Page 1 ROBOTICS Product manual IRB 760...
Page 2 Trace back information: Workspace R18-2 version a18 Checked in 2018-11-20 Skribenta version 5.3.012...
Page 4 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.
Page 5: Table Of Contents
Extended working range, axis 1 (option 561-1) ..........Robot in cold environments ................. 2.5.1 Start of robot in cold environments ............Electrical connections ..................2.6.1 Robot cabling and connection points ............Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 6 Replacing the balancing device ..............4.5.2 Replacing the balancing weight ..............Motors ......................4.6.1 Replacing motor, axis 1 ................4.6.2 Replacing motors, axes 2 and 3 ..............Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 7 Standard tools ....................Special tools ....................Lifting accessories and lifting instructions .............. Spare parts Spare part lists and illustrations ................Circuit diagrams Circuit diagrams ....................Index Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
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Page 9: Overview Of This Manual
Prerequisites Maintenance/repair/installation personnel working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Product manual scope The manual covers covers all variants and designs of the IRB 760. Some variants and designs may have been removed from the business offer and are no longer available for purchase.
Page 10 This manual contains all safety instructions from the product manuals for the manipulators and the controllers. Revisions Revision Description First edition Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 11 Type and amount of oil in gearboxes on page 124. • A new SMB unit and battery is introduced, with longer battery lifetime. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 12 Updated information regarding disconnecting and reconnecting battery cable to serial measurement board. • Updated information regarding replacing the balancing device. • Definition of reference calibration clarified. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 13 Published in release R18.2. The following updates are done in this revision: • Added locating hole position in tool flange view. Published in release R18.2. The following updates are made in this revision: • Updated references. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 14: How To Read The Product Manual
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. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 15: Product Documentation
Product documentation 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.
Page 16 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. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 17: Safety
Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment that can influence the safety of the entire system.
Page 18 Unauthorized modifications of the originally delivered robot are prohibited. Without the consent of ABB, it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength of the robot could be affected.
Page 19: Protective Stop And Emergency Stop
1.1.2 Protective stop and emergency stop 1.1.2 Protective stop and emergency stop Overview The protective stops and emergency stops are described in the product manual for the controller. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 20: Safety Actions
1.2 Safety actions 1.2.1 Fire extinguishing Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the manipulator or controller. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 21: Emergency Release Of The Robot Axes
When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways. Make sure no personnel is near or beneath the robot. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 22: Make Sure That The Main Power Has Been Switched Off
To avoid these personal injuries, switch off the main power on the controller before proceeding work. Note Switch off all main power switches in a MultiMove system. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 23: Safety Risks
Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 24 ABB is not liable for damages caused by the use of non-original spare parts and special equipment. ABB is not liable for damages or injuries caused by unauthorized modifications to the robot.
Page 25: Moving Robots Are Potentially Lethal
The hold-to-run function is used in manual mode, not in automatic mode. Make sure no personnel are present within the working range of the robot before pressing the start button. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 26: First Test Run May Cause Injury Or Damage
If maintenance or repair has been done, pay special attention to the function of the part that was serviced. Collision risks CAUTION When programming the movements of the robot, always identify potential collision risks before the first test run. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 28: Enabling Device And Hold-To-Run Functionality
How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 29: Risks Associated With Live Electric Parts
The power supply for the motors (up to 800 VDC). • The user connections for tools or other parts of the installation (max. 230 VAC). Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 30 Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 31: The Unit Is Sensitive To Esd
The mat must be grounded through a current-limit- ing resistor. Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 32: Hot Parts May Cause Burns
Wait until the potentially hot component has cooled if it is to be removed or handled in any other way. Do not put anything on hot metal surfaces, e.g. paper or plastic. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 33: Safety Risks Related To Pneumatic/Hydraulic Systems
Gravity may cause any parts or objects held by these systems to drop. Dump valves should be used in case of emergency. Shot bolts should be used to prevent tools, etc., from falling due to gravity. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 34: Brake Testing
3 Inspect and verify that the axis maintains its position. If the robot does not change position as the motors are switched off, then the brake function is adequate. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 35: Safety Risks During Handling Of Batteries
Risk of fire or explosion. Operating temperatures are listed in Pre-installation procedure on page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 36: Safety Risks During Work With Gearbox Lubricants (Oil Or Grease)
Possible pressure build-up in gearbox Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 37 The magnetic oil plugs will take Contaminated oil in care of any remaining metal gear boxes chips. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 38: Safety Signals And Symbols
ELECTROSTATIC Warns for electrostatic hazards which could result DISCHARGE (ESD) in severe damage to the product. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 39 Symbol Designation Significance NOTE Describes important facts and conditions. Describes where to find additional information or how to do an operation in an easier way. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 40: Safety Symbols On Product Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 41 Brake release Pressing this button will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 42 Tip risk when loosening bolts The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 43 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 xx1500002616 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 44 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 45 Shut off with handle Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
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Page 47: Installation And Commissioning
If the IRB 760 is connected to power, always make sure that the robot is connected to protective earth before starting any installation work. For more information see: • Product manual - IRC5 Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 48: Unpacking
It also contains information useful during later re-installation of the robot. Prerequisites for installation personnel Installation personnel working with an ABB product must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work • conform to all national and local codes.
Page 49 The robot installation is restricted to the mounting options given in following load table(s). Floor mounted Force Endurance load (in operation) Max. load (emergency stop) Force xy ± 9.1 kN ± 17.7 kN Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 50 Maximum ambient temperature +55° C Maximum ambient temperature (less than 24 hrs) +70° C Maximum ambient humidity 95% at constant temperature (gaseous only) Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 51 The table shows the available protection types of the robot, with the corresponding protection class. Protection type Protection class Manipulator, protection type Standard IP 67 Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 52: Working Range And Type Of Motion
Maximum working range Position in figure Position (mm) Angles (°) Axis 2 Axis 3 1940 1824,5 1002 1957 1190 -513 3169 2839 1829 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 53 Option 610-1 "Independent axis" can be used for resetting the revolution counter after the axis has been rotated (no need for "rewinding" the axis). Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 54 2 Installation and commissioning 2.2.2 Working range and type of motion Continued Turning radius xx1000001068 Motor, axis 3 Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 55: Risk Of Tipping/Stability
This figure shows the robot in its shipping position and transportation position. xx1000001161 WARNING The robot is likely to be mechanically unstable if not secured to the foundation. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 56: On-Site Installation
See figure Fork lift set, 3HAC023044-001 hardware on page Standard toolkit Content is defined in section Standard tools on page 389. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 57 Horizontal attachment screws (4 pcs / fork lift pocket) Attachment screw for adapter (1 pc / adapter) Vertical attachment screws (2 pcs) Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 58 Attachment points are shown in figure Attachment points on robot on page Attachment screws, 2 pcs, M16 x 90. Tightening torque: 270 Nm. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 59 However, they are tightened with different torque! xx0500002279 A Horizontal attachment screws, 4 pcs, M16 x 60. Tightening torque: 60 Nm. B Adapter Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 60 Attachment points on robot on page Double-check that pockets are properly se- cured to the robot! Insert fork lift forks into the pockets. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 61 Carefully lift the robot and move it to its install- ation site. WARNING Personnel must not, under any circumstances, be present under the suspended load! Refit the cooling fan to the motor, if any. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 62: Lifting Robot With Roundslings
All lifting accessories used must be sized accordingly! WARNING Personnel must not, under any circum- stances, be present under the suspended load! Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 63 Roundsling, 1.5 m. Lifting capacity: 2,000 kg. Roundsling, 1 m. Lifting capacity: 2,000 kg. Roundsling, 1 m. Lifting capacity: 2,000 kg. Note! No sharp edges! Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 64: Lifting Robot With Lifting Slings
Attempting to lift a robot in any other position may result in the robot tipping over, causing severe damage or injury! Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 65 Note! Make sure to run lifting sling between parallel stag and frame! Required equipment Equipment Article number Note Lifting accessory, robot 3HAC15607-1 Includes user instructions 3HAC15971-2 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 66 Make sure all hooks and attachments maintain their correct positions while lifting the robot! Always move the robot at very low speeds, making sure it does not tip. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 67: Manually Releasing The Brakes
Make sure no personnel is near or beneath the ro- bot. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 68 Incorrect connections, such as supplying power to the wrong pin, may cause all brakes to be released simultaneously! Supply 0V on pin 12 and 24V on pin 11. xx0600002937 Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 69: Lifting The Base Plate
Fit lifting slings to the eyes and to the lifting accessory. CAUTION Lift and move the base plate very slowly. If the base plate starts to swing it is a risk for injuries or damage. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 70: Securing The Base Plate
E, F, G, H Common tolerance zone (accuracy all over the base plate from one contact surface to the other) Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 71 325 (2x) 241,1 250,5 225,8 138,4 109,1 xx1000001054 ¤ Four holes for alternative clamping, 4x Ø18 Color: RAL 9005. Thickness: 80-100 µm Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 72 The illustration below shows the orienting grooves and attachment holes for leveling bolts in the base plate. xx1500000312 Orienting grooves (3 pcs) Levelling bolts, attachment holes (4 pcs) Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 73 Base plate This section details how to secure the base plate to the foundation. Action Note Make sure the foundation is levelled. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 74 0.3 mm. If it is not, use pieces of sheet metal or similar to bring the base plate to a levelled position. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 75: Orienting And Securing The Robot
M24 x 140 Quality: Quality 8.8 Suitable washer: Thickness: 4 mm Outer diameter: 44 mm Inner diameter: 25 mm Tightening torque: 725 Nm Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 76 Note Lightly lubricate screws before as- sembly! Tighten bolts in a criss-cross pattern to ensure that the base is not distorted. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 77 2.3.7 Orienting and securing the robot Continued Hole configuration, base This illustration shows the hole configuration used when securing the robot. xx1000001050 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 78 2 Installation and commissioning 2.3.7 Orienting and securing the robot Continued Cross section, guide sleeve hole This illustration shows the cross section of the guide sleeve holes. xx1000001051 Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 79: Fitting Equipment On Robot
IRB 760 - 450/3.2 = 35 kg Note! The weight of the extra equipment on the upper arm must be deducted from the maximal handling capacity. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 80 450- 35 = 415 kg. xx1000001069 Mounting holes, M10 Through (6 pcs) Mounting holes, M8 Depth 12 mm (4 pcs) Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 81 Illustration, fitting of extra equipment on frame The illustration below shows the mounting holes available for fitting extra equipment on the frame. xx1000001070 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 82 The illustration below shows the mounting holes available for fitting equipment on the turning disk. xx1000001058 Mounting flange xx1800001403 Tool flange in bottom view Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 83 When fitting tools on the turning disk (see the figures above), only use screws with quality 12.9. When fitting other equipment to mounting holes standard screws with quality 8.8 may be used. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 84: Installation Of Signal Lamp, Upper Arm (Option)
Complete kit with signal lamp, page 393. cables, adapter, gasket, screws etc. Gasket 3HAC033206-001 Fitted between motor and cable gland, replace if damaged. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 85 Attachment screws for the signal lamp (2 pcs) Cable straps (2 pcs) Cable gland cover Motor adapter including gasket Attachment screw, M6x40 (1 pc) Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 86 Remove the motor cover by unscrewing the four See figure Location of signal lamp, attachment screws. upper arm on page Disconnect the motor connectors. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 87 Secure motor cables at cable gland again. Fit the motor cover with the attachment screws. Make sure the cabling is placed correctly when refitting the cover and does not get jammed. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 88: Loads Fitted To The Robot, Stopping Time And Braking Distances
The performance of the motor brake depends on if there are any loads attached to the robot. For more information, see product specification for the robot. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 89: Restricting The Working Range
This section describes how to install hardware that restricts the working range. Note Adjustments must also be made in the robot configuration software (system parameters). References to relevant manuals are included in the installation procedures. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 90: Mechanically Restricting The Working Range Of Axis 1
Includes attachment screws and an assembly drawing. Standard toolkit Technical reference manual - System Article number is specified in parameters section References on page Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 91 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 92: Extended Working Range, Axis 1 (Option 561-1)
Boundand Lower Joint Bound must be reference manual - System parameters. changed to 3.84 respectively -3.84. The values are in radians, that is 3.84 radians = 220 degrees. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 93: Robot In Cold Environments
If the program consists of large wrist movements, it is possible that the reorientation velocity, which is always high in predefined velocities, needs to be included in the ramping up. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 94: Electrical Connections
Robot cable, power: 22 m 3HAC026787-003 Robot cable, power: 30 m 3HAC026787-004 Robot cable, signals Cable Art. no. Robot cable signal, shielded: 7 m 3HAC7998-1 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 95 There is a grounding/bonding point on the manipulator base. The grounding/bonding point is used for potential equalizing between control cabinet, manipulator and any peripheral devices. xx1600001005 Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
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Page 97: Maintenance
If the IRB 760 is connected to power, always make sure that the IRB 760 is connected to protective earth before starting any maintenance work. For more information see: • Product manual - IRC5 Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 98: Maintenance Schedule And Expected Component Life
40000 hours. ABB Connected Services and its Assessment tools can help you to identify the real stress level of your robot, and define the optimal ABB support to maintain your robot working. Contact your local ABB Customer Service to get more information.
Page 99: Maintenance Schedule
First change when DTC reads: • 6,000 hours Second change when DTC reads: • 24,000 hours Following changes: • Every 24,000 hours Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 100 The maintenance of other external equipment for the robot is detailed in separate documentation. Maintenance activity Equipment Interval Inspection Signal lamp Every: 12 months Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 101: Expected Component Life
Deviations from this cycle will result in differences in expected life! The SIS for an IRC5 system is described in the Operating manual - Service Information System. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 102: Inspection Activities
124. Do not mix with other oils! Standard toolkit Content is defined in section Standard tools on page 389. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 103 Further information about how to fill with oil is found in section Changing oil, axis-1 gearbox on page 126. Refit the oil plug. Tightening torque:20 Nm Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 104: Inspecting, Oil Level Gearbox Axes 2 - 3
The gearboxes axes 2-3 are located in the lower arm rotational center, underneath the motor attachment. xx0500002482 Gearbox, axis 2 Oil plug, draining Oil plug, filling Ventilation hole, gearbox axis 2 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 105 Before proceeding, please read the safety inform- ation in the section Safety risks during work with gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 106 Filling of oil is detailed further in section Changing oil, gearbox axes 2 and 3 on page 129. Refit oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 107: Inspecting, Oil Level Gearbox Axis 6
Before proceeding, please read the safety informa- tion in the section Safety risks during work with gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 108 Changing oil, gearbox axis 6 on page 133. Refit oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 109: Inspecting, Balancing Device Bearings And Piston Rod Guide Ring
These procedures include refer- be required. See references to ences to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 110 Replace damaged component. xx1000001145 A Spacer ring B Lock nut KM10 C Support washers (2 pcs) Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 111 B Circlip Note If there is a risk of metallic contact between the piston rod and the end cover, the guide ring must be replaced! Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 112: Inspecting, Cable Harness
Motor cables (4 locations) Cable guide, axis 2 Cable guide, axis 3 Metal clamps with nuts Required equipment Visual inspection, no tools are needed. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 113 Detailed in section: is detected! Replacing cable harness, lower end (axes 1-3) on page 153. Replacing the cable harness, upper end (incl. axis 6) on page 163. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 114: Inspecting The Information Labels
Combined warning label "Brake release", "Brake release buttons" and "Moving robot", 3HAC054583-001 Combined warning label "Extended rotation", "See user documentation" and "No mechanical stop", 3HAC021761-001 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 115 Inspect the labels, located as shown in the figures. Replace any missing or damaged labels. Article numbers for the labels and plate set is specified in Spare parts on page 393. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 116: Inspecting The Axis-1 Mechanical Stop Pin
• electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 117 The expected life of gearboxes can be reduced after collision with the mechanical stop. Make sure the mechanical stop pin can move in both directions. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 118: Inspecting The Additional Mechanical Stops
• electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 119 If any damage is detected, the mechanical stops must Article number is specified in be replaced. Required equipment on page 118. Correct attachment screws: • Axis 1: M16 x 35, quality 12.9. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 120: Inspection, Dampers
Damper, lower arm, lower (1 pc) Damper, axis 2 (2 pcs) Damper, axis 3 (2 pcs). Not visible in this view. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 121 Check attachment screws for deformation. If any damage is detected, the damper must be Art.no. is specified in Required replaced with a new one. equipment on page 121. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 122: Inspecting The Signal Lamp (Option)
To be replaced if damage is detected. page 393. Standard toolkit Content is defined in section Stand- ard tools on page 389. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 123 • measuring the voltage in the connectors of motor axis 6 (=24V). • inspecting the cabling. Replace the cabling if a fault is detected. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 124: Replacement/Changing Activities
Before starting any inspection, maintenance, or changing activities of lubrication, always contact the local ABB Service organization for more information. For ABB personnel: Always check ABB Library for the latest revision of the manual Technical reference manual - Lubrication in gearboxes, in order to always get the latest information of updates about lubrication in gearboxes.
Page 125 Includes pump with outlet pipe. Use the suggested dispenser or a similar one: • Orion OriCan article number 22590 (pneumatic) Nipple for quick connect fitting, with o-ring Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 126: Changing Oil, Axis-1 Gearbox
124. oil in gear- Do not mix with other oils! boxes on page 124. Oil collecting vessel Capacity: 8,000 ml. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 127 126. Remove oil plug, filling in order to drain oil Shown in figure Location of oil plugs quicker! on page 126. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 129: Changing Oil, Gearbox Axes 2 And 3
The figure shows the position of gearbox, axis 2. xx0500002482 Gearbox axis 2 Oil plug, draining Oil plug, filling Ventilation hole plug, gearbox axis 2 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 130 Content is defined in section ment Special tools on page 390. Standard toolkit Content is defined in section Standard tools on page 389. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 131 • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 132 Refit oil plug,filling and ventilation hole plug. Shown in Location of oil plugs on page 129. Tightening torque: 24 Nm. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 133: Changing Oil, Gearbox Axis 6
Use this procedure to drain oil from gearbox axis 6. When using oil change equipment, follow the instructions enclosed with kit. Action Note Put tilt house in a suitable position. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 134 Correct oil level is detailed in section Inspection, oil level axis-6 gearbox on page 107. Refit the oil plug. Tightening torque: 24 Nm. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 135: Replacing The Smb Battery
Battery pack with a 2-pole battery contact (DSQC) xx0500002486 SMB battery cover SMB battery pack Battery cable Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 136 Spare part no. Note Battery unit For spare part no. Battery includes protection circuits. Only re- see: place with a specified spare part or an ABB- • Spare parts approved equivalent. on page 393 Standard toolkit Content is defined in section...
Page 137 Shown in figure Location of SMB Battery includes protection circuits. Only replace battery on page 135. with a specified spare part or with an ABB- ap- proved equivalent. Refitting, battery Use this procedure to refit the SMB battery. Action Note...
Page 138 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 139: Lubrication Activities
Note! Balancing device must be fitted on robot when lubricating bearings! xx0500002489 Ear (bearing located inside) Support washer Lock nut Piston rod Guide ring (not visible in this view) Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 140 Also clean of old grease on the the shaft ends of grease. inner side! Apply some grease to the support washers. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 141 Clean piston rod with isopropanol before applying new grease. Apply new grease. Type of grease is specified in Required equipment on page140. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 142: Cleaning Activities
Never point the water jet at connectors, joints, sealings, or gaskets. • Do not use compressed air to clean the robot. • Never use solvents that are not approved by ABB to clean the robot. • Do not spray from a distance closer than 0.4 m. •...
Page 143 Cleaning with water and steam Instructions for rinsing with water ABB robots with protection types Standard, Foundry Plus, Wash, or Foundry Prime can be cleaned by rinsing with water (water cleaner). The following list defines the prerequisites: •...
Page 144 This page is intentionally left blank...
Page 145: Repair
Each procedure contains all the information required to perform the activity, for example spare parts numbers, required special tools, and materials. WARNING Repair activities not described in this chapter must only be carried out by ABB. Otherwise damage to the mechanics and electronics may occur. Required equipment The details of the equipment required to perform a specific repair activity are listed in the respective procedures.
Page 146: General Procedures
Spray any suspected leak areas with the leak detec- tion spray. Bubbles indicate a leak. When the leak has been localized, take the necessary measures to correct the leak. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 147: Mounting Instructions For Bearings
Make sure the bearing is properly aligned as this will directly affect the durab- ility of the bearing. Greasing of bearings Note This instruction is not valid for solid oil bearings. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 148 Grooved ball bearings must be filled with grease from both sides. • Tapered roller bearings and axial needle bearings must be greased in the split condition. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 149: Mounting Instructions For Seals
Never hammer directly on the seal as this may result in leakage. Make sure no grease left on the robot surface. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 150 If the flange surfaces are defective, the parts may not be used because leakage could occur. Clean the surfaces properly in accordance with the recommendations of ABB. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.
Page 151: Cut The Paint Or Surface On The Robot Before Replacing Parts
Carefully grind the paint edge that is left on the structure to a smooth surface. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 152: The Brake Release Buttons May Be Jammed After Service Work
If a button gets jammed in the depressed position, the alignment of the brake release unit must be adjusted so that the buttons can move freely in their tubes. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 153: Complete Robot
How to replace the upper end can be found in section Replacing the cable harness, upper end (incl. axis 6) on page 163. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 154 The cable harness, lower end (axes 1-3) is located throughout the base, frame and lower arm as shown in the figure. xx1000001177 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 155 Motor, axes 1-3 Replace if damaged. Standard toolkit The content is defined in the sec- tion Standard tools on page 389. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 156 Disconnect the connectors R1.MP and R1.SMB. See the figure Location of cable har- ness - lower end (axes 1-3) on page 154. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 157 1, 2 and 3. • Replacing motor, axis 1 on page 291 • Replacing motors, axes 2 and 3 on page 298 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 158 Perform this removal with care, in order not to damage any of the components inside the SMB recess. xx1000001330 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 159 1 in the center of the frame. CAUTION Make sure the cables are not twisted with each other or with customer harness (if any)! xx1000001331 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 160 Attachment points are shown in the figure Location of cable harness - lower end (axes 1-3) on page 154. Reconnect the earth cable. xx1000001314 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 161 Push the cable harness up through the lower arm. Fasten the metal clamp that hold the cable harness in the lower arm with the nuts. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 162 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 163: Replacing The Cable Harness, Upper End (Incl. Axis 6)
Location of cable harness, upper end The upper end of the cable harness is located as shown in the figure. xx1000001176 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 164 Spare parts on page 393 Gasket Motor, axis 6 Standard toolkit Content is defined in section Standard tools on page 389. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 165 Remove the axis 6 motor cover by removing its attachment screws, in order to reach the connectors. xx1000001106 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 166 Remove the metal clamp that holds the cable at the tilt house, by removing its nuts. xx1000001336 Carefully pull the cable harness out of motor axis 6. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 167 Start by fitting the cable harness, lower end Detailed in section Replacing cable har- if it has been removed. ness, lower end (axes 1-3) on page 153 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 168 (2 + 2 pcs) from the outside of the upper arm. Twist the cable one turn between the cable clamps. xx1000001338 Refit the axis 3 cable guide. xx1000001340 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 169 Refit the cable gland with its attachment screw. xx0600002694 • A: Screw holding the cable gland Make sure the gasket is not damaged! Replace if damaged. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 170 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 171: Replacing The Smb Unit
For spare part number, see: Spare parts on page 393. Standard toolkit Content is defined in section Standard tools on page 389. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 172 Disconnect the battery cable by pressing down the upper lip of the R2.G connector to release the lock while pulling the connector upwards. xx1700000993 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 173 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 174: Replacing The Brake Release Board
These procedures include references be required. See references to to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 175 Location of the brake release unit is shown in the figure Location of brake release board on page 174. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 176 Refit the push button guard to the SMB cover. Shown in the figure Location of brake release board on page 174. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 177 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 178: Replacing The Base, Including Axis 1 Gearbox
Guide pins that are longer than 140 mm will not be pos- sible to remove because the lack of space. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 179 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 181 Make sure the lift is done completely described in the enclosed user instructions. level. This is detailed in section Lifting robot with lifting slings on page Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 182 Refit the axis 1 gearbox, if it has been re- Replacing the axis 1 gearbox on moved. page 316. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 183 Look through the empty mounting hole of the axis 1 motor to assist in aligning the as- sembly during refitting of the complete arm system. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 184 Replacing cable harness, lower end frame. (axes 1-3) on page 153. Refit the axis 1 motor. Replacing motor, axis 1 on page 291. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 185 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 186: Upper And Lower Arm
Used to lubricate the o-rings. Flange sealant 3HAC034903-001 Loctite 574 Standard toolkit Content is defined in section Standard tools on page 389. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 187 See section • Changing oil, gearbox axis 6 on page 133 Remove the attachment screws that secure the turning disk. xx1000001134 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 188 Lubricate the o-ring of the turning disk with Art. no. is specified in Required equip- grease and fit it to the turning disk. ment on page 186. xx1000001285 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 189 Reused screws may be used, providing they are lubricated as detailed in sec- tion Screw joints on page 385 before fit- ting. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 190 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 191: Replacing The Tilthouse Unit
Refitting lock nuts and the remaining parts on page 209 Location of tilthouse unit The tilthouse unit is located as shown in the figure. xx1000001418 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 192 (axis 2) and the parallel arm (axis 3). These two sides of the robot will be referred to in the replacing procedures. xx1000001427 Axis 2 side (See marking on lower arm) Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 193 4 Repair 4.4.2 Replacing the tilthouse unit Continued xx1000001428 Axis 3 side (See marking on parallel arm) Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 194 VK cover VK 19x6 (2 pcs) Screw M6x10 quality 8.8-A2F (4 pcs) + Washers (4 pcs) Retaining ring, bore Steel 80 (2 pcs) Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 195 Circuit diagram For art. no. see chapter Circuit diagrams on page 395. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 196 Threaded bar Stop nut Hydraulic cylinder (must be ordered separately) Distance (and screws M6x14, 2 pcs) Press housing (3HAC039277-004) Press washer (3HAC039277-005) Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 197 Adapter Press housing Support housing (3HAC039277-003) Torsion bar M20 L=650 mm (fitting) Torsion bar M20 L=900 mm (removal) Shims T=2 mm Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 198 Move the robot to a position where the tilthouse rests on a workbench, some pallets or similar. xx1000001132 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 199 Disconnect motor cables from motor axis 6. Replacing motor, axis 6 on page 309. Place the motor cables in a way that it will not be damaged. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 200 Part: A Upper link Remove the M6 screws and washer for filling grease, on both sides. xx1000001420 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 201 CAUTION Only a very low air pressure is needed! xx1000001072 Parts: A Screw M6x10 quality steel 8.8- B Washer Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 202 6 by following the steps below. Note A longer threaded bar M16 is needed when re- moving the shaft than the one specified when fitting. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 203 Follow steps above. way. CAUTION The robot tilt house weighs 85 kg. All lifting accessories used must be sized ac- cordingly! Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 204 Lift the tilthouse unit to a workbench or similar with a roundsling in an overhead crane. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 205 Shown in the figure Cut away view of sealing ring with dustlip. the assembly of the tilthouse unit on page 194. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 206 Before starting this procedure, prepare the tilthouse as described in: • Premounting the outer races of the bearings and other parts, axis 2 side on page 204 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 207 Shown in the figure Location of axes 2 and 3 sides of the robot on page 192. Note Fit axis 3 side first. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 208 Secure the parts with the stop nut. Shown in the figure Press tool as- sembly/disassembly axis 6 on page 197. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 209 Secure the axis 2 shaft with the lock nut. Tightening torque: • 90 Nm Note Flat side of the lock nut facing inwards! Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 210 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 211: Replacing The Upper Arm
4.4.3 Replacing the upper arm Location of the upper arm The upper arm is located as shown in the figure. xx1100000016 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 212 O-ring D119x3 (1 + 1 pc) Sealing (1 + 1) Sealing ring (1 + 1 pc) Oil plug (1 + 1 pcs) Bushing Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 213 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 214 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot work- ing area. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 215 Removing the shafts Action Note Before continuing, make sure that the upper arm is secured in the lifting accessories and overhead crane. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 216 Attach a horseshoe shim (2.5 mm) between 3HAC038174-031 Horseshoe shim, 2.5 upper and lower arm, on the same side as the shaft being removed. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 217 This is done as a safety precau- tion. CAUTION DO NOT stand close to the robot on any side, when the shaft is being removed. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 218 Cut away view of the assembly of the hole where the shafts shall be refitted. the upper arm components on page 212 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 219 Required equipment on page 213 CAUTION The upper arm (excluding the tilthouse unit) weighs 150 kg. All lifting equipment used must be sized accordingly. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 220 Fit the glycerine connection (3HAC038174- For art. no. see: 004) of the shaft fitting/removing tool to the • Required equipment on page 213 shaft. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 221 Note Feel that the shaft guides into the arm joint. Tighten with torque 20 Nm. Set the dial gauge to zero. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 222 There must not be any grease at all on the radial sealing. Otherwise grease will appear on the surface supposed to be cleaned from grease with isopropanol. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 223 • Cut away view of the assembly of the upper arm components on page 212 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 224 KM nut type 15 (3HAC038174-024) with a tightening torque of 175 Nm. Let the shims remain mounted. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 225 (0.3 mm). The measure shall be 0.3 mm. xx1100000040 Wipe off residual grease from the shaft. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 226 (incl. axis 6) on page 163 Move the robot to synchronization position. Refit the balancing device. See section • Replacing the balancing device on page 278 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 227 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 228: Replacing Linkage - Upper Link Arm
Location of upper link arm The upper link arm is located as shown in the figure. xx1000001083 Upper link arm Link Lower link arm Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 229 CAUTION In order to avoid accidents, also secure the tilthouse unit in an overhead crane or similar. xx1000001132 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 230 Use a KM10 socket. xx1000001080 CAUTION The link weighs 23 kg. All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 231 If needed, replace the bearings in the upper link arm. Note The bearings are sensitive for pushes. Make sure they are not damaged! Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 232 Refit the spacer rings complete on the shaft ends of the link and tilthouse. xx1000001263 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 233 Place the upper link arm on the shafts as shown in the figure. Note The link arm must be pushed in completely. xx1000001088 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 234 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 235: Replacing The Linkage - Lower Link Arm
Location of lower link arm The lower link arm is located as shown in the figure below. xx1000001083 Upper link arm Link Lower link arm Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 236 • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 237 CAUTION The link weighs 23 kg. All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 238 Spare part no. is specified in Required equipment on page 236. Note The bearings are sensitive for pushes. Make sure they are not damaged! Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 239 236. be fitted. xx1000001086 Refit the sealing/spacer rings to the shaft ends on the link and frame. xx1000001258 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 240 CAUTION The link weighs 23 kg. All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 241 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 242: Replacement Of Linkage - Link
Replacing the linkage - lower link arm on page 235. Location of link The link is located as shown in the figure. xx1000001083 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 243 Lock nut Locking liquid (Loctite 243) Bearing, outer races (2 pcs) Bearing, inner races (2 pcs) Bearing grease Link Support ring Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 244 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 245 This is done to prevent the link from moving when the upper link arm and lower link arm are removed. xx1000001265 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 246 VK cover in order to catch it when re- leased. Remove the small VK cover. Shown in Cut away view of the assembly of the link on page 243. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 247 Remove the link. Remove the support ring with the radial seal. Wipe off residual grease. If needed, replace the bearings and radial seal. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 248 Pressring, bearing Distance Hydraulic cylinder Connecting rod Stop nut M16 D=80 mm, T=20 mm Action Note Put the link on a workbench. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 249 Tapered roller bearing (2 pcs) Auxiliary shaft Press housing Distance, fitted on hydraulic cylinder with M6x15 screws (2 pcs) Connection rod Hydraulic cylinder Stop nut Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 250 Apply the pressing tool and secure the link. Art.no. is specified in Required equipment on page 244 Apply locking liquid on the lock nut. Loctite 243 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 251 Axis Calibration is described in Calibrating with Axis Calibration method on page 360. General calibration information is included in section Calibration on page 349. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 252 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 253: Replacing The Parallel Rod
For spare part no. see: • Spare parts on page 393. Mounting/Demounting tool 3HAC5021-1 Locking liquid 3HAB7116-1 Loctite 243 Rust preventive 3HAC034903-001 Mercasol 3110 Waxcoat Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 254 Secure the upper arm with a roundsling in an overhead crane or similar, in order to avoid accidents. xx1100000088 Foundry Plus: Remove the protection plugs Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 255 C Parallel rod D Sealed spherical bearing E Bearing grease F Thrust washer Remove the thrust washer (F). See figure above! Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 256 Action Note Start by refitting the lower end. Verify that the bearings are in correct posi- tion in the parallel rod. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 257 Apply rust preventive on the highlighted areas. Note Rust preventive should be applied in both ends of the parallel rod. xx1400001126 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 258 253. See figure above! Apply locking liquid in the hole of the lock Loctite 243 screw. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 259 Refit the upper end of the parallel rod in the same way as the lower end. Foundry Plus: Refit the protection plugs. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 260 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 261: Replacing The Complete Lower Arm
Used to keep the axes 2/3 sealing in place during refitting of lower arm. Crank 3HAC023132-001 Lock screw M16x55 Roundsling Lifting capacity: 500 kg. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 262 The procedure below details how to remove the lower arm. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 263 Replacing motors, axes 2 and 3 on page 298. Remove the axes 2 and 3 gearboxes. Replacing the gearbox, axes 2- 3 on page 329. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 264 261. overhead crane or similar. xx1000001361 Remove the lock screw that secures the lower arm system. xx1000001101 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 265 CAUTION The parallel arm system weighs 125 kg. All lifting accessories used must be sized accord- ingly! Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 266 Remove the complete lower arm (including the parallel arm). xx1000001358 How to replace the parallel arm is detailed in section Replacement of parallel arm on page 271. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 267 Art. no. is specified in Required to the lower arm and put the sealings on them. equipment on page 261. See figure. xx1000001368 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 268 Change the position of the lower arm in order to reach the remaining attachment holes, and fit the remaining screws. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 269 Calib- rating with Axis Calibration method on page 360. General calibration information is in- cluded in section Calibration on page 349. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 270 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 271: Replacement Of Parallel Arm
3HAA2166-23 D=120 mm, T=12 mm VK cover 3HAA2166-18 D=35 mm, T=8 mm Bearing grease 3HAB9408-1 Rust preventive 3HAC034903-001 Mercasol 3110 Waxcoat Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 272 Use this procedure to remove the parallel arm. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 273 Removal of the parallel arm is best performed on a workbench. xx1000001024 Remove the two VK covers. xx1000001371 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 274 The parallel arm system weighs 125 kg. All lifting accessories used must be sized accord- ingly! Remove the parallel arm. xx1000001018 If needed, change the bearings. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 275 Refit a bearing on each shaft with pressing tool, Art. no. is specified in Required lower arm. equipment on page 271 xx1000001377 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 276 Apply some grease in the holes in the lower arm (thick blue arrows). Note Do not put grease on the surfaces for the VK covers (thin red arrow)! xx1000001380 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 277 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in the section First test run may cause injury or damage on page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 278: Frame And Base
Spare parts on page 393. Spacer ring (complete) 3HAC037262-001 Replace if damaged. Lock screw M16 x 55 For securing the lower arm. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 279 • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 280 Attach a lifting accessories to the balancing device. Use the hole in the lifting ear. xx1000001112 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 281 See figure! xx1000001115 CAUTION The balancing device weighs 100 kg. All lifting accessories used must be sized ac- cordingly! Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 282 Remove residual grease and sealing compound. Refitting, balancing device use this procedure to refit the balancing device. Action Note Check the bearings. Replace if needed. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 283 CAUTION The balancing device weighs 100 kg. All lifting accessories used must be sized ac- cordingly! Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 284 0.1 mm too long. If the distance is too long the bearings may be damaged when erecting the balancing device. xx1000001111 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 285 Check play (min. 0.1 mm) between support washers and bearing seat at both bearings. Remove the M12x50 screws from the balancing device to restore the springforce. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 286 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 287: Replacing The Balancing Weight
Balancing weight For art. no. see: • Spare parts on page 393 Lifting lugs (2 pcs) Locking liquid 3HAB7116-1 Loctite 243 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 288 All lifting accessories used must be sized accordingly! Secure the balancing weight with round- slings (using the lifting lugs) in an overhead crane or similar. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 289 Fit two lifting lugs (M16) in the balancing weight. xx1000001298 CAUTION The balancing weight weighs 350 kg. All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 290 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 291: Motors
• Spare parts on • pinion page 393 • o-ring (The old o-ring must be replaced when replacing the motor) Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 292 Use this procedure to remove motor axis 1. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 293 • + : pin 2 • -: pin 5 Remove the attachment screws of the motor. Use the bits extension. xx1000001090 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 294 Be careful not to damage the pinion in the pro- cess! xx1000001021 Disconnect the brake release voltage. Check the pinion. If there is any damage, the pinion must be replaced. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 295 Make sure the motor is turned the right way. See figure. Note Make sure the motor pinion does not get dam- xx1000001269 aged! Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 296 Calib- rating with Axis Calibration method on page 360. General calibration information is in- cluded in section Calibration on page 349. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 297 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 298: Replacing Motors, Axes 2 And
• motor page 393 chapter • pinion • o-ring (the o-ring must be re- placed when the motor is re- placed) Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 299 Read more about reference calibration for then reference calibration is not possible. Pendulum Calibration in Operating manu- al - Calibration Pendulum. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 300 • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 301 In order to release the brake, connect the 24 Connect to connector R2.MP2 VDC power supply. • + : pin 2 • -: pin 5 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 302 Fit two guide pins in two of the motors attach- Art. no. is specified in Required ment holes. equipment on page 298. xx1000001131 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 303 Remove the motor by gently lifting it straight out and place it on a secure surface. Disconnect the brake release voltage! Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 304 -: pin 5 Fit the lifting tool, motor axes 2-3 to the motor. Art. no. is specified in Required equipment on page 298. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 305 Remove the lifting tool and allow the motor to rest on the guide pins. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 306 50 Nm Disconnect the brake release voltage. Reconnect all connectors beneath the motor Connect in accordance with markings cover. on connectors. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 307 146. Refill the gearbox with oil. See section Changing oil, gearbox axes 2 and 3 on page 129. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 308 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 309: Replacing Motor, Axis
(the o-ring must be replaced when the motor is replaced) Bits extension 3HAC023760-001 Used to reach attachment screws for motor. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 310 Use this procedure to remove motor, axis 6. Action Information Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 311 Remove the cable gland cover at the cable exit by unscrewing its attachment screw (A) on the inside. Note Make sure the gasket is not damaged! xx0600002694 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 312 Lift the motor carefully to get the pinion away from the gear. Note Make sure the pinion does not get dam- aged! xx1000001108 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 313 Make sure the motor pinion is properly mated to the gearbox, axis 6. Note Make sure the motor is turned the correct way. See figure! xx1000001108 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 314 Refit the connections to the UL lamp, if the ro- bot is equipped with one. Check the gasket. If damaged, replace it. xx1000001224 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 315 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 316: Gearboxes
• gearbox • Spare parts • all o-rings and seal- on page 393. ing rings O-ring 3HAB3772-54 Replace if damaged! Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 317 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 319 Make sure the base remains in a stable position before performing any work under- neath the base! xx1000000364 A Support base (4 pcs) Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 320 It may be necessary to also remove the rear connector plate. xx1000001385 xx0300000612 A Bottom plate B Rear connector plate C Attachment screw D Groove Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 321 The gearbox weighs 200 kg. All lifting accessories used must be sized accordingly! Lift the gearbox away with the already mounted lifting tools. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 322 Mounting of the support, base and gear 1 is detailed in section Removal, gear- box axis 1 on page 318. xx1000000364 A Support base (4 pcs) Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 323 Lubricate them with grease. xx1000001390 Make sure the small o-ring around the oil hole is fitted properly! xx1000001392 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 324 316. CAUTION The gearbox weighs 200 kg. All lifting accessories used must be sized ac- cordingly! Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 325 Lift gearbox axis 1 onto the guide pins and Always use guide pins in pairs! lower it carefully to its mounting position. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 326 Screw joints on page 385 before fit- ting. xx1000001394 Refit the cable guide in the center of gearbox 1 with its attachment screws. xx1000001393 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 327 Calibrat- ing with Axis Calibration method on page 360. General calibration information is in- cluded in section Calibration on page 349. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 328 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 329: Replacing The Gearbox, Axes
2 pcs, must have full thread. Use to press the gearbox free from the frame. Guide pins M12 Use guide pins in pairs. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 330 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 331 Put two loading pallets on the foot of the robot and run axis 3 so that the balancing weight is put onto the pallets. Run axis 2 to 0°. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 332 The length of the cylinder is now locked and the balancing device is unloaded. It should now be possible to easily rotate the balancing device. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 333 Remove all remaining attachment screws that secure the gearbox to the lower arm system. Axis 2: M16 and M12. Axis 3: M12. xx1000001405 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 335 Remove the sealing from the lower arm and clean it. Note The sealing can hang onto the gearbox, sticking to the oil. xx1000001403 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 336 Fit the lifting accessory to the gearbox and Specified in Required equipment on lift it with an overhead crane. page 329. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 337 Note Do not apply grease closer than 20 mm from the edge of the holes in the sealing. xx1400000993 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 338 M12 screws. • Tightening torque: 120 Nm. Secure the gearbox to the frame. M12, quality 8.8-A2F Tightening torque: 120 Nm. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 339 Refit the motors axes 2-3. Replacing motors, axes 2 and 3 on page 298 Perform a leakdown test. Performing a leak-down test on page 146. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 340 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 341: Replacing Gearbox Axis
Must be replaced when reas- sembling gearbox. 150.0x2.0 3HAB3772-64 Must be replaced when reas- sembling gearbox. 13.1x1.6 3HAB3772-61 Must be replaced when reas- sembling gearbox. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 342 Jog the robot to a position where the tilt- house unit is placed in an appropriate ser- vice position. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 343 Remove the calibration plate axis 6. xx1000001410 Remove the gearbox by unscrewing the at- tachment screws and washers that secure xx1000001411 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 344 A: M8 holes for pressing out the gearbox Remove gearbox axis 6 carefully without damaging pinion or gear. xx1000001412 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 345 Required equipment on ted to the gearbox. If the o-ring is damaged, page 341. replace! Lubricate the o-ring with grease. xx1000001414 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 346 Make sure the gears of the gearbox mate with the pinion of the axis 6 motor. CAUTION Do not damage pinion or gears in the pro- cess! xx1000001412 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 347 Refill the gearbox with oil. See section • Changing oil, gearbox axis 6 on page 133 Refit the calibration plate. xx1000001410 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 348 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 349: Calibration
Term Definition Calibration method A collective term for several methods that might be available for calibrating the ABB robot. Each method contains calibration routines. Synchronization position Known position of the complete robot where the angle of each axis can be checked against visual synchronization marks.
Page 350: Calibration Methods
Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant. If no data is found related to standard calibration, Calibration Pendulum is used as default. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 351 Brief description of calibration methods Calibration Pendulum method Calibration Pendulum is a standard calibration method for calibration of all ABB robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S). Two different routines are available for the Calibration Pendulum method: •...
Page 352: When To Calibrate
The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration, according to information in this manual. If the robot has absolute accuracy calibration, it is also recommended, but not always necessary to calibrate for new absolute accuracy.
Page 353: Synchronization Marks And Axis Movement Directions
Synchronization plate, axis 1 Synchronization tab on robot Synchronization mark, axis 2 Synchronization mark, axis 3 Synchronization plate and mark, axis 6 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 354 One of the marks is more narrow than the other and should be positioned within the limits of the wider mark. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 355: Calibration Movement Directions For All Axes
Manual movement directions, 4 axes Note! The graphic shows an IRB 260. The positive direction is the same for all 4-axis robots xx0500001927 Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 357 All mechanical units connected to the system are shown with their calibration status. Tap the mechanical unit in question. xx1500000943 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 358 Calibration method used at factory for each axis is shown, as well as calibration method used during last field calibration. Tap Manual Method (Advanced). xx1500000944 A screen is displayed, tap Rev. Counters. en0400000771 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 359 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 374. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 360: Calibrating With Axis Calibration Method
FlexPendant. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. WARNING The calibration tool must be fully inserted into the calibration bushing, until the steel spring ring snaps into place.
Page 361 A benefit with reference calibration is that the current state of the robot is stored and not the state when the robot left the ABB factory. The reference value will be named according to tool name, date etc.
Page 362: Calibration Tools For Axis Calibration
There is no risk for bad calibrations as long as the calibration tool is in one piece. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. Equipment, etc. Article number...
Page 363 It is possible to make the calibration tool identifiable with, for example, an RFID chip. The procedure of how to install an RFID chip is described below. Note The tool identifier is NOT delivered from ABB, it is a customized solution. Action Note It is possible to use any RFID solution, with the correct dimensions.
Page 365 Replace damaged parts with new, if needed. Spare part Article number Note Protection cover and plug set 3HAC056806-001 Contains replacement calibration pin covers and protective plugs for the bushing. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 366: Axis Calibration - Running The Calibration Procedure
WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration holes may cause severe damage to the robot and/or personnel. Equipment, etc.
Page 367 Use this procedure to call for the Axis Calibration method on the FlexPendant. Action Note On the ABB menu, tap Calibration. xx1500000942 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 368 The three-position enabling device on the Press and hold the three-position enabling FlexPendant has been released during robot device and press Play. movement. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 369 Confirm unsynchronized state by pressing Ac- knowledge to continue Axis Calibration proced- ure. Restart Axis Calibration procedure by pressing Play. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 370 SafeMove generates the message "Unsynchron- ized time limit expired" (anytime). xx1500002482 Press OK to continue Axis Calibration procedure. Restart Axis Calibration procedure by pressing Play. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 371 Ensure that the sealing is not damaged. Replace the plug and the sealing with new spare part, if missing or damaged. xx1500000952 Protection cover and plug set: 3HAC056806-001. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 372: Calibrating With Calibration Pendulum Method
Where to find information for Calibration Pendulum Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 373: Verifying The Calibration
Write down the values on a new label and stick it on top of the calibration label. The label is located on the lower arm. Remove any calibration equipment from the robot. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 374: Checking The Synchronization Position
If they do not, up- ization position for axes on page 353 date the revolution counters. Updating revolution counters on page 356. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 375: Decommissioning
Incineration must be carried out under controlled conditions in accordance with local regulations. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 376 Spills can form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. • Spillage can penetrate the soil causing ground water contamination. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 377: Scrapping Of Robot
• When motors are removed from the robot, the robot will collapse if it is not properly supported before the motor is removed. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 378: Decommissioning Of Balancing Device
The following procedure contains useful information about decommissioning. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 379 Cut a hole in the housing as shown in the Use a cutting torch with a long shaft. figure. xx1100000098 * Minimum measure, in millimeters. ** Maximum measure, in millimeters. Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 380 Double-check the number of coils cut and make sure all the tension in the springs is removed. Cut more coils if there is still tension in the springs. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 381: Reference Information
7.1 Introduction 7 Reference information 7.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 382: Applicable Standards
Terminology and general principles EN 574:1996 + A1:2008 Safety of machinery - Two-hand control devices - Functional aspects - Principles for design Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 383 Safety requirements for industrial robots and robot systems ANSI/UL 1740 Safety standard for robots and robotic equipment CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require- ments Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 384: Unit Conversion
1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 385: Screw Joints
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.
Page 386 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 387 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm - Nominal Min. Max. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 388: Weight Specifications
All components exceeding 22 kg (50 lbs) are highlighted in this way. To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.
Page 389: Standard Tools
Hex bit socket head cap no. 6 socket 40mm bit L=220 mm Slide caliper Width=400 mm Feeler gage, 0.4 mm Bearing puller, three legs Level Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 390: Special Tools
Lifting accessory, complete robot 3HAC15607-1 Lifting accessory, parallel arm 3HAC038377-002 Lifting accessory, motors ax 2-3 3HAC14586-1 Lifting lugs M16 2 pcs Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 391 Lubrication tool, spherical roller bearing 3HAC039296-001 Lubrication tool, conical roller bearing 3HAC039571-002 Pinion crank RV 450E 3HAC023132-001 Bits extension 3HAC023760-001 Support base 3HAC15535-1 Lock screw M16x55 Guide sleeves 3HAC14446-1 Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 392: Lifting Accessories And Lifting Instructions
This implies that the instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 393: Spare Parts
Spare parts and exploded views are not included in the manual but delivered as a separate document for registered users on myABB Business Portal, www.mypo- rtal.abb.com. Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 394 This page is intentionally left blank...
Page 395: Circuit Diagrams
Circuit diagram - IRB 6400RF 3HAC8935-1 Circuit diagram - IRB 6600 type A 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6600 type B 3HAC13347-1 3HAC025744-001 Continues on next page Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 396 3HAC029940-001 Circuit diagram - IRB 6700 3HAC043446-005 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 Circuit diagram - Product.ProductName 3HAC050778-003 Circuit diagram - IRB 910SC 3HAC056159-002 Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 397: Index
356 disposal, 375 standard type, 350 fork lift, 56 verification, 373 foundation when to calibrate, 352 requirements, 50 calibration, Absolute Accuracy, 351 frame Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 398 1, 316 replacing upper rod, 228 turning disk, 186 Lithium replacing disposal, 375 upper rod, linkage, 228 loads on foundation, 49 requirements on foundation, 50 lubricating Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 399 52 replacing, 171 restricting axis 1, 90 SMB battery extension of lifetime, 135, 171 replacing, 135, 171 zero position special tools, 390 checking, 374 Product manual - IRB 760 3HAC039838-001 Revision: M © Copyright 2011-2018 ABB. All rights reserved.
Page 402 PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics and Motion 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2011-2018 ABB. All rights reserved. Specifications subject to change without notice.

This manual is also suitable for:

Irb 760-450/3.2

ABB IRB 760 Series Product Manual

1 Safety

2 Installation and Commissioning

3 Maintenance

4 Repair

5 Calibration

6 Decommissioning

7 Reference Information

8 Spare Parts

9 Circuit Diagrams

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