3 (lower arm) due to removal of hole
in new design of the lower arm.
• Cooling fans (option) is available for axes 1 and 2.
• Applicable standards updated
• Added text regarding overhaul in section specification of maintenance
intervals.
• Section Start of robot in cold environments on page 113 added.
• Updated information regarding replacement of brake release board.
•Updated information regarding disconnecting and reconnecting battery
cable to serial measurement board.
• Updated information regarding lubrication of gearbox oil for all axis.
• Definition of reference calibration clarified.
Published in release R18.1. The following updates are made in this revision:V
•Information added about fatigue to Axis Calibration tool, see Calibration
tools for Axis Calibration on page 392.
• Updated information about locking liquid in replacement of cable har-
ness, axes 1-4.
• Added sections in General procedures on page 206.
• Safety restructured.
• Updated spare part number brake release unit (was DSQC561, is
DSQC1052).
• Type B motors are introduced throughout the manual.
- New periodic maintenance activity regarding inspection of the
type B motor oil seal.
- New gasket at axis-6 motor cable inlet.
• Note added to calibration chapter to emphasize the requirement of
equally dressed robot when using previously created reference calibra-
tion values.
• Information about myABB Business Portal added.
• Revised tightening torque for gearbox axis 2.
• Added Nickel in Environmental information.
•Changed direction of installed cooling fan on axis-2 motor and removed
a faulty image showing the design of the cooling fan. Also added de-
tailed images to installation procedure for the fan.
Published in release 19B. The following updates are made in this revision:W
• New touch up color Graphite White available. See Cut the paint or sur-
face on the robot before replacing parts on page 213.
• Levelmeter 2000 kit (6369901-347) no longer available.
• Updated oil plug torque on axis 6 gearbox to 20 Nm.
Published in release 19C. The following updates are made in this revision:X
• Added three velcro straps to the cable harness in the lower arm.
Published in release 19D. The following updates are made in this revision:Y
•Added references to DressPack manual in Robot cabling and connection
points on page 109.
Published in release 20B. The following updates are made in this revision:Z
• Clarified and added information in mounting instructions for rotating
sealings, see Mounting instructions for sealings on page 209.
•Clarified text about position of robot and added table with dependencies
between axes during Axis Calibration.
• Added information about Wrist Optimization in calibration chapter.
• Replaced article number and name of grease, previously 3HAB3537-1.
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Overview of this manual
Continued

DescriptionRevision
Published in release 20C. The following updates are made in this revision:AA
• New press equipment for unloading balancing device introduced. New
article number. User instructions for the equipment are enclosed with
the tool and removed from this manual.
•New press equipment for replacing the lower arm shaft introduced. New
article numbers. User instructions for the equipment are enclosed with
the tools and removed from this manual.
• New press equipment introduced for following repair procedures. New
article numbers added. User instructions for the equipment are enclosed
with the tool and removed from this manual.
- unloading balancing device
- replacing lower arm shaft
- replacing balancing device shaft
Published in release 20D. The following updates are made in this revision:AB
• Recommended fastener quality is replaced with a general text, see
Fitting equipment on robot on page 82.
Published in release 21A. The following updates are made in this revision:AC
• Changed lifting accessory for lifting axis-2 and axis-3 gearboxes.
• Tool number for Press device, axis 2 shaft and axis 2 bearing changed,
see Required equipment on page 258
• New tool/adapter added to required equipment, see Replacing the bal-
ancing device on page 280.
Published in release 21B. The following updates are made in this revision:AD
• Oil name Optimol PD0 is changed to Tribol GR 100-0-PD in Lubrication
of spherical roller bearing, balancing device and Replacement of balan-
cing device.
• Information regarding documentation of Installation of Foundry Plus
Cable guard (option no. 908-1) is changed since DVDs are removed.
See Installation of Foundry Plus Cable guard (option) on page 96.
• Text regarding fastener quality is updated, see Fastener quality on
page 86.
• The information about extended working range for axis 1 is updated,
see Extended working range, axis 1 (option) on page 99.
Published in release 22A. The following updates are done in this revision:AE
• Updated information about Gleitmo treated screws, see Screw joints
on page 422.
• Removed information about position switches as they are no longer
available.
Published in release 22C. The following updates are made in this revision:AF
• Corrected article numbers for axis-6 gearbox o-ring and turning disk o-
ring.
Published in release 23B. The following updates are done in this revision:AG
• Added a step for overall inspection of cabling after cable harness has
been replaced.
• Corrected the section Lubrication of spherical roller bearing, balancing
device on page 189.
• Added note about oscillations in section about reference calibration.
• Updated the torque value for transparent plug.
Published in release 23D. The following updates are done in this revision:AH
• Added illustrations to cleaning section.
• Added information for the OmniCore robot controller.
• Removed information about the M2000 and M2000A controllers.
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© Copyright 2007 - 2023 ABB. All rights reserved.
Overview of this manual
Continued

Product documentation, IRC5, OmniCore
Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories.
This listing is based on the type of information in the documents, regardless of
whether the products are standard or optional.
Tip
All documents can be found via myABB Business Portal, www.abb.com/myABB.
Product manuals
Manipulators, controllers, DressPack, and most other hardware is delivered with
aProduct manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
•Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Troubleshooting.
• Decommissioning.
•Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.
Technical reference manuals
The technical reference manuals describe reference information for robotics
products, for example lubrication, the RAPID language, and system parameters.
Application manuals
Specific applications (for example 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 (for example cables, I/O boards, RAPID instructions, system
parameters, software).
• How to install included or required hardware.
• How to use the application.
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Product documentation, IRC5, OmniCore

• Examples of how to use the application.
Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.
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Product documentation, IRC5, OmniCore
Continued

How to read the product manual
Reading the procedures
The procedures contain references to figures, tools, material, and so on. The
references are read as described below.
References to figures
The procedures often include references to components or attachment points
located on the manipulator/controller. The components or attachment points are
marked with italic text in the procedures and completed with a reference to the
figure where the current component or attachment point is shown.
The denomination in the procedure for the component or attachment point
corresponds to the denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a
procedure.
Note/IllustrationAction
Shown in the figure Location of
gearbox on page xx.
Remove the rear attachment screws, gearbox.8.
References to required equipment
The procedures often include references to equipment (spare parts, tools, etc.)
required for the different actions in the procedure. The equipment is marked with
italic text in the procedures and completed with a reference to the section where
the equipment is listed with further information, that is article number and
dimensions.
The designation in the procedure for the component or attachment point
corresponds to the designation in the referenced list.
The table below shows an example of a reference to a list of required equipment
from a step in a procedure.
Note/IllustrationAction
Art. no. is specified in Required
equipment on page xx.
Fit a new sealing, axis 2 to the gearbox.3.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 21.
Illustrations
The robot is illustrated with general figures that does not take painting or protection
type in consideration.
Likewise, certain work methods or general information that is valid for several robot
models, can be illustrated with illustrations that show a different robot model than
the one that is described in the current manual.
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How to read the product manual

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