ROBOTICS

Product manual
IRB 2600
Trace back information:
Workspace R18-2 version a18
Checked in 2018-11-20
Skribenta version 5.3.012
 Product manual
IRB 2600-20/1.65
IRB 2600-12/1.65
IRB 2600-12/1.85
IRB 2600ID-15/1.85
IRB 2600ID-8/2.0
IRC5

Document ID: 3HAC035504-001

Revision: Q

© Copyright 2009-2018 ABB. All rights reserved.

Specifications subject to change without notice.
The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.

© Copyright 2009-2018 ABB. All rights reserved.

Specifications subject to change without notice.
ABB AB, Robotics
Robotics and Motion
Se-721 68 Västerås
Sweden
 Table of contents

Table of contents
Overview of this manual ................................................................................................................... 9
Product documentation .................................................................................................................... 16
How to read the product manual ...................................................................................................... 18

1 Safety 19
1.1 General safety information .................................................................................. 19
1.1.1 Limitation of liability ................................................................................. 19
1.1.2 Protective stop and emergency stop ........................................................... 21
1.2 Safety actions ................................................................................................... 22
1.2.1 Fire extinguishing .................................................................................... 22
1.2.2 Emergency release of the robot axes .......................................................... 23
1.2.3 Make sure that the main power has been switched off .................................... 24
1.3 Safety risks ...................................................................................................... 25
1.3.1 Safety risks during installation and service work on robots .............................. 25
1.3.2 Moving robots are potentially lethal ............................................................ 27
1.3.3 First test run may cause injury or damage .................................................... 28
1.3.4 Work inside the working range of the robot .................................................. 29
1.3.5 Enabling device and hold-to-run functionality ............................................... 30
1.3.6 Risks associated with live electric parts ....................................................... 31
1.3.7 The unit is sensitive to ESD ....................................................................... 33
1.3.8 Hot parts may cause burns ....................................................................... 34
1.3.9 Safety risks related to pneumatic/hydraulic systems ...................................... 35
1.3.10 Safety risks with pressure relief valve ......................................................... 36
1.3.11 Brake testing .......................................................................................... 37
1.3.12 Safety risks during handling of batteries ...................................................... 38
1.3.13 Safety risks during work with gearbox lubricants (oil or grease) ....................... 39
1.4 Safety signals and symbols ................................................................................. 41
1.4.1 Safety signals in the manual ...................................................................... 41
1.4.2 Safety symbols on product labels ............................................................... 43

2 Installation and commissioning 49

2.1 Introduction ...................................................................................................... 49
2.2 Unpacking ....................................................................................................... 50
2.2.1 Pre-installation procedure ......................................................................... 50
2.2.2 Working range and type of motion .............................................................. 54
2.2.3 Risk of tipping/stability ............................................................................. 59
2.3 On-site installation ............................................................................................ 60
2.3.1 Lifting robot with roundslings .................................................................... 60
2.3.2 Lifting and turning a suspended mounted robot ............................................ 63
2.3.3 Setting the system parameters for a suspended or tilted robot ......................... 64
2.3.4 Manually releasing the brakes ................................................................... 68
2.3.5 Orienting and securing the robot ................................................................ 71
2.3.6 Fitting equipment on robot ........................................................................ 75
2.3.7 Loads fitted to the robot, stopping time and braking distances ......................... 88
2.4 Restricting the working range .............................................................................. 89
2.4.1 Axes with restricted working range ............................................................. 89
2.4.2 Mechanically restricting the working range of axis 1 ...................................... 90
2.5 Installing options ............................................................................................... 93
2.5.1 Installation of cooling fan for motors (option) ................................................ 93
2.5.2 Installing an expansion container ............................................................... 97
2.5.3 Installation of Foundry Plus Cable guard (option no. 908-1) ............................. 100
2.5.4 Signal lamp (option) ................................................................................. 101
2.6 Robot in hot environments .................................................................................. 102
2.6.1 Start of robot in hot environments .............................................................. 102
2.7 Robot in cold environments ................................................................................. 103
2.7.1 Start of robot in cold environments ............................................................ 103

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Table of contents

2.8 Electrical connections ........................................................................................ 104

2.8.1 Robot cabling and connection points .......................................................... 104
2.8.2 Customer connection on robot ................................................................... 108
2.8.3 Customer connections on upper arm .......................................................... 111

3 Maintenance 113
3.1 Introduction ...................................................................................................... 113
3.2 Maintenance schedule and expected component life ............................................... 114
3.2.1 Specification of maintenance intervals ........................................................ 114
3.2.2 Maintenance schedule ............................................................................. 115
3.2.3 Expected component life ......................................................................... 118
3.3 Inspection activities ........................................................................................... 119
3.3.1 Inspecting oil level, axis-1 gearbox ............................................................. 119
3.3.2 Inspecting the oil level, axis 2 gearbox ........................................................ 124
3.3.3 Inspecting the oil level, axis 3 gearbox ........................................................ 127
3.3.4 Inspecting the oil level, axis 4 gearbox ........................................................ 129
3.3.5 Inspecting oil level, gearbox axes 5 - 6 ........................................................ 131
3.3.6 Inspecting the cable harness ..................................................................... 133
3.3.7 Inspecting information labels ..................................................................... 135
3.3.8 Inspecting the mechanical stop pin, axis 1 ................................................... 137
3.3.9 Inspecting additional mechanical stops ....................................................... 140
3.3.10 Inspecting dampers ................................................................................. 142
3.3.11 Inspecting the pressure relief valve ............................................................ 144
3.3.12 Inspecting Signal lamp (option) .................................................................. 146
3.4 Replacement / Changing activities ........................................................................ 148
3.4.1 Type of lubrication in gearboxes ................................................................ 148
3.4.2 Changing the oil, axis 1 gearbox on floor mounted robots ............................... 150
3.4.3 Changing the oil, axis-1 gearbox on suspended robots ................................... 158
3.4.4 Changing the oil, axis-2 gearbox ................................................................ 163
3.4.5 Changing the oil, axis-3 gearbox ................................................................ 167
3.4.6 Changing the oil, axis-4 gearbox ................................................................ 171
3.4.7 Changing oil, axes-5 and -6 gearboxes ........................................................ 175
3.4.8 Replacing SMB battery ............................................................................. 179
3.5 Cleaning .......................................................................................................... 184
3.5.1 Cleaning the IRB 2600/IRB 2600 ID ............................................................. 184

4 Repair 187
4.1 Introduction ...................................................................................................... 187
4.2 General procedures ........................................................................................... 188
4.2.1 Performing a leak-down test ...................................................................... 188
4.2.2 Mounting instructions for bearings ............................................................. 189
4.2.3 Mounting instructions for seals .................................................................. 191
4.2.4 Cut the paint or surface on the robot before replacing parts ............................ 193
4.2.5 The brake release buttons may be jammed after service work ......................... 194
4.3 Complete robot ................................................................................................. 195
4.3.1 Removing the complete cable harness ........................................................ 195
4.3.2 Refitting the complete cable harness .......................................................... 207
4.3.3 Replacing the cable harness in the upper arm - IRB 2600ID ............................ 222
4.3.4 Replacing SMB unit ................................................................................. 234
4.3.5 Replacing the brake release board ............................................................. 240
4.4 Upper arm ....................................................................................................... 245
4.4.1 Replacing the complete upper arm ............................................................. 245
4.4.2 Replacing complete tubular shaft unit ......................................................... 255
4.4.3 Replacing wrist unit ................................................................................. 262
4.4.4 Measuring the play, axis 5 ......................................................................... 268
4.4.5 Measuring the play, axis 6 ......................................................................... 270
4.4.6 Measuring the play, axis 5 (ID upper arm) .................................................... 272
4.4.7 Measuring the play, axis 6 (ID upper arm) .................................................... 275

6 Product manual - IRB 2600

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 Table of contents

4.5 Lower arm ....................................................................................................... 278

4.5.1 Replacing the lower arm ........................................................................... 278
4.6 Frame and base ................................................................................................ 286
4.6.1 Replacing stop pin axis 1 .......................................................................... 286
4.6.2 Replacing the base .................................................................................. 289
4.7 Motors ............................................................................................................ 301
4.7.1 Removing motors .................................................................................... 301
4.7.2 Refitting motors ...................................................................................... 313
4.7.3 Replacing motor axis 5 - IRB 2600ID ........................................................... 329
4.7.4 Replacing motor axis 6 and wrist unit - IRB 2600ID ........................................ 341
4.7.5 Adjusting the play ................................................................................... 352
4.8 Gearboxes ....................................................................................................... 357
4.8.1 Replacing gearbox axis 1 .......................................................................... 357
4.8.2 Replacing gearbox axis 2 .......................................................................... 370
4.8.3 Replacing gearbox axis 3 .......................................................................... 383

5 Calibration 391
5.1 Introduction to calibration ................................................................................... 391
5.1.1 Introduction and calibration terminology ...................................................... 391
5.1.2 Calibration methods ................................................................................. 392
5.1.3 When to calibrate ................................................................................... 394
5.2 Synchronization marks and axis movement directions ............................................. 395
5.2.1 Synchronization marks and synchronization position for axes ......................... 395
5.2.2 Calibration movement directions for all axes ................................................ 398
5.3 Updating revolution counters ............................................................................... 399
5.4 Calibrating with Axis Calibration method ............................................................... 403
5.4.1 Description of Axis Calibration .................................................................. 403
5.4.2 Calibration tools for Axis Calibration ........................................................... 406
5.4.3 Installation locations for the calibration tools ............................................... 408
5.4.4 Axis Calibration - Running the calibration procedure ...................................... 412
5.5 Calibrating with Calibration Pendulum method ........................................................ 420
5.6 Verifying the calibration ...................................................................................... 421
5.7 Checking the synchronization position .................................................................. 422

6 Decommissioning 423
6.1 Introduction ...................................................................................................... 423
6.2 Environmental information .................................................................................. 424
6.3 Scrapping of robot ............................................................................................. 426

7 Robot description 427

7.1 Robot types ..................................................................................................... 427
7.2 Non-compatible versions of axis-1 and axis-2 gearboxes .......................................... 428

8 Reference information 433

8.1 Introduction ...................................................................................................... 433
8.2 Applicable standards ......................................................................................... 434
8.3 Unit conversion ................................................................................................. 436
8.4 Screw joints .................................................................................................... 437
8.5 Weight specifications ......................................................................................... 440
8.6 Standard tools .................................................................................................. 441
8.7 Special tools .................................................................................................... 442
8.8 Lifting accessories and lifting instructions .............................................................. 444

9 Spare part lists 445

9.1 Spare part lists and illustrations ........................................................................... 445

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10 Circuit diagram 447

10.1 Circuit diagrams ................................................................................................ 447

Index 449

8 Product manual - IRB 2600

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 Overview of this manual

Overview of this manual

About this manual
This manual contains instructions for:
• mechanical and electrical installation of the robot
• maintenance of the robot
• mechanical and electrical repair of the robot.
The manual also contains reference information for all procedures detailed in the
manual.

Usage
This manual should be used during:
• installation, from lifting the robot to its work site and securing it to the
foundation, to making it ready for operation
• maintenance work
• repair work and calibration.

Who should read this manual?

This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.

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 2600/IRB 2600 ID.
Some variants and designs may have been removed from the business offer and
are no longer available for purchase.

Organization of chapters
The manual is organized in the following chapters:
Chapter Contents
Safety Safety information that must be read through before performing
any installation or service work on the robot. Contains general
safety aspects as well as more specific information on how to
avoid personal injuries and damage to the product.
Installation and commis- Required information about lifting and installation of the robot.
sioning
Maintenance Step-by-step procedures that describe how to perform mainten-
ance of the robot. Based on a maintenance schedule that may
be used to plan periodical maintenance.

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Chapter Contents
Repair Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.
Calibration Calibration procedures and general information about calibration.
Decommissioning Environmental information about the robot and its components.
Reference information Useful information when performing installation, maintenance
or repair work. Includes lists of necessary tools, additional doc-
uments, safety standards etc.
Spare part / part list Complete spare part list and complete list of robot components,
shown in exploded views.
Exploded views Detailed illustrations of the robot with reference numbers to the
part list.
Circuit diagram Reference to the circuit diagram for the robot.

References

Reference Document ID
Product specification - IRB 2600 3HAC035959-001
Circuit diagram - IRB 2600 3HAC029570-007
Product manual, spare parts - IRB 2600 3HAC049106-001
Operating manual - General safety information i 3HAC031045-001
Product manual - IRC5 3HAC021313-001
IRC5 with main computer DSQC 639.
Product manual - IRC5 3HAC047136-001
IRC5 with main computer DSQC1000.
Operating manual - Emergency safety information 3HAC027098-001
Operating manual - IRC5 with FlexPendant 3HAC050941-001
Operating manual - Troubleshooting IRC5 3HAC020738-001
Operating manual - Calibration Pendulum 3HAC16578-1
Operating manual - Service Information System 3HAC050944-001
Technical reference manual - Lubrication in gearboxes 3HAC042927-001
Technical reference manual - System parameters 3HAC050948-001
Application manual - Additional axes and stand alone controller 3HAC051016-001
Application manual - Electronic Position Switches 3HAC050996-001
Application manual - CalibWare Field 5.0 3HAC030421-001
i This manual contains all safety instructions from the product manuals for the manipulators and the
controllers.

Revisions

Revision Description
- First edition
A The following updates and additions have been made in this revision:
• Variant IRB 2600ID added throughout the manual.
• Safety symbols updated throughout the manual.

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Continued

Revision Description
• Section Safety signals in the manual on page 41 added in Safety chapter.
• Section Safety risks with pressure relief valve on page 36 added in
Safety chapter.
• Force and Torque loads updated in section Pre-installation procedure
on page 50.
• Section Installing an expansion container on page 97 added.
• Interval for inspection of signal lamp added in section Maintenance
schedule on page 115.
• New design of frame added in sections Inspecting oil level, axis-1
gearbox on page 119 and Changing the oil, axis 1 gearbox on floor
mounted robots on page 150.
• Required oil level updated in section Inspecting oil level, axis-1 gearbox
on page 119.
• Required oil level updated in section Inspecting the oil level, axis 3
gearbox on page 127.
• Required oil level updated in section Inspecting the oil level, axis 4
gearbox on page 129.
• Required oil level updated in section Inspecting oil level, gearbox axes
5 - 6 on page 131.
B The following updates and additions have been made in this revision:
• The difference in weight between the different robot variants is minor,
therefor the weight specification for the robot is simplified. See Weight,
robot on page 50.
• Figure and describing text edited for the stress forces. See Loads on
foundation, robot on page 51.
• Removed Foundry from table with protection classes. See Protection
classes, robot on page 53.
• Text added for the maximum levelness. See Requirements, foundation
on page 52.
• Length of roundslings for lifting the robot is changed from 4 m to 2 m.
See Lifting robot with roundslings on page 60.
• Note about fan cabling added in the cable list. See Robot cabling and
connection points on page 104.
• Minor editorial changes made throughout the maintenance chapter.
• Note about ambient temperature deleted from the maintenance schedule.
See Maintenance schedule on page 115.
• Added figure of suspended robot in maintenance sections for axis 1
gearbox. See Inspecting oil level, axis-1 gearbox on page 119 and
Changing the oil, axis 1 gearbox on floor mounted robots on page 150.
• A new block, about general illustrations, added in section How to read
the product manual on page 18.
• Figure of axis 1 stop pin is updated. See Replacing stop pin axis 1 on
page 286.
• Figure of axis 1 gearbox is updated. See Replacing gearbox axis 1 on
page 357.
• Figure with movement directions of axes added. See Calibration
movement directions for all axes on page 398.
• Figure of suspended robot added. See Lifting and turning a suspended
mounted robot on page 63.
• Warning of heavy weight is changed to include the complete robot in-
stead of only the arm system, section Replacing the base on page 289.
• Separated robot dimensions and mounting hole measurements in
drawings. See Fitting equipment on robot on page 75.
• Added section Setting the system parameters for a suspended or tilted
robot on page 64.

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Continued

Revision Description
• Corrected spare part numbers for axes 3, 4, 5 and 6 motors. See Upper
arm and Upper arm ID.
• Added VK covers to the instruction for upper arm cabling replacement,
IRB 2600ID. See Replacing the cable harness in the upper arm - IRB
2600ID on page 222.
• Changed information about which attachment screws to remove when
removing the base from the robot. Previously the instruction said "Re-
move the attachment screws securing the gearbox to the frame", now
it says "Remove the attachment screws that secure the base to the axis
1 gearbox". See step in the end of the removal procedure in section
Replacing the base on page 289.
• Changed information about the robot position when removing motor.
See Removing motors on page 301.
• Added step about removing/refitting axis 1 motor when replacing the
axis 1 gearbox. Also added information about guide pins. See Replacing
gearbox axis 1 on page 357. Also minor additions concerning the mating
of gearbox and motor, in all such instructions.
• Added information about lifting accessories and how to attach them to
the upper arm of the robot, see Attaching the lifting accessories to the
upper arm on page 250.
• Additional information in the procedure for replacing the base with im-
proved lifting instruction etc., see Replacing the base on page 289.
• Added a second roundsling to the lifting instruction for the complet robot,
see Lifting robot with roundslings on page 60.
• Changed type of oil in axes 1, 2 and 4 gearboxes. See Type of lubrication
in gearboxes on page 148.
C The following updates and changes have been made in this revision:
• Added instructions for how to measure the play of axis 5 and 6 of an ID
upper arm. See sections Measuring the play, axis 5 (ID upper arm) on
page 272 and Required equipment on page 275.
• Deleted the spare part number for harnesses in Spare parts - lower arm
and instead inserted a reference to the Electrical connections.
• Corrected the spare part numbers for cable harnesses, see Electrical
connections.
• Corrected measurement that belong to figure xx0300000187, when fitting
tools for measuring the play of axis 5, see Measuring the play, axis 5
on page 268.
• Corrected faulty information about attachment screws between upper
and lower arm (figure, screw dimension and tightening torque), see
Replacing the complete upper arm on page 245.
• Added information about releasing the motor brakes in order to set the
weight of different axes onto lifting accessories, see Replacing the
complete upper arm on page 245, Replacing gearbox axis 3 on page 383
and Replacing gearbox axis 2 on page 370.
• Changed the instruction for how to replace the axes 2 and 3 gearboxes
without having to remove the cable harness, see Replacing gearbox
axis 3 on page 383 and Replacing gearbox axis 2 on page 370.
• Added safety information about preventing roundslings from sliding
when lifting the upper arm tube, see Replacing complete tubular shaft
unit on page 255.
• Added information about removing painting, if any, from assembly sur-
faces when replacing gearboxes and motors.
• Corrected the specified weight for the tubular shaft unit to 30 kg.
• Added tip to speed up the draining of axis 4 gearbox, see Changing the
oil, axis-4 gearbox on page 171.
• Corrected data for which motor pins to connect when releasing the
brakes, see Removing motors on page 301 and Refitting motors on
page 313.

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Continued

Revision Description
• Added information about o-ring and made other minor improvements
to the instruction for replacing wrist unit, see Replacing wrist unit on
page 262.
• Added information about disconnecting the battery cable when removing
the cable harness, see Removing the complete cable harness on
page 195.
• Corrected the figure that shows location of oil plugs of axis 3 gearbox,
added a funnel to equipment list, see Changing the oil, axis-3 gearbox
on page 167.
• Corrected the figure that shows location of oil plugs of axis 3 gearbox
and adjusted the oil level, see Inspecting the oil level, axis 3 gearbox
on page 127.
• Changed instruction for replacing the wrist unit so that the wrist do not
need to be drained, see Replacing wrist unit on page 262.
• Added Profibus to the section about connections to extra equipment,
see Customer connection on robot on page 108.
• New section added to the manual, see Installation of Foundry Plus Cable
guard (option no. 908-1) on page 100.
• Some general tightening torques have been changed/added, see updated
values in Screw joints on page 437.
• The method of changing the axis-1 gearbox oil in suspended robots is
improved, see the new section Changing the oil, axis-1 gearbox on
suspended robots on page 158.
• Corrected the motor connector pin numbers used for releasing the motor
brakes with external power supply, see Removing motors on page 301
and Refitting motors on page 313.
• Complete process wrist for IRB 2600ID is added to the spare part list
and to the service instructions, see Spare partsand Replacing motor
axis 6 and wrist unit - IRB 2600ID on page 341, also the section Wrist
unit is deleted from the spare part list, since the wrist unit spare part
number already is specified in the upper arm spare part list.
• Added instructions for adjusting the play on motors, see Adjusting the
play on page 352.
• Added Safety risks during handling of batteries on page 38.
D The following updates and changes have been made in this revision:
• Removed faulty information about motors when rebuilding the robot,
see Rebuilding parts.
• Removed faulty information about expansion container for wall mounted
robots, see Changing the oil, axis-1 gearbox on suspended robots on
page 158. Expansion container is not used on wall mounted robots.
• Added ID variants to the information about lower arm when rebuilding
the robot, see Rebuilding parts. Also corrected the ID information in the
spare part list for the lower arm.
• Added correct variant descriptions to the information about IRB 2600ID
upper arms. See Upper arm (IRB 2600ID).
• Mounting angles and values for tilted the variant of the robot added.
• Corrected the spare part numbers for cable harnesses, see Electrical
connections.
• Corrected the spare part number for o-ring pos (5). See Base and frame
unit.
• Spare part number for VK cover, pos 41 was wrong. Has been corrected.
See Upper arm (IRB 2600ID).
• Corrected tightening torque value for oil plugs on axis-1 and axis-2
gearboxes. Correct value is 24 Nm. (Earlier incorrect value: 60 Nm.)
• Information about the type and amount of oil has been removed from
the manual and can now be found in Technical reference manual - Lub-
rication in gearboxes. For article number see References on page 10.

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Revision Description
• Information about sealing washer oil plugs on the axis-1 and axis-2
gearbox changed. Also spare part number is added.
• New frame introduced throughout the manual.
• A new SMB unit and battery is introduced, with longer battery lifetime.
E The following updates and changes have been made in this revision:
• Corrected links to lubrication in gearboxes.
• Spare part numbers in general corrected.
• Added information about risks when scrapping a decommissioned robot,
see Scrapping of robot on page 426.
• Spare parts and exploded views are not included in this document but
delivered as a separate document. See Product manual, spare
parts - IRB 2600.
F The following updates have been made in this revision:
• Illustration changes in Dimension, mounting surface and guide bushing
on page 72.
• Term "Guide sleeves" changed to "Guide bushings", see Dimension,
mounting surface and guide bushing on page 72.
• Information in 2.3.4 Manually releasing the brakes has been updated
and two figures are added.
• Motors Type B added for IRB 2600 and IRB 2600ID.
• A new WARNING! is added in the section about motor replacement,
informing not to mix different motor types.
• Minor corrections.
G The following updates have been made in this revision:
• Information about removing the mech stop bracket added in section
2.4.1
• Illustrations of cable harness and motors in upper arm, improved
throughout the manual.
H The following updates have been made in this revision:
• Turning disk fixture is removed from special tools for Levelmeter calib-
ration.
• Valid serial numbers changed to type designations (Type A and Type
B) in the section "Checking the oil level" to avoid confusion between
different serial number series.
• Oil levels adjusted.
J The following updates have been made in this revision:
• Information about expansion container added.
• Updated number of screws and sizes of screws in Replacing the lower
arm.
K Published in release R16.2. The following updates are done in this revision:
• Corrections due to updates in SAP terminology.
• New standard calibration method is introduced (Axis Calibration). See
Calibration on page 391.
• Clarifications in maintenance schedule.
• Information about grounding point added. See Robot cabling and con-
nection points on page 104.
L Published in release R17.1. The following updates are done in this revision:
• Added information about how to handle cabling in the upper arm tube,
and upper arm housing, during wrist removal and cable replacement,
see Removing the wrist unit on page 343 and Replacing the cable harness
in the upper arm - IRB 2600ID on page 222.
• Changed the tightening torque of the oil plug located on axis-1 gearbox.
• Recommendation about changing oil in axis-2 gearbox in floor standing
position added.

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Revision Description
• Clarification for types of motors, Motors on page 301.
M Published in release R17.2. The following updates are done in this revision:
• Information about coupled axes in Updating revolution counters on
page 399.
• Caution about removing metal residues added in sections about SMB
boards.
• Information added into calibration procedure regarding installation of
calibration tool on turning disc, see Overview of the calibration procedure
on the FlexPendant on page 412.
• Information about minimum resonance frequency added.
• Bending radius for static floor cables added.
• Updated list of applicable standards.
• Article number for the Calibration tool box, Axis Calibration is changed.
• Added text regarding overhaul in section specification of maintenance
intervals.
• Updated the section Start of robot in cold environments on page 103.
• Information about isolating arc welding manipulator added.
• Updated information regarding replacement of brake release board.
• Updated information regarding disconnecting and reconnecting battery
cable to serial measurement board.
• Definition of reference calibration clarified.
N Published in release R18.1. The following updates are done in this revision:
• Information added about fatigue to Axis Calibration tool, see Calibration
tools for Axis Calibration on page 406.
• Added sections in General procedures on page 188.
• Illustration updated in dimension, mounting surface and guide bushing.
• Safety restructured.
• Added information about harness customer ethernet connection.
• Updated spare parts number for Brake release boards.
• Note added to calibration chapter to emphasize the requirement of
equally dressed robot when using previously created reference calibra-
tion values.
• Information about myABB Business Portal added.
• Added Nickel in Environmental information.
P Published in release R18.2. The following updates are done in this revision:
• Updates related to mechanical stop pin.
• Changed the method for replacing the axis-1 gearbox and the base.
Q Published in release R18.2. The following updates are done in this revision:
• Updated reference.

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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.
All documents can be found via myABB Business Portal, www.myportal.abb.com.

Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.

Technical reference manuals

The technical reference manuals describe reference information for robotics
products, for example lubrication, the RAPID language, and system parameters.

Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
• What is included (for example cables, I/O boards, RAPID instructions, system
parameters, software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.

Continues on next page

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 Product documentation
Continued

Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.

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How to read the product manual

How to read the product manual

Reading the procedures
The procedures contain references to figures, tools, material, and so on. The
references are read as described below.

References to figures
The procedures often include references to components or attachment points
located on the manipulator/controller. The components or attachment points are
marked with italic text in the procedures and completed with a reference to the
figure where the current component or attachment point is shown.
The denomination in the procedure for the component or attachment point
corresponds to the denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a
procedure.
Action Note/Illustration
8. Remove the rear attachment screws, gearbox. Shown in the figure Location of
gearbox on page xx.

References to required equipment

The procedures often include references to equipment (spare parts, tools, etc.)
required for the different actions in the procedure. The equipment is marked with
italic text in the procedures and completed with a reference to the section where
the equipment is listed with further information, that is article number and
dimensions.
The designation in the procedure for the component or attachment point
corresponds to the designation in the referenced list.
The table below shows an example of a reference to a list of required equipment
from a step in a procedure.
Action Note/Illustration
3. Fit a new sealing, axis 2 to the gearbox. Art. no. is specified in Required
equipment on page xx.

Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 19.

Illustrations
The robot is illustrated with general figures that does not take painting or protection
type in consideration.
Likewise, certain work methods or general information that is valid for several robot
models, can be illustrated with illustrations that show a different robot model than
the one that is described in the current manual.

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 1 Safety
1.1.1 Limitation of liability

1 Safety
1.1 General safety information

1.1.1 Limitation of liability

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.
In particular, liability cannot be accepted if injury/damage has been caused for any
of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed.
• Non-authorized design modifications made in or around the robot.
• Repairs carried out by in-experienced or non-qualified personnel.
• Foreign objects.
• Force majeure.

Nation/region specific regulations

To protect personnel, the complete system must be designed and installed in
accordance with the safety requirements set forth in the standards and regulations
of the country where the robot is installed.

To be observed by the supplier of the complete system

The integrator is responsible that the safety devices necessary to protect people
working with the robot system are designed and installed correctly.
When integrating the robot with external devices and machines:
• The supplier of the complete system must ensure that all circuits used in the
safety function are interlocked in accordance with the applicable standards
for that function.
• The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance
with the applicable standards for the emergency stop function.

Continues on next page

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1 Safety
1.1.1 Limitation of liability
Continued

The integrator of the final application is required to perform an assessment of the

hazards and risks (HRA).

Note

The integrator is responsible for the safety of the final application.

Safe access
The robot system shall be designed to allow safe access to all areas where
intervention is necessary during operation, adjustment, and maintenance.
Where it is necessary to perform tasks within the safeguarded space there shall
be safe and adequate access to the task locations.
Safety zones, which must be crossed before admittance, must be set up in front
of the robot's working space. Light beams or sensitive mats are suitable devices.
Turntables or the like should be used to keep the operator out of the robot's working
space.
A safety fence is recommended to ensure safeguarded space. Sufficient space
must be provided around the manipulator to protect those working with or on it
from hazards such as crushing.
The fence or enclosure must be dimensioned to withstand the force created if the
load being handled by the robot is dropped or released at maximum speed.
Determine the maximum speed from the maximum velocities of the robot axes and
from the position at which the robot is working in the work cell (see the section
Robot motion in the Product specification).
Also consider the maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the robot.

Safe handling
Users shall not be exposed to hazards, including slipping, tripping, and falling
hazards.
It must be possible to safely turn off tools, such as milling cutters, etc. Make sure
that guards remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).

Safe design
Emergency stop buttons must be positioned in easily accessible places so that
the robot can be stopped quickly. If any of the buttons do not stop all the robot
workcell motion, each emergency stop button must be marked, if more than one
is provided, to indicate its designated safety function.
Grippers/end effectors must be designed so that they do not drop work pieces/tools
in the event of a power failure or a disturbance to the controller.
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.

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 1 Safety
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.

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1 Safety
1.2.1 Fire extinguishing

1.2 Safety actions

1.2.1 Fire extinguishing

Note

Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the

manipulator or controller.

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 1 Safety
1.2.2 Emergency release of the robot axes

1.2.2 Emergency release of the robot axes

Description
In an emergency situation, the brakes on a robot axis can be released manually
by pushing a brake release button.
How to release the brakes is described in the section:
• Manually releasing the brakes on page 68.
The robot may be moved manually on smaller robot models, but larger models
may require using an overhead crane or similar equipment.

Increased injury
Before releasing the brakes, make sure that the weight of the robot does not
increase the pressure on the trapped person, further increasing any injury.

DANGER

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.

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1 Safety
1.2.3 Make sure that the main power has been switched off

1.2.3 Make sure that the main power has been switched off

Description
Working with high voltage is potentially lethal. Persons subjected to high voltage
may suffer cardiac arrest, burn injuries, or other severe injuries. 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.

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 1 Safety
1.3.1 Safety risks during installation and service work on robots

1.3 Safety risks

1.3.1 Safety risks during installation and service work on robots

Requirements on personnel
Only persons who know the robot and are trained in the operation and handling
of the robot are allowed to maintain the robot. Persons who are under the influence
of alcohol, drugs or any other intoxicating substances are not allowed to install,
maintain, repair, or use the robot.
• Those in charge of operations must make sure that safety instructions are
available for the installation in question.
• Those who install or service/maintain the robot must have the appropriate
training for the equipment in question and in any safety matters associated
with it.
• Personnel should be trained on responding to emergency or abnormal
situations.

General risks during installation and service

The instructions in the product manual must always be followed.
Never turn the power on to the robot before it is properly fixed and bolted to its
foundation/support.
Make sure that no one else can turn on the power to the controller and robot while
you are working with the system. A good method is to always lock the main switch
on the controller cabinet with a safety lock.
Make sure that no one else can turn on the power to the controller and robot while
you are working with the system. A good method is to remove the power cable to
the controller.
If the robot is installed at a height, hanging, or other than standing directly on the
floor, there may be additional risks than those for a robot standing directly on the
floor.
Energy stored in the robot for the purpose of counterbalancing certain axes may
be released if the robot, or parts thereof, are dismantled.
Never use the robot as a ladder, which means, do not climb on the controller,
motors, or other parts during service work. There is a risk of slipping because of
the high temperature of the motors and oil spills that can occur on the robot. There
is also a risk of the robot being damaged.
To avoid damaging the product, make sure that there are no loose screws, turnings,
or other parts inside the product after work has been performed.

Safety risks during operational disturbances

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

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1 Safety
1.3.1 Safety risks during installation and service work on robots
Continued

If the working process is interrupted, extra care must be taken due to risks other
than those associated with regular operation. Such an interruption may have to be
rectified manually.

Spare parts and special equipment

ABB does not supply spare parts and special equipment which have not been
tested and approved by ABB. The installation and/or use of such products could
negatively affect the structural properties of the robot and as a result of that affect
the active or passive safety operation. 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.

Connection of external safety devices

Apart from the built-in safety functions, the robot is also supplied with an interface
for the connection of external safety devices. An external safety function can
interact with other machines and peripheral equipment via this interface. This
means that control signals can act on safety signals received from the peripheral
equipment as well as from the robot.

Personal protective equipment

Always use suitable personal protective equipment, based on the risk assessment
for the installation.

Allergenic material
See Environmental information on page 424 for specification of allergenic materials
in the product, if any.

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 1 Safety
1.3.2 Moving robots are potentially lethal

1.3.2 Moving robots are potentially lethal

Description
Any moving robot is a potentially lethal machine.
When running, the robot may perform unexpected and sometimes irrational
movements. Moreover, all movements are performed with great force and may
seriously injure any personnel and/or damage any piece of equipment located
within the working range of the robot.

Safe handling

Action Note
1 Before attempting to run the robot, make Emergency stop equipment such as gates,
sure all emergency stop equipment is cor- tread mats, light curtains, etc.
rectly installed and connected.
2 Usually the hold-to-run function is active How to use the hold-to-run function is de-
only in manual full speed mode. To in- scribed in section How to use the hold-to-
crease safety it is also possible to activate run function in the Operating manual - IRC5
hold-to-run for manual reduced speed with with FlexPendant.
a system parameter.
The hold-to-run function is used in manual
mode, not in automatic mode.
3 Make sure no personnel are present within
the working range of the robot before
pressing the start button.

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1 Safety
1.3.3 First test run may cause injury or damage

1.3.3 First test run may cause injury or damage

Description
After installation and performing service activities, there are several safety risks
to take into consideration before the first test run.

Safe handling
Use this procedure when performing the first test run after installation, maintenance,
or repair.

DANGER

Running the robot without fulfilling the following aspects, may involve a risk of
injury and cause severe damage to the robot.

Action
1 Remove all tools and foreign objects from the robot and its working area.
2 Verify that the robot is properly secured to its position by all screws, before it is powered
up.
3 Verify that any safety equipment installed to secure the position or restrict the robot
motion during service activity is removed.
4 Verify that the fixture and work piece are well secured, if applicable.
5 Install all safety equipment properly.
6 Make sure all personnel are standing at a safe distance from the robot, and is out of
its reach behind safety fences, or similar.
7 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.

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 1 Safety
1.3.4 Work inside the working range of the robot

1.3.4 Work inside the working range of the robot

WARNING

If work must be carried out within the work area of the robot, then the following
points must be observed:
• The operating mode selector on the controller must be in the manual mode
position to render the three-position enabling device operational and to block
operation from a computer link or remote control panel.
• The maximum speed of the robot is limited to 250 mm/s when the operating
mode selector is in the position Manual mode with reduced speed. This
should be the normal position when entering the working space.
The position Manual mode with full speed (100%) may only be used by
trained personnel who are aware of the risks that this entails. Manual mode
with full speed (100%) is not available in USA or Canada.
• Pay attention to the rotating axes of the robot. Keep away from axes to not
get entangled with hair or clothing. Also, be aware of any danger that may
be caused by rotating tools or other devices mounted on the robot or inside
the cell.
• Keep clear of moving parts so that limbs, hands, or fingers do not get trapped
or crushed by the robot.
• To prevent anyone else from taking control of the robot, always put a safety
lock on the cell door and bring the three-position enabling device with you
when entering the working space.

WARNING

NEVER, under any circumstances, stay beneath any of the robot's axes! There
is always a risk that the robot will move unexpectedly when robot axes are moved
using the three-position enabling device or during other work inside the working
range of the robot.

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1 Safety
1.3.5 Enabling device and hold-to-run functionality

1.3.5 Enabling device and hold-to-run functionality

Three-position enabling device

The three-position enabling device is a manually operated, constant pressure
push-button which, when continuously activated in one position only, allows
potentially hazardous functions but does not initiate them. In any other position,
hazardous functions are stopped safely.
The three-position enabling device is of a specific type where you must press the
push-button only half-way to activate it. In the fully in and fully out positions,
operating the robot is impossible.

Note

The three-position enabling device is a push-button located on the teach pendant

which, when pressed halfway in, switches the system to MOTORS ON. When
the enabling device is released or pushed all the way in, the manipulator switches
to the MOTORS OFF state.
To ensure safe use of the teach pendant, the following must be implemented:
• The enabling device must never be rendered inoperational in any way.
• During programming and testing, the enabling device must be released as
soon as there is no need for the robot to move.
• Anyone entering the working space of the robot must always hold the teach
pendant. This is to prevent anyone else from taking control of the robot
without his/her knowledge.

Hold-to-run function
The hold-to-run function allows movement when a button connected to the function
is actuated manually and immediately stops any movement when released. The
hold-to-run function can only be used in manual mode.
How to operate the hold-to-run function for IRC5 is described in Operating
manual - IRC5 with FlexPendant.

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 1 Safety
1.3.6 Risks associated with live electric parts

1.3.6 Risks associated with live electric parts

Voltage related risks, general

Work on the electrical equipment of the robot must be performed by a qualified
electrician in accordance with electrical regulations.
Although troubleshooting may, on occasion, need to be carried out while the power
supply is turned on, the robot must be turned off (by setting the main switch to
OFF) when repairing faults, disconnecting electric leads, and disconnecting or
connecting units.
The main supply to the robot must be connected in such a way that it can be turned
off from outside the working space of the robot.
Make sure that no one else can turn on the power to the controller and robot while
you are working with the system. A good method is to always lock the main switch
on the controller cabinet with a safety lock.
The necessary protection for the electrical equipment and robot during installation,
commissioning, and maintenance is guaranteed if the valid regulations are followed.

Voltage related risks, IRC5 controller

A danger of high voltage is associated with, for example, the following parts:
• Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in
the controller.
• Units such as I/O modules, can be supplied with power from an external
source.
• The main supply/main switch
• The transformers
• The power unit
• The control power supply (230 VAC)
• The rectifier unit (262/400-480 VAC and 400/700 VDC. Note: capacitors!)
• The drive unit (400/700 VDC)
• The drive system power supply (230 VAC)
• The service outlets (115/230 VAC)
• The customer power supply (230 VAC)
• The power supply unit for additional tools, or special power supply units for
the machining process.
• The external voltage connected to the controller remains live even when the
robot is disconnected from the mains.
• Additional connections.

Voltage related risks, manipulator

A danger of low voltage is associated with the manipulator in:
• 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

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1 Safety
1.3.6 Risks associated with live electric parts
Continued

Voltage related risks, tools, material handling devices, etc.

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.

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 1 Safety
1.3.7 The unit is sensitive to ESD

1.3.7 The unit is sensitive to ESD

Description
ESD (electrostatic discharge) is the transfer of electrical static charge between two
bodies at different potentials, either through direct contact or through an induced
electrical field. When handling parts or their containers, personnel not grounded
may potentially transfer high static charges. This discharge may destroy sensitive
electronics.

Safe handling

Action Note
1 Use a wrist strap. The wrist strap Wrist straps must be tested frequently to ensure
button is located inside the control- that they are not damaged and are operating cor-
ler. rectly.
• Product manual - IRC5
• Product manual - IRC5 Panel Mounted
Controller
2 Use an ESD protective floor mat. The mat must be grounded through a current-limit-
ing resistor.
3 Use a dissipative table mat. The mat should provide a controlled discharge of
static voltages and must be grounded.

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1 Safety
1.3.8 Hot parts may cause burns

1.3.8 Hot parts may cause burns

Description
During normal operation, many parts become hot. Touching these may cause
burns.
There is also a risk of fire if flammable materials are put on hot surfaces.

Safe handling
Always use your hand, at some distance, to feel if heat is radiating from the
potentially hot component before actually touching it.
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.

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 1 Safety
1.3.9 Safety risks related to pneumatic/hydraulic systems

1.3.9 Safety risks related to pneumatic/hydraulic systems

General
Special safety regulations apply to pneumatic and hydraulic systems.

Note

All components that remain pressurized after separating the machine from the
power supply must be provided with clearly visible drain facilities and a warning
sign that indicates the need for pressure relief before adjustments or performing
any maintenance on the robot system.

Residual energy
Residual energy can be present in these systems. After shutdown, particular care
must be taken.
The pressure must be released in the complete pneumatic or hydraulic systems
before starting to repair them.
Work on hydraulic equipment may only be performed by persons with special
knowledge and experience of hydraulics.
All pipes, hoses, and connections have to be inspected regularly for leaks and
damage. Damage must be repaired immediately.
Splashed oil may cause injury or fire.

Safe design
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.

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1 Safety
1.3.10 Safety risks with pressure relief valve

1.3.10 Safety risks with pressure relief valve

Introduction
The pressure relief valve must be kept clean and open, for it to be able to function
properly.

Safety risks
The pressure relief valve is a vital part preventing too much air pressure being built
up inside the robot. If too much air pressure has been built up, there is a risk of
personal injury and mechanical damage.

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 1 Safety
1.3.11 Brake testing

1.3.11 Brake testing

When to test
During operation, the holding brake of each axis normally wears down. A test can
be performed to determine whether the brake can still perform its function.

How to test
The function of the holding brake of each axis motor may be verified as described
below:
1 Run each robot axis to a position where the combined weight of the robot
arm and any load is maximized (maximum static load).
2 Switch the motor to the MOTORS OFF.
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.

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1 Safety
1.3.12 Safety risks during handling of batteries

1.3.12 Safety risks during handling of batteries

Description
Under normal conditions of use, the electrode materials and liquid electrolyte in
the batteries are not exposed to the outside, provided the battery integrity is
maintained and seals remain intact.
There is a risk of exposure only in case of abuse (mechanical, thermal, electrical)
which leads to the activation of safety valves and/or the rupture of the battery
container. Electrolyte leakage, electrode materials reaction with moisture/water or
battery vent/explosion/fire may follow, depending upon the circumstances.

Note

Appropriate disposal regulations must be observed.

Safe handling
Use safety glasses when handling the batteries.
In the event of leakage, wear rubber gloves and chemical apron.
In the event of fire, use self-contained breathing apparatus.
Do not short circuit, recharge, puncture, incinerate, crush, immerse, force discharge
or expose to temperatures above the declared operating temperature range of the
product. Risk of fire or explosion.
Operating temperatures are listed in Pre-installation procedure on page 50.

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 1 Safety
1.3.13 Safety risks during work with gearbox lubricants (oil or grease)

1.3.13 Safety risks during work with gearbox lubricants (oil or grease)

Description
When handling gearbox lubricants, there is a risk of both personal injury and
product damage occurring. The following safety information must be regarded
before performing any work with lubricants in the gearboxes.

Note

When handling oil, grease, or other chemical substances the safety information
of the manufacturer must be observed.

Note

When aggressive media is handled, an appropriate skin protection must be

provided. Gloves and goggles are recommended.

Note

Appropriate disposal regulations must be observed.

Note

Take special care when handling hot lubricants.

Safe handling

Warning Description Elimination/Action

Changing and draining gearbox Make sure that protective gear
oil or grease may require hand- like goggles and gloves are al-
ling hot lubricant heated up to ways worn during this activity.
90 °C.
Hot oil or grease
When working with gearbox lub- Make sure that protective gear
ricant there is a risk of an allergic like goggles and gloves are al-
reaction. ways worn.

Allergic reaction
When opening the oil or grease Open the plug carefully and keep
plug, there may be pressure away from the opening. Do not
present in the gearbox, causing overfill the gearbox when filling.
lubricant to spray from the
opening.
Possible pressure
build-up in gearbox

Continues on next page

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1 Safety
1.3.13 Safety risks during work with gearbox lubricants (oil or grease)
Continued

Warning Description Elimination/Action

Overfilling of gearbox lubricant Make sure not to overfill the
can lead to internal over-pres- gearbox when filling it with oil or
sure inside the gearbox which in grease.
turn may: After filling, verify that the level
• damage seals and gas- is correct.
Do not overfill kets
• completely press out
seals and gaskets
• prevent the robot from
moving freely.
Mixing types of oil may cause When filling gearbox oil, do not
severe damage to the gearbox. mix different types of oil unless
specified in the instructions. Al-
ways use the type of oil specified
by the manufacturer.
Do not mix types of oil
Warm oil drains quicker than When changing gearbox oil, first
cold oil. run the robot for a time to heat
up the oil.

Heat up the oil

The specified amount of oil or After filling, verify that the level
grease is based on the total is correct.
volume of the gearbox. When
changing the lubricant, the
amount refilled may differ from
the specified amount, depending
Specified amount de- on how much has previously
pends on drained been drained from the gearbox.
volume
When draining the oil make sure
that as much oil as possible is
drained from the gearbox. The
reason for this is to drain as
much oil sludge and metal chips
as possible from the gearbox.
The magnetic oil plugs will take
Contaminated oil in care of any remaining metal
gear boxes chips.

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 1 Safety
1.4.1 Safety signals in the manual

1.4 Safety signals and symbols

1.4.1 Safety signals in the manual

Introduction to safety signals

This section specifies all safety signals used in the user manuals. Each signal
consists of:
• A caption specifying the danger level (DANGER, WARNING, or CAUTION)
and the type of danger.
• A brief description of what will happen if the the danger is not eliminated.
• Instruction about how to eliminate danger to simplify doing the work.

Danger levels
The table below defines the captions specifying the danger levels used throughout
this manual.
Symbol Designation Significance
DANGER Warns that an accident will occur if the instructions
are not followed, resulting in a serious or fatal injury
and/or severe damage to the product. It applies to
warnings that apply to danger with, for example,
contact with high voltage electrical units, explosion
or fire risk, risk of poisonous gases, risk of crushing,
impact, fall from height, and so on.
WARNING Warns that an accident may occur if the instructions
are not followed that can lead to serious injury, pos-
sibly fatal, and/or great damage to the product. It
applies to warnings that apply to danger with, for
example, contact with high voltage electrical units,
explosion or fire risk, risk of poisonous gases, risk
of crushing, impact, fall from height, etc.
ELECTRICAL Warns for electrical hazards which could result in
SHOCK severe personal injury or death.

CAUTION Warns that an accident may occur if the instructions

are not followed that can result in injury and/or
damage to the product. It also applies to warnings
of risks that include burns, eye injury, skin injury,
hearing damage, crushing or slipping, tripping, im-
pact, fall from height, etc. Furthermore, it applies to
warnings that include function requirements when
fitting and removing equipment where there is a risk
of damaging the product or causing a breakdown.
ELECTROSTATIC Warns for electrostatic hazards which could result
DISCHARGE (ESD) in severe damage to the product.

Continues on next page

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1 Safety
1.4.1 Safety signals in the manual
Continued

Symbol Designation Significance

NOTE Describes important facts and conditions.

TIP Describes where to find additional information or

how to do an operation in an easier way.

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 1 Safety
1.4.2 Safety symbols on product labels

1.4.2 Safety symbols on product labels

Introduction to labels
This section describes safety symbols used on labels (stickers) on the product.
Symbols are used in combinations on the labels, describing each specific warning.
The descriptions in this section are generic, the labels can contain additional
information such as values.

Note

The safety and health symbols on the labels on the product must be observed.
Additional safety information given by the system builder or integrator must also
be observed.

Types of labels
Both the manipulator and the controller are marked with several safety and
information labels, containing important information about the product. The
information is useful for all personnel handling the robot, for example during
installation, service, or operation.
The safety labels are language independent, they only use graphics. See Symbols
on safety labels on page 43.
The information labels can contain information in text (English, German, and
French).

Symbols on safety labels

Symbol Description
Warning!
Warns that an accident may occur if the instructions are not
followed that can lead to serious injury, possibly fatal, and/or
great damage to the product. It applies to warnings that apply
xx0900000812
to danger with, for example, contact with high voltage electrical
units, explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height, etc.
Caution!
Warns that an accident may occur if the instructions are not
followed that can result in injury and/or damage to the product.
It also applies to warnings of risks that include burns, eye injury,
skin injury, hearing damage, crushing or slipping, tripping, im-
xx0900000811 pact, fall from height, etc. Furthermore, it applies to warnings
that include function requirements when fitting and removing
equipment where there is a risk of damaging the product or
causing a breakdown.
Prohibition
Used in combinations with other symbols.

xx0900000839

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1 Safety
1.4.2 Safety symbols on product labels
Continued

Symbol Description
See user documentation
Read user documentation for details.
Which manual to read is defined by the symbol:
• No text: Product manual.
• EPS: Application manual - Electronic Position Switches.
xx0900000813

Before disassemble, see product manual

xx0900000816

Do not disassemble
Disassembling this part can cause injury.

xx0900000815

Extended rotation
This axis has extended rotation (working area) compared to
standard.

xx0900000814

Brake release
Pressing this button will release the brakes. This means that
the robot arm can fall down.
xx0900000808

Continues on next page

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 1 Safety
1.4.2 Safety symbols on product labels
Continued

Symbol Description
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

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1 Safety
1.4.2 Safety symbols on product labels
Continued

Symbol Description
Heat
Risk of heat that can cause burns. (Both signs are used)

xx0900000818

!
3HAC 4431-1/06

xx1300001087

Moving robot
4 6 The robot can move unexpectedly.
3 5

1
xx0900000819

xx1000001141

2 3

xx1500002616

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 1 Safety
1.4.2 Safety symbols on product labels
Continued

Symbol Description
Brake release buttons

xx0900000820

xx1000001140

Lifting bolt

xx0900000821

Chain sling with shortener

xx1000001242

Lifting of robot

xx0900000822

Oil
Can be used in combination with prohibition if oil is not allowed.

xx0900000823

Mechanical stop

xx0900000824

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1 Safety
1.4.2 Safety symbols on product labels
Continued

Symbol Description
No mechanical stop

xx1000001144

Stored energy
Warns that this part contains stored energy.
Used in combination with Do not disassemble symbol.

xx0900000825

Pressure
Warns that this part is pressurized. Usually contains additional
text with the pressure level.

xx0900000826

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

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 2 Installation and commissioning
2.1 Introduction

2 Installation and commissioning

2.1 Introduction

General
This chapter contains assembly instructions and information for installing the IRB
2600/IRB 2600 ID at the working site.
More detailed technical data can be found in the Product specification for the IRB
2600/IRB 2600 ID, such as:
• Load diagram
• Permitted extra loads (equipment), if any
• Location of extra loads (equipment), if any.

Safety information
Before any installation work is commenced, it is extremely important that all safety
information is observed.
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 19 before performing any installation
work.

Note

If the IRB 2600/IRB 2600 ID 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

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2 Installation and commissioning
2.2.1 Pre-installation procedure

2.2 Unpacking

2.2.1 Pre-installation procedure

Introduction
This section is intended for use when unpacking and installing the robot for the
first time. 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.

Checking the pre-requisites for installation

Action
1 Make a visual inspection of the packaging and make sure that nothing is damaged.
2 Remove the packaging.
3 Check for any visible transport damage.

Note

Stop unpacking and contact ABB if transport damages are found.

4 Clean the unit with a lint-free cloth, if necessary.

5 Make sure that the lifting accessory used (if required) is suitable to handle the weight
of the robot as specified in: Weight, robot on page 50
6 If the robot is not installed directly, it must be stored as described in: Storage condi-
tions, robot on page 53
7 Make sure that the expected operating environment of the robot conforms to the
specifications as described in: Operating conditions, robot on page 53
8 Before taking the robot to its installation site, make sure that the site conforms to:
• Loads on foundation, robot on page 51
• Protection classes, robot on page 53
• Requirements, foundation on page 52
9 Before moving the robot, please observe the stability of the robot: Risk of tipping/sta-
bility on page 59
10 When these prerequisites are met, the robot can be taken to its installation site as
described in section: On-site installation on page 60
11 Install required equipment, if any.
• Signal lamp (option) on page 101

Weight, robot
The table shows the weight of the robot.
Robot model Weight
IRB 2600/IRB 2600 ID 280 kg

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 2 Installation and commissioning
2.2.1 Pre-installation procedure
Continued

Note

The weight does not include tools and other equipment fitted on the robot.

Loads on foundation, robot

The illustration shows the directions of the robots stress forces.
The directions are valid for all floor mounted, suspended and inverted robots.

Txy

Fz

Fxy

Tz

xx1100000521

Fxy Force in any direction in the XY plane

Fz Force in the Z plane
Txy Bending torque in any direction in the XY plane
Tz Bending torque in the Z plane

The table shows the various forces and torques working on the robot during different
kinds of operation.

Note

These forces and torques are extreme values that are rarely encountered during
operation. The values also never reach their maximum at the same time!

WARNING

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 ±2330 N ±5450 N
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2 Installation and commissioning
2.2.1 Pre-installation procedure
Continued

Force Endurance load (in operation) Max. load (emergency stop)

Force z 2750 ±1420 N 2750 ±3970 N
Torque xy ±3360 Nm ±7690 Nm
Torque z ±1120 Nm ±3050 Nm

Wall mounted

Force Endurance load (in operation) Max. load (emergency stop)

Force xy 2750 ±880 N 2750 ±4600 N
Force z ±1780 N ±4560 N
Torque xy 1470 ±1990 Nm 1470 ±5620 Nm
Torque z ±1150 Nm ±3130 Nm

Suspended

Force Endurance load (in operation) Max. load (emergency stop)

Force xy ±2250 N i ±5380 N i
Force z -2750 ±1420 N i -2750 ±4280 N i
Torque xy ±3440 Nm i ±7800 Nm i
Torque z ±1110 Nm i ±3050 Nm i
i Only valid for IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB
2600ID-8/2.0.
IRB 2600 Type C-20/1.65, IRB 2600 Type C-12/1.65 is not available for suspended installation.

Requirements, foundation
The table shows the requirements for the foundation where the weight of the
installed robot is included:
Requirement Value Note
Flatness of foundation 0.5 mm Flat foundations give better repeatability of the
surface resolver calibration compared to original settings
on delivery from ABB.
The value for levelness aims at the circumstance
of the anchoring points in the robot base.
In order to compensate for an uneven surface,
the robot can be recalibrated during installation.
If resolver/encoder calibration is changed this
will influence the absolute accuracy.
Maximum tilt 15° The limit for the maximum payload on the robot
is reduced if the robot is tilted from 0°.
Contact ABB for further information about accept-
able loads.

Continues on next page

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 2 Installation and commissioning
2.2.1 Pre-installation procedure
Continued

Requirement Value Note

Minimum resonance 25 Hz The value is recommended for optimal perform-
frequency ance.
Note Due to foundation stiffness, consider robot mass
including equipment. i
It may affect the For information about compensating for founda-
manipulator life- tion flexibility, see Application manual - Control-
time to have a ler software IRC5, section Motion Process Mode.
lower resonance
frequency than
recommended.

i The minimum resonance frequency given should be interpreted as the frequency of the robot
mass/inertia, robot assumed stiff, when a foundation translational/torsional elasticity is added, i.e.,
the stiffness of the pedestal where the robot is mounted. The minimum resonance frequency should
not be interpreted as the resonance frequency of the building, floor etc. For example, if the equivalent
mass of the floor is very high, it will not affect robot movement, even if the frequency is well below
the stated 25 Hz. The robot should be mounted as rigid as possibly to the floor.
Disturbances from other machinery will affect the robot and the tool accuracy. The robot has
resonance frequencies in the region 10 – 20 Hz and disturbances in this region will be amplified,
although somewhat damped by the servo control. This might be a problem, depending on the
requirements from the applications. If this is a problem, the robot needs to be isolated from the
environment.

Storage conditions, robot

The table shows the allowed storage conditions for the robot:
Parameter Value
Minimum ambient temperature -25° C
Maximum ambient temperature +55° C
Maximum ambient temperature (less than 24 hrs) +70° C
Maximum ambient humidity 95% at constant temperature
(gaseous only)

Operating conditions, robot

The table shows the allowed operating conditions for the robot:
Parameter Value
Minimum ambient temperature +5°C
Maximum ambient temperature +45°C
Maximum ambient humidity 95% at constant temperature

Protection classes, robot

The table shows the available protection types of the robot, with the corresponding
protection class.
Protection type Protection class
Manipulator, protection type Standard IRB 2600: IP 67
IRB 2600ID upper arm: IP 54
Manipulator, protection type Foundry Plus IP 67

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2 Installation and commissioning
2.2.2 Working range and type of motion

2.2.2 Working range and type of motion

Working range
The figures show the working ranges of the robot variants mounted in different
ways.
The extreme positions of the robot arm are specified at the wrist center (dimensions
in mm).

Working range, floor mounted

The illustration shows the unrestricted working range for a floor mounted robot.
IRB 2600 Standard

xx0900000194

Variant Pos. A Pos. B Pos. C Pos. D Pos. E Pos. F

IRB 2600-20/1.65 1948 mm 993 mm 837 mm 469 mm 1353 mm 1653 mm
IRB 2600-12/1.65
IRB 2600 Type C-20/1.65
IRB 2600 Type C-12/1.65
IRB 2600-12/1.85 2148 mm 1174 mm 967 mm 506 mm 1553 mm 1853 mm

Continues on next page

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 2 Installation and commissioning
2.2.2 Working range and type of motion
Continued

IRB 2600ID

xx1000000300

Variant Pos. A Pos. B Pos. C Pos. D Pos. E Pos. F

IRB 2600ID-15/1.85 2145 mm 1171 mm 936 mm 542 mm 1550 mm 1850 mm
IRB 2600ID-8/2.00 2295 mm 1321 mm 1051 mm 539 mm 1700 mm 2000 mm

Continues on next page

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2.2.2 Working range and type of motion
Continued

Working range, suspended mounted

The illustration shows the unrestricted working range for a suspended mounted
robot.

xx0900000195

Variant Pos. A Pos. B Pos. C Pos. D Pos. E Pos. F

IRB 2600 - 20/1.65 1948 mm 993 mm 837 mm 469 mm 1353 mm 1653 mm
IRB 2600 - 12/1.65 1948 mm 993 mm 837 mm 469 mm 1353 mm 1653 mm
IRB 2600 - 12/1.85 2148 mm 1174 mm 967 mm 506 mm 1553 mm 1853 mm

Continues on next page

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 2 Installation and commissioning
2.2.2 Working range and type of motion
Continued

xx1000000986

Variant Pos. A Pos. B Pos. C Pos. D Pos. E Pos. F

IRB 2600ID-15/1.85 2145 mm 1171 mm 936 mm 542 mm 1550 mm 1850 mm
IRB 2600ID-8/2.00 2295 mm 1321 mm 1051 mm 539 mm 1700 mm 2000 mm

Continues on next page

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2 Installation and commissioning
2.2.2 Working range and type of motion
Continued

Turning radius
The turning radius of the robot that is floor or suspended mounted is shown in the
figure.

xx0900000199

Variant Pos. A Pos. B

IRB 2600-20/1.65 R1653 R469
IRB 2600-12/1.65
IRB 2600 Type C-20/1.65
IRB 2600 Type C-12/1.65
IRB 2600-12/1.85 R1853 R506
IRB 2600ID-15/1.85 R1850 R542
IRB 2600ID-8/2.00 R2000 R539

Robot motion,
The table specifies the types and ranges of motion in every axes.
Location of motion Type of motion Range of movement
Axis 1 Rotation motion ±180°
Axis 2 Arm motion +155° / -95°
Axis 3 Arm motion +75° / -180°
Axis 4 (IRB 2600 standard) Wrist motion ±400°
Axis 4 (IRB 2600ID) Wrist motion ±175°
Axis 5 Bend motion ±120°
Axis 6 Turn motion ±400°

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 2 Installation and commissioning
2.2.3 Risk of tipping/stability

2.2.3 Risk of tipping/stability

Risk of tipping
If the robot is not fastened to the foundation while moving the arm, the robot is not
stable in the whole working area. Moving the arm will displace the center of gravity,
which may cause the robot to tip over.
The shipping position is the most stable position.
Do not change the robot position before securing it to the foundation!

Shipping and transportation position

This figure shows the robot in its shipping position and transportation position.
The figure shows IRB 2600 but is also valid for IRB 2600ID. Best position of IRB
2600ID axis 4 is ±90°.
The position where part of the lower arm (A) is beginning to show in the hole, is
approximate.

0°

45
°

A
15
°

xx0900000211

WARNING

The robot is likely to be mechanically unstable if not secured to the foundation.

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2 Installation and commissioning
2.3.1 Lifting robot with roundslings

2.3 On-site installation

2.3.1 Lifting robot with roundslings

Introduction
When lifting the robot use roundslings and an overhead crane.

Required equipment

Equipment Note
Overhead crane Lifting capacity 1 000 kg (Max load at 90°)
Roundslings (2 pcs) • Lifting capacity/roundsling: 1 000 kg
• Lengths: 2 m, 1.5 m

Lifting
Attach the roundslings as shown in the figure.

45°

B
A
1000

°
15

xx0900000236

A Roundsling, length 2 m (put folded in U-shape around the upper arm)

B Roundsling, length 1.5 m (put folded in U-shape around gearbox axis 3)
C Lifting lug

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 2 Installation and commissioning
2.3.1 Lifting robot with roundslings
Continued

Lifting instructions
Use this procedure to lift the robot in a safe way.
Action Note
1
CAUTION

The IRB 2600/IRB 2600 ID robot weighs 280

kg.
All lifting accessories used must be sized ac-
cordingly!

2
CAUTION

Attempting to lift the robot in any other posi-

tion than that recommended may result in the
robot tipping over and causing severe damage
or injury!

3
WARNING

Personnel must not, under any circumstances,

be present under the suspended load!

4 Move the robot to its most stable position. Detailed in section:

For robot versions IRB 2600ID: The best pos- • Risk of tipping/stability on
ition of axis 4 is ±90°. page 59

5
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

6 Attach roundsling A to the lifting lug on the See the figure in:
frame, and put folded in a U-shape on either • Lifting on page 60
side of the upper arm.
7 Attach roundsling B at axis 3 gearbox by run- See the figure in:
ning it folded in a U-shape around the gear- • Lifting on page 60
box.
8 Make sure the roundslings do not rub against
any sharp edges.

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2 Installation and commissioning
2.3.1 Lifting robot with roundslings
Continued

Action Note
9 When the robot is lifted the roundslings will
adjust themselves.

CAUTION

When lifting, the robot will tilt slightly back-

wards! Be careful not to damage the connec-
tion box at the base of the robot!

xx0800000291

• A: Area where the connection

box can be damaged while lifting.
10 Lift the robot with an overhead crane. Lifting capacity:
• See Required equipment on
page 60

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 2 Installation and commissioning
2.3.2 Lifting and turning a suspended mounted robot

2.3.2 Lifting and turning a suspended mounted robot

Validity of this section

This section is only valid for IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85,
IRB 2600ID-15/1.85, IRB 2600ID-8/2.0.

Introduction
How to lift and turn the robot to a suspended position using the turning accessory
is described in the lifting instruction delivered with the turning accessory. Article
numbers for the accessory and the instruction is specified in Special tools on
page 442. Any additional equipment required is specified in the instruction for the
lifting accessory. Contact ABB for more information.
How to lift and turn the robot into position for wall position: Contact ABB for more
information.
How to lift and turn the robot into position for tilted position: Contact ABB for more
information.

Illustration

xx1500002117

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2 Installation and commissioning
2.3.3 Setting the system parameters for a suspended or tilted robot

2.3.3 Setting the system parameters for a suspended or tilted robot

General
The robot is configured for mounting parallel to the floor, without tilting, on delivery.
The method for mounting the robot in a suspended (upside down) or tilted position
is basically the same as for floor mounting, but the system parameters that describe
the mounting angle (how the robot is oriented relative to the gravity) must be
re-defined.

Note

IRB 2600 Type C-20/1.65, IRB 2600 Type C-12/1.65 is not available for suspended
installation.

Note

With suspended installation, make sure that the gantry or corresponding structure
is rigid enough to prevent unacceptable vibrations and deflections, so that
optimum performance can be achieved.

Note

The allowed mounting positions are described in the product specification for
the robot. The requirements on the foundation are described in Requirements,
foundation on page 52.

System parameters

Note

The mounting angle must be configured correctly in the system parameters so

that the robot system can control the movements in the best possible way. An
incorrect definition of the mounting angle will result in:
• Overloading the mechanical structure.
• Lower path performance and path accuracy.
• Some functions will not work properly, for example Load Identification and
Collision detection.

Gravity Beta
If the robot is mounted upside down or on a wall (rotated around the y-axis), then
the robot base frame and the system parameter Gravity Beta must be redefined.
Gravity Beta should then be π (+3.141593) if the robot is mounted upside down
(suspended), or ±π/2 (±1.570796) if mounted on a wall.
The Gravity Beta is a positive rotation direction around the y-axis in the base
coordinate system. The value is set in radians.

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2.3.3 Setting the system parameters for a suspended or tilted robot
Continued

Gravity Alpha
If the robot is mounted on a wall (rotated around the x-axis), then the robot base
frame and the system parameter Gravity Alpha must be redefined. The value of
Gravity Alpha should then be ±π/2 (±1.570796).
The Gravity Alpha is a positive rotation direction around the x-axis in the base
coordinate system. The value is set in radians.

Note

The system parameter Gravity Alpha is not supported for all robot types. It is not
supported for IRB 140, IRB 1410, IRB 1600ID, IRB 2400, IRB 4400, IRB 6400R,
IRB 6400 (except for IRB 6400 200/2.5 and IRB 6400 200/2.8), IRB 6600, IRB
6650, IRB 6650S and IRB 7600 (except for IRB 7600 325/3.1).
If the robot does not support Gravity Alpha, then use Gravity Beta along with the
recalibration of axis 1 to define the rotation of the robot around the x-axis.

Note

The parameter is supported for all robots on track when the system parameter
7 axes high performance motion is set, see Technical reference manual - System
parameters.

Gamma Rotation
Gamma Rotation defines the orientation of the robot foot on the travel carriage
(track motion).

Mounting angles and values

The parameter Gravity Beta (or Gravity Alpha) specifies the mounting angle of the
robot in radians. It is calculated in the following way.
Gravity Beta = A° x 3.141593/180 = B radians, where A is the mounting
angle in degrees and B is the mounting angle in radians.

Example of position Mounting angle (A°) Gravity Beta

Floor mounted 0° 0.000000 (Default)
Tilted mounting 15° 0.261799
Wall mounting 90° 1.570796
Suspended mounting 180° 3.141593

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2.3.3 Setting the system parameters for a suspended or tilted robot
Continued

Examples of mounting angles tilted around the X axis (Gravity Alpha)

The following illustration shows the IRB 120, but the same principle applies for all
robots.

xx1500000532

Pos Mounting angle Gravity Alpha

1 0° (Floor mounted) 0
2 45° (Tilted) 0.785398
3 90° (Wall) 1.570796
4 -90° (Wall) -1.570796

Note

For suspended robots (180°), it is recommended to use Gravity Beta instead of

Gravity Alpha.

Continues on next page

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2.3.3 Setting the system parameters for a suspended or tilted robot
Continued

Defining the parameter in the IRC5 software

The value of the system parameters that define the mounting angle must be
redefined when changing the mounting angle of the robot. The parameters belong
to the type Robot, in the topic Motion.
How to calculate a new value is detailed in Mounting angles and values on page 65.
The system parameters are described in Technical reference manual - System
parameters.
The system parameters are redefined in the Configuration Editor, in RobotStudio
or on the FlexPendant.

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2 Installation and commissioning
2.3.4 Manually releasing the brakes

2.3.4 Manually releasing the brakes

General
The section below describes how to release the holding brakes of each axis' motor.
This can be done in one of three ways:
• using the push-button when the robot is connected to the controller.
• using the push-button on the robot with an external power supply.
• using an external voltage supply directly on the respective brake.

DANGER

When releasing the holding brakes with push-buttons, the robot must be properly
attached!

DANGER

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 arm!

Using the push-button when the robot is connected to the controller

This procedure details how to release the holding brakes with push-buttons, when
the robot is connected to the controller.
Action Note
1 The internal brake release unit is located
at the base of the robot.

xx0800000272

2 The brake release unit is equipped with

six buttons for controlling the axes brakes.
The buttons are numbered according to
the numbers of the axes.
3 Release the holding brake on a particular
axis by pressing the corresponding button
on the push-button unit and keeping it
depressed.
4 The brake will function again as soon as
the button is released.

Continues on next page

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2.3.4 Manually releasing the brakes
Continued

Using the push-button on the robot with an external power supply

This procedure details how to release the holding brakes with the push-buttons,
when the robot is not connected to the controller.
Action Note
1 Connect an external 24VDC power supply to
the connector R1.MP on the robot base.

Note

Be careful not to interchange the 24V and 0V

pins!
If they are mixed up, damage can be caused
to the brake release unit and the system
board!

WARNING

Incorrect connections can cause all brakes

to be released simultaneously!

xx0800000269

Connect to connector R1.MP:

• 0V to pin 12
• +24V to pin 11
2 Release the holding brake on a particular The brake release unit is equipped with
axis by pressing the corresponding button six buttons for controlling the axes
on the push-button unit and keeping it de- brakes. The buttons are numbered accord-
pressed. ing to the numbers of the axes.
See the previous figure.
3 The brake will function again as soon as the
button is released.

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2.3.4 Manually releasing the brakes
Continued

Using an external voltage supply directly on the respective brake

This procedure details how to release the holding brake of a specific axis by
supplying external voltage directly on the brake.
Action Note
1 Every axis has a holding brake built into the Make the connection to the current motor
axis motor. This holding brake may be re- according to the Circuit Diagram.
leased by connecting 24VDC power supply See chapter Circuit diagram on page 447.
directly to one of the connectors in the motor.

DANGER

When power is connected directly to the

brake cable, the brake will be released imme-
diately when the power is switched on.
This may cause some unexpected robot
movements!

2 Connect an external 24 VDC power supply Axes 1, 2 and 3:

to the motor, according to the figures. Pos 2: +24 V
Note

Be careful not to interchange the 24V and 0V

pins!
If they are mixed up, damage can be caused Pos 5: 0 V
to the intergrated quenching circuits.

WARNING

Incorrect connections can cause all brakes

to be released simultaneously! xx1400001984

Axes 4, 5 and 6:
Pos 6: 0 V Pos 4: +24 V

xx1400001985

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 2 Installation and commissioning
2.3.5 Orienting and securing the robot

2.3.5 Orienting and securing the robot

Introduction
This section describes how to orient and secure the robot to the foundation or base
plate in order to run the robot safely. The requirements made on the foundation
are shown in sections Loads on foundation, robot on page 51 and Requirements,
foundation on page 52.

Hole configuration, base

The illustration shows the hole configuration used when securing the robot.

xx0900000193

A Center axis 1

Note

Only the three outer holes are used to secure the robot!

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2.3.5 Orienting and securing the robot
Continued

Dimension, mounting surface and guide bushing

The figure shows the dimension of the mounting surface and guide bushings.

E F
Ø60
Ø0.5 AB
C C (3 2.5 25
X1
20 2x 1x45º

Ø 35 -0.025 f7
º) (A)

-0.050
Ø22
1.6
Ø 500

A B B
A

0.5 (C)

Ø35 +0.024 J8
1

-0.015
216.5 2x Ø 90 R
B
(433±0.5)
G 433 ±0.5
G (D)

Ø35 +0.024 J8
-0.015
A (37)
1.6
1x45º
10 10
20 min 20 min 30 min

M16 M16 M16

A-A B-B C-C

xx1700001492

(C) 3x common zone

E Position of the front of the robot
F M16 (3 pcs)
G Guide bushings (2 pcs)

Specification, attachment screws

The table specifies the type of securing screws and washers to be used to secure
the robot to the foundation or base plate.
Securing parts/Facts Dimension Note
Securing screws, oiled M16 x 60 3 pcs
Quality 8.8 200 Nm
Washers 17 x 30 x 3 3 pcs

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2.3.5 Orienting and securing the robot
Continued

Securing parts/Facts Dimension Note

Guide bushings Article number: 21510024-
169.
Added to the rear bolt holes,
to allow the same robot to be
re-mounted without program
adjustments.

xx1200000885

Level surface requirements

xx0300000251

Orienting and securing the robot

Use this procedure to orient and secure the robot.
Action Note
1 Make sure the installation site for the robot
conforms to the specifications in section Pre-
installation procedure on page 50.
2 Prepare the installation site with attachment Hole configuration of the base is shown
holes. in the figure in:
• Hole configuration, base on
page 71
3
CAUTION

The IRB 2600/IRB 2600 ID robot weighs 280

kg.
All lifting accessories used must be sized
accordingly!

4
CAUTION

When the robot is put down after being lifted

or transported, there is a risk of it tipping, if
not properly secured.

5 Lift the robot to its installation site. How to lift the robot is described in sec-
tion:
• Lifting robot with roundslings on
page 60
6 Fit two guide bushings to the rear bolts in the
base.
7 Guide the robot gently, using the attachment Make sure the robot base is correctly fit-
screws while lowering it into its mounting ted onto the guide sleeves.
position.

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2 Installation and commissioning
2.3.5 Orienting and securing the robot
Continued

Action Note
8 Fit the securing screws and washers in the
attachment holes of the base.
9 Tighten the bolts in a criss-cross pattern to
ensure that the base is not distorted.

Isolating AW manipulator

CAUTION

If the manipulator is used for arc welding and is mounted on a pedestal, make
sure that the manipulator is isolated from the pedestal with isolators.

xx1400000831

A Attachment point, front (no guide sleeve)

B Manipulator base
C Screw M16x120
D Plain washer
E Guide sleeve
F Isolator
G Nut M16

Securing robot on a mounting plate

When bolting a mounting plate or frame to a concrete floor, follow the general
instructions for expansion-shell bolts.
Screw joints must be able to withstand the stress loads defined in section Loads
on foundation, robot on page 51.

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 2 Installation and commissioning
2.3.6 Fitting equipment on robot

2.3.6 Fitting equipment on robot

Introduction
The robot features mounting holes for additional equipment.
Access to any of the following mounting holes may be obstructed by any additional
cabling, equipment, etc., fitted by the robot user. Make sure the required mounting
holes are accessible when planning the robot cell.

Note

All equipment and cables used on the robot, must be designed and fitted not to
damage the robot and/or its parts.

Note

Never drill a hole in the robot without first consulting ABB!

Robot dimensions
Dimensions IRB 2600-20(12)/1.65, IRB 2600 Type C-20(12)/1.65
1019
323
238,4 190,6 795 85
115
700
1382

445

255,7 255,7 CL Axis 1 150

291 A
275
C
676

B
A

xx0900000481

Pos Description
A R 337 Minimum turning radius of axis 1
B R 98 Minimum turning radius of axis 4

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2.3.6 Fitting equipment on robot
Continued

Pos Description
C IRB 2600ID = 281 mm
Other types than Type A (IRB 2600ID) = 276 mm

Dimensions IRB 2600-12/1.85

xx0900000680

Pos Description
B For all other dimensions see IRB 2600-20(12)/1.65

Continues on next page

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2.3.6 Fitting equipment on robot
Continued

Dimensions IRB 2600ID-15/1.85

xx1000000962

Pos Description
A For dimensions, see IRB 2600-X/1.85
B R 172 Minimum turning radius for axis 4

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2.3.6 Fitting equipment on robot
Continued

Dimensions IRB 2600ID-8/2.00

xx1000000963

Pos Description
A For dimensions, see IRB 2600-X/1.85
B R 172 Minimum turning radius for axis 4

Continues on next page

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2.3.6 Fitting equipment on robot
Continued

Fitting equipment on robot - Load areas

The shaded area indicates the permitted positions (center of gravity) for any extra
equipment fitted in the holes intended for this purpose.
IRB 2600 standard
B
200 180 240 120 200

300
300

250
280 360
A

260
260

C
IRB 2600 -1.65 = 700
IRB 2600 -1.85 = 900

200

380
xx0900000189

Variant Max load A Max load B Max load C Max load Max load D
A+C
IRB 2600-20/1.65 10 kg 1 kg 10 kg 10 kg 35 kg
IRB 2600 Type C-
20/1.65
IRB 2600-12/1.85
IRB 2600-12/1.65 15 kg 1 kg 15 kg 15 kg 35 kg
IRB 2600 Type C-
12/1.65

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2.3.6 Fitting equipment on robot
Continued

IRB 2600ID

xx1000000319

Variant Max load A Max load B Max load C Max load Max load D
A+C
IRB 2600ID-15/1.85 10 kg 1 kg 10 kg 10 kg 35 kg
IRB 2600ID-8/2.00 15 kg 1 kg 15 kg 15 kg 35 kg

Note

Maximum loads must never be exceeded!

Continues on next page

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2.3.6 Fitting equipment on robot
Continued

Fitting equipment on base and frame

The illustrations show the fitting holes available for fitting extra equipment on the
base and frame of the robot.
IRB 2600 Standard & ID.

xx0900000227

A Attachment holes on base

B Center axis 2

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2.3.6 Fitting equipment on robot
Continued

Fitting equipment on lower and upper arm

The illustrations show the fitting holes available for fitting extra equipment on the
lower and upper arms of the robot.

IRB 2600 standard

xx0900000234

A Center axis 4
B Center axis 3

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2.3.6 Fitting equipment on robot
Continued

IRB 2600ID

xx1000000707

A Hole through axis 4, diameter 50

B Center axis 3
C 2x M8 through

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2.3.6 Fitting equipment on robot
Continued

Lower arm of IRB 2600 -12/1.85, IRB 2600ID -15/1.85 and -8/2.00

445

xx0900000492

- The uppermost holes for fitting equipment on the lower arm are only applicable
to variant IRB 2600 -12/1.85.

Lower arm of IRB 2600 -20/1.65 and -12/1.65, IRB 2600 Type C-20(12)/1.65
445

xx0900000491

Continues on next page

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2.3.6 Fitting equipment on robot
Continued

Upper arm

xx1000000823

A Holes on top of upper arm, 2 pcs

B Holes on other side (symmetrical to A), 2 pcs

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2.3.6 Fitting equipment on robot
Continued

Fitting equipment on wrist and mounting flange IRB 2600/IRB 2600 ID.
The illustration shows the fitting holes available for fitting extra equipment on the
wrist of the robot.
The illustration also shows the mechanical interface for the mounting flange.
IRB 2600 standard

110
6 H7 8

12,5
D
0,05 B C
30°

25
P

50
P-P

60°
2x M6 12 10
C
B
79 (2x M6)

6x M6

63 h8
31,5H8
0,3 B C D
P
7

A = R98

xx0800000278

A Smallest circumscribed radius axis 4

Note

Use attachment screws M6, quality 12.9 and 10 mm used thread length.

Continues on next page

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2.3.6 Fitting equipment on robot
Continued

IRB 2600ID

xx1000000822

A Smallest circumscribed radius axis 5

B Hole through axis 6, diameter 50 mm
C See table below!

Variant C mm
IRB 2600ID-15/1.85 135
IRB 2600ID-8/2.00 200

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2 Installation and commissioning
2.3.7 Loads fitted to the robot, stopping time and braking distances

2.3.7 Loads fitted to the robot, stopping time and braking distances

General
Any loads mounted on the robot must be defined correctly and carefully (with
regard to the position of center of gravity and mass moments of inertia) in order
to avoid jolting movements and overloading motors, gears and structure.

CAUTION

Incorrectly defined loads may result in operational stops or major damage to the
robot.

References
Load diagrams, permitted extra loads (equipment) and their positions are specified
in the product specification. The loads must be defined in the software.
• Operating manual - IRC5 with FlexPendant

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.

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 2 Installation and commissioning
2.4.1 Axes with restricted working range

2.4 Restricting the working range

2.4.1 Axes with restricted working range

General
When installing the robot, make sure that it can move freely within its entire working
space. If there is a risk that it may collide with other objects, its working space
should be limited.
The working range of the following axes may be restricted:
• Axis 1, hardware (mechanical stop) and software
• Axis 2, software
• Axis 3, software.
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.

WARNING

Remove the mechancial stop bracket if the robots full working range is from a
mechanical stop to another mechanical stop. Otherwise the mechanical stop pin
will be worn out.

xx1500000253

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2 Installation and commissioning
2.4.2 Mechanically restricting the working range of axis 1

2.4.2 Mechanically restricting the working range of axis 1

Mechanically restricting the working range

The information in this section is valid both for the floor and the suspended mounted
robot.
The working range of axis 1 is limited by fixed mechanical stops. The working
range can be reduced further by adding movable mechanical stops.
The mechanical turning range can be limited in steps of 22.5° from the
synchronization position, between values defined in the table. The values differ
depending on which design of the gearbox (and base) the robot is equipped with.
Robot variant Limitation in mechanical turning range, calculated
from synchronization position
IRB 2600 Type C-20/1.65, IRB 2600 ±126° to ±13.5° in steps of 22.5°
Type C-12/1.65
IRB 2600-20/1.65, IRB 2600-12/1.65, ±129° to ±16.5° in steps of 22.5°
IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0

Note

The software working range limitations must be adjusted to correspond to the

changes in the mechanical limitations of the working range. The system
parameters that must be changed (Upper joint bound and Lower joint bound)
are described in Technical reference manual - System parameters.

Required equipment

Equipment, etc. Art. no. Note

Mechanical stop, axis 1 See Spare part Includes two additional stop lugs, attachment
lists on page 445. screws, washers and instruction
Attachment screw See Spare part 2 pcs/stop lug
lists on page 445. Hex socket head cap screw M12x40, quality
8.8-A3F
Washer See Spare part 2 pcs/lug
lists on page 445. 13x24x2.5

Standard toolkit Content is defined in section Standard tools

on page 441.
Other tools and procedures These procedures include references to the
may be required. See refer- tools required.
ences to these procedures
in the step-by-step instruc-
tions below.

Continues on next page

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2.4.2 Mechanically restricting the working range of axis 1
Continued

Additional stops
The additional stops are fitted as shown in the figure.

D, E
xx0800000273

A Movable mechanical stop. Limited to:

• -126° (IRB 2600 Type C-20/1.65, IRB 2600 Type C-12/1.65)
• -129° (IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0)
B Movable mechanical stop. Limited to:
• +13.5° (IRB 2600 Type C-20/1.65, IRB 2600 Type C-12/1.65)
• +16.5° (IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0)
C Movable mechanical stop. Limited to:
• -13.5° (IRB 2600 Type C-20/1.65, IRB 2600 Type C-12/1.65)
• -16.5° (IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0)
D Attachment screws
E Washers

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2 Installation and commissioning
2.4.2 Mechanically restricting the working range of axis 1
Continued

Fitting, mechanical stop axis 1

How to fit the additional mechanical stop to the base is described in the procedure.
Mounting instructions are also supplied with the kit.
Action Note
1 Determine the position of the stop lugs. See the figure Additional stops on
page 91 for guidance.
2 Fit the stop lugs firmly with attachment Specified in Required equipment on
screws and washers according to the figure page 90.
Additional stops on page 91. Tightening torque: 82 Nm

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 2 Installation and commissioning
2.5.1 Installation of cooling fan for motors (option)

2.5 Installing options

2.5.1 Installation of cooling fan for motors (option)

General
A cooling fan can be installed on motor axis 1 and/or axis 2!

Location of cooling fans

The fans are installed on the motors, axes 1 or 2, as shown in the figure below.

xx0900000232

A Fan, motor axis 1

B Fan, motor axis 2
C Protection cover

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2.5.1 Installation of cooling fan for motors (option)
Continued

Cooling fan
The details of the cooling fan are shown in the figure below.

xx0900000137

A Fanbox
B Groove in the connector
C Back plate
D Part of the fanbox that can be removed, if needed. NOTE! Only valid on motor
axis 1!

Required equipment

Equipment Article number Note

Cooling fans axes 1 and 2 - For Spare part no. see chapter Spare
parts:
• Spare part lists on page 445
Locking liquid - Loctite 243. Used for the three tightening
screws.
Standard toolkit - Content is defined in section Standard
tools on page 441.
Circuit diagram - See chapter Circuit diagram on page 447.
Other tools and procedures These procedures include references to
may be required. See refer- the tools required.
ences to these procedures
in the step-by-step instruc-
tions below.

Continues on next page

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2.5.1 Installation of cooling fan for motors (option)
Continued

Installation, fan on motor axis 1 and 2

Use this procedure to install the cooling fan on motor axis 1 and 2.
Action Note
1
DANGER

Turn off all:

• electric power supply to the robot
• hydraulic pressure supply to the robot
• air pressure supply to the robot
Before entering the robot working area.

2 Remove the back plate of the fanbox. See the figure in:
• Cooling fan on page 94
3 Place the fanbox around motor axis 1 and 2. See the figure in:
• Cooling fan on page 94
4 Refit the back plate of the fanbox.
5 See the figure in:
Tip • Cooling fan on page 94

Only applicable to fan fitted on axis 1!

If there is a lack of space between motor and
robot, it is possible to remove part of the fanbox.

6 Push the fanbox in line with the connection box. Align the upper part of the fan with the
lower part of the connection box.
A B C

xx1000000124

Parts:
• A: Connection box
• B: Position where the fan shall
be aligned with connection box
• C: Fan
7 Fit the fanbox with two attachment screws
M6x25.

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2.5.1 Installation of cooling fan for motors (option)
Continued

Action Note
8 Connect the fan connector to motor and fan.

xx0900000405

Parts:
• A: Connector, signal
• B: Connector, power
• C: Fan cable
• D: Connector, fan
• E: Cable gland
• F: Motor cover, with fan cable
9 After fitting the motor cover, fit the protection A
cover using two attachment screws for the
motor cover.

xx0900000406

Parts:
• A: Protection cover
• B: Fan
10 Secure the fan cable to the protection cover
with a cable strap.

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 2 Installation and commissioning
2.5.2 Installing an expansion container

2.5.2 Installing an expansion container

Validity of this section

This section is only valid for IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85,
IRB 2600ID-15/1.85, IRB 2600ID-8/2.0.

Introduction to the expansion container

The expansion container is needed on suspended robots (IRB 2600-20/1.65, IRB
2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB 2600ID-8/2.0) to make
sure that the amount of oil in gearbox axis 1 covers all important parts. Robots
ordered as suspended robots have the expansion container installed on delivery.

Expansion container

xx1000000318

A Cover
B Attachment screw M6x16, quality 8.8-A2F (5 pcs)
C Oil expansion container with cover
D Base
E O-ring D220x5
F Attachment screw M5x20, quality 8.8-A2F and washer (2+2 pcs)
G O-ring D1=9.5 D2=1.6
H Oil plug (to be removed)

Continues on next page

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2.5.2 Installing an expansion container
Continued

Required equipment

Equipment Note
Expansion container Kit including oil.
Lifting accessory 3HAC034766-001
Lifting instruction Included with the lifting accessory.
Grease -
O-ring for base cover Replace if damaged.

Installing an expansion container

Use this procedure to install the expansion container.
Action Information
1 Lift the robot using the lifting accessory and See Lifting and turning a suspended
place it in suspended position with the base mounted robot on page 63.
free for installation work.
2 Remove the cover and the o-ring from the
base.
3 Remove the two existing attachment screws.

xx1500001958

The screws must be replaced with longer

screws.
4 Remove the oil plug from the base.
5 Apply some grease on the small o-ring and
place it in the recess on the expansion con-
tainer.
6 Fit a plastic plug in the oil drain hole.

xx1500001956

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2.5.2 Installing an expansion container
Continued

Action Information
7 Fill oil in expansion container, and press
down the VK-cover. Secure with three screws
and washers.

xx1500001957

8 Place the expansion container in the base

and place it so the drain holes match.
9 Secure the expansion container with the at-
tachment screws and washers.

xx1500001959

Tightening torque 6 Nm.

10 Check the o-ring used on the cover. Replace
it if damaged.
11 Refit the cover on the base with its attach-
ment screws.
12 Turn the robot so it is not suspended.
13 Turn the robot to suspended position.
14 Inspect the oil level. See procedure for suspended robot, In-
specting oil level, axis-1 gearbox on
page 119.

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2 Installation and commissioning
2.5.3 Installation of Foundry Plus Cable guard (option no. 908-1)

2.5.3 Installation of Foundry Plus Cable guard (option no. 908-1)

Introduction
Separate instructions for IRB 2600, 4600, 6620, 6640, 6650S, 6660 and 7600 are
available in English, German, French, Spanish and Italian and can be found on the
DVD delivered with the Cable guard, article number 3HAC035933-001.

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 2 Installation and commissioning
2.5.4 Signal lamp (option)

2.5.4 Signal lamp (option)

Description
A signal lamp with a yellow fixed light can be mounted on the robot, as a safety
device.

Installation
See the assembly instruction delivered with the signal lamp.

Function
The lamp is active in MOTORS ON mode.

Further information
Further information about the MOTORS ON/MOTORS OFF mode may be found in
the product manual for the controller.

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2 Installation and commissioning
2.6.1 Start of robot in hot environments

2.6 Robot in hot environments

2.6.1 Start of robot in hot environments

Introduction
This procedure describes how to start the robot in a hot environment. This
procedure must be performed the first time the robot is started in a hot environment
or if it has not been used for some time in a hot environment.
There is a possibility that some overpressure has been built up in the system. This
overpressure must be released before starting up the robot.

Releasing overpressure in gearboxes

Use this procedure before the start of the robot in a hot environment to release
potential overpressure being built up in gearboxes.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot work-
ing area.

2
CAUTION

Before approaching the potentially hot robot

component, observe the safety information
in section Hot parts may cause burns on
page 34.

3
Note

Before opening the oil plug, make certain that

the oil plug is above the oil level. Place the
robot accordingly.

4 Open oil plug filling very carefully!

Tip
Note
Hold a cloth or some paper over the oil
Open the oil plug just enough for the overpres- plug while opening it to prevent surplus
sure to be released. oil causing burns or other injuries.

5 Let the overpressure leave the gearbox.

6 Refit the oil plug.
7 Continue releasing the overpressure on all
gearboxes.

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 2 Installation and commissioning
2.7.1 Start of robot in cold environments

2.7 Robot in cold environments

2.7.1 Start of robot in cold environments

Introduction
This section describes how to start the robot in a cold environment if it is not starting
the normal way.

Problems with starting the robot

Event message from Motion Supervision
Use this procedure if an event message indicates a problem with Motion supervision
at start-up. More information about Motion Supervision is found in Technical
reference manual - System parameters.
Action Note
1 Turn off Motion Supervision.
2 Start the robot.
3 When the robot has reached normal working temper-
ature, the Motion Supervision can be turned on
again.

Robot stopping with other event message

Use this procedure if the robot is not starting.
Action Note
1 Start the robot with its normal program but The speed can be regulated with the
with reduced speed. RAPID instruction VelSet.

Adjusting the speed and acceleration during warm-up

Depending on how cold the environment is and what program is being used, the
speed might need to be ramped up until reached maximum. The table shows
examples of how to adjust the speed:
Work cycles AccSet Speed/velocity
3 Work cycles 20, 20 v100 (100 mm/s)
5 Work cycles 40, 40 v400 (400 mm/s)
5 Work cycles 60, 60 v600 (600 mm/s)
5 Work cycles 100, 100 v1000 (1000 mm/s)
More than 5 Work cycles 100, 100 Max.

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.

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2 Installation and commissioning
2.8.1 Robot cabling and connection points

2.8 Electrical connections

2.8.1 Robot cabling and connection points

Introduction
Connect the robot and controller to each other after securing them to the foundation.
The lists below specify which cables to use for each respective application.

Main cable categories

All cables between the robot and controller are divided into the following categories:
Cable category Description
Robot cables Handles power supply to and control of the robot's motors
as well as feedback from the serial measurement board.
Specified in the table Robot cables on page 104.
Fan cables (option) Handles supply to and feedback from any cooling fan on
the robot.
Specified in the table Fan cables (option) on page 106.
Customer cables (option) Handles communication with equipment fitted on the robot
by the customer, low voltage signals and high voltage power
supply + protective ground.
The customer cables also handle databus communication.
See the product manual for the controller, see document
number in References on page 10.
External axes cables (option) Handles power supply to and control of the external axes'
motors as well as feedback from the servo system.
See the Application manual - Additional axes and stand
alone controller (M2004), see document number in Refer-
ences on page 10.

Robot cables
These cables are included in the standard delivery. They are completely
pre-manufactured and ready to plug in.
Cable sub-category Description Connection Connection
point, cabinet point, robot
Robot cable, power Transfers drive power from the XS1 R1.MP
drive units in the control cabinet
to the robot motors.
Robot cable, signals Transfers resolver data from XS2 R1.SMB
and power supply to the serial
measurement board.

Robot cable, power

Cable Art. no.

Robot cable, power: 7 m 3HAC026787-001
Robot cable, power: 15 m 3HAC026787-002
Robot cable, power: 22 m 3HAC026787-003
Robot cable, power: 30 m 3HAC026787-004

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2.8.1 Robot cabling and connection points
Continued

Robot cable, signals

Cable Art. no.

Robot cable signal, shielded: 7 m 3HAC2493-1
Robot cable signal, shielded: 15 m 3HAC2530-1
Robot cable signal, shielded: 22 m 3HAC2540-1
Robot cable signal, shielded: 30 m 3HAC2566-1

Bending radius for static floor cables

The minimum bending radius is 10 times the cable diameter for static floor cables.

A
B

xx1600002016

A Diameter
B Diameter x10

Grounding and bonding point on manipulator

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.

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2 Installation and commissioning
2.8.1 Robot cabling and connection points
Continued

IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB

2600ID-8/2.0

xx1600001001

IRB 2600 Type C-20/1.65, IRB 2600 Type C-12/1.65

xx1800001155

Fan cables (option)

These cables are not included in the standard delivery, but are included in the
delivery if the fan option is ordered. The cables are completely pre-manufactured
and ready to plug in.

Continues on next page

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 2 Installation and commissioning
2.8.1 Robot cabling and connection points
Continued

Cabling to be installed on the robot is specified in section Installation of cooling

fan for motors (option) on page 93.

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2 Installation and commissioning
2.8.2 Customer connection on robot

2.8.2 Customer connection on robot

Location of customer connection

For the connection of extra equipment to the robot, cables and air hose are
integrated into the robot´s cabling, and there is one UTOW71210SH06 and one
UTOW71626SH06 connector on the front part of the upper arm.
The customer connections are located on the robot as shown in the figure.
The figure shows signal lamp fitted on IRB 2600 Standard.
Customer connection.

xx1700002239

A Air M16x1.5 (24° cone sealing)

B R2.CP
C R2.CS
D R2.ETHERNET

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 2 Installation and commissioning
2.8.2 Customer connection on robot
Continued

Customer connections base

xx0800000288

A R1.CP/CS
B Air M16x1.5
C R1.ETHERNET
D R1.SMB

Extra equipment connections

Connections to the:
• air hose ( 3/8") is located on the front part of the upper arm and at the base.
Max. 8 bar. Inner hose diameter: 9.5 mm.
• signal cabling (option) is located on the front of the upper arm.
Number of signals, customer connections R1.CP/CS:
• 23 (50V, 0.5A)
• 9 (300V, 2A). 8 are double crimped in R1.CP/CS and one is only accessible
in the robot base.
• 2 DeviceNet or Profibus R1.CP/CS
• One protective ground
Number of signals, customer connections R1.ETHERNET:
• 4 EtherNet R1.ETHERNET

Connection sets
To connect power and signal conductors to the robot base/upper arm connectors,
the following parts are recommended.
Connection Connector Art. no. Content
set
PROC1 on R1.CP/CS 3HAC16667-1 • Sockets for cable area of 0.14-2.5
base mm²
• Hood foundry
• Hinged frame, hood
• Multicontact-module, female
Connector set R1.CP/CS 3HAC033181-001 • Hose coupling
on base • M12 connector, male

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2 Installation and commissioning
2.8.2 Customer connection on robot
Continued

Connection Connector Art. no. Content

set
R2.CP/R2.CS R2.CP/R2.CS 3HAC025396-001 • Pins for cable area 0.21 - 0.93
mm²
• Bottle shaped shrinking hose
• Angle shaped shrinking hose

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 2 Installation and commissioning
2.8.3 Customer connections on upper arm

2.8.3 Customer connections on upper arm

Customer connections on upper arm

The figure shows the customer connections on the upper arm, including the optional
signal lamp that can be fitted to the armhouse.
The figure shows the signal lamp fitted on IRB 2600 Standard.

xx1700002240

A Signal lamp
B R3.H1 +, R3.H2 -
C R2.CP
D R2.CS
E R2.ETHERNET

Power supply connections on upper arm

Signal name Customer Ter- Customer Contact Customer Contact on robot base
minal Controller on Upper arm, R2 (cable between robot and controller
not supplied)
CPA XP6.1 R2.CP.A R1.CP/CS.d1
CPB XP6.2 R2.CP.B R1.CP/CS.d6
CPC XP6.3 R2.CP.C R1.CP/CS.d3
CPD XP6.4 R2.CP.D R1.CP/CS.d4
CPE XP6.1 R2.CP.E R1.CP/CS.d1
CPF XP6.2 R2.CP.F R1.CP/CS.d6
CPG R2.CP.G (Earth)

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2 Installation and commissioning
2.8.3 Customer connections on upper arm
Continued

Signal name Customer Ter- Customer Contact Customer Contact on robot base
minal Controller on Upper arm, R2 (cable between robot and controller
not supplied)
CPH - R2.CP.H R1.CP/CS.d7
CPJ XP6.3 R2.CP.J R1.CP/CS.d3
CPK XP6.4 R2.CP.K R1.CP/CS.d4

Signal connection on upper arm

Signal name Customer Ter- Customer Contact Customer Contact on robot base
minal Controller on Upper arm, R2 (cable between robot and controller
not supplied)
CSA XP5.1.1 R2.CS.A R1.CP/CS.b1
CSB XP5.1.2 R2.CS.B R1.CP/CS.b2
CSC XP5.2.1 R2.CS.C R1.CP/CS.b3
CSD XP5.2.2 R2.CS.D R1.CP/CS.b4
CSE XP5.2.3 R2.CS.E R1.CP/CS.b5
CSF XP5.2.4 R2.CS.F R1.CP/CS.b6
CSG XP5.1.9 R2.CS.G R1.CP/CS.b7
CSH XP5.1.10 R2.CS.H R1.CP/CS.b8
CSJ XP5.1.11 R2.CS.J R1.CP/CS.b9
CSK XP5.1.12 R2.CS.K R1.CP/CS.b10
CSL XP5.1.3 R2.CS.L R1.CP/CS.b11
CSM XP5.1.4 R2.CS.M R1.CP/CS.b12
CSN XP5.1.5 R2.CS.N R1.CP/CS.b13
CSP XP5.1.6 R2.CS.P R1.CP/CS.b14
CSR XP5.3.1 R2.CS.R R1.CP/CS.b15
CSS XP5.3.2 R2.CS.S R1.CP/CS.b16
CST XP5.3.3 R2.CS.T R1.CP/CS.b18
CSU XP5.3.4 R2.CS.U R1.CP/CS.b19
CSV XP5.3.5 R2.CS.V R1.CP/CS.b20
CSW XP5.3.6 R2.CS.W R1.CP/CS.b21
CSX XP5.2.9 R2.CS.X R1.CP/CS.b22
CSY XP5.2.10 R2.CS.Y R1.CP/CS.b23
CSZ XP5.2.11 R2.CS.Z R1.CP/CS.b24

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 3 Maintenance
3.1 Introduction

3 Maintenance
3.1 Introduction

Structure of this chapter

This chapter describes all the maintenance activities recommended for the IRB
2600/IRB 2600 ID.
It is based on the maintenance schedule found at the beginning of the chapter.
The schedule contains information about required maintenance activities including
intervals, and refers to procedures for the activities.
Each procedure contains all the information required to perform the activity,
including required tools and materials.
The procedures are gathered in different sections and divided according to the
maintenance activity.

Safety information
Observe all safety information before conducting any service work.
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 19 before performing any service
work.

Note

If the IRB 2600/IRB 2600 ID is connected to power, always make sure that the
IRB 2600/IRB 2600 ID is connected to protective earth before starting any
maintenance work.
For more information see:
• Product manual - IRC5

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3 Maintenance
3.2.1 Specification of maintenance intervals

3.2 Maintenance schedule and expected component life

3.2.1 Specification of maintenance intervals

Introduction
The intervals are specified in different ways depending on the type of maintenance
activity to be carried out and the working conditions of the IRB 2600/IRB 2600 ID:
• Calendar time: specified in months regardless of whether the system is
running or not.
• Operating time: specified in operating hours. More frequent running means
more frequent maintenance activities.
• SIS: specified by the robot's SIS (Service Information System). A typical
value is given for a typical work cycle, but the value will differ depending on
how hard each part is run. The SIS used in M2004 is further described in the
Operating manual - Service Information System.

Overhaul
Depending on application and operational environment a complete overhaul may
be necessary in average around 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.

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 3 Maintenance
3.2.2 Maintenance schedule

3.2.2 Maintenance schedule

General
The robot must be maintained regularly to ensure proper function. The maintenance
activities and intervals are specified in the following table.
Non-predictable situations also give rise to inspections of the robot. Any damages
must be attended to immediately!
The inspection intervals do not specify the life of each component. Values for these
are specified in the section Expected component life on page 118
Instructions for how to perform the different maintenance activities are found in
sections:
• Inspection activities on page 119
• Replacement / Changing activities on page 148
• Cleaning on page 184

Activities and intervals, standard equipment

The following table specifies the required maintenance activities and intervals.
Maintenance activity Equipment Interval
Cleaning Robot Cleaning the IRB 2600/IRB 2600 ID
on page 184
Inspection Oil level in axis-1 gearbox Every 12 months.
Inspection Oil level in axis-2 gearbox Every 12 months.
Inspection Oil level in axis-3 gearbox Every 12 months.
Inspection Oil level in axis-4 gearbox Every 12 months.
Inspection Oil level in axis-5 gearbox Every 12 months.
(ID)
Inspection Oil level in axis-5-6 gearbox Every 12 months.
Inspection Oil level in axis-5-6 gearbox Every 12 months.
(ID)
Inspection Robot harness Every 12 months i .
Inspection Information labels Every 12 months.
Inspection Dampers Every 12 months.
Inspection Pressure relief valve Every 12 months ii .
Inspection Mechanical stop Every 12 months.
Change Oil in axis-1 gearbox First change when DTC iii reads:
• 6,000 hours
Second change when DTC iii reads:
• 24,000 hours
Following changes:
• Every 24,000 hours.

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3 Maintenance
3.2.2 Maintenance schedule
Continued

Maintenance activity Equipment Interval

Change Oil in axis-2 gearbox First change when DTC iii reads:
• 6,000 hours
Second change when DTC iii reads:
• 24,000 hours
Following changes:
• Every 24,000 hours.
Change Oil in axis-3 gearbox First change when DTC iii reads:
• 6,000 hours
Second change when DTC iii reads:
• 24,000 hours
Following changes:
• Every 24,000 hours.
Change Oil in axis-4 gearbox No change needed.
Change Oil in axis-5 gearbox No change needed.
(ID)
Change Oil in axis-5-6 gearbox First change when DTC iii reads:
• 6,000 hours
Second change when DTC iii reads:
• 24,000 hours
Following changes:
• Every 24,000 hours.
Change Oil in axis-5-6 gearbox First change when DTC iii reads:
(ID) • 6,000 hours
Second change when DTC iii reads:
• 24,000 hours
Following changes:
• Every 24,000 hours.
Overhaul Robot Every:
• 40,000 hours .
Replacement Battery pack, measurement 36 months or battery low alert iv
system of type RMU101 or
RMU102 (3-pole battery con-
tact)
Replacement Battery pack, measurement Battery low alert v
system with 2-pole battery
contact, e.g. DSQC633A
i Replace when damage or cracks is detected or life limit is approaching that specified in section
Expected component life on page 118.
ii Check more often if the environment is very contaminated.
iii DTC = Duty Time Counter. Shows the operational time of the robot.
iv The battery low alert (38213 Battery charge low) is displayed when the battery needs to be replaced.
The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned
on until the battery is to be replaced.
See the replacement instruction for more details.
v The battery low alert (38213 Battery charge low) is displayed when remaining backup capacity
(robot powered off) is less than 2 months. The typical lifetime of a new battery is 36 months if the
robot is powered off 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime
can be extended with a battery shutdown service routine. See Operating manual - IRC5 with
FlexPendant for instructions.

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 3 Maintenance
3.2.2 Maintenance schedule
Continued

Activities and intervals, optional equipment

The following table specifies the required maintenance activities and intervals for
common optional equipment. The maintenance of other external equipment for the
robot is detailed in separate documents.
Maintenance activity Equipment Interval Note
Inspection Signal lamp Every:
12 months
Inspection Additional mechanical Every:
stop, axis 1 12 months
Inspection Motor fan Every 12 Inspect the fan for contam-
months ination that could hinder
the air supply. Clean if ne-
cessary.

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3 Maintenance
3.2.3 Expected component life

3.2.3 Expected component life

General
The expected life of a specific component of the robot can vary greatly depending
on how hard it is run.

Expected component life - protection type Standard

Component Expected life Note

Cable harness 40,000 hours ii Not including:
Normal usage i • Possible SpotPack
harnesses
• Optional upper arm
harnesses
Cable harness 20,000 hours ii Not including:
Extreme usage iii • Possible SpotPack
harnesses
• Optional upper arm
harnesses
Gearboxes iv 40,000 hours
i Examples of "normal usage" in regard to movement: most material handling applications.
ii Severe chemical or thermal environments, or similar environments, can result in shortened life
expectancy.
iii Examples of "extreme usage" in regard to movement: press tending, very severe palletizing
applications, major use of axis 1 movement.
iv Depending on application, the lifetime can vary. The Service Information System (SIS), integrated
in the robot software, can be used as a guidance for planning service of gearbox for the individual
robot. This applies to gearboxes on axes 1, 2 and 3. The lifetime of gearbox axes 4, 5 and 6 is not
calculated by SIS (See the Operating manual - Service Infomation System) In applications such as
Foundry or Washing the robot can be exposed to chemicals, high temperature or humidity which
can have an effect on the lifetime of gearboxes. Contact the local ABB Robotics Service team for
more information.
The SIS for an IRC5 system is described in the Operating manual - Service Information System.

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 3 Maintenance
3.3.1 Inspecting oil level, axis-1 gearbox

3.3 Inspection activities

3.3.1 Inspecting oil level, axis-1 gearbox

Different versions of the gearbox

There are two different versions of the axis-1 and axis-2 gearboxes. The different
versions affect the mechanical structure of the base, frame and lower arm.
Differences in the mechanical structure are pointed out in the procedure as valid
for different robot version:
• IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-15/1.85,
IRB 2600ID-8/2.0
• IRB 2600 Type C-20/1.65, IRB 2600 Type C-12/1.65
Further information about the differences are given in Non-compatible versions of
axis-1 and axis-2 gearboxes on page 428.

Mounting position of the robot

If the robot is floor mounted, follow the procedures in Inspecting oil level, axis-1
gearbox (floor mounted) on page 121.
If the robot is suspended, follow the procedures in Inspecting oil level, axis-1
gearbox (suspended robot) on page 122.

Location of oil plugs (floor mounted)

The axis 1 gearbox is located between the frame and base of the robot. The oil
plug for inspection is shown in the figure.

IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB 2600ID-8/2.0

xx0800000304

A Oil plug, inspection

B Oil plug, gearbox, with sealing washer

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3 Maintenance
3.3.1 Inspecting oil level, axis-1 gearbox
Continued

IRB 2600 Type C-20/1.65, IRB 2600 Type C-12/1.65

xx1800001132

A Oil plug, inspection

Location of oil plugs (suspended mounted)

The axis 1 gearbox is located between the frame and base of the robot. The oil
plug for inspection is shown in the figure.

IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB 2600ID-8/2.0

xx1200000883

A Oil plug, inspection, with sealing washer

B Oil plug

IRB 2600 Type C-20/1.65, IRB 2600 Type C-12/1.65

IRB 2600 Type C-20/1.65, IRB 2600 Type C-12/1.65 is not available for suspended
installation.

Continues on next page

120 Product manual - IRB 2600
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 3 Maintenance
3.3.1 Inspecting oil level, axis-1 gearbox
Continued

Required equipment

Equipment Note
Oil plug sealing washer, gearbox 3HAC029646-001
Lubrication oil See section Type of lubrication in gearboxes
on page 148.
Standard toolkit Content is defined in section Standard tools
on page 441.
Other tools and procedures may be required. These procedures include references to the
See references to these procedures in the tools required.
step-by-step instructions below.

Inspecting oil level, axis-1 gearbox (floor mounted)

Use this procedure to inspect the oil level in the axis-1 gearbox, when the robot is
floor mounted.
Action Note
1
WARNING

Handling gearbox oil involves several safety

risks. Before proceeding, please read the
safety information in the section Safety risks
during work with gearbox lubricants (oil or
grease) on page 39.

2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3
CAUTION

The gearbox can contain an excess of

pressure that can be hazardous. Open the
oil plug carefully in order to let out the ex-
cess pressure.

4 Open the oil plug, inspection. See Location of oil plugs (floor mounted)
on page 119.

Continues on next page

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3 Maintenance
3.3.1 Inspecting oil level, axis-1 gearbox
Continued

Action Note
5 Measure the oil level at the oil plug hole.
A C
Required oil level for IRB 2600-20/1.65, IRB
2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0: B
• 10 mm ± 3 mm below the lower edge
of the oil plug inspection hole.
Required oil level for IRB 2600 Type C-
20/1.65, IRB 2600 Type C-12/1.65: D

• 12 mm ± 3 mm below the lower edge

of the oil plug inspection hole.

xx1200001352

Parts:
A Oil level
B Measurement of required oil level
C Oil plug hole inspection
D Gear
6 Add oil if required. How to fill oil is described in section:
• Changing the oil, axis 1 gearbox on
floor mounted robots on page 150
7 Refit the oil plug, inspection. Tightening torque:
• 24 Nm

Inspecting oil level, axis-1 gearbox (suspended robot)

Use this procedure to inspect the oil level in the axis-1 gearbox for IRB 2600-20/1.65,
IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB 2600ID-8/2.0.
IRB 2600 Type C-20/1.65, IRB 2600 Type C-12/1.65 is not available for suspended
installation.

CAUTION

If the robot has the earlier design of the frame, and the robot is filled with an
amount of oil suited for an inverted position, the oil level of the axis-1 gearbox
will be above the oil plug hole when the robot is standing on the floor, which will
result in oil leakage if the plug is opened while robot stands on the floor! The oil
level of axis-1 gearbox can therefore only be inspected when the robot is mounted
in an inverted position!

Action Note
1
WARNING

Handling gearbox oil involves several safety

risks. Before proceeding, please read the
safety information in the section Safety risks
during work with gearbox lubricants (oil or
grease) on page 39.

Continues on next page

122 Product manual - IRB 2600
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 3 Maintenance
3.3.1 Inspecting oil level, axis-1 gearbox
Continued

Action Note
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3
CAUTION

The gearbox can contain an excess of

pressure that can be hazardous. Open the
oil plug carefully in order to let out the ex-
cess pressure.

4 Open the oil plug inspection on the axis 1 See the figure in:
gearbox. • Location of oil plugs (suspended
mounted) on page 120
5 Required oil level:
• up to the lower edge of the oil plug
hole.

Note

The oil plugs on gearbox axis 1 are now on

top.

xx1100000008

6 Add oil if required. How to fill oil is described in section:

• Changing the oil, axis-1 gearbox
on suspended robots on page 158
7 Refit the oil plug. Tightening torque:
• 3-8 Nm
Note

Before refitting the oil plug in the gearbox,

always replace the oil plug sealing washer
with a new one. If not there is a risk of
leakage.

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3 Maintenance
3.3.2 Inspecting the oil level, axis 2 gearbox

3.3.2 Inspecting the oil level, axis 2 gearbox

Different versions of the gearbox

There are two different versions of the axis-1 and axis-2 gearboxes. The different
versions affect the mechanical structure of the base, frame and lower arm.
Differences in the mechanical structure are pointed out in the procedure as valid
for different robot version:
• IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-15/1.85,
IRB 2600ID-8/2.0
• IRB 2600 Type C-20/1.65, IRB 2600 Type C-12/1.65
Further information about the differences are given in Non-compatible versions of
axis-1 and axis-2 gearboxes on page 428.

Location of axis 2 gearbox

The axis 2 gearbox is located in the lower arm rotational center, underneath the
motor attachment. The oil plugs are shown in the figure.

xx0800000305

A Oil plug, inspection, when robot is floor mounted

B Oil plug, inspection, when robot is suspended (Quick connect fitting)

Required equipment

Equipment Note
Oil plug sealing washer, gearbox 3HAC029646-001
Lubrication oil See section Type of lubrication in gearboxes
on page 148.
Oil plug (Quick connect fitting) For article number see Spare part lists on
page 445.
Standard toolkit Content is defined in section Standard tools
on page 441.

Continues on next page

124 Product manual - IRB 2600
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 3 Maintenance
3.3.2 Inspecting the oil level, axis 2 gearbox
Continued

Equipment Note
Other tools and procedures may be required. These procedures include references to the
See references to these procedures in the tools required.
step-by-step instructions below.

Inspecting oil level, axis 2 gearbox

Use this procedure to inspect the oil level in the axis 2 gearbox.
Action Note
1
WARNING

Handling gearbox oil involves several safety

risks. Before proceeding, please read the
safety information in the section Safety risks
during work with gearbox lubricants (oil or
grease) on page 39.

2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3
CAUTION

The gearbox can contain an excess of

pressure that can be hazardous. Open the
oil plug carefully in order to let out the ex-
cess pressure.

4 Open the oil plug, inspection (location de- See the figure in:
pends on how the robot is mounted). • Location of axis 2 gearbox on
page 124
Note

Always open the oil plug on top, depending

how the robot is mounted.

5 Measure the oil level at the oil plug hole.

Required oil level:
• 42 mm ± 5 mm below the lower edge
of the oil plug hole (IRB 2600-20/1.65,
IRB 2600-12/1.65, IRB 2600-12/1.85,
IRB 2600ID-15/1.85, IRB 2600ID-
8/2.0).
28 mm ± 3 mm below the lower edge
of the oil plug hole (IRB 2600 Type
C-20/1.65, IRB 2600 Type C-12/1.65).
6 Add oil if required. How to fill oil is described in section
• Changing the oil, axis-2 gearbox
on page 163

Continues on next page

Product manual - IRB 2600 125
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3 Maintenance
3.3.2 Inspecting the oil level, axis 2 gearbox
Continued

Action Note
7 Refit the oil plug. Tightening torque:
• 24 Nm
Note

Before refitting the oil plug in the gearbox,

always replace the oil plug sealing washer
with a new one. If not there is a risk of
leakage.

126 Product manual - IRB 2600

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 3 Maintenance
3.3.3 Inspecting the oil level, axis 3 gearbox

3.3.3 Inspecting the oil level, axis 3 gearbox

Location of axis 3 gearbox

The axis 3 gearbox is located in the upper arm rotational center, underneath the
motor attachment. The oil plug for inspection is shown in the figure.
The figure shows IRB 2600 Standard but the position of plugs are approximately
the same on IRB 2600ID.

xx0800000306

A Oil plug, armhouse

B Oil plug, gearbox (not visible in this figure)

Required equipment

Equipment Note
Lubrication oil See section Type of lubrication in gearboxes
on page 148.
Standard toolkit Content is defined in section Standard tools
on page 441.
Other tools and procedures may be required. These procedures include references to the
See references to these procedures in the tools required.
step-by-step instructions below.

Continues on next page

Product manual - IRB 2600 127
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© Copyright 2009-2018 ABB. All rights reserved.
3 Maintenance
3.3.3 Inspecting the oil level, axis 3 gearbox
Continued

Inspecting the oil level, axis 3 gearbox

Use this procedure to inspect the oil level in the axis 3 gearbox.
Action Note
1
WARNING

Handling gearbox oil involves several safety

risks. Before proceeding, please read the
safety information in the section Safety risks
during work with gearbox lubricants (oil or
grease) on page 39.

2 IRB 2600: Move the robot to where the upper

arm points either straight up or straight down.
IRB 2600ID: Move the robot to where the
upper arm points straight up.
3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot work-
ing area.

4
CAUTION

The gearbox can contain an excess of pres-

sure that can be hazardous. Open the oil plug
carefully in order to let out the excess pres-
sure.

5 Open the upper oil plug. See the figure in:

• Location of axis 3 gearbox on
page 127
6 Measure the oil level at the oil plug hole.
Required oil level:
• IRB 2600: 45 ± 5 mm from the upper
edge of oil plug hole.
• IRB 2600ID: 70 ± 3 mm from the upper
edge of oil plug hole.
7 Add oil if required. How to fill oil is described in section:
• Changing the oil, axis-3 gearbox
on page 167
8 Refit the oil plug. Tightening torque:
• in armhouse: 10 Nm
• in gearbox: 3 Nm

128 Product manual - IRB 2600

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 3 Maintenance
3.3.4 Inspecting the oil level, axis 4 gearbox

3.3.4 Inspecting the oil level, axis 4 gearbox

Location of axis 4 gearbox

The axis 4 gearbox is located in the upper armhouse. The oil plug is shown in the
figure.

xx0800000307

A Oil plug, for filling and draining

Required equipment

Equipment Note
Lubrication oil See section Type of lubrication in gearboxes
on page 148.
Standard toolkit Content is defined in section Standard tools
on page 441.
Other tools and procedures may be required. These procedures include references to the
See references to these procedures in the tools required.
step-by-step instructions below.

Continues on next page

Product manual - IRB 2600 129
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3 Maintenance
3.3.4 Inspecting the oil level, axis 4 gearbox
Continued

Inspecting the oil level, axis 4 gearbox

Use this procedure to inspect the oil level in the axis 4 gearbox.
Action Note
1
WARNING

Handling gearbox oil involves several safety

risks. Before proceeding, please read the
safety information in the section Safety risks
during work with gearbox lubricants (oil or
grease) on page 39.

2 Move the robot to where the upper arm points

straight up and the oil plug hole is on top of
the axis 4 gearbox.
3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot work-
ing area.

4
CAUTION

The gearbox can contain an excess of pres-

sure that can be hazardous. Open the oil plug
carefully in order to let out the excess pres-
sure.

5 Open the oil plug. See the figure in:

• Location of axis 4 gearbox on
page 129
6 Measure the oil level at the oil plug hole.
Required oil level:
• IRB 2600: 15 ±3 mm below the oil plug
flange.
IRB 2600ID: 30 ±5 mm below the oil
plug flange.
7 Add oil if required. How to fill oil is described in section:
• Changing the oil, axis-4 gearbox
on page 171
8 Refit the oil plug, filling. Tightening torque:
• 10 Nm

130 Product manual - IRB 2600

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 3 Maintenance
3.3.5 Inspecting oil level, gearbox axes 5 - 6

3.3.5 Inspecting oil level, gearbox axes 5 - 6

Location of gearbox, axes 5-6

The gearbox axes 5-6 is located in the wrist unit. The oil plug is shown in the figure.

xx0900000139

A Oil plug, tilthouse

B Oil plug, wrist (also used as air inlet when draining from oil plug A)

Required equipment

Equipment Note
Lubrication oil See section Type of lubrication in gearboxes
on page 148.
Standard toolkit Content is defined in section Standard tools
on page 441.
Other tools and procedures may be required. These procedures include references to the
See references to these procedures in the tools required.
step-by-step instructions below.

Inspecting oil level, gearbox axes 5-6 - wrist 12/20 kg

Use this procedure to fill oil in the gearbox.
Action Note
1 IRB 2600: Move the robot to a position where
the upper arm is close to horizontal and axis
4 in the calibration position.
IRB 2600ID: Move the robot to a position
where axis 4 is placed in -25°.

Continues on next page

Product manual - IRB 2600 131
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3 Maintenance
3.3.5 Inspecting oil level, gearbox axes 5 - 6
Continued

Action Note
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot work-
ing area.

3
CAUTION

The gearbox can contain an excess of pres-

sure that can be hazardous. Open the oil plug
carefully in order to let out the excess pres-
sure.

4 Remove the oil plug, wrist. See the figure in:

• Location of gearbox, axes 5-6 on
page 131
5 Required oil level:
• IRB 2600: 3 ± 3 mm from the lower
edge of the oil plug in the wrist house.
Open the oil plug in the tilthouse to al-
low the oil level between axis 5 and 6
to level.
• IRB 2600ID: Oil shall be visible in the
rear oil plug hole, almost on its way to
pour out of the hole.
6 If necessary, refill oil. How to fill oil is described in section:
• Changing oil, axes-5 and -6 gear-
boxes on page 175
7 Refit the oil plug. Tightening torque:
• 10 Nm

132 Product manual - IRB 2600

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 3 Maintenance
3.3.6 Inspecting the cable harness

3.3.6 Inspecting the cable harness

Location of cable harness

The figure shows the location of the cable harness.
The figure shows IRB 2600 with standard upper arm.

xx0900000384

A Cable harness
B Bracket, lower arm
C Bracket, lower arm
D Cable straps, one not visible here (steel)
E Bracket, frame
F Cable strap, lower arm (plastic)
G Bracket, upper arm

Required equipment

Equipment Note
Standard toolkit Content is defined in section Standard tools
on page 441.
Other tools and procedures may be required. These procedures include references to the
See references to these procedures in the tools required.
step-by-step instructions below.
Circuit diagram See chapter Circuit diagram on page 447.

Continues on next page

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3 Maintenance
3.3.6 Inspecting the cable harness
Continued

Inspecting the cable harness

Use this procedure to inspect the cable harness. The inspection points are shown
in the figure Location of cable harness on page 133

Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot work-
ing area.

2 Make an overall visual inspection of the cable

harness in order to detect wear or damage.
3 Check the connectors at the base.
4 Check the connectors at the armhouse.
5 Check all brackets and straps are properly
attached to the robot.
6 Replace the cable harness if wear, cracks or How to replace the cable harness is de-
damage is detected. scribed in Repair on page 187.

134 Product manual - IRB 2600

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 3 Maintenance
3.3.7 Inspecting information labels

3.3.7 Inspecting information labels

Location of information labels

The figure shows the location of the information labels to be inspected.

xx1000000205

A Warning - Symbol of flash (4 pcs)

B Warning - Risk of tipping
C Label - Lifting instruction
D Warning - "High temperature"
E Label - Max. air pressure
F Warning - Brake release unit
G Label - Calibration
H Label - Suspended robot

Required equipment

Equipment Spare part number Note

Labels See Spare part lists on
page 445.

Inspecting labels
Use this procedure to inspect the labels on the robot.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot work-
ing area.

Continues on next page

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3 Maintenance
3.3.7 Inspecting information labels
Continued

Action Note
2 Check all labels. See the figure in Location of information
labels on page 135.
3 Replace any missing or damaged labels.

136 Product manual - IRB 2600

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 3 Maintenance
3.3.8 Inspecting the mechanical stop pin, axis 1

3.3.8 Inspecting the mechanical stop pin, axis 1

Location of mechanical stop pin, axis 1

The mechanical stop pin is located on the frame as shown in the figure.

xx0800000298

A Fixed stop
B Mechanical stop pin, axis 1

Required equipment

Equipment Article number Note

Mechanical stop pin axis 1 See Spare part lists on
page 445.
Standard toolkit Content is defined in section
Standard tools on page 441.
Other tools and procedures These procedures include
may be required. See refer- references to the tools re-
ences to these procedures in quired.
the step-by-step instructions
below.

Continues on next page

Product manual - IRB 2600 137
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© Copyright 2009-2018 ABB. All rights reserved.
3 Maintenance
3.3.8 Inspecting the mechanical stop pin, axis 1
Continued

Inspection of mechanical stop pin, axis 1

Use this procedure to inspect the mechanical stop pin, axis 1.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot work-
ing area.

2 Regularly check that the mechanical stop pin See the figure in:
is not bent or damaged in any other way. • Location of mechanical stop pin,
axis 1 on page 137
3 How to replace the stop pin is described
Note in section Replacing stop pin axis 1 on
page 286.
If the mechanical stop pin has been deformed
or damaged, all of its mounting parts have to
be replaced.

xx0800000045

Parts:
A Attachment screws
B Bracket
C O-ring (2 pcs) - Not used if bracket (D)
is installed.
D Bracket
E Stop pin

4 Check that the mechanical stop pin is prop-

erly attached.
Continues on next page
138 Product manual - IRB 2600
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© Copyright 2009-2018 ABB. All rights reserved.
 3 Maintenance
3.3.8 Inspecting the mechanical stop pin, axis 1
Continued

Action Note
5 Check that the mechanical stop pin can move
freely in both directions and the bracket
works as it is supposed to.

xx1000000222

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3 Maintenance
3.3.9 Inspecting additional mechanical stops

3.3.9 Inspecting additional mechanical stops

Location of additional mechanical stops

The figure shows the location of the additional stops.

D, E
xx0800000273

A Movable mechanical stop. Limited to:

• -126° (IRB 2600 Type C-20/1.65, IRB 2600 Type C-12/1.65)
• -129° (IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0)
B Movable mechanical stop. Limited to:
• +13.5° (IRB 2600 Type C-20/1.65, IRB 2600 Type C-12/1.65)
• +16.5° (IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0)
C Movable mechanical stop. Limited to:
• -13.5° (IRB 2600 Type C-20/1.65, IRB 2600 Type C-12/1.65)
• -16.5° (IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0)
D Attachment screws
E Washers

Required equipment

Equipment etc. Note

Mechanical stop set, axis 1 Includes:
• Stop
• Attachment screws plus washers
• Document for movable mechanical stop
For spare part number see Spare part lists on
page 445.

Continues on next page

140 Product manual - IRB 2600
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 3 Maintenance
3.3.9 Inspecting additional mechanical stops
Continued

Equipment etc. Note

Standard toolkit Content is defined in section Standard tools on
page 441.
Other tools and procedures may be re- These procedures include references to the
quired. See references to these procedures tools required.
in the step-by-step instructions below.

Inspecting additional mechanical stops

Use this procedure to inspect the additional mechanical stops on axis 1.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot work-
ing area.

2 Check the additional mechanical stops on See the figure in:

axis 1 for damage. • Location of additional mechanical
stops on page 140
3 Make sure the stops are properly attached. Tightening torque:
• 82 Nm
4 If any damage on stops or attachment screws Attachment screws:
etc. is detected, the mechanical stops must • M12x40, quality 8.8-A3F
be replaced! • 2 pcs/stop lug

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© Copyright 2009-2018 ABB. All rights reserved.
3 Maintenance
3.3.10 Inspecting dampers

3.3.10 Inspecting dampers

Location of dampers
The figure shows the location of all dampers to be inspected.
The figure shows IRB 2600 with Standard upper arm.

xx0800000297

A Dampers axis 2 (IRB 2600 Standard and ID)

B Dampers axis 3 (IRB 2600 Standard and ID)
C Damper axis 5 (only on IRB 2600 Standard)

Required equipment

Equipment Spare part no. Note

Damper See Spare part lists on
page 445.
Standard toolkit - Content is defined in section
Standard tools on page 441.

Continues on next page

142 Product manual - IRB 2600
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 3 Maintenance
3.3.10 Inspecting dampers
Continued

Inspecting dampers
Use this procedure to inspect the dampers.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot work-
ing area.

2 Check all dampers for damage or cracks. See the figure in:
• Location of dampers on page 142
3 Check all dampers for existing impressions
larger than 2-3 mm.
4 Check attachment screws for deformation.
5 If any damage is detected the damper must
be replaced.

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3 Maintenance
3.3.11 Inspecting the pressure relief valve

3.3.11 Inspecting the pressure relief valve

Location of the pressure relief valve

The figure shows the location of the pressure relief valve.

xx0900000131

A Pressure relief valve

Required equipment

Equipment Note
Standard toolkit Content is defined in section Standard tools
on page 441.

Inspecting pressure relief valve

Use this procedure to inspect the pressure relief valve.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot work-
ing area.

2
DANGER

It is important to keep the pressure relief

valve open and clean. If the air pressure is
stopped up, too much pressure can be built
up which can be hazardous.

Continues on next page

144 Product manual - IRB 2600
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 3 Maintenance
3.3.11 Inspecting the pressure relief valve
Continued

Action Note
3 Check if the pressure relief valve is contam-
inated or covered with litter.
4 Clean if necessary.

Note

Use a cloth or a brush.

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3 Maintenance
3.3.12 Inspecting Signal lamp (option)

3.3.12 Inspecting Signal lamp (option)

Location of signal lamp

Signal lamp is an option.
Located as shown in the figure.
The figure shows IRB 2600 Standard.

B C D
xx0800000290

A Signal lamp
B R3.H1 +, R3.H2 -
C R2.CP
D R2.CS

Required equipment

Equipment Note
Signal lamp For spare parts no. see Spare parts - Spare
parts options in Product manual, spare
parts - IRB 2600.
Standard toolkit Content is defined in section Standard tools
on page 441.
Other tools and procedures may be required. These procedures include references to the
See references to these procedures in the tools required.
step-by-step instructions below.

Inspecting signal lamp

Use this procedure to inspect the function of the signal lamp.

Note

If the signal lamp is damaged, it shall be replaced!

Action Note
1 Check that the signal lamp is lit when motors
are put in operation ("MOTORS ON").

Continues on next page

146 Product manual - IRB 2600
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 3 Maintenance
3.3.12 Inspecting Signal lamp (option)
Continued

Action Note
2 If the signal lamp is not lit, continue tracing
the fault with the steps below.
3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot work-
ing area.

4 Check whether the signal lamp is broken. If

so, replace.
5 Check the cable connections.
6 Measure the voltage in connectors, motor 24V
axis 3.
7 Check the cabling. If a fault is detected, re-
place.
8 Seal and paint the joints that have been
opened. Also repair possible damages of the
special Foundry Prime paint coat of the robot.
See Cut the paint or surface on the robot be-
fore replacing parts on page 193.

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3 Maintenance
3.4.1 Type of lubrication in gearboxes

3.4 Replacement / Changing activities

3.4.1 Type of lubrication in gearboxes

Introduction
This section describes where to find information about the type of lubrication,
article number and the amount of lubrication in the specific gearbox. It also
describes the equipment needed when working with lubrication.

Type and amount of oil in gearboxes

Information about the type of lubrication, article number as well as the amount in
the specific gearbox can be found in Technical reference manual - Lubrication in
gearboxes available for registered users on myABB Business Portal, www.mypo-
rtal.abb.com.
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. A new revision will
be published on ABB Library immediately after updates.

Location of gearboxes
The figure shows the location of the gearboxes.

xx0900000312

1 IRB 2600 Standard

Continues on next page

148 Product manual - IRB 2600
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 3 Maintenance
3.4.1 Type of lubrication in gearboxes
Continued

2 IRB 2600ID
A Gearbox, axis 1
B Gearbox, axis 2
C Gearbox, axis 3
D Gearbox, axis 4
E Gearbox, axis 5-6

Equipment

Equipment Note
Oil dispenser 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 Used on the axis-2 gearbox (IRB 2600-20/1.65,
IRB 2600-12/1.65, IRB 2600-12/1.85, IRB
2600ID-15/1.85, IRB 2600ID-8/2.0).
Used on the axis-1 and axis-2 gearboxes (IRB
2600 Type C-20/1.65, IRB 2600 Type C-12/1.65).
Expansion container, gearbox axis 1 Used when the robot is fitted in a suspended
position.
(valid for IRB 2600-20/1.65, IRB 2600-12/1.65,
IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB
2600ID-8/2.0)

Product manual - IRB 2600 149

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© Copyright 2009-2018 ABB. All rights reserved.
3 Maintenance
3.4.2 Changing the oil, axis 1 gearbox on floor mounted robots

3.4.2 Changing the oil, axis 1 gearbox on floor mounted robots

Floor mounted or suspended robot

Depending on whether the robot is floor mounted or suspended, the method of
changing the oil differs.
This section describes how to change the axis-1 gearbox oil in a floor mounted
robot. If the robot is suspended, see Changing the oil, axis-1 gearbox on suspended
robots on page 158.

Different versions of the gearbox

There are two different versions of the axis-1 and axis-2 gearboxes. The different
versions affect the mechanical structure of the base, frame and lower arm.
Differences in the mechanical structure are pointed out in the procedure as valid
for different robot version:
• IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-15/1.85,
IRB 2600ID-8/2.0
• IRB 2600 Type C-20/1.65, IRB 2600 Type C-12/1.65
Further information about the differences are given in Non-compatible versions of
axis-1 and axis-2 gearboxes on page 428.

Location of oil plugs

The axis 1 gearbox is located between the frame and base of the robot.
The oil plugs are shown in the figure.

IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB 2600ID-8/2.0

xx0800000304

A Oil plug, filling and venting

B Oil plug, draining, with sealing washer

Continues on next page

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 3 Maintenance
3.4.2 Changing the oil, axis 1 gearbox on floor mounted robots
Continued

IRB 2600 Type C-20/1.65, IRB 2600 Type C-12/1.65

xx1800001135

A Oil plug, filling and draining

B Oil plug, venting

Required equipment

Equipment Note
Oil plug sealing washer, gearbox Valid for IRB 2600-20/1.65, IRB 2600-12/1.65,
IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB
2600ID-8/2.0
3HAC029646-001
Lubricating oil See section Type of lubrication in gearboxes
on page 148.
Oil collecting vessel The capacity of the vessel must be sufficient
to take the complete amount of oil.
Oil dispenser One example of oil dispenser can be found
in section:
• Type of lubrication in gearboxes on
page 148
Standard toolkit Content is defined in section Standard tools
on page 441.

Continues on next page

Product manual - IRB 2600 151
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3 Maintenance
3.4.2 Changing the oil, axis 1 gearbox on floor mounted robots
Continued

Draining, axis 1 gearbox

Use this procedure to drain the gearbox of oil.
The oil must be sucked out from the gearbox. It is recommended to use a pneumatic
oil dispenser to drain oil from the gearbox.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2
WARNING

Handling gearbox oil involves several safety

risks. Before proceeding, please read the
safety information in the section Safety risks
during work with gearbox lubricants (oil or
grease) on page 39.

3
CAUTION

The gearbox can contain an excess of

pressure that can be hazardous. Open the
oil plug carefully in order to let out the ex-
cess pressure.

4 Valid for IRB 2600 Type C-20/1.65, IRB

2600 Type C-12/1.65:
Remove the protective cap from the oil
nipple and connect the oil dispenser.

xx1800001136

Continues on next page

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 3 Maintenance
3.4.2 Changing the oil, axis 1 gearbox on floor mounted robots
Continued

Action Note
5 Valid for IRB 2600-20/1.65, IRB 2600- The capacity of the vessel must be suffi-
12/1.65, IRB 2600-12/1.85, IRB 2600ID- cient to take the complete amount of oil.
15/1.85, IRB 2600ID-8/2.0:
• Put an oil collecting vessel as close
as possible to the draining hole of
the gearbox.
• Replace oil plug draining quickly with
a nipple (M10x1.5) where a draining
hose is fitted and connect the oil
dispenser.

xx1800001138

Note

Draining is time-consuming.
Elapsed time varies depending on the
temperature of the oil.
One example of oil dispenser can be
found in section:
• Type of lubrication in gearboxes on
page 148
6 Remove the plug from the vent hole. Different position due to design differ-
ences:
WARNING

If the oil plug for venting is not open when

the oil dispenser is working, there is a risk
of damaging vital parts in the gearbox!

xx1800001137

xx1800001139

7 Suck out the oil with the oil dispenser.

Note

There will be some oil left in the gear after

draining.

Continues on next page

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3 Maintenance
3.4.2 Changing the oil, axis 1 gearbox on floor mounted robots
Continued

Action Note
8
WARNING

Used oil is hazardous material and must be

disposed of in a safe way. See section De-
commissioning on page 423 for more inform-
ation.

9 Remove the oil dispenser.

10 Valid for IRB 2600 Type C-20/1.65, IRB
2600 Type C-12/1.65:
Refit the protective cap on the nipple.

xx1800001136

11 Valid for IRB 2600-20/1.65, IRB 2600- Tightening torque: 3-8 Nm

12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0:
Refit the oil plug, draining.

Note

Before refitting the oil plug in the gearbox,

always replace the oil plug gasket with a
new gasket. If not there is a risk of leakage.
xx1800001138

Continues on next page

154 Product manual - IRB 2600
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 3 Maintenance
3.4.2 Changing the oil, axis 1 gearbox on floor mounted robots
Continued

Action Note
12 Refit the oil plug, venting. Tightening torque: 24 Nm
Different position due to design differ-
ences:

xx1800001137

xx1800001139

Filling oil, axis 1 gearbox

Use this procedure to fill the gearbox with oil.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

2
WARNING

Handling gearbox oil involves several safety

risks. Before proceeding, please read the safety
information in the section Safety risks during
work with gearbox lubricants (oil or grease) on
page 39.

Continues on next page

Product manual - IRB 2600 155
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© Copyright 2009-2018 ABB. All rights reserved.
3 Maintenance
3.4.2 Changing the oil, axis 1 gearbox on floor mounted robots
Continued

Action Note
3
CAUTION

The gearbox can contain an excess of pressure

that can be hazardous. Open the oil plug care-
fully in order to let out the excess pressure.

4 Valid for IRB 2600 Type C-20/1.65, IRB 2600

Type C-12/1.65:
Remove the protective cap from the oil nipple
and connect the oil dispenser.

xx1800001136

5 Valid for IRB 2600 Type C-20/1.65, IRB 2600

Type C-12/1.65:
Remove the plug from the vent hole.

Note

The vent hole is opened to let out air during the

filling process.

xx1800001137

6 Valid for IRB 2600-20/1.65, IRB 2600-12/1.65, Different position due to design differ-
IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB ences:
2600ID-8/2.0:
Open the oil plug, filling.

xx1800001137

xx1800001139

Continues on next page

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© Copyright 2009-2018 ABB. All rights reserved.
 3 Maintenance
3.4.2 Changing the oil, axis 1 gearbox on floor mounted robots
Continued

Action Note
7 Refill the gearbox with lubrication oil. Where to find type of oil and total
Valid for IRB 2600 Type C-20/1.65, IRB 2600 amount is detailed in Type and
Type C-12/1.65: amount of oil in gearboxes on
page 148.
Use the oil dispenser.

Note

The amount of oil to be filled depends on the

amount previously being drained.

8 Inspect the oil level. How to inspect the oil level is de-
scribed in section:
• Inspecting oil level, axis-1
gearbox on page 119
9 Valid for IRB 2600 Type C-20/1.65, IRB 2600
Type C-12/1.65:
Remove the oil dispenser and refit the protect-
ive cap to the nipple.

xx1800001136

10 Refit the oil plug. Tightening torque: 24 Nm

Different position due to design differ-
ences:

xx1800001137

xx1800001139

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© Copyright 2009-2018 ABB. All rights reserved.
3 Maintenance
3.4.3 Changing the oil, axis-1 gearbox on suspended robots

3.4.3 Changing the oil, axis-1 gearbox on suspended robots

Validity of this section

This section is only valid for IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85,
IRB 2600ID-15/1.85, IRB 2600ID-8/2.0.

Floor mounted or suspended robot

Depending on whether the robot is floor mounted or suspended, the method of
changing the oil is different.
How to change oil if the robot is floor mounted, see Changing the oil, axis 1 gearbox
on floor mounted robots on page 150.

Location of oil plugs

The axis-1 gearbox is located between the frame and base of the robot. The oil
plugs are shown in the figures.

IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB 2600ID-8/2.0

xx1200000883

A Oil plug, venting

B Oil plug, draining and filling

Required equipment

Equipment Note
Oil plug sealing washer, gearbox 3HAC029646-001
Lubricating oil See section Type of lubrication in gearboxes
on page 148
Oil collecting vessel The capacity of the vessel must be sufficient
to take the complete amount of oil.
Oil dispenser One example of oil dispenser can be found
in section:
• Type of lubrication in gearboxes on
page 148

Continues on next page

158 Product manual - IRB 2600
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© Copyright 2009-2018 ABB. All rights reserved.
 3 Maintenance
3.4.3 Changing the oil, axis-1 gearbox on suspended robots
Continued

Equipment Note
Oil change equipment
Hose Used with the oil dispenser
Standard toolkit Content is defined in section Standard tools
on page 441.

Draining, axis-1 gearbox

Use this procedure to drain the gearbox of oil.

Tip

In order to save time, a pneumatic oil dispenser can be used to suck the oil out
from the gearbox.

Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2
WARNING

Handling gearbox oil involves several safety

risks. Before proceeding, please read the
safety information in the section Safety risks
during work with gearbox lubricants (oil or
grease) on page 39.

3
CAUTION

The gearbox can contain an excess of

pressure that can be hazardous. Open the
oil plug carefully in order to let out the ex-
cess pressure.

4 Connect the oil dispenser to the oil plug for See Required equipment on page 158.
draining.

xx1800001271

Continues on next page

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© Copyright 2009-2018 ABB. All rights reserved.
3 Maintenance
3.4.3 Changing the oil, axis-1 gearbox on suspended robots
Continued

Action Note
5 Put the end of the hose in an oil collecting The capacity of the vessel must be suffi-
vessel. cient to take the complete amount of oil.
6 Open the end plug of the hose.
7 Open the oil plug, venting. See Location of oil plugs on page 158.

xx1800001272

8 Using a low air pressure, start sucking the

oil out from the gearbox with the oil change
equipment.
9
WARNING

Used oil is hazardous material and must be

disposed of in a safe way. See section De-
commissioning on page 423 for more inform-
ation.

10 Let the oil drain until the gearbox is empty.

Tip
Note
Make a note how much oil was drained.
There will be some oil left in the gearbox The same amount shall later be refilled.
after draining. Measure the volume of the
drained oil in the vessel.

11 Remove the hose and clean it.

Filling oil, axis-1 gearbox

Use this procedure to fill the gearbox with oil.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

Continues on next page

160 Product manual - IRB 2600
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© Copyright 2009-2018 ABB. All rights reserved.
 3 Maintenance
3.4.3 Changing the oil, axis-1 gearbox on suspended robots
Continued

Action Note
2
WARNING

Handling gearbox oil involves several safety

risks. Before proceeding, please read the safety
information in the section Safety risks during
work with gearbox lubricants (oil or grease) on
page 39.

3
CAUTION

The gearbox can contain an excess of pressure

that can be hazardous. Open the oil plug care-
fully in order to let out the excess pressure.

4 Verify that the hose of the oil change equipment

is clean and then fit the quick connection to the
oil plug for filling.

xx1800001271

5 Open the oil plug for venting.

xx1800001272

6 Prepare oil change equipment with the same Where to find type of oil and total
amount of lubrication oil that was drained. amount is detailed in Type and
amount of oil in gearboxes on
Note page 148.

The amount of oil to be filled depends on the

amount previously being drained.

7 Inspect the oil level. How to inspect the oil level is de-
scribed in section:
• Inspecting oil level, axis-1
gearbox on page 119
8 Disconnect the oil change equipment and put
on the protective hood on the oil plug.

Continues on next page

Product manual - IRB 2600 161
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© Copyright 2009-2018 ABB. All rights reserved.
3 Maintenance
3.4.3 Changing the oil, axis-1 gearbox on suspended robots
Continued

Action Note
9 Refit the oil plug for venting. Tightening torque:
• 3-8 Nm
Note

Before refitting the oil plug in the gearbox, al-

ways replace the oil plug sealing washer with
a new one. If not there is a risk of leakage.

Expansion container axis-1 gearbox, suspended mounted robots

When the robot is fitted in a suspended mounted position, an expansion container
for oil must be fitted on gearbox axis 1.

xx0900000129

A Expansion container

Note

The expansion container is installed on delivery on the robot if ordered as option

suspended/inverted mounted. If a floor mounted robot shall be fitted in a
suspended mounted position, an expansion container must be installed. See
Installing an expansion container on page 97.

162 Product manual - IRB 2600

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 3 Maintenance
3.4.4 Changing the oil, axis-2 gearbox

3.4.4 Changing the oil, axis-2 gearbox

Location of oil plugs

The axis-2 gearbox is located in the lower arm rotational center, underneath the
motor attachment.
Oil plugs are shown in the figure.

xx0800000305

A Oil plug, filling (draining when robot is suspended)

B Oil plug, draining (filling when robot is suspended) (Quick connect fitting)

Note

On a wall-mounted IRB 2600 the oil plugs are rotated into such a position that it
is not possible to drain the oil, or fill the correct amount of oil. Therefore it is
recommended that the manipulator is being taken down when changing oil.

Required equipment

Equipment Note
Oil plug sealing washer, gearbox 3HAC029646-001
Lubricating oil Information about the oil is found in Technical
reference manual - Lubrication in gearboxes.
See Type and amount of oil in gearboxes on
page 148.
Oil collecting vessel The capacity of the vessel must be sufficient
to take the complete amount of oil.
Nipple (TEMA IF 3820 S06) To be fitted on a hose, and then used for
draining connected to the quick connect fit-
ting.
See Location of oil plugs on page 163.

Continues on next page

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© Copyright 2009-2018 ABB. All rights reserved.
3 Maintenance
3.4.4 Changing the oil, axis-2 gearbox
Continued

Equipment Note
Standard toolkit Content is defined in section Standard tools
on page 441.

Draining, axis-2 gearbox

Use this procedure to drain the gearbox of oil.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2
WARNING

Handling gearbox oil involves several safety

risks. Before proceeding, please read the
safety information in the section Safety risks
during work with gearbox lubricants (oil or
grease) on page 39.

3
CAUTION

The gearbox can contain an excess of

pressure that can be hazardous. Open the
oil plug carefully in order to let out the ex-
cess pressure.

4 Either See the figure in:

• connect a nipple to the quick connect • Location of oil plugs on page 163
fitting in the hole for draining
or
• remove the quick connect fitting.
5 Open the oil plug, filling. See the figure in:
• Location of oil plugs on page 163

Note

Drainage will be quicker if the oil plug,

filling is removed.

6 Drain the gearbox oil using an oil collecting

vessel. Note

Draining is time-consuming.
Elapsed time varies depending on the
temperature of the oil.

Continues on next page

164 Product manual - IRB 2600
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 3 Maintenance
3.4.4 Changing the oil, axis-2 gearbox
Continued

Action Note
7
WARNING

Used oil is hazardous material and must be

disposed of in a safe way. See section De-
commissioning on page 423 for more inform-
ation.

8
Note

There will be some oil left in the gearbox

after draining.

9 Refit oil plug. Tightening torque:

• 24 Nm
Note

Before refitting the oil plug in the gearbox,

always replace the oil plug sealing washer
with a new one. If not there is a risk of
leakage.

Filling oil, axis-2 gearbox

Use this procedure to fill the gearbox with oil.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2
WARNING

Handling gearbox oil involves several safety

risks. Before proceeding, please read the
safety information in the section Safety risks
during work with gearbox lubricants (oil or
grease) on page 39.

3
CAUTION

The gearbox can contain an excess of

pressure that can be hazardous. Open the
oil plug carefully in order to let out the ex-
cess pressure.

4 Open oil plug, filling. See the figure in:

• Location of oil plugs on page 163

Continues on next page

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© Copyright 2009-2018 ABB. All rights reserved.
3 Maintenance
3.4.4 Changing the oil, axis-2 gearbox
Continued

Action Note
5 Refill the gearbox with lubrication oil. Where to find type of oil and total amount
is detailed in Type and amount of oil in
Note gearboxes on page 148.

The amount of oil to be filled depends on

the amount previously being drained.

6 Inspect the oil level. How to inspect the oil level is described
in section:
• Inspecting the oil level, axis 2
gearbox on page 124
7 Refit oil plug. Tightening torque:
• 24 Nm
Note

Before refitting the oil plug in the gearbox,

always replace the oil plug sealing washer
with a new one. If not there is a risk of
leakage.

166 Product manual - IRB 2600

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© Copyright 2009-2018 ABB. All rights reserved.
 3 Maintenance
3.4.5 Changing the oil, axis-3 gearbox

3.4.5 Changing the oil, axis-3 gearbox

Location of oil plugs

The axis-3 gearbox is located in the upper arm rotational center.
Oil plugs are shown in the figure.

xx0800000306

A Oil plug, armhouse

B Oil plug, gearbox (not visible in this figure)

Required equipment

Equipment Note
Lubricating oil Information about the oil is found in Technical
reference manual - Lubrication in gearboxes.
See Type and amount of oil in gearboxes on
page 148.
Oil collecting vessel The capacity of the vessel must be sufficient
to take the complete amount of oil.
Oil dispenser One example of oil dispenser can be found
in section:
• Type of lubrication in gearboxes on
page 148
Funnel

xx1200000862

Standard toolkit Content is defined in section Standard tools

on page 441.

Continues on next page

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© Copyright 2009-2018 ABB. All rights reserved.
3 Maintenance
3.4.5 Changing the oil, axis-3 gearbox
Continued

Draining, axis-3 gearbox

Use this procedure to drain the gearbox of oil.
Action Note
1 Move the robot to an upright position as shown
in the figure.

xx0800000327

• A: Oil collecting vessel

2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

3
WARNING

Handling gearbox oil involves several safety

risks. Before proceeding, please read the safety
information in the section Safety risks during
work with gearbox lubricants (oil or grease) on
page 39.

4
CAUTION

The gearbox can contain an excess of pressure

that can be hazardous. Open the oil plug care-
fully in order to let out the excess pressure.

5 Open the oil plug, armhouse See the figure in:

• Location of oil plugs on page 167
6 Open the oil plug, gearbox and use it as a See the figure in:
ventilation hole. • Location of oil plugs on page 167

Continues on next page

168 Product manual - IRB 2600
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© Copyright 2009-2018 ABB. All rights reserved.
 3 Maintenance
3.4.5 Changing the oil, axis-3 gearbox
Continued

Action Note
7 Drain the gearbox oil using an oil collecting
vessel. Note

Draining is time-consuming.
Elapsed time varies depending on the
temperature of the oil.

8
WARNING

Used oil is hazardous material and must be

disposed of in a proper way. See section De-
commissioning for more information.

9 Refit oil plugs. Tightening torque:

• in armhouse: 10 Nm
• in gearbox: 3 Nm

Filling oil, axis-3 gearbox

Use this procedure to fill the gearbox with oil.
Action Note
1 Move the upper arm to a position where the
wrist is pointing towards the floor as shown in
the figure.

xx0800000329

2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

3
WARNING

Handling gearbox oil involves several safety

risks. Before proceeding, please read the safety
information in the section Safety risks during
work with gearbox lubricants (oil or grease) on
page 39.

Continues on next page

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© Copyright 2009-2018 ABB. All rights reserved.
3 Maintenance
3.4.5 Changing the oil, axis-3 gearbox
Continued

Action Note
4
CAUTION

The gearbox can contain an excess of pressure

that can be hazardous. Open the oil plug care-
fully in order to let out the excess pressure.

5 Open the oil plug, armhouse. See the figure in:

• Location of oil plugs on page 167
6 Refill the gearbox with lubricating oil. Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
Tip page 148.

Use a funnel.

Note

The amount of oil to be filled depends on the

amount previously being drained.

7 Inspect the oil level. How to inspect oil is described in

section:
• Inspecting the oil level, axis 3
gearbox on page 127
8 Refit the oil plug. Tightening torque:
• in armhouse: 10 Nm
• in gearbox: 3 Nm

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 3 Maintenance
3.4.6 Changing the oil, axis-4 gearbox

3.4.6 Changing the oil, axis-4 gearbox

Location of oil plugs

The axis-4 gearbox is located in the front of the upper armhouse.
The oil plug is shown in the figure.
The figure shows IRB 2600 Standard but the position of oil plug is the same on
IRB2600ID.

xx0900000311

A Oil plug, for filling and draining

Required equipment

Equipment Note
Lubricating oil Where to find information of the type of oil,
article number and the amount in the gear-
box, see section Type of lubrication in gear-
boxes on page 148
Oil collecting vessel The capacity of the vessel must be sufficient
to take the complete amount of oil.
Plastic hose Used for venting the gearbox during draining.
A suitable hose would be a hose normally
used for compressed air.
Length: minimum 300 mm. Diameter: 5 mm.
Funnel

xx1200000862

Standard toolkit Content is defined in section Standard tools

on page 441.

Continues on next page

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3 Maintenance
3.4.6 Changing the oil, axis-4 gearbox
Continued

Draining oil
Use this procedure to drain oil from the gearbox.
Action Note
1 Move the robot to the position shown in the
figure.

xx0800000328

• A: Oil collecting vessel

2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3
WARNING

Handling gearbox oil involves several safety

risks. Before proceeding, please read the
safety information in the section Safety risks
during work with gearbox lubricants (oil or
grease) on page 39.

4
CAUTION

The gearbox can contain an excess of

pressure that can be hazardous. Open the
oil plug carefully in order to let out the ex-
cess pressure.

5 Open oil plug, draining. See the figure in:

• Location of oil plugs on page 171
6 Drain the gearbox oil using an oil collecting
vessel. Note

Draining is time-consuming.
Tip
Elapsed time varies depending on the
temperature of the oil.
Insert a compressed air hose approximately
100 mm into the gearbox, to vent the gear-
box.
This speeds up the draining significantly.

Continues on next page

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 3 Maintenance
3.4.6 Changing the oil, axis-4 gearbox
Continued

Action Note
7
WARNING

Used oil is hazardous material and must be

disposed of in a safe way. See section De-
commissioning on page 423 for more inform-
ation.

8 Refit the oil plug. Tightening torque: 10 Nm.

Filling oil
Use this procedure to fill oil in the gearbox.
Action Note
1 Move the upper arm to the position shown
in the figure.

xx0800000330

2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3
WARNING

Handling gearbox oil involves several safety

risks. Before proceeding, please read the
safety information in the section Safety risks
during work with gearbox lubricants (oil or
grease) on page 39.

Continues on next page

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3 Maintenance
3.4.6 Changing the oil, axis-4 gearbox
Continued

Action Note
4
CAUTION

The gearbox can contain an excess of

pressure that can be hazardous. Open the
oil plug carefully in order to let out the ex-
cess pressure.

5 Open the oil plug, filling. See the figure in:

• Location of oil plugs on page 171
6 Refill the gearbox with lubricating oil. Where to find type of oil and total amount
is detailed in Type and amount of oil in
gearboxes on page 148.
Tip

Use a funnel.

Note

The amount of oil to be filled depends on

the amount previously being drained.

7 Refit the oil plug. Tightening torque: 10 Nm.

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 3 Maintenance
3.4.7 Changing oil, axes-5 and -6 gearboxes

3.4.7 Changing oil, axes-5 and -6 gearboxes

Location of oil plugs

The axes-5 and -6 gearboxes are located in the wrist unit.
The oil plug is shown in the figure.
The figure shows wrist variant 12/20 kg

xx0900000139

A Oil plug, tilthouse

B Oil plug, wrist (also used as air inlet when draining from oil plug A)

Wrist IRB 2600ID shown in position for filling.

xx1000000987

A Oil plug, filling

B Oil plug, draining

Continues on next page

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3 Maintenance
3.4.7 Changing oil, axes-5 and -6 gearboxes
Continued

Note

The gearboxes for axes-5 and -6 are the same.

Required equipment

Equipment Note
Lubrication oil Where to find information of the type of oil,
article number and the amount in the gear-
box, see section: Type of lubrication in gear-
boxes on page 148
Oil collecting vessel The capacity of the vessel must be sufficient
to take the complete amount of oil.
Standard toolkit Content is defined in section Standard tools
on page 441.

Draining axes-5 and -6 gearbox - wrist 12/20 kg

Use this procedure to drain oil from the gearbox.

CAUTION

The gearbox can contain an excess of pressure that can be hazardous. Open
the oil plug carefully in order to let out the excess pressure.

Action Note
1 Move the upper arm to a horizontal position.
2 Turn axis-4 to the calibration position.
3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

4
WARNING

Handling gearbox oil involves several safety

risks. Before proceeding, please read the
safety information in the section Safety risks
during work with gearbox lubricants (oil or
grease) on page 39.

5 Remove the oil plugs in the wrist. See the figure in:
• Location of oil plugs on page 175
6 Turn axis-4 through 90° so that the oil plug
on the side of the wrist points downwards.
7 Then turn axis-4 another 90°.

Continues on next page

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 3 Maintenance
3.4.7 Changing oil, axes-5 and -6 gearboxes
Continued

Action Note
8 Let the remaining oil run out through the oil
plug hole, tilthouse.

Filling oil axes-5 and -6 gearbox - wrist 12/20 kg

Use this procedure to fill oil in the gearbox.

CAUTION

The gearbox can contain an excess of pressure that can be hazardous. Open
the oil plug carefully in order to let out the excess pressure.

Action Note
1 Run the upper arm to a horizontal position.
2 Turn axis-4 to the calibration position.
3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

4
WARNING

Handling gearbox oil involves several safety

risks. Before proceeding, please read the
safety information in the section Safety risks
during work with gearbox lubricants (oil or
grease) on page 39.

5 Open the oil plug, tilthouse. See in figure:

• Location of oil plugs on page 175
6 Refill the gearbox with lubrication oil. Where to find type of oil and total amount
is detailed in Type and amount of oil in
Note gearboxes on page 148.

The amount of oil to be filled depends on

the amount previously being drained.

7 Inspect the oil level. How to inspect the oil level is described
in section:
• Inspecting oil level, gearbox axes
5 - 6 on page 131
8
Note

If the robot is fitted in a suspended position,

the wrist should be turned 180°.

Continues on next page

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3 Maintenance
3.4.7 Changing oil, axes-5 and -6 gearboxes
Continued

Action Note
9 Refit the oil plugs. Tightening torque:
• 10 Nm

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 3 Maintenance
3.4.8 Replacing SMB battery

3.4.8 Replacing SMB battery

Note

The battery low alert (38213 Battery charge low) is displayed when the battery
needs to be replaced. The recommendation to avoid an unsynchronized robot
is to keep the power to the controller turned on until the battery is to be replaced.
For an SMB board with 3-pole battery contact (RMU101 3HAC044168-001 or
RMU102 3HAC043904-001), the lifetime of a new battery is typically 36 months.
For an SMB board with 2-pole battery contact, the typical lifetime of a new battery
is 36 months if the robot is powered off 2 days/week or 18 months if the robot is
powered off 16 h/day. The lifetime can be extended for longer production breaks
with a battery shutdown service routine. See Operating manual - IRC5 with
FlexPendant for instructions.

WARNING

See instructions for batteries, Safety risks during handling of batteries on page 38.

Continues on next page

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3 Maintenance
3.4.8 Replacing SMB battery
Continued

Location of SMB battery

The SMB battery is located at the base of the robot, as shown in the figure.

DSQC 633A

xx0800000322

A SMB battery (2-pole battery contact)

B Battery cover
C Attachment screws
D SMB battery cable
E How to arrange the battery cable

Continues on next page

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 3 Maintenance
3.4.8 Replacing SMB battery
Continued

RMU 101

A
B
xx1300000339

A SMB battery (3-pole battery contact)

B Battery cover

Required equipment

Note

There are two variants of SMB units and batteries. One with 2-pole battery contact
and one with 3-pole battery contact. The variant with the 3-pole battery contact
has longer lifetime for the battery.
It is important that the SMB unit uses the correct battery. Make sure to order the
correct spare parts. Do not replace the battery contact!

Equipment Note
SMB battery pack Battery includes protection circuits. Replace it only with given
spare part no. or an ABB approved equivalent.
See Spare part lists on page 445.
Standard toolkit Content is defined in section Standard tools on page 441.
Circuit diagram See chapter Circuit diagram on page 447.

Removing SMB battery

Use this procedure to remove the SMB battery.
Action Note
1 Move the robot to its calibration position. This is done in order to facilitate
the updating of the revolution
counter.

Continues on next page

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3 Maintenance
3.4.8 Replacing SMB battery
Continued

Action Note
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working area.

3
ELECTROSTATIC DISCHARGE (ESD)

The unit is sensitive to ESD. Before handling the

unit please read the safety information in the section
The unit is sensitive to ESD on page 33

4 Remove the SMB battery cover. See the figure in Location of SMB
battery on page 180.
CAUTION

Clean cover from metal residues before opening.

Metal residues can cause shortage on the boards
which can result in hazardous failures.

5 Pull out the SMB battery. See the figure in Location of SMB
battery on page 180.
6 Disconnect the battery cable and remove the bat- See the figure in Location of SMB
tery. battery on page 180.
7 How to dispose of the used SMB battery, see
chapter Decommissioning on page 423.

Refitting SMB battery

Use this procedure to refit the SMB battery.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working area.

2
ELECTROSTATIC DISCHARGE (ESD)

The unit is sensitive to ESD. Before handling the

unit please read the safety information in the section
The unit is sensitive to ESD on page 33

3 Reconnect the battery cable to the SMB battery. See the figure in Location of SMB
battery on page 180.

Continues on next page

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 3 Maintenance
3.4.8 Replacing SMB battery
Continued

Action Note
4 Put the battery unit into its recess while arranging See the figure in Location of SMB
the SMB cables as shown in the figure. battery on page 180.
5 Secure the SMB cover with its attachment screws. See the figure in Location of SMB
battery on page 180.
6 Update the revolution counter. Detailed in Updating revolution
counters on page 399.
7
DANGER

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 28.

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3 Maintenance
3.5.1 Cleaning the IRB 2600/IRB 2600 ID

3.5 Cleaning

3.5.1 Cleaning the IRB 2600/IRB 2600 ID

WARNING

Turn off all electrical power supplies to the manipulator before entering its work
space.

General
To secure high uptime it is important that the IRB 2600/IRB 2600 ID is cleaned
regularly. The frequency of cleaning depends on the environment in which the
product works.
Different cleaning methods are allowed depending on the type of protection of the
IRB 2600/IRB 2600 ID.

Note

Always verify the protection type of the robot before cleaning.

Oil spills
Oil spills from gearboxes
Use the following procedure if any oil spills are detected that can be suspected to
originate from a gearbox.
1 Inspect that the oil level in the suspected gearbox is according to the
recommendations, see Inspection activities on page 119.
2 Write down the oil level.
3 Inspect the oil level again after, for example, 6 months.
4 If the oil level is decreased then replace the gearbox.

Special cleaning considerations

This section specifies some special considerations when cleaning the robot.
• Always use cleaning equipment as specified. Any other cleaning equipment
may shorten the life of the robot.
• Always check that all protective covers are fitted to the robot before cleaning.
• 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.
• Do not remove any covers or other protective devices before cleaning the
robot.

Continues on next page

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 3 Maintenance
3.5.1 Cleaning the IRB 2600/IRB 2600 ID
Continued

Cleaning methods
The following table defines what cleaning methods are allowed depending on the
protection type.

Note

Rinsing with water is not allowed for a robot with integrated dressing (ID variants).

Protection Cleaning method

type
Vacuum Wipe with cloth Rinse with water i High pressure water or
cleaner steam
Standard Yes Yes. With light Yes. It is highly re- No
cleaning deter- commended that
gent. the water contains
a rust-prevention
solution and that
the manipulator is
dried afterwards.
Foundry Plus Yes Yes. With light Yes. It is highly re- Yes ii .
cleaning deter- commended that It is highly recommended
gent or spirit. the water contains that the water and steam
a rust-prevention contains rust preventive,
solution. without cleaning deter-
gents.
i Rinsing with water is not allowed for a robot with integrated dressing (ID variants)!
ii Perform according to section Cleaning with water and steam on page 185.

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). 1
The following list defines the prerequisites:
• Maximum water pressure at the nozzle: 700 kN/m 2 (7 bar) I

• Fan jet nozzle should be used, min. 45° spread

• Minimum distance from nozzle to encapsulation: 0.4 meters
• Maximum flow: 20 liters/min I
I Typical tap water pressure and flow

Instructions for steam or high pressure water cleaning

ABB robots with protection types Foundry Plus, Wash, or Foundry Prime can be
cleaned using a steam cleaner or high pressure water cleaner. 2
The following list defines the prerequisites:
• Maximum water pressure at the nozzle: 2500 kN/m 2 (25 bar)
• Fan jet nozzle should be used, min. 45° spread
• Minimum distance from nozzle to encapsulation: 0.4 meters
• Maximum water temperature: 80° C

1 See Cleaning methods on page 185 for exceptions.

2 See Cleaning methods on page 185 for exceptions.

Continues on next page

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3 Maintenance
3.5.1 Cleaning the IRB 2600/IRB 2600 ID
Continued

Cables
Movable cables need to be able to move freely:
• Remove waste material, such as sand, dust and chips, if it prevents cable
movement.
• Clean the cables if they have a crusty surface, for example from dry release
agents.

Cooling fans
Inspect the air supply inlet of the the motor cooling fans. Clean to remove any
contamination that could hinder the air supply.

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 4 Repair
4.1 Introduction

4 Repair
4.1 Introduction

Structure of this chapter

This chapter describes all repair activities recommended for the IRB 2600/IRB 2600
ID and any external unit.
It is made up of separate procedures, each describing a specific repair activity.
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.
The details of equipment are also available in different lists in the chapter Reference
information on page 433.

Safety information
There are general safety information and specific safety information. The specific
safety information describes the danger and safety risks while performing specific
steps in a procedure. Make sure to read through the chapter Safety on page 19
before commencing any service work.

Note

If the IRB 2600/IRB 2600 ID is connected to power, always make sure that the
IRB 2600/IRB 2600 ID is connected to earth before starting any repair work.
For more information see:
• Product manual - IRC5

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4 Repair
4.2.1 Performing a leak-down test

4.2 General procedures

4.2.1 Performing a leak-down test

When to perform a leak-down test

After refitting any motor and gearbox, the integrity of all seals enclosing the gearbox
oil must be tested. This is done in a leak-down test.

Required equipment

Equipment, etc. Article number Note

Leak-down tester -
Leak detection spray -

Performing a leak-down test

Action Note
1 Finish the refitting procedure of the motor or gear in
question.
2 Remove the upper oil plug on the gear and replace
it with the leak-down tester.
Regulators, which are included in the leak-down test,
may be required.
3 Use caution, apply compressed air and raise the Correct value:
pressure with the knob until the correct value is 0.2-0.25 bar (20-25 kPa)
shown on the manometer.

CAUTION

The pressure must under no circumstance be higher

than 0.25 bar (20-25 kPa). Also during the time when
the pressure is raised.

4 Disconnect the compressed air supply.

5 Wait for approximately 8-10 minutes and make sure If the compressed air is signific-
that no pressure loss occurs. antly colder or warmer than the
gearbox to be tested, a slight
pressure increase or decrease
may occur. This is quite normal.
6 If any pressure drop occurred, then localize the leak
as described in step 7.
If no pressure drop occurred, then remove the leak-
down tester and refit the oil plug. The test is complete.
7 Spray any suspected leak areas with the leak detec-
tion spray. Bubbles indicate a leak.
8 When the leak has been localized, take the necessary
measures to correct the leak.

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 4 Repair
4.2.2 Mounting instructions for bearings

4.2.2 Mounting instructions for bearings

General
This section describes how to mount and grease different types of bearings on the
robot.

Equipment

Equipment, etc. Article number Note

Grease 3HAB3537-1 Used to grease the bearings, if not
specified otherwise.

Assembly of all bearings

Attend to the following instructions while mounting a bearing on the robot.
Action Note
1 To avoid contamination, let a new bearing remain in its wrapping
until it is time for fitting.
2 Ensure that the parts included in the bearing fitting are free from
burrs, grinding waste, and other contamination. Cast components
must be free of foundry sand.
3 Bearing rings, inner rings, and roller elements must not be subjec-
ted to direct impact. The roller elements must not be exposed to
any stresses during the assembly work.

Assembly of tapered bearings

Follow the preceding instructions for the assembly of the bearings when mounting
a tapered bearing on the robot.
In addition to those instructions, the following procedure must be carried out to
enable the roller elements to adjust to the correct position against the race flange.
Action Note
1 Tension the bearing gradually until the recommended pre-tension is achieved.

Note

The roller elements must be rotated a specified number of turns before pre-
tensioning is carried out and also rotated during the pre-tensioning sequence.

2 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

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4 Repair
4.2.2 Mounting instructions for bearings
Continued

The bearings must be greased after assembly according to the following

instructions:
• The bearings must not be completely filled with grease. However, if space
is available beside the bearing fitting, the bearing may be totally filled with
grease when mounted, as excessive grease will be pressed out from the
bearing when the robot is started.
• During operation, the bearing should be filled to 70-80% of the available
volume.
• Ensure that grease is handled and stored properly to avoid contamination.
Grease the different types of bearings as following description:
• 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.

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 4 Repair
4.2.3 Mounting instructions for seals

4.2.3 Mounting instructions for seals

General
This section describes how to mount different types of seals.

Equipment

Equipment, etc. Article number Note

Grease 3HAB3537-1 Used to lubricate the seals.

Rotating seals
The procedure below describes how to fit rotating seals.

CAUTION

Please observe the following before commencing any assembly of seals:

• Protect the sealing surfaces during transport and mounting.
• Keep the seal in its original wrappings or protect it well before actual
mounting.
• The fitting of seals and gears must be carried out on clean workbenches.
• Use a protective sleeve for the sealing lip during mounting, when sliding
over threads, keyways, etc.

Action Note
1 Check the seal to ensure that:
• The seal is of the correct type (provided with cutting
edge).
• There is no damage to the sealing edge (feel with a
fingernail).
2 Inspect the sealing surface before mounting. If scratches
or damage are found, the seal must be replaced since it
may result in future leakage.
3 Lubricate the seal with grease just before fitting. (Not too Article number is specified
early - there is a risk of dirt and foreign particles adhering in Equipment on page 191.
to the seal.)
Fill 2/3 of the space between the dust tongue and sealing
lip with grease. The rubber coated external diameter must
also be greased, unless otherwise specified.
4 Mount the seal correctly with a mounting tool.
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

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4 Repair
4.2.3 Mounting instructions for seals
Continued

Flange seals and static seals

The following procedure describes how to fit flange seals and static seals.
Action
1 Check the flange surfaces. They must be even and free from pores.
It is easy to check flatness using a gauge on the fastened joint (without sealing com-
pound).
If the flange surfaces are defective, the parts may not be used because leakage could
occur.
2 Clean the surfaces properly in accordance with the recommendations of ABB.
3 Distribute the sealing compound evenly over the surface, preferably with a brush.
4 Tighten the screws evenly when fastening the flange joint.

O-rings
The following procedure describes how to fit o-rings.
Action Note
1 Ensure that the correct o-ring size is used.
2 Check the o-ring for surface defects, burrs, Defective o-rings, including damaged
shape accuracy, or deformation. or deformed o-rings, may not be used.
3 Check the o-ring grooves. Defective o-rings may not be used.
The grooves must be geometrically correct and
should be free of pores and contamination.
4 Lubricate the o-ring with grease.
5 Tighten the screws evenly while assembling.
Make sure that no grease is left on the robot
surface.

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 4 Repair
4.2.4 Cut the paint or surface on the robot before replacing parts

4.2.4 Cut the paint or surface on the robot before replacing parts

General
Follow the procedures in this section whenever breaking the paint of the robot
during replacement of parts.

Required equipment

Equipment Spare parts Note

Cleaning agent Ethanol
Knife
Lint free cloth
Touch up paint Standard/Foundry 3HAC037052-001
Plus, ABB Orange

Removing

Action Description
1 Cut the paint with a knife in the joint between
the part that will be removed and the struc-
ture, to avoid that the paint cracks.

xx0900000121

2 Carefully grind the paint edge that is left on

the structure to a smooth surface.

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4 Repair
4.2.5 The brake release buttons may be jammed after service work

4.2.5 The brake release buttons may be jammed after service work

Description
The brake release unit has push-buttons for the brake release of each axis motor.
When service work is performed inside the SMB recess that includes removal and
refitting of the brake release unit, the brake release buttons may be jammed after
refitting.

DANGER

If the power is turned on while a brake release button is jammed in depressed

position, the affected motor brake is released. This may cause serious personal
injuries and damage to the robot.

Elimination
To eliminate the danger after service work has been performed inside the SMB
recess, follow the procedure below.
Action
1 Make sure the power is turned off.
2 Remove the push-button guard, if necessary.
3 Verify that the push-buttons of the brake release unit are working by pressing them
down, one by one.
Make sure none of the buttons are jammed in the tube.
4 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.

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 4 Repair
4.3.1 Removing the complete cable harness

4.3 Complete robot

4.3.1 Removing the complete cable harness

Introduction
This procedure describes how to remove the cable harness on the different variants
of IRB 2600:
• IRB 2600 Standard: Axes 1, 2, 3, 4, 5 and 6
• IRB 2600ID: Axes 1, 2, 3 and 4. How to remove the cable harness on axes 5
and 6 is described in section Replacing the cable harness in the upper arm
- IRB 2600ID on page 222.
How to refit the cable harness is described in section Refitting the complete cable
harness on page 207.
The removal procedure is presented in the order the work is recommended to be
performed. Therefore the order is different in the two procedures removal and
refitting of the cable harness. Cross references will make it easy to find what is
needed to know as the work continues.
The section Removing the complete cable harness consists of the following parts
presented in the order the work is recommended to be performed:
• Removal in the base Removing cable harness in base on page 198
• Removal in the frame Removing cable harness in frame on page 203
• Removal in lower arm and armhouse Removing cable harness in lower arm
and armhouse on page 204.
How to replace the SMB unit, brake release unit and motors can be found in:
• SMB unit Removing the SMB unit on page 235
• Brake release unit Removing the brake release board on page 241
• Motors Removing motors on page 301

Continues on next page

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4 Repair
4.3.1 Removing the complete cable harness
Continued

Location of the cable harness

The location of the cable harness in the base, frame and lower arm is shown in the
figures.
Cable harness, base and frame.

xx0900000009

A Cover base
B Bracket
C Cable harness
D Axis-1 motor cable
E Axis-2 motor cable
F Axis-2 motor
G Axis-1 motor

Continues on next page

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 4 Repair
4.3.1 Removing the complete cable harness
Continued

xx0900000384

A Cable harness
B Bracket, lower arm
C Bracket, lower arm
D Cable straps, one not visible here (steel)
E Bracket, frame
F Cable strap, lower arm (plastic)
G Bracket, upper arm

Required equipment

Equipment Note
Deep well hexagon socket Width 30 mm
Standard toolkit Content is defined in section Standard tools
on page 441.
Other tools and procedures may be re- These procedures include references to the
quired. See references to these procedures tools required.
in the step-by-step instructions below.

Continues on next page

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4 Repair
4.3.1 Removing the complete cable harness
Continued

Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Action Note
1 Decide which calibration routine to use for
calibrating the robot.
• Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
• Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
If the robot is to be calibrated with refer- Follow the instructions given in the refer-
ence calibration: ence calibration routine on the FlexPendant
Find previous reference values for the axis to create reference values.
or create new reference values. These val- Creating new values requires possibility to
ues are to be used after the repair proced- move the robot.
ure is completed, for calibration of the ro- Read more about reference calibration for
bot. Axis Calibration in Reference calibration
If no previous reference values exist, and routine on page 404.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Removing cable harness in base

Use this procedure to remove the cable harness in the base.
Action Note
1 Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Continues on next page

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 4 Repair
4.3.1 Removing the complete cable harness
Continued

Action Note
3 Disconnect the following connectors on the
base cover:
• R1.CP/CS
• R1.MP
• R1.ETHERNET (if used)

Tip
xx0900000014
Do not remove the R1.SMB-connector and
air hose connector at this stage. It will be Parts:
easier to remove these two when the cover • A: R1.CP/CS
base has been removed. • B: R1.MP
• C: Air hose connector
• D: Position of R1.ETHERNET (if
used)
• E: R1.SMB
4 Remove the cover base.

C
xx0800000456

A Base
B Cover base
C Attachment screws
5 Disconnect connectors on the brake release
unit:
• X8
• X9
• X10

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4 Repair
4.3.1 Removing the complete cable harness
Continued

Action Note
6 Cut the cable straps securing the battery
cable.

xx0900000099

Parts:
• A: Cable straps (2 pcs)
7 Disconnect the battery cable.
8 Unscrew the thin nut securing the R1.SMB
connector on the outside of the bracket.

Tip

Use a deep well hexagon socket, width 30

mm (like the ones used for spark plugs, or A
similar).

xx1200000888 D
C
B
xx1200000889

A Thin nut, width 30 mm

B R1.SMB
C Bracket
D Air connector
9 Unscrew the nut for the air connection on
the inside of the bracket.

Continues on next page

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 4 Repair
4.3.1 Removing the complete cable harness
Continued

Action Note
10 Remove the screw that secures the bracket
and unscrew the three other screws a little
just enough to be able to slide the bracket
sideways.

xx0900000100

Parts:
• A: Screw to be removed
• B: Screws to be unscrewed (3 pcs)
11 Remove the bracket by sliding it off the re-
maining three attachment screws and put
it at a 90° angle from the base.
Putting the bracket at a 90° angle facilitates
the disconnecting of cables from the
bracket.

Note xx0900000013

Use caution when performing this procedure Parts:

in order not to damage cables or other • A: Bracket at a 90° angle
components! • B: Base

12 Remove connectors and air hose connector

completely from the bracket:
• R1.CP/CS
• R1.MP
• R1.SMB
• Air hose connector
• R1.ETHERNET (if used)

A
B
C
D
xx1200000890

A R1.CP/CS
B R1.MP
C Air hose connector
D R1.SMB
13 Remove the SMB unit from its attachment How to remove the SMB unit is described
screws. in section:
Leave the screws in the base. • Removing the SMB unit on page 235

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4 Repair
4.3.1 Removing the complete cable harness
Continued

Action Note
14 Disconnect connectors on the SMB unit:
• R1.SMB1-2
• R1.SMB2-6
• R2.SMB
15 Disconnect the screen connections of:
• R1.SMB1-2
• R1.SMB2-6

A
xx0900000035

Parts:
• A: Screen connection (4 pcs)
16 Disconnect the earth cables.

xx0900000015

Parts:
• A: Earth
• B: Distance screws

Continues on next page

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 4 Repair
4.3.1 Removing the complete cable harness
Continued

Action Note
17 Remove the bracket securing the cable
package inside the base on the left side, by
following these steps:
• Unscrew the attachment screws just
enough to be able to remove the
bracket.
• Lift the bracket off the screws.

xx0900000018

Parts:
• A: Base
• B: Attachment screws
• C: Bracket
18 Continue removal of the cable package from How to remove the cable package from
the frame. the frame is described in section
• Removing cable harness in frame
on page 203

Removing cable harness in frame

Use this procedure to remove the cable harness in the frame.

Tip

Before starting this procedure, first remove the cable harness in the base. See
Removing the complete cable harness on page 195.

Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2 Disconnect the motor cables on the axis-1 How to remove the motor cables is de-
and axis-2 motors. scribed in section:
• Removing motors on page 301
3 Remove the bracket securing the cable See the figure in:
package to the frame. • Location of the cable harness on
page 196

Continues on next page

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4 Repair
4.3.1 Removing the complete cable harness
Continued

Action Note
4 Cut the cable straps securing the cable See the figure in:
harness to the frame and lower arm. • Location of the cable harness on
page 196
5 Prepare the end of the cable package in the
base with tape as shown in the figure.

Tip

A
In order to protect the connectors from
getting residual grease on the cable har-
ness, put some plastic over them prior to F
pushing it through the hole in the frame.

C
B
xx1200000886

A Tape
B Connectors to SMB unit and Brake
release unit
C R1.CP/CS
D Air hose
E R1.MP
F R1.SMB (Connector bent and taped
upwards)
6 Pull out the cable package through the hole
in the frame.

Note

Use caution when performing this proced-

ure in order not to damage cables or other
components!

7 Continue the removal of the cable package How to remove the cable package from
from the lower arm and armhouse. the lower arm and armhouse is described
in section:
• Removing cable harness in lower
arm and armhouse on page 204

Removing cable harness in lower arm and armhouse

Use this procedure to remove the cable harness in the lower arm and armhouse.

Tip

Before starting this procedure, first remove the cable harness in the base
Removing the complete cable harness on page 195 and frame Removing the
complete cable harness on page 195.

Continues on next page

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 4 Repair
4.3.1 Removing the complete cable harness
Continued

Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2 Cut the cable strap on the lower arm. See the figure in:
• Location of the cable harness on
page 196 (Cable harness, lower arm)
3 Remove the brackets on the lower arm.

D
C

xx0900000020

Parts:
• A: Bracket, lower arm
• B: Bracket, lower arm
• C: Bracket, armhouse
• D: Cable bracket

Continues on next page

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4 Repair
4.3.1 Removing the complete cable harness
Continued

Action Note
4 Remove the bracket on the armhouse.

xx0800000335

Parts:
• A: Tubular shaft unit
• B: Attachment screws
• C: Bracket, armhouse
5 Remove the cable cover on the armhouse.

xx0800000338

Parts:
• A: Signal lamp
• B: Bracket
• C: Cable cover, armhouse
6 Remove signal lamp if used.
7 IRB 2600 Standard: How to remove the motor cables from the
Continue the removal of the cable package axis-3, axis-4, axis-5 and axis-6 motors
by disconnecting the motor cables of the see section:
axis-3, axis-4, axis-5 and axis-6 motors. • Removing motors on page 301

8 IRB 2600ID: How to remove the motor cables from

Continue the removal of the cable package motors axes 3 and 4 see section:
by disconnecting the motor cables of mo- • Removing motors on page 301
tors axes 3 and 4.
9 IRB 2600ID: See section
Remove the cable package in the upper • Replacing the cable harness in the
arm. upper arm - IRB 2600ID on page 222

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 4 Repair
4.3.2 Refitting the complete cable harness

4.3.2 Refitting the complete cable harness

Introduction
This procedure describes how to refit the cable harness on the different variants
of IRB 2600:
• IRB 2600 Standard: Axes 1, 2, 3, 4, 4, 5 and 6
• IRB 2600ID: Axes 1, 2, 3 and 4. How to refit the cable harness on axes 5 and
6 is described in section Replacing the cable harness in the upper arm - IRB
2600ID on page 222.
How to remove the cable harness is described in Removing the complete cable
harness on page 195.
The refitting procedure is presented in the order the work is recommended to be
performed.
Therefore the order is different in the two procedures removal and refitting of the
cable harness. Cross references will make it easy to find what is needed to know
as the work continues.
The section Refitting the complete cable harness consists of the following parts
presented in the order the work is recommended to be performed:
• Refitting in the frame Refitting the cable harness in the frame on page 210
• Refitting in the base Refitting the cable harness in the base on page 213
• Refitting in the lower arm and armhouse Refitting the cable harness in the
lower arm and armhouse on page 219.
How to refit the SMB unit, brake release unit and motors can be found in:
• SMB unit Refitting the SMB unit on page 238
• Brake release unit Refitting the brake release board on page 242
• Motors Refitting motors on page 313

Continues on next page

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4 Repair
4.3.2 Refitting the complete cable harness
Continued

Location of the cable harness

The location of the cable harness in the base, frame and lower arm is shown in the
figures.
Cable harness, base and frame.

xx0900000009

A Cover base
B Bracket
C Cable harness
D Axis-1 motor cable
E Axis-2 motor cable
F Axis-2 motor
G Axis-1 motor

Continues on next page

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 4 Repair
4.3.2 Refitting the complete cable harness
Continued

The figure shows IRB 2600 Standard but is also valid for IRB 2600ID.

xx0900000384

A Cable harness
B Bracket, lower arm
C Bracket, lower arm
D Cable straps, one not visible here (steel)
E Bracket, frame
F Cable strap (plastic)
G Bracket, upper arm

Required equipment

Equipment Note
Deep well hexagon socket Width 30 mm
Standard toolkit Content is defined in section Standard tools
on page 441.
Other tools and procedures may be re- These procedures include references to the
quired. See references to these procedures tools required.
in the step-by-step instructions below.
Cable grease Shell Alvania WR2

Continues on next page

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4 Repair
4.3.2 Refitting the complete cable harness
Continued

Refitting the cable harness in the frame

Use this procedure to refit the cable harness in the frame.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2 Apply cable grease on these surfaces: Cable grease is specified in:

• cable guide inside the hole • Required equipment on page 209
• the part of the cable harness that
runs through the cable guide.
3
Note

Two alternative methods to insert the cable

package in frame and base are presented
below. Chose one of the methods.

4 Use this procedure when replacing the old

cable harness:
Method 1, step 1:
Prepare the end of the cable package in the
base with tape as shown in the figure.
A

Tip
F

In order to protect the connectors from get-

ting residual grease on the cable harness,
put some plastic over them prior to pushing E
it through the hole in the frame.

C
B
xx1200000886

A Tape
B Connectors to SMB unit and Brake
release unit
C R1.CP/CS
D Air hose
E R1.MP
F R1.SMB (Connector bent and taped
upwards)

Continues on next page

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 4 Repair
4.3.2 Refitting the complete cable harness
Continued

Action Note
5 Use this procedure when replacing the old
cable harness:
Method 1, step 2:
Push the cable package carefully in through
the base and up through the hole in the
frame.

Note

Use caution when performing this procedure

in order not to damage cables or other
components!

6 Use this procedure when replacing the old

cable harness:
Method 2:
Push the cable harness carefully into the
hole in the frame and out of the hole in the
base.
Perform the procedure in the following or-
der:
• R1.MP
• R1.CP/CS
• R1.SMB1-2 and R1.SMB3-6
• Air hose.

Note

Use caution when performing this procedure

in order not to damage cables or other
components!

Tip

In order to protect the connectors from get-

ting residual grease on the cable harness,
put some plastic over them prior to pushing
it through the hole in the frame.

7 Use this procedure when fitting a new cable

harness: Note
Without removing the plastic around cables
and hose, push the cable harness through Check that cables and air hose are placed
the hole in the frame. as shown in the figure above.

Note

Use caution when performing this procedure

in order not to damage cables or other
components!

Continues on next page

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4 Repair
4.3.2 Refitting the complete cable harness
Continued

Action Note
8
Note

It is vital that the position of the air hose is

correct, as shown in the figure!

xx0900000096

Parts:
• A: Cables
• B: Air hose
• C: Hole in frame
• D: Cable guide
• E: Position of the front of the robot
9 Secure the cover to the frame with its attach-
ment screws.

xx0900000016

Parts:
• A: Frame
• B: Hole in frame
• C: Cover
10 Connect the axis-1 and axis-2 motor cables. How to refit the motor cables is described
in section:
• Refitting motors on page 313

Continues on next page

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 4 Repair
4.3.2 Refitting the complete cable harness
Continued

Action Note
11 Sort out the different cables the way they
later will be fit on the bracket in the base.

xx0900000017

Connections:
• A: Earth cables
• B: R1.SMB1-2
• C: R1.SMB3-6
• D: R2.SMB
• E: R1.CP/CS
• F: R1.MP
• G: Air hose
• H: Position of R1.ETHERNET (if
used)
• J: R1.SMB
12 Continue the refitting of the cable harness How to refit the cable harness in the base
in the base. is described in section:
• Refitting the cable harness in the
base on page 213

Refitting the cable harness in the base

Use this procedure to refit the cable harness in the base.

Tip

Before starting this procedure, first refit the cable harness in the frame. See:
• Refitting the complete cable harness on page 207

Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Continues on next page

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4 Repair
4.3.2 Refitting the complete cable harness
Continued

Action Note
2 Attach the cable harness to the bracket.

xx0900000098

Parts:
• A: Attachment screw and nut
• B: Bracket
• C: Cable harness
3 Secure the bracket on its attachment screws
in the base.

Tip

Perform this in the following order:

• Put the attachment screws in the
holes but do not tighten them yet (if
they have been removed earlier).
• Place the bracket on the attachment
screws.
• Secure the bracket with its attach-
ment screws.

xx0900000018

Parts:
• A: Base
• B: Attachment screws (2 pcs)
• C: Bracket

Continues on next page

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 4 Repair
4.3.2 Refitting the complete cable harness
Continued

Action Note
4 Refit the earth cables.

xx0900000015

Parts:
• A: Earth
• B: Distance screws
5 Connect the contacts on the SMB unit:
• R1.SMB1-2
• R1.SMB3-6
• R2.SMB
6 Refit the SMB unit. How to refit the SMB unit is described in
section:
• Refitting the SMB unit on page 238
7 Refit the cables with the screen connec-
tions.

A
xx0900000035

Parts:
• A: Screen connections (4 pcs)
8
Tip

When refitting connectors on the bracket,

put it at a 90° angle.

xx0900000013

Parts:
• A: Bracket
• B: Base

Continues on next page

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4 Repair
4.3.2 Refitting the complete cable harness
Continued

Action Note
9 Before refitting the connectors on the
bracket, arrange cables and connectors as
shown in the figure.

A B C
xx1200000857

A R1.CP/CS
B R1.MP
C Air hose
10 Refit the connectors and air hose on the
bracket:
• R1.CP/CS
• R1.ETHERNET (if used)
• R1.MP

Tip

Do not refit the R1.SMB-connector and air

hose at this stage. It will be easier to refit
these two when the bracket has been fitted
to the distance screws.

xx0900000017

Connectors:
• A: Earth cables
• B: R1.SMB1-2
• C: R1.SMB3-6
• D: R2.SMB
• E: R1.CP/CS
• F: R1.MP
• G: Air hose
• H: Position of R1.ETHERNET (if
used)
• J: R1.SMB

Continues on next page

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 4 Repair
4.3.2 Refitting the complete cable harness
Continued

Action Note
11 Secure the bracket on the distance screws.

B
C

D
xx1200000887

A Base
B Distance screw
C Attachment screw
D Bracket
12 Reconnect connectors on the brake release
unit:
• X8
• X9
• X10
13 Refit the R1.SMB-connector on the bracket.

Tip

Use a deep well hexagon socket, width 30

mm (like the ones used for spark plugs, or
similar). A

xx1200000888
D
C
B
xx1200000889

A Thin nut, width 30 mm

B R1.SMB
C Bracket
D Air connector
14 Refit the air hose connector on the bracket.

Note

Check that there is no leakage from the air

hose.

15 Reconnect the battery cable.

Continues on next page

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4 Repair
4.3.2 Refitting the complete cable harness
Continued

Action Note
16 Secure the battery cable with cable straps.

xx0900000099

Parts:
• A: Cable straps (2 pcs)
17 Use caution when pushing the base cover
into position while at the same time check-
ing that no cables are damaged.

C
xx0800000456

Parts:
• A: Base
• B: Base cover
• C: Attachment screws (6 pcs)
18 Secure the base cover with its attachment
screws.
19 Refit the bracket on the frame. See the figure in:
• Location of the cable harness on
page 208
20 Refit the cable straps securing the cable See the figure in:
harness to the frame. • Location of the cable harness on
page 208
21 Continue the refitting of the cable package How to refit the cable harness on the
on lower arm and armhouse. lower arm and armhouse is described in
section:
• Refitting the cable harness in the
lower arm and armhouse on
page 219

Continues on next page

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 4 Repair
4.3.2 Refitting the complete cable harness
Continued

Refitting the cable harness in the lower arm and armhouse

Use this procedure to refit the cable harness in the lower arm and armhouse.

Tip

Before starting this procedure, first refit the cable harness in the frame and base.
See:
• Refitting the complete cable harness on page 207
• Refitting the complete cable harness on page 207

Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2 Secure the brackets on the lower arm.

D
C

xx0900000020

Parts:
• A: Bracket, lower arm
• B: Bracket, lower arm
• C: Bracket, armhouse
• D: Cable bracket
3 Refit the cable straps securing the cable See the figure in:
harness to the lower arm. • Location of the cable harness on
page 208 (Cable harness, lower arm)
4 Push the cable harness carefully into the
armhouse.

Continues on next page

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4 Repair
4.3.2 Refitting the complete cable harness
Continued

Action Note
5 Secure the bracket, armhouse with its at-
tachment screws.

xx0800000335

Parts:
• A: Tubular shaft unit
• B: Attachment screws
• C: Bracket, armhouse
6 Secure the bracket to the armhouse with
its attachment screws.

xx0800000338

Parts:
• A: Signal lamp
• B: Bracket, armhouse
• C: Cable bracket
7 IRB 2600 Standard: How to connect the axis-3, axis-4, axis-5
Reconnect the axis-3, axis-4, axis-5 and and axis-6 motor cables, see:
axis-6 motor cables. • Refitting motors on page 313

8 IRB 2600ID: How to connect the axis-3 and axis-4 mo-

Reconnect the axis-3 and axis-4 motor tor cables, see section:
cables. • Refitting motors on page 313

9 IRB 2600ID: See section

Refit the cable package in the upper arm. • Replacing the cable harness in the
upper arm - IRB 2600ID on page 222

Continues on next page

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 4 Repair
4.3.2 Refitting the complete cable harness
Continued

Action Note
10 Recalibrate the robot. Pendulum Calibration is described in Op-
erating manual - Calibration Pendulum,
enclosed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 403.
General calibration information is included
in section Calibration on page 391.
11
WARNING

The cover on the armhouse must be fitted

when the robot is running. It is a vital part
for the stability of the robot.

12
DANGER

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 28.

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© Copyright 2009-2018 ABB. All rights reserved.
4 Repair
4.3.3 Replacing the cable harness in the upper arm - IRB 2600ID

4.3.3 Replacing the cable harness in the upper arm - IRB 2600ID

Introduction
This procedure describes how to replace the cable harness in the upper arm on
IRB 2600ID.

Note

In order to perform this procedure it is necessary to follow instructions in these

sections as well:
• Replacing motor axis 5 - IRB 2600ID on page 329
• Replacing motor axis 6 and wrist unit - IRB 2600ID on page 341

Location of the cable harness in the upper arm - IRB 2600ID

The location of the cable harness in the upper arm is shown in the figure.

xx1000001000

A Bracket (inside armhouse)

B Cover
C Cable harness
D Connectors motor axis 6 (2 pcs)
E Bracket (securing cable harness to arm tube)

Continues on next page

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 4 Repair
4.3.3 Replacing the cable harness in the upper arm - IRB 2600ID
Continued

Required equipment

Equipment Note
VK cover 2 pcs.
Art. no. is specified in Spare part lists on
page 445.
Sikaflex 521FC Art. no. 3HAC026759-001
Flange sealant 12340011-116
Loctite 574
Grease 3HAB3537-1
Shell Gadus S2V220 AC
For lubrication of the cable spiral.
Standard toolkit Content is defined in section Standard
tools on page 441.
Other tools and procedures may be required. These procedures include references to
See references to these procedures in the step- the tools required.
by-step instructions below.

Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Action Note
1 Decide which calibration routine to use for
calibrating the robot.
• Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
• Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
If the robot is to be calibrated with refer- Follow the instructions given in the refer-
ence calibration: ence calibration routine on the FlexPendant
Find previous reference values for the axis to create reference values.
or create new reference values. These val- Creating new values requires possibility to
ues are to be used after the repair proced- move the robot.
ure is completed, for calibration of the ro- Read more about reference calibration for
bot. Axis Calibration in Reference calibration
If no previous reference values exist, and routine on page 404.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
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 2600 223
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© Copyright 2009-2018 ABB. All rights reserved.
4 Repair
4.3.3 Replacing the cable harness in the upper arm - IRB 2600ID
Continued

Removing the cable harness

Use this procedure to remove the cable harness.
Action Information
1 Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.
2 Move the robot to synchronization position.
3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

4 Remove all extra equipment fitted on the

upper arm and wrist.
5 Secure the upper arm with roundslings in
an overhead crane or similar.
6 Remove the cover on the arm house.
7 Disconnect the cables to motors axes 3, 4,
5 and 6. D

A B C
xx1000000991

Parts:
A Motor axis 4
B Motor axis 3
C MP connectors axes 3, 4, 5 and 6
(see markings for axis)
D FP connectors axes 3, 4, 5 and 6
(see markings for axis)
8 Remove the wrist. See section
(This is done in order to be able to discon- • Removing the wrist unit on page 343
nect the motor cables of motor axis 6)
Note

No need to remove the axis-6 motor. Only

the motor cables need to be disconnected.

Continues on next page

224 Product manual - IRB 2600
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© Copyright 2009-2018 ABB. All rights reserved.
 4 Repair
4.3.3 Replacing the cable harness in the upper arm - IRB 2600ID
Continued

Action Information
9 Remove the mechanical stop, bracket and See section
cover . • Replacing motor axis 5 - IRB
2600ID on page 329

xx1000000879

Parts:
A Attachment screws (5 pcs)
B Mechanical stop
C O-ring
D Distance ring
E Bracket
F Cover
10 Remove the two VK-covers, covering the
attachment screws securing the cable har-
ness to the arm tube.

xx1000000934

Parts:
A VK-covers (2 pcs)

Continues on next page

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4 Repair
4.3.3 Replacing the cable harness in the upper arm - IRB 2600ID
Continued

Action Information
11 Remove the attachment screws (2 pcs),
securing the cable harness bracket to the
arm tube.

Note

The arm tube is not shown here.

xx1000000998

Parts:
A Bracket
B Attachment screws (2 pcs)
C Connectors motor axis 5
D Motor axis 5
12 Remove the attachment screws (A) securing
the cover (B) on the arm house.
13 Remove the attachment screws (C) (8 pcs)
securing the arm tube.

xx1000001001

Parts:
A Attachments screws (6 pcs)
B Cover
C Attachment screws (8 pcs) securing
arm tube
14 Pull out the tube of the arm house a little,
enough to be able to disconnect cables to
the axis-5 motor.
15 Disconnect connectors to motor axis 5. How to remove the motor cables, see:
• Replacing motor axis 5 - IRB
2600ID on page 329

Note

No need to remove motor axis 5!

16 Pull carefully out the cable harness off the

arm house at the same time as the tube of CAUTION
the arm house is pulled out.
Pull the cable harness out carefully! The
space in the armhouse is cramp.

17 Place the upper arm tube somewhere safe.

Continues on next page

226 Product manual - IRB 2600
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 4 Repair
4.3.3 Replacing the cable harness in the upper arm - IRB 2600ID
Continued

Action Information
18 Pull carefully out the cables off the hole in
the arm house from the arm house where
the connectors are.

xx1000000996

Part:
A Hole in arm house
19 Remove the cable harness.

Refitting cable harness

Use this procedure to refit the cable harness.
Action Information
1 Push carefully in the cables to the connect-
ors for motors axes 3, 4, 5 and 6 through
the hole in the arm house.

xx1000000996

Part:
A Hole for cables

Continues on next page

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4 Repair
4.3.3 Replacing the cable harness in the upper arm - IRB 2600ID
Continued

Action Information
2 Place the cable harness spiral into its pos- Grease: Shell Gadus S2V220 AC,
ition in the arm house. 3HAB3537-1.
Lubricate the cables in the spiral with
grease.

Note

Do not cut the strap used as transport

protection of the cable harness spiral at
this point!

xx1000001005

Parts:
A Cable harness spiral
B Attachment screws (8 pcs) M8x25
quality Steel 12.9 Gleitmo
3 Apply flange sealant on the surface where
the cover shall be fitted. See figure!

xx1000001006

Part:
A Flange sealant: Loctite 574,
12340011-116

Continues on next page

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 4 Repair
4.3.3 Replacing the cable harness in the upper arm - IRB 2600ID
Continued

Action Information
4 Secure the cover with its attachment Tightening torque: 10 Nm.
screws.

xx1000001001

Parts:
A Attachment screws (6 pcs) M6x20
quality 8.8-A2F
B Cover
C Attachment screws (8 pcs) M8x25
quality Steel 12.9 Gleitmo
5 Use an overhead crane (or similar) and lift
the upper arm tube almost all the way into Note
its position.
It must still be possible to reach inside the
armtube for the remaining assembly inside.

6 Push the motor cables for the axis-6 motor

through the upper arm tube.
7 Connect the connectors to the axis-5 mo-
tor.
8 Fit the bracket (A) to the arm house.

xx1000000998

Parts:
A Bracket
B Attachment screws (2 pcs)
C Connectors motor axis 5
D Motor axis 5

Continues on next page

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4 Repair
4.3.3 Replacing the cable harness in the upper arm - IRB 2600ID
Continued

Action Information
9 For IRB 2600ID - 8/2.0: cut the cable tie
that holds the harness loop together to
loosen the cabling and make it longer.
Fasten the cabling to the MP5 cable.
Tighten the cable ties gently with hand
force.
For IRB 2600ID - 15/1.85: remake the har-
ness loop if it is missing. Fasten the loop
to the MP5 cable. Tighten the cable ties
gently with hand force. Diameter of the loop
should be approximately Ø40 mm.

xx1600001494

10 Check that axis 4 is in the same position

as it was when the cable harness was re- Note
moved.
If axis 4 is being moved in the continued
refitting process it must be returned to the
position it was when the mechanical stop
was removed in order to get the cable har-
ness spiral fitted correctly.

11
CAUTION

When the spiral of the cable harness is ar-

ranged check that:
• none of the cables are twisted
• the two cables running in the spiral
runs parallel to each other all the
way
• the cables are not arranged too tight
or too loose.

12 Hold the cable harness with one hand and

cut the cable strap used as transport pro-
tection.

CAUTION

When the cable strap is cut, the spiral of

the cable harness can unwind and the
cables can start to cross each other.

xx1000001004

Part:
A Cable strap used as transport protec-
tion

Continues on next page

230 Product manual - IRB 2600
3HAC035504-001 Revision: Q
© Copyright 2009-2018 ABB. All rights reserved.
 4 Repair
4.3.3 Replacing the cable harness in the upper arm - IRB 2600ID
Continued

Action Information
13 Check that the cable harness is fitted cor-
rectly by releasing the brakes on the axis- Note
4 motor and manually moving axis 4 very
carefully all the way to each end position. If axis 4 is not running correctly the spiral
of the cable harness must be refitted.
CAUTION

Too much force when turning axis 4 can

result in damage to the cable harness!

14 Apply flange sealant Loctite 574 on the

surface B, shown in the figure.

Note

Do not apply flange sealant on the surfaces

where Sikaflex 521FC shall be applied!
See figure!

xx1000001003

Parts:
A Surface where Sikaflex 521FC shall
be applied
B Surface where Loctite 574 shall be
applied.
15 Secure the upper arm tube with its attach- Tightening torque: 35 Nm.
ment screws.
16 Refit the wrist. See section
• Refitting the wrist on page 348

Continues on next page

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4 Repair
4.3.3 Replacing the cable harness in the upper arm - IRB 2600ID
Continued

Action Information
17 Refit the cover (A) with two screws (B).
18 Refit the bracket (C) with two screws.
19 Apply Sikaflex 521FC on the surfaces A
shown in the figure.

xx1600001557

Parts:
A Cover
B Attachment screws for the cover (2
A pcs of totally 5 pcs)
C Bracket (including 2 cover attach-
ment screws)
D Mechanical stop (including o-ring
and one cover attachment screw)

xx1600001558

20 Refit the o-ring and the mechanical stop

(D) with one screw.
21 Connect the connectors to motors axes 3,
4, 5 and 6 in the arm house.
D

A B C
xx1000000991

Parts:
A Motor axis 4
B Motor axis 3
C MP connectors axes 3, 4, 5 and 6
(see markings for axis)
D FP connectors axes 3, 4, 5 and 6
(see markings for axis)
22 Refit the cover on the arm house with its Tightening torque: 14 Nm.
attachment screws.

Continues on next page

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© Copyright 2009-2018 ABB. All rights reserved.
 4 Repair
4.3.3 Replacing the cable harness in the upper arm - IRB 2600ID
Continued

Action Information
23 Fit new VK covers to the arm tube.

xx1000000934

Parts:
A VK-covers (2 pcs). See article num-
ber in section Spare part lists on
page 445.
24 Recalibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 403.
General calibration information is included
in section Calibration on page 391.
25
DANGER

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 28.

Product manual - IRB 2600 233

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© Copyright 2009-2018 ABB. All rights reserved.
4 Repair
4.3.4 Replacing SMB unit

4.3.4 Replacing SMB unit

Location of SMB unit

The SMB unit (SMB = Serial measurement board) is located in the base below the
brake release unit, as shown in the figure.

xx0800000466

A R1.SMB3-6
B R1.SMB1-2
C R2.SMB
D SMB unit
E Attachment screws M6x16 quality 8.8-A2F (2 pcs)
F Brake release unit
G Bracket

Required equipment

Note

There are different variants of SMB units and batteries. The variant with the
3-pole battery contact (RMU) has longer lifetime for the battery.
It is important that the SMB unit uses the correct battery. Make sure to order the
correct spare parts. Do not replace the battery contact!

Equipment Note
Standard toolkit Content is defined in section Standard tools
on page 441.

Continues on next page

234 Product manual - IRB 2600
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© Copyright 2009-2018 ABB. All rights reserved.
 4 Repair
4.3.4 Replacing SMB unit
Continued

Equipment Note
Other tools and procedures may be re- These procedures include references to the
quired. See references to these procedures tools required.
in the step-by-step instructions below.
SMB unit For spare part no. see chapter Spare parts,
section:
• Spare part lists on page 445

Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Action Note
1 Decide which calibration routine to use for
calibrating the robot.
• Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
• Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
If the robot is to be calibrated with refer- Follow the instructions given in the refer-
ence calibration: ence calibration routine on the FlexPendant
Find previous reference values for the axis to create reference values.
or create new reference values. These val- Creating new values requires possibility to
ues are to be used after the repair proced- move the robot.
ure is completed, for calibration of the ro- Read more about reference calibration for
bot. Axis Calibration in Reference calibration
If no previous reference values exist, and routine on page 404.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Removing the SMB unit

Use this procedure to remove the SMB unit.
Action Note
1 Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Continues on next page

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© Copyright 2009-2018 ABB. All rights reserved.
4 Repair
4.3.4 Replacing SMB unit
Continued

Action Note
3 Remove the base cover.

CAUTION
C
Clean cover from metal residues before
opening.
Metal residues can cause shortage on the
boards which can result in hazardous fail-
ures.

A
xx0900000103

Parts:
A Attachment screws (6 pcs)
B Base cover
C Cable straps, securing the battery
cable (2 pcs)
4 Cut the cable straps securing the battery
cable.
5 Remove the screw that secures the bracket
and unscrew the three other screws a little
just enough to be able to slide the bracket
sideways.

Note

It is not needed to remove these three

screws.

xx0900000100

Parts:
A Screw to be removed
B Screws to be unscrewed a little (3
pcs)

Continues on next page

236 Product manual - IRB 2600
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© Copyright 2009-2018 ABB. All rights reserved.
 4 Repair
4.3.4 Replacing SMB unit
Continued

Action Note
6 Remove the bracket by sliding it off the re- Cable harness can stay connected to all
maining three attachment screws and put connectors except to the SMB unit.
it at a 90° angle from the base.
Putting the bracket at a 90° angle facilitates
the disconnecting of cables from the
bracket.

Note

Use caution when performing this procedure xx0900000013

order not to damage cables or other com-
ponents! Parts:
A Bracket at a 90° angle
B Base
7 Disconnect cable clamps.

A
xx0900000035

Parts:
A Cable clamps
8 Unscrew the attachment screws securing See the figure in:
the SMB unit just enough to be able to re- • Location of SMB unit on page 234
move the SMB unit.
9 Remove the SMB unit.
10 Disconnect the battery cable by pressing
down the upper lip of the R1.G connector
to release the lock while pulling the connect-
or upwards.

xx1700000993

11 Disconnect the remaining connectors on See the figure in:

the SMB unit: • Location of SMB unit on page 234
• R1.SMB1-2
• R1.SMB3-6
• R2.SMB

Continues on next page

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© Copyright 2009-2018 ABB. All rights reserved.
4 Repair
4.3.4 Replacing SMB unit
Continued

Refitting the SMB unit

Use this procedure to refit the SMB unit.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2 Reconnect contacts on the SMB unit:

• R1.SMB1-2
• R1.SMB3-6
• R2.SMB
• Battery cable R1.G (X3) Make sure
the lock snaps into place during refit-
ting.

xx1700000994

3 Place the SMB unit on its attachment See the figure in:
screws. • Location of SMB unit on page 234
4 Secure the SMB unit with its attachment
screws.
5 Refit the cable clamps.

A
xx0900000035

Parts:
A Cable clamps
6 Put back the cable harness in the base and See the figure in:
refit the bracket on the distance screws. • Location of SMB unit on page 234

Note

Use caution when performing this procedure

order not to damage cables or other com-
ponents!

Continues on next page

238 Product manual - IRB 2600
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© Copyright 2009-2018 ABB. All rights reserved.
 4 Repair
4.3.4 Replacing SMB unit
Continued

Action Note
7 Secure the battery cable with cable straps.
8 Use caution when pushing the base cover
into position while at the same time check-
ing that no cables are damaged.
9 Secure the base cover with the attachment
screws.

C
xx0800000456

Parts:
A Attachment screws (6 pcs)
B Base cover
C Base
10 Recalibrate the robot. Pendulum Calibration is described in Op-
erating manual - Calibration Pendulum,
enclosed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 403.
General calibration information is included
in section Calibration on page 391.
11
DANGER

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 28.

Product manual - IRB 2600 239

3HAC035504-001 Revision: Q
© Copyright 2009-2018 ABB. All rights reserved.
4 Repair
4.3.5 Replacing the brake release board

4.3.5 Replacing the brake release board

Location of brake release board

The brake release board is located as shown in the figure.

xx0900000101

A Brake release board

Connectors on push-button board

The connectors X8, X9 and X10 are placed on the push-button board as shown in
the figure below.

X8
X10
X9

xx1700000978

Continues on next page

240 Product manual - IRB 2600
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© Copyright 2009-2018 ABB. All rights reserved.
 4 Repair
4.3.5 Replacing the brake release board
Continued

Required equipment

Equipment Note
Brake release board 3HAC065020-001 i DSQC1050
3HAC062021-001 ii DSQC1052
Standard toolkit Content is defined in section
Standard tools on page 441.
Other tools and procedures These procedures include refer-
may be required. See refer- ences to the tools required.
ences to these procedures
in the step-by-step instruc-
tions below.
i Valid for robots that are equipped with motors of Type A and Type B (see Product manual, spare
parts - IRB 2600).
Includes brake release board and harness.
ii Valid for robots that are equipped with motors of Type B (see Product manual, spare parts - IRB
2600).
Includes brake release board and harness.

Removing the brake release board

Use this procedure to remove the brake release board.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before handling

the unit read the safety information in sec-
tion The unit is sensitive to ESD on page 33

3 Remove the push button guard from the The guard must be removed to ensure a
SMB cover. correct refitting of the brake release
board.

Continues on next page

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© Copyright 2009-2018 ABB. All rights reserved.
4 Repair
4.3.5 Replacing the brake release board
Continued

Action Note
4 Remove the base cover.

CAUTION

Clean cover from metal residues before

opening.
Metal residues can cause shortage on the
boards which can result in hazardous fail- A
ures.

C
xx0800000456

Parts:
A Base
B Base cover
C Attachment screws M6x16 quality
8.8-A2F (6 pcs)
5 Take a picture or make notes of how the
robot cabling is positioned in regard to the
brake release board.
6 Disconnect connectors X8, X9 and X10 from
the brake release board.

X8
X10
X9

xx1700000978

7 Remove the nuts securing the brake release

board.
8 Remove the brake release board.

Refitting the brake release board

Use this procedure to refit the brake release board.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

Continues on next page

242 Product manual - IRB 2600
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© Copyright 2009-2018 ABB. All rights reserved.
 4 Repair
4.3.5 Replacing the brake release board
Continued

Action Note
2
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before handling

the unit read the safety information in section
The unit is sensitive to ESD on page 33

3 Secure the brake release board to the bracket Maximum tightening torque: 5 Nm.
with its nuts with flange. See the figure in:
• Location of brake release board
on page 240
4 Reconnect connectors X8, X9 and X10 to the
brake release board.
Be careful not to damage the sockets or pins.
Make sure the connector and its locking arms X8
X10
are snapped down properly. X9

xx1700000978

5 Verify that the robot cabling is positioned

correctly, according to previously taken pic-
ture/notes.

WARNING

Screened cables must not get in contact with

the brake release board after installation.
Eliminate all risks of contact between
screened cables and the brake release board.

6 Use caution when pushing the base cover

into position while at the same time checking
that no cables are damaged.

C
xx0800000456

Parts:
A Base
B Base cover
C Attachment screws M6x16 quality
8.8-A2F (6 pcs)
7 Secure the base cover with its attachment
screws.

Continues on next page

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© Copyright 2009-2018 ABB. All rights reserved.
4 Repair
4.3.5 Replacing the brake release board
Continued

Action Note
8
WARNING

Before continuing any service work, follow

the safety procedure in section The brake
release buttons may be jammed after service
work on page 194!

9 Refit the push button guard to the SMB cover.

10 Press the push buttons 1 to 6, one at a time,
to make sure that the buttons are moving
freely and do not stay in any locked position.
11
DANGER

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 28.

244 Product manual - IRB 2600

3HAC035504-001 Revision: Q
© Copyright 2009-2018 ABB. All rights reserved.
 4 Repair
4.4.1 Replacing the complete upper arm

4.4 Upper arm

4.4.1 Replacing the complete upper arm

Location of the complete upper arm

The complete upper arm is located as shown in the figure.
The figure shows IRB 2600 Standard but is also valid for IRB 2600ID.

xx1100000947

A Upper arm
B Attachment screws M8x40, quality steel 12.9 gleitmo (12 pcs)

Continues on next page

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© Copyright 2009-2018 ABB. All rights reserved.
4 Repair
4.4.1 Replacing the complete upper arm
Continued

Required equipment

Equipment Note
Armhouse For spare parts no. see Spare parts - Upper arm
(2.05/2.50/2.55) in Product manual, spare
parts - IRB 2600.
Tubular shaft unit For spare parts no. see Spare parts - Upper arm
(2.05/2.50/2.55) in Product manual, spare
parts - IRB 2600.
Rotating lifting point 2 pcs. Dimension: M8.
Example: Gunnebo RLP GrabiQ M8-10.

xx1100000564

Washer Required if the screw in the rotating lifting point

bottoms.
Inner diameter: 12 mm. Outer diameter: min. 23
mm. Thickness: enough to prevent the screw in
the rotating lifting point to bottom.
Roundslings 3 pcs.
Lengths: 1.5 m (1 pc, run around the wrist unit),
2 m (2 pcs).
Lifting capacity: 500 kg.
Screws 2 pcs. Used to prevent the roundsling at the wrist
from sliding.
Dimension:
• M6. Length: 70 mm. Quality: 8.8.
Guide pins M8 (2 pcs)
Standard toolkit Content is defined in section Standard tools on
page 441.
Other tools and procedures may be re- These procedures include references to the tools
quired. See references to these proced- required.
ures in the step-by-step instructions be-
low.

Continues on next page

246 Product manual - IRB 2600
3HAC035504-001 Revision: Q
© Copyright 2009-2018 ABB. All rights reserved.
 4 Repair
4.4.1 Replacing the complete upper arm
Continued

Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Action Note
1 Decide which calibration routine to use for
calibrating the robot.
• Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
• Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
If the robot is to be calibrated with refer- Follow the instructions given in the refer-
ence calibration: ence calibration routine on the FlexPendant
Find previous reference values for the axis to create reference values.
or create new reference values. These val- Creating new values requires possibility to
ues are to be used after the repair proced- move the robot.
ure is completed, for calibration of the ro- Read more about reference calibration for
bot. Axis Calibration in Reference calibration
If no previous reference values exist, and routine on page 404.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Removing the complete upper arm

Use this procedure to remove the complete upper arm. This procedure can be
done without draining the axis 3 gearbox.
Action Note
1 Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.
2 Run the robot to the position shown in the
figure.
The robot must be floor mounted and the
upper arm must be horizontally positioned.

xx0800000336

Continues on next page

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4 Repair
4.4.1 Replacing the complete upper arm
Continued

Action Note
3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

4
CAUTION

The weight of the complete upper arm (in-

cluding the wrist) is 65 kg
All lifting accessories used must be sized
accordingly.

5 Attach the lifting accessories to the upper See Attaching the lifting accessories to
arm. the upper arm on page 250.
6 Unload the weight of the upper arm by
stretching the roundslings.

Tip

Turn on the power temporarily and release

the brakes of axis 3 to rest the weight onto
the roundslings.

7
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

8 Disconnect all motor cables from motors How to disconnect cables from motors is
axes 3, 4, 5 and 6. detailed in sections:
• Removing motors on page 301

Continues on next page

248 Product manual - IRB 2600
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© Copyright 2009-2018 ABB. All rights reserved.
 4 Repair
4.4.1 Replacing the complete upper arm
Continued

Action Note
9 Remove the bracket fitted on the tubular
shaft unit.

xx0800000335

Parts:
• A: Tubular shaft unit
• B: Attachment screws M6x16 qual-
ity 8.8-A2F (2 pcs)
• C: Bracket
10 Remove the signal lamp, if used.
11 Remove the cable bracket on the armhouse.

xx0800000338

Parts:
• A: Signal lamp
• B: Bracket
• C: Cable bracket
12 Using caution, pull the cable package out
of the hole where the cable bracket was fit-
ted.
13 Remove the attachment screws securing See the figure in:
the upper arm to the lower arm. • Location of the complete upper arm
on page 245

Note

Do not remove the attachment screws

securing the gearbox axis 3 to the arm-
house!

Continues on next page

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4 Repair
4.4.1 Replacing the complete upper arm
Continued

Action Note
14 Remove the complete upper arm.

Attaching the lifting accessories to the upper arm

Attaching the lifting accessories

Action Note
1 Fit two screws in the wrist unit. Dimension is specified in Required equipment on
The purpose of these screws is page 246.
to prevent the roundsling from
sliding.
The wrist unit of IRB 2600ID looks
a bit different. Either run the
roundsling around the ID wrist in
such a way that the sling can not
slide, or remove the mechanical xx1100000581
stop at the wrist temporarily and
use the attachment holes to fit the
screws to prevent the sling from
sliding.
2 Fit two rotating lifting points to the Dimension is specified in Required equipment on
attachment holes in the arm page 246.
house, see the figure. Secure the The figures show IRB 4600 but the same attachment
lifting point tightly against the arm holes are used also for IRB 2600.
house, but at the same time mak-
ing sure that the screw does not
bottom. Use an extra washer if
the screw does bottom.
Tightening torque: 30 Nm.

xx1100000565

xx1100000566

3 Run a roundsling through each Dimension is specified in Required equipment on

rotating lifting point and fasten page 246.
both ends at the lifting hook. See figure Attaching the roundslings to the upper
Use the longest roundslings (2 arm on page 251.
m).

Continues on next page

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 4 Repair
4.4.1 Replacing the complete upper arm
Continued

Action Note
4 Make a loop of the third round- Dimension is specified in Required equipment on
sling, running it around the wrist page 246.
unit. Run the roundsling on both See figure Attaching the roundslings to the upper
sides of the screws and fasten the arm on page 251.
free end of the roundsling to the
lifting hook.
Use the shortest roundsling (1.5
m).

Attaching the roundslings to the upper arm

The figure shows IRB 4600 but the principle is the same for IRB 2600. Make sure
the roundsling looped around the wrist unit is run on both sides of the screws.

xx1100000567

A Screws to prevent the roundsling from sliding, 2 pcs

B Rotating lifting point, 2 pcs
C Roundsling around wrist unit
Length: 1.5 m.
D Roundsling attached to arm house, 2 pcs
Length: 2 m

Continues on next page

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4 Repair
4.4.1 Replacing the complete upper arm
Continued

Refitting the complete upper arm

Use this procedure to refit the complete upper arm.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2
CAUTION

The weight of the complete upper arm (in-

cluding the wrist) is 65 kg
All lifting accessories used must be sized
accordingly.

3 Clean all assembly surfaces.

4 Attach the lifting accessories to the upper See Attaching the lifting accessories to
arm. the upper arm on page 250.
5 Fit guide pins to the upper arm. Specified in Required equipment on
page 246.
6 Lift the upper arm to the robot using an
overhead crane.
7 Release the brakes of the axis 3 motor.
8 Refit the upper arm to the lower arm with See the figure in:
its attachment screws. • Location of the complete upper arm
It may be necessary to turn the gear by ro- on page 245
tating the motor pinion with a rotation tool, Tightening torque :
motor beneath the motor cover. • 35 Nm

Continues on next page

252 Product manual - IRB 2600
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 4 Repair
4.4.1 Replacing the complete upper arm
Continued

Action Note
9 Using caution, push the cable package
through the hole where the cable bracket
will be fitted.

xx0800000338

Parts:
• A: Signal lamp
• B: Bracket
• C: Cable bracket
10 Refit the cable bracket with its attachment
screws.
11 Reconnect all motor cables. How to connect motor cables is detailed
in sections:
• Refitting motors on page 313
12 Refit the bracket on the tubular shaft unit.

xx0800000335

Parts:
• A: Tubular shaft unit
• B: Attachment screws M6x16 qual-
ity 8.8-A2F (2 pcs)
• C: Bracket
13 Refit the signal lamp, if used.

Continues on next page

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4 Repair
4.4.1 Replacing the complete upper arm
Continued

Action Note
14 Recalibrate the robot. Pendulum Calibration is described in Op-
erating manual - Calibration Pendulum,
enclosed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 403.
General calibration information is included
in section Calibration on page 391.
15
DANGER

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 28.

254 Product manual - IRB 2600

3HAC035504-001 Revision: Q
© Copyright 2009-2018 ABB. All rights reserved.
 4 Repair
4.4.2 Replacing complete tubular shaft unit

4.4.2 Replacing complete tubular shaft unit

Introduction
This section is not valid for IRB 2600ID.

Location of tubular shaft unit

The tubular shaft unit is located as shown in the figure.

xx0900000385

A Armhouse
B Parallel pin, hardened M8x16 m6 (2 pcs)
C Attachment screws M8x35 quality 8.8-A2F and washers (6+6 pcs)
D Tubular shaft unit
E Wrist

Required equipment

Equipment Note
Tubular shaft unit For spare parts no. see Spare parts - Upper arm
(2.05/2.50/2.55) in Product manual, spare
parts - IRB 2600.
Guide pins 2 pcs. Dimension: M8.
Cleaning agent Isopropanol
Sealing liquid Loctite 574
Standard toolkit Content is defined in section Standard tools on
page 441.

Continues on next page

Product manual - IRB 2600 255
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© Copyright 2009-2018 ABB. All rights reserved.
4 Repair
4.4.2 Replacing complete tubular shaft unit
Continued

Equipment Note
Other tools and procedures may be re- These procedures include references to the tools
quired. See references to these proced- required.
ures in the step-by-step instructions be-
low.

Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Action Note
1 Decide which calibration routine to use for
calibrating the robot.
• Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
• Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
If the robot is to be calibrated with refer- Follow the instructions given in the refer-
ence calibration: ence calibration routine on the FlexPendant
Find previous reference values for the axis to create reference values.
or create new reference values. These val- Creating new values requires possibility to
ues are to be used after the repair proced- move the robot.
ure is completed, for calibration of the ro- Read more about reference calibration for
bot. Axis Calibration in Reference calibration
If no previous reference values exist, and routine on page 404.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Removing complete tubular shaft unit

Use this procedure to remove the complete tubular shaft unit.
Action Note
1 Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.
2 Drain oil from gearbox axis 4. How to drain the oil from the gearbox is
described in section:
• Changing the oil, axis-4 gearbox
on page 171

Continues on next page

256 Product manual - IRB 2600
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© Copyright 2009-2018 ABB. All rights reserved.
 4 Repair
4.4.2 Replacing complete tubular shaft unit
Continued

Action Note
3 Move the robot to the position shown in the
figure.

xx0800000336

4
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

5 Remove the bracket securing the cable

package to the tubular shaft unit by remov-
ing its attachment screws.

xx0800000335

Parts:
• A: Tubular shaft unit
• B: Attachment screws M6x16 qual-
ity 8.8-A2F (2 pcs)
• C: Bracket
6 Place the cable package in a way that it will
not be damaged in the continued removal
procedure.
7 Remove motors axes 4, 5 and 6. How to remove motors is described in
section:
• Removing motors on page 301
8 How to remove the wrist unit is detailed
Tip in section:
• Removal of wrist unit on page 263
If only the tubular shaft unit shall be re-
placed, it is a good idea to remove the wrist
unit at this stage.

Continues on next page

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4 Repair
4.4.2 Replacing complete tubular shaft unit
Continued

Action Note
9
CAUTION

The robot arm tube weighs 30 kg.

All lifting accessories used must be sized
accordingly!

10 Secure the tubular shaft unit with round-

slings in an overhead crane.

CAUTION

Prevent the slings from sliding!

For example a small plate can be fitted to
the lower attachment hole for the cable
bracket (removed in a previous step). The
plate should be fitted so it points down-
wards and functions as a mechanical stop
for the roundsling.
At the other end of the tubular shaft unit, a
shackle can be fitted if the wrist unit is re-
moved.

11 Remove the attachment screws that secure See the figure in:
the tubular shaft unit. • Location of tubular shaft unit on
page 255
12 Remove the tubular shaft unit using caution.
The tubular shaft unit is fitted with Loctite. Note

There are two parallel pins guiding the

CAUTION
tubular shaft unit into its place. See figure
in Replacing complete tubular shaft unit
Do not damage the gears when removing on page 255.
the tubular shaft unit.

CAUTION

Remaining oil will drain out from the gear-

box cavity when the tubular shaft is lifted
out.

Refitting complete tubular shaft unit

Use this procedure to refit the tubular shaft unit.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Continues on next page

258 Product manual - IRB 2600
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© Copyright 2009-2018 ABB. All rights reserved.
 4 Repair
4.4.2 Replacing complete tubular shaft unit
Continued

Action Note
2 Remove residues of old Loctite and other
contaminations from the assembly surfaces.
Remove any painting from the assembly
surfaces, with a knife.
3 Apply sealing liquid (Loctite 574) on the A
surface between the tubular shaft unit and
the armhouse. B C
Make sure to apply the sealing liquid in
circles around each of the attachment holes.

xx0800000457

Parts:
A Armhouse
B Surface where Loctite 574 shall be
applied
C Tubular shaft unit
D Cylindrical pin (2 pcs)
4
CAUTION

The robot arm tube weighs 30 kg.

All lifting accessories used must be sized
accordingly!

5 Secure the tubular shaft unit with a round-

sling in an overhead crane.

CAUTION

Prevent the slings from sliding!

For example a small plate can be fitted to
the lower attachment hole for the cable
bracket (removed in a previous step). The
plate should be fitted so it points down-
wards and functions as a mechanical stop
for the roundsling.
At the other end of the tubular shaft unit, a
shackle can be fitted if the wrist unit is re-
moved.

6 Fit guide pins in the upper arm house. Specified in Required equipment on
page 255.

Continues on next page

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4 Repair
4.4.2 Replacing complete tubular shaft unit
Continued

Action Note
7 Refit the tubular shaft unit, using caution.
Note
CAUTION
There are two parallel pins guiding the
Do not damage the gears when refitting the tubular shaft unit into its place.
tubular shaft unit.

8 Secure the tubular shaft unit with its attach- See the figure in:
ment screws. • Location of tubular shaft unit on
page 255
Tightening torque: 22 Nm
9 Refit motors axes 4, 5 and 6. How to refit motors is described in sec-
tion:
• Refitting motors on page 313
10 Perform a leak-down test. See Performing a leak-down test on
page 188.
11 Refit the bracket securing the cable package
to the tubular shaft unit, with its attachment
screws.

xx0800000335

Parts:
• A: Tubular shaft unit
• B: Attachment screws M6x16 qual-
ity 8.8-A2F (2 pcs)
• C: Bracket
12 If the wrist unit has been removed from the How to refit the wrist unit is detailed in
tubular shaft unit, refit it now. section:
• Refitting of wrist unit on page 265
13 Refill gearbox axis 4 with oil. How to refill oil in gearbox is described in
section:
• Changing the oil, axis-4 gearbox
on page 171
14 Recalibrate the robot. Pendulum Calibration is described in Op-
erating manual - Calibration Pendulum,
enclosed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 403.
General calibration information is included
in section Calibration on page 391.

Continues on next page

260 Product manual - IRB 2600
3HAC035504-001 Revision: Q
© Copyright 2009-2018 ABB. All rights reserved.
 4 Repair
4.4.2 Replacing complete tubular shaft unit
Continued

Action Note
15
DANGER

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 28.

Product manual - IRB 2600 261

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© Copyright 2009-2018 ABB. All rights reserved.
4 Repair
4.4.3 Replacing wrist unit

4.4.3 Replacing wrist unit

Introduction
This section describes how to replace the wrist on IRB 2600 Standard.
How to remove and refit the wrist unit on IRB 2600ID is described in section
Replacing motor axis 6 and wrist unit - IRB 2600ID on page 341.

Location of wrist unit

The wrist unit is located in the upper arm as shown in the figures.

B
C
D
G
E

xx0800000341

A Upper arm
B Attachment screw M8x40, quality steel 12.9 Gleitmo (5 pcs)
C Spring washer, conical 8.4x18x2, quality steel-mZn12c (5 pcs)
D Gears
E Wrist unit
F O-ring (Placed on the wrist. Not visible here)
G Guide pin
(only available for robots that are calibrated with Axis Calibration)
(not available on IRB 2600ID)

Required equipment

Equipment Note
Wrist unit For spare parts no. see Spare parts - Upper
arm (2.05/2.50/2.55) in Product manual, spare
parts - IRB 2600.
O-ring For spare parts no. see Spare parts - Upper
arm (2.05/2.50/2.55) in Product manual, spare
parts - IRB 2600.

Continues on next page

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 4 Repair
4.4.3 Replacing wrist unit
Continued

Equipment Note
Standard toolkit Content is defined in section Standard tools
on page 441.
Other tools and procedures may be required. These procedures include references to the
See references to these procedures in the tools required.
step-by-step instructions below.

Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Action Note
1 Decide which calibration routine to use for
calibrating the robot.
• Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
• Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
If the robot is to be calibrated with refer- Follow the instructions given in the refer-
ence calibration: ence calibration routine on the FlexPendant
Find previous reference values for the axis to create reference values.
or create new reference values. These val- Creating new values requires possibility to
ues are to be used after the repair proced- move the robot.
ure is completed, for calibration of the ro- Read more about reference calibration for
bot. Axis Calibration in Reference calibration
If no previous reference values exist, and routine on page 404.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Removal of wrist unit

Use this procedure to remove the wrist unit.
Action Note
1 Decide which calibration routine to use, and
take actions accordingly prior to beginning the
repair procedure.

Continues on next page

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© Copyright 2009-2018 ABB. All rights reserved.
4 Repair
4.4.3 Replacing wrist unit
Continued

Action Note
2 Move the upper arm to a position where the
wrist is pointing towards the floor as shown in
the figure.
This way the wrist can be removed without
drainage.

xx0800000329

3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

4
WARNING

Handling gearbox oil involves several safety

risks. Before proceeding, please read the safety
information in the section Safety risks during
work with gearbox lubricants (oil or grease) on
page 39.

5
CAUTION

The robot wrist unit weighs 15 kg.

All lifting accessories used must be sized ac-
cordingly!

6 Remove the attachment screws and carefully See the figure in:
remove the wrist unit. • Location of wrist unit on
page 262
CAUTION

Do not damage gears!

WARNING

The wrist unit is filled with oil. Perform removal

with care.

7 Pour out the oil from the wrist unit. See the figure in
• Location of wrist unit on
page 262

Continues on next page

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 4 Repair
4.4.3 Replacing wrist unit
Continued

Refitting of wrist unit

Use this procedure to refit the wrist unit.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

2 Check if there is a parallel pin hole in the upper

arm tube.
The hole is available on robots that are calib-
rated with the Axis Calibration method.

xx1600000690

3 If there is a hole, fit the parallel pin into the

corresponding hole in the wrist (enclosed with
the new wrist spare part).

Note

If the parallel pin is not installed on a robot cal-

ibrated with Axis Calibration, the calibration
result will be affected negatively.
xx1600000689

Verify that the parallel pin sticks out

from the wrist according to the meas-
urement given below.
0
4 -0,5

xx1600000703

Continues on next page

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4 Repair
4.4.3 Replacing wrist unit
Continued

Action Note
4 Clean all assembly surfaces.
Remove any painting from the assembly sur-
faces, with a knife.
5 Check the o-ring. Replace if damaged. See the figure in:
• Location of wrist unit on
6 Prepare the refitting of the wrist by inserting the page 262
attachment screws and washers in the upper
arm tube.
7
CAUTION

The robot wrist unit weighs 15 kg.

All lifting accessories used must be sized ac-
cordingly!

8 Carefully put the wrist unit in its place on the

upper arm.

CAUTION

Do not damage gears!

CAUTION

Make sure that the o-ring stays in place on the

wrist unit!

9 Adjust the play of the wrist by following these

steps:
• Push the wrist as shown in the figure to
locate the smallest play in the same way
as for adjustment of motors for axes 4,
5 and 6. See Refitting motors on page 313.

xx1000000223

Parts:
• A: Gears on drive shaft unit,
axes 5-6
• B: Gears on the wrist
10 Secure the wrist unit with its attachment screws See the figure in
and washers. • Location of wrist unit on
page 262
Tightening torque: 35 Nm.

Continues on next page

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 4 Repair
4.4.3 Replacing wrist unit
Continued

Action Note
11 Measure the play by moving axes 5 and 6 with How to measure the play is described
the measuring tool. in sections:
• Measuring the play, axis 5 on
page 268
• Measuring the play, axis 6 on
page 270
• Measuring the play, axis 5 (ID
upper arm) on page 272
• Measuring the play, axis 6 (ID
upper arm) on page 275
12 Perform a leak-down test. See Performing a leak-down test on
page 188.
13 Refill oil in gearbox axes 5-6. How to fill oil in gearbox axes 5-6 is
described in section:
• Changing oil, axes-5 and -6
gearboxes on page 175
14 Recalibrate the robot. Pendulum Calibration is described in
Operating manual - Calibration Pendu-
lum, enclosed with the calibration
tools.
Axis Calibration is described in Calib-
rating with Axis Calibration method on
page 403.
General calibration information is in-
cluded in section Calibration on
page 391.
15
DANGER

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 28.

Product manual - IRB 2600 267

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© Copyright 2009-2018 ABB. All rights reserved.
4 Repair
4.4.4 Measuring the play, axis 5

4.4.4 Measuring the play, axis 5

General
This section is only valid for IRB 2600. For IRB 2600ID, see section Measuring the
play, axis 5 (ID upper arm) on page 272.
After reassembly due to repair work or any other reason, the play in axis 5 and 6
must be checked to ensure the repetition accuracy of the robot positioning. The
procedure for axis 5 is detailed below.

Required equipment

Equipment, etc. Article number Note

Standard toolkit - Content is defined in sec-
tion Standard tools on
page 441.
Other tools and procedures may be required. These procedures include
See references to these procedures in the references to the tools re-
step-by-step instructions below. quired.

Measurement, axis 5
The procedure below details how to measure the play of axis 5.
Action Information
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2 Move the robot to calibration position and

turn the axis 4 90°.
3 Fit the measuring tool, play to the turning Article number is specified in Required
disc. equipment on page 268.

Continues on next page

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 4 Repair
4.4.4 Measuring the play, axis 5
Continued

Action Information
4 Apply load F in one direction, as shown in
the figure to the right.

xx0300000186

Values for IRB 2600 -20/1.65, -12/1.65,

-12/1.85:
• A: Measuring tool, play
• B: 140 mm
• C: 85 mm
• F: 40N
5 Remove the load and set the dial indicator
to zero.
6 Apply load F in the opposite direction, as
shown in the figure to the right.

xx0300000187

Values for IRB 2600 - 20/1.65, -12/1.65,

-12/1.85:
• A: Measuring tool, play
• B: 140 mm
• C: 85 mm
• F: 40N
7 Remove the load and measure the play by The maximum play allowed at the given
reading the dial indicator. distance from the center of axis 5 is, for
robot version:
• IRB 2600 -20/1.65, -12/1.65, -
12/1.85: 0.12 mm

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4 Repair
4.4.5 Measuring the play, axis 6

4.4.5 Measuring the play, axis 6

General
This section is only valid for IRB 2600. For IRB 2600ID, see section Measuring the
play, axis 6 (ID upper arm) on page 275.
After reassembly due to repair work or any other reason, the play in axis 5 and 6
must be checked to ensure the repetition accuracy of the robot positioning. The
procedure for axis 6 is detailed below.

Required equipment

Equipment Article number Note

Standard toolkit - Content is defined in sec-
tion Standard tools on
page 441.
Other tools and procedures may be required. These procedures include
See references to these procedures in the references to the tools re-
step-by-step instructions below. quired.

Measurement, axis 6
The procedure below details how to measure the play in axis 6.
Action Information
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2 Fit the measuring tool, play to the turning Article number is specified in Required
disc. equipment on page 270.
3 Attach a weight (m) at a distance (B) from
the wrist flange, in order to avoid the ef-
fects of play on axis 5.

xx0300000188

Values for robot versions IRB 2600 -

20/1.65, -12/1.65, -12/1.85:
• A: Measuring tool, play
• B: 140 mm
• m: 10 kg

Continues on next page

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 4 Repair
4.4.5 Measuring the play, axis 6
Continued

Action Information
4 Apply load F in one direction.

xx0300000189

Values for robot versions IRB 2600 -

20/1.65, -12/1.65, -12/1.85:
• A: Measuring tool, play
• B: 100 mm
• C: 150 mm
• F: 40N
5 Remove the load and set the dial indicat-
or to zero.
6 Apply load F in the opposite direction,
as shown in the figure to the right.

xx0300000190

Values for robot versions IRB 2600 -

20/1.65, -12/1.65, -12/1.85:
• A: Measuring tool, play
• B: 100 mm
• C: 150 mm
• F: 40N
7 Remove the load and measure the play The maximum play allowed at the given
by reading the dial indicator. distance (B) from the center of axis 6 is, for
robot version:
• Values for IRB 2600 -20/1.65, -
12/1.65, -12/1.85: 0.22 mm

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4 Repair
4.4.6 Measuring the play, axis 5 (ID upper arm)

4.4.6 Measuring the play, axis 5 (ID upper arm)

General
This section is only valid for IRB 2600ID. For measuring the play of IRB 2600, see
Measuring the play, axis 5 on page 268.
After reassembly due to repair work or any other reason, the play in axis 5 and 6
must be checked to ensure the repetition accuracy of the robot positioning.

Required equipment

Equipment, etc. Art. no. Note

Standard toolkit - Content is defined in sec-
tion Standard tools on
page 441.
Turning disk adapter 3HAC027717-
020
Measuring tool 3HAB9238-1 For measuring play.
Measuring bracket 3HAC032976-
001
Dial indicator with a magnetic foot -
Other tools and procedures may be required. These procedures include
See references to these procedures in the references to the tools re-
step-by-step instructions below. quired.

Measurement, axis 5
Use this procedure to measure the play of axis 5.
Action Information
1 Move the robot to calibration position. Turn
axis 4 to +90°.
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3 Fit the turning disk adapter to the turning Art. no. is specified in Required equip-
disk. ment on page 272.
4 Fit the measuring tool to the turning disk Art. no. is specified in Required equip-
adapter. ment on page 272.

Continues on next page

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 4 Repair
4.4.6 Measuring the play, axis 5 (ID upper arm)
Continued

Action Information
5 Fit the measuring bracket to the wrist. Use Art. no. is specified in Required equip-
the holes that are pointed out in the figure. ment on page 272.

xx1100000688

6 Fit the magnetic foot of the dial indicator

on the measuring bracket.
7 Place the tip of the dial indicator on the
milled surface of the measuring tool shaft.

xx1100000689

Distance from the center line of axis 5.

IRB 2600ID - 15/1.85:
A 235 mm
IRB 2600ID - 8/2.00:
A 300 mm
8 Verify that axis 5 is put in calibration posi-
tion.
9 Apply load F=30N with a dynamometer at
the distance A from the turning disk.
F

A
xx1100000691

A 140 mm
10 Remove the load and set the dial indicator
to zero.

Continues on next page

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4 Repair
4.4.6 Measuring the play, axis 5 (ID upper arm)
Continued

Action Information
11 Apply load F=30N in the opposite direction
(180°), at the distance A from the turning
disk. A

F
xx1100000693

A 140 mm
12 Remove the load and measure the play by The maximum play allowed is:
reading the dial indicator. • IRB 2600ID - 15/1.85: 0.25 mm
• IRB 2600ID - 8/2.00: 0.32 mm
13 Turn axis 5 to +90°.
14 Repeat step 9 to step 12.
15 Turn axis 5 to -90°.
16 Repeat step 9 to step 12.

274 Product manual - IRB 2600

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 4 Repair
4.4.7 Measuring the play, axis 6 (ID upper arm)

4.4.7 Measuring the play, axis 6 (ID upper arm)

General
This section is only valid for IRB 2600ID. For measuring the play of IRB 2600, see
Measuring the play, axis 6 on page 270.
After reassembly due to repair work or any other reason, the play in axis 5 and 6
must be checked to ensure the repetition accuracy of the robot positioning.

Required equipment

Equipment, etc. Art. no. Note

Standard toolkit - Content is defined in sec-
tion Standard tools on
page 441.
Turning disk adapter 3HAC027717-
020
Measuring tool 3HAB9238-1 For measuring play.
Measuring bracket 3HAC032976-
001
Dial indicator with magnetic foot -
Other tools and procedures may be required. These procedures include
See references to these procedures in the references to the tools re-
step-by-step instructions below. quired.

Measurement, axis 6
Use this procedure to measure the play of axis 6.
Action Information
1 Move the robot to calibration position. Turn
axis 4 to +90°.
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3 Fit the turning disk adapter to the turning Art. no. is specified in Required equip-
disk. ment on page 275.
4 Fit the measuring tool to the turning disk Art. no. is specified in Required equip-
adapter. ment on page 275.

Continues on next page

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4 Repair
4.4.7 Measuring the play, axis 6 (ID upper arm)
Continued

Action Information
5 Fit the measuring bracket to the wrist. Use Art. no. is specified in Required equip-
the holes that are pointed out in the figure. ment on page 275.

xx1100000688

6 Fit the magnetic foot of the dial indicator

on the measuring bracket.
7 Place the tip of the dial indicator on the
marking.

xx1100000690

Distance from the rotation center of axis

6:
A 100 mm
8 Verify that axis 6 is put in calibration posi-
tion.
9 Apply load F=40N upwards with a dynamo-
meter on the opposite side of the dial indic-
ator, at a distance B from the rotation cen-
ter of axis 6.

F
A
B
xx1100000692

A 100 mm (dial indicator)

B 140 mm
10 Remove the load and set the dial indicator
to zero.

Continues on next page

276 Product manual - IRB 2600
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 4 Repair
4.4.7 Measuring the play, axis 6 (ID upper arm)
Continued

Action Information
11 Apply load F=40N downwards at a distance
B from the rotation center of axis 6.

A
B

F
xx1100000694

A 100 mm (dial indicator)

B 140 mm
12 Remove the load and measure the play by The maximum play allowed is:
reading the dial indicator. • IRB 2600ID - 15/1.85: 0.20 mm
• IRB 2600ID - 8/2.00: 0.22 mm
13 Turn axis 6 to +180°.
14 Repeat step 9 to step 12.

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4 Repair
4.5.1 Replacing the lower arm

4.5 Lower arm

4.5.1 Replacing the lower arm

Location of lower arm

The lower arm is located as shown in the figure.

IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB 2600ID-8/2.0

B C D E

G
H J

xx0800000360

A Upper arm
B Gearbox axis 3
C Lower arm
D Washer (12 pcs)
E Attachment screws M8x40 quality Steel 12.9 Gleitmo (12 pcs)
F Frame
G Gearbox axis 2
H Washer (17 pcs)
J Attachment screws M8x40 quality Steel 12.9 Gleitmo (17 pcs)

Continues on next page

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 4 Repair
4.5.1 Replacing the lower arm
Continued

IRB 2600 Type C-20/1.65, IRB 2600 Type C-12/1.65

xx1800000933

A Upper arm
B Gearbox axis 3
C Lower arm
D Washer (12 pcs)
E Attachment screws M8x40 quality Steel 12.9 Gleitmo (12 pcs)
F Frame
G Gearbox axis 2
H Washer (3 pcs)
J Attachment screws M10x40 12.9 Gleitmo 603+Geo500 (15 pcs)

Continues on next page

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4 Repair
4.5.1 Replacing the lower arm
Continued

Required equipment

Equipment Note
Lower arm For spare parts no. see Spare parts - Lower
arm and motors in Product manual, spare
parts - IRB 2600.
Lifting eye M8
Standard toolkit Content is defined in section Standard tools
on page 441.
Other tools and procedures may be re- These procedures include references to the
quired. See references to these procedures tools required.
in the step-by-step instructions below.

Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Action Note
1 Decide which calibration routine to use for
calibrating the robot.
• Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
• Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
If the robot is to be calibrated with refer- Follow the instructions given in the refer-
ence calibration: ence calibration routine on the FlexPendant
Find previous reference values for the axis to create reference values.
or create new reference values. These val- Creating new values requires possibility to
ues are to be used after the repair proced- move the robot.
ure is completed, for calibration of the ro- Read more about reference calibration for
bot. Axis Calibration in Reference calibration
If no previous reference values exist, and routine on page 404.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Removing the lower arm

Use this procedure to remove the lower arm.
Action Note
1 Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.

Continues on next page

280 Product manual - IRB 2600
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 4 Repair
4.5.1 Replacing the lower arm
Continued

Action Note
2 Move the robot to the position shown in the
figure.

xx0800000336

3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

4 Remove the cable package from all axes How to remove the cable package in
except in the base. frame, lower arm and armhouse is de-
scribed in sections:
• Removing cable harness in frame
on page 203
• Removing cable harness in lower
arm and armhouse on page 204
5 Secure the upper arm with a roundsling in
an overhead crane.
6 Remove the complete upper arm and put it How to remove the complete upper arm
on a loading pallet. is described in section:
• Removing the complete upper arm
on page 247
7
CAUTION

The robot lower arm weighs .

35 kg (IRB 2600-20/1.65, IRB 2600-12/1.65,
IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB
2600ID-8/2.0)
30 kg (IRB 2600 Type C-20/1.65, IRB 2600
Type C-12/1.65)
All lifting accessories used must be sized
accordingly!

Continues on next page

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4 Repair
4.5.1 Replacing the lower arm
Continued

Action Note
8 Fit a lifting lug in one of the upper holes in
the lower arm, for the attachment screws.

xx0800000379

Parts:
• A: Lifting lug
9 Remove the attachment screws and wash- Valid for IRB 2600-20/1.65, IRB 2600-
ers that secure the lower arm to the axis-2 12/1.65, IRB 2600-12/1.85, IRB 2600ID-
gearbox. 15/1.85, IRB 2600ID-8/2.0:

xx1800000935

Valid for IRB 2600 Type C-20/1.65, IRB

2600 Type C-12/1.65:

xx1800000934

10 Remove the lower arm.

Continues on next page

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 4 Repair
4.5.1 Replacing the lower arm
Continued

Refitting the lower arm

Use this procedure to refit the lower arm.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2
CAUTION

The robot lower arm weighs .

35 kg (IRB 2600-20/1.65, IRB 2600-12/1.65,
IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB
2600ID-8/2.0)
30 kg (IRB 2600 Type C-20/1.65, IRB 2600
Type C-12/1.65)
All lifting accessories used must be sized
accordingly!

3 Fit a lifting lug in one of the upper holes in

the lower arm, for the attachment screws.

xx0800000379

Parts:
• A: Lifting lug
4 Secure the lower arm with a roundsling in
an overhead crane and lift it to the robot.

Continues on next page

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4 Repair
4.5.1 Replacing the lower arm
Continued

Action Note
5 Refit the attachment screws and washers Valid for IRB 2600-20/1.65, IRB 2600-
to secure the lower arm to the axis-2 gear- 12/1.65, IRB 2600-12/1.85, IRB 2600ID-
box. 15/1.85, IRB 2600ID-8/2.0:
Attachment screws: M8x40 quality steel
Gleitmo 12.9 (17 pcs)
Washers: 3HAA1001-172 (17 pcs)
Tightening torque: 35 Nm.

xx1800000935

Valid for IRB 2600 Type C-20/1.65, IRB

2600 Type C-12/1.65:
Attachment screws: M10x40 12.9 Gleitmo
603+Geo500 (15 pcs)
Washers: 3HAC043534-001 (3 pcs)
Tightening torque: 50 Nm ± 5 Nm and 90°
angle ± 10°.

xx1800000934

6 Secure the complete upper arm with round-

slings in an overhead crane and lift it to the
robot.
7 Refit the complete upper arm. How to refit the complete upper arm is
described in section:
• Refitting the complete upper arm
on page 252
8 Refit the cable package. How to refit the cable package in frame,
lower arm and armhouse is described in
sections:
• Refitting the cable harness in the
frame on page 210
• Refitting the cable harness in the
lower arm and armhouse on
page 219

Continues on next page

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 4 Repair
4.5.1 Replacing the lower arm
Continued

Action Note
9 Recalibrate the robot. Pendulum Calibration is described in Op-
erating manual - Calibration Pendulum,
enclosed with the calibration tools.
Axis Calibration is described in Calibrat-
ing with Axis Calibration method on
page 403.
General calibration information is included
in section Calibration on page 391.
10
DANGER

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 28.

Product manual - IRB 2600 285

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© Copyright 2009-2018 ABB. All rights reserved.
4 Repair
4.6.1 Replacing stop pin axis 1

4.6 Frame and base

4.6.1 Replacing stop pin axis 1

Location of stop pin axis 1

The stop pin axis 1 is located as shown in the figure.

xx0800000045

A Attachment screws M6x16 quality 8.8-A2F (2 pcs)

B Bracket
C O-ring (2 pcs) - Not used if bracket (D) is installed.
D Bracket
E Stop pin

Required equipment

Equipment Note
Stop pin For spare parts number, see Spare parts -
Frame and base in Product manual, spare
parts - IRB 2600.
Standard toolkit Content is defined in section Standard tools on
page 441.

Continues on next page

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 4 Repair
4.6.1 Replacing stop pin axis 1
Continued

Equipment Note
Other tools and procedures may be re- These procedures include references to the
quired. See references to these procedures tools required.
in the step-by-step instructions below.

Removing the stop pin, axis 1

Use this procedure to remove the stop pin axis 1.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2 Remove the attachment screws securing See the figure in

the bracket and stop pin. • Location of stop pin axis 1 on
page 286
3 Remove the bracket and stop pin. See the figure in
• Location of stop pin axis 1 on
page 286

Refitting the stop pin, axis 1

Use this procedure to refit the stop pin axis 1.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2 Fit the two o-rings on the stop pin. See the figure in
• Location of stop pin axis 1 on
Note page 286

The o-rings are not used when bracket (D)

is installed.

Continues on next page

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4 Repair
4.6.1 Replacing stop pin axis 1
Continued

Action Note
3 Fit the stop pin on the bracket.

Note

The small spike on the bracket shall be

pointing downwards for correct fitting of the
stop pin.
A

B
xx0800000453

Parts:
• A: Bracket
• B: Stop pin
• C: Small spike
4 Secure the stop pin together with bracket 3HAB7116-1 (Loctite 243).
(D) on the frame with its attachment screws. Tightening torque: 10 Nm
Use Locking liquid
See the figure in
• Location of stop pin axis 1 on
page 286
5
DANGER

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 28.

288 Product manual - IRB 2600

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© Copyright 2009-2018 ABB. All rights reserved.
 4 Repair
4.6.2 Replacing the base

4.6.2 Replacing the base

Location of base and complete arm system

The complete arm system is defined as:
• complete upper arm (includes: wrist unit, tubular shaft unit and armhouse)
• lower arm
• frame
• axis-1 gearbox
The location of the base and the complete arm system is shown in the figure.
The figure shows IRB 2600 Standard but is also valid for IRB 2600ID.

xx0900000320

A Base
B Frame
C Lower arm
D Arm house (part of complete upper arm)
E Tubular shaft (part of complete upper arm)
F Wrist unit (part of complete upper arm)

Continues on next page

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4 Repair
4.6.2 Replacing the base
Continued

Required equipment

Equipment Article number Note

Roundslings - Lengths: 2 m (1 pcs), 1.5 m (1
pcs)
Lifting capacity: 1,000 kg.
Support legs 3HAC15535-1 3 pcs
Guide pin, M8x150 3HAC15520-2 Valid for IRB 2600-20/1.65, IRB
2600-12/1.65, IRB 2600-12/1.85,
IRB 2600ID-15/1.85, IRB 2600ID-
8/2.0.
Always use guide pins in pairs.
Guide pin, M12x150 3HAC13056-2 Valid for IRB 2600 Type C-
20/1.65, IRB 2600 Type C-
12/1.65.
Always use guide pins in pairs.
Lifting eye - Valid for IRB 2600-20/1.65, IRB
2600-12/1.65, IRB 2600-12/1.85,
IRB 2600ID-15/1.85, IRB 2600ID-
8/2.0.
M8
3 pcs
Lifting eye - Valid for IRB 2600 Type C-
20/1.65, IRB 2600 Type C-
12/1.65.
M12
3 pcs
Standard toolkit Content is defined in section
Standard tools on page 441.
Other tools and procedures may These procedures include refer-
be required. See references to ences to the tools required.
these procedures in the step-by-
step instructions below.
Gasket 3HAC065190-001 Included with spare part base. 3
pcs
Cleaning agent - Loctite 7063
For cleaning.
Flange sealant 12340011-116 Loctite 574
Only valid for IRB 2600-20/1.65, For sealing.
IRB 2600-12/1.65, IRB 2600-
12/1.85, IRB 2600ID-15/1.85, IRB
2600ID-8/2.0.

Continues on next page

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 4 Repair
4.6.2 Replacing the base
Continued

Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Action Note
1 Decide which calibration routine to use for
calibrating the robot.
• Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
• Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
If the robot is to be calibrated with refer- Follow the instructions given in the refer-
ence calibration: ence calibration routine on the FlexPendant
Find previous reference values for the axis to create reference values.
or create new reference values. These val- Creating new values requires possibility to
ues are to be used after the repair proced- move the robot.
ure is completed, for calibration of the ro- Read more about reference calibration for
bot. Axis Calibration in Reference calibration
If no previous reference values exist, and routine on page 404.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Removing the base

Use this procedure to remove the complete arm system from the base.
Action Note
1 Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.
2 Jog the robot to:
• Axis 1: 0°
• Axis 2: 0°
• Axis 3: -10°
• Axis 4: 0°
• Axis 5: 0°
• Axis 6: 0°
3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Continues on next page

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4 Repair
4.6.2 Replacing the base
Continued

Action Note
4 Drain the axis-1 gearbox. How to drain oil is detailed in section
• Changing the oil, axis 1 gearbox on
Note floor mounted robots on page 150

Draining is time-consuming.
Elapsed time varies depending on the tem-
perature of the oil.

5 Remove the cable harness in the base, the How to remove the cable harness in base
frame and the lower arm of the robot. and frame is detailed in sections:
• Removing cable harness in base
on page 198
Tip
• Removing cable harness in frame
on page 203
Wrap up the cabling against the frame to
keep it undamaged during the remaining • Removing cable harness in lower
work. arm and armhouse on page 204

6 Secure the robot with roundslings in an Dimensions are specified in Required

overhead crane. equipment on page 290.
Stretch the roundslings so that the robot B
weight is secured when removing founda-
tion bolts in next step.

xx1800001211

A Roundsling 1.5 m
B Roundsling 2 m
7
CAUTION

The IRB 2600/IRB 2600 ID robot weighs 280

kg.
All lifting accessories used must be sized
accordingly!

8 Remove the bolts that secure the robot to

the foundation.

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 4 Repair
4.6.2 Replacing the base
Continued

Action Note
9 Lift the robot and fit three support legs to
the robot base, using bolts, washers and
nuts.

DANGER

Working underneath the manipulator without

safely securing the support legs between
the robot base and the foundation will result
in serious or fatal injury.
Make sure the robot is stable and safely
secured to the foundation via the support
legs, before working underneath the robot.
Keep the lifting accessories stretched for xx1800000874
extra safety precautions.

10 Lower the robot and secure the support legs

to the foundation, using bolts and washers.

xx1800000875

11 Remove the cover plate at the bottom of the

base.

xx1800000879

12 Valid for IRB 2600-20/1.65, IRB 2600-

12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0:
Remove the expansion container, if avail-
able.

xx1800000881

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4.6.2 Replacing the base
Continued

Action Note
13 Remove the base attachment screws and Valid for IRB 2600-20/1.65, IRB 2600-
washers. 12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0:

xx1800000882

Valid for IRB 2600 Type C-20/1.65, IRB

2600 Type C-12/1.65:

xx1800000880

14 Fit two guide pins in opposite holes in the Valid for IRB 2600-20/1.65, IRB 2600-
axis-1 gearbox. 12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0:
Guide pin, M8x150: 3HAC15520-2
Valid for IRB 2600 Type C-20/1.65, IRB
2600 Type C-12/1.65:
Guide pin, M12x150: 3HAC13056-2
Always use guide pins in pairs.

xx1800000883

15
CAUTION

The arm system and axis-1 gearbox weighs

235 kg together.
All lifting accessories must be sized accord-
ingly.

Continues on next page

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 4 Repair
4.6.2 Replacing the base
Continued

Action Note
16 Lift away the robot arm system.
Remove the guide pins, if the arm system
is about to be laid down on the floor. See
Illustration of robot put down on its side on
page 360.

xx1800000884

17
CAUTION

The weight of the base is 49 kg

All lifting accessories used must be sized
accordingly.

18 Fit three lifting eyes to the base and secure Valid for IRB 2600-20/1.65, IRB 2600-
with roundslings in an overhead crane or 12/1.65, IRB 2600-12/1.85, IRB 2600ID-
similar. 15/1.85, IRB 2600ID-8/2.0:
Lifting eye: M8
Valid for IRB 2600 Type C-20/1.65, IRB
2600 Type C-12/1.65:
Lifting eye: M12

xx1800000931

19 Remove the support legs attachments

screws and remove the base from the sup-
port legs.

xx1800000885

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4 Repair
4.6.2 Replacing the base
Continued

Refitting the base

Use this procedure to refit the complete arm system to the base.
Action Note
1
CAUTION

The weight of the base is 49 kg

All lifting accessories used must be sized
accordingly.

2 Fit three lifting eyes to the base and secure Valid for IRB 2600-20/1.65, IRB 2600-
with roundslings in an overhead crane or 12/1.65, IRB 2600-12/1.85, IRB 2600ID-
similar. 15/1.85, IRB 2600ID-8/2.0:
Lifting eye: M8
Valid for IRB 2600 Type C-20/1.65, IRB
2600 Type C-12/1.65:
Lifting eye: M12
3 Fit the new base to the support legs and
secure with the attachment screws.

xx1800000885

4 Valid for IRB 2600-20/1.65, IRB 2600-

12/1.65, IRB 2600-12/1.85, IRB 2600ID- Tip
15/1.85, IRB 2600ID-8/2.0:
Remove residues of old Loctite and other Use Loctite 7063 (or similar) for cleaning.
contaminations from surfaces before apply-
ing new Loctite 574.

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 4 Repair
4.6.2 Replacing the base
Continued

Action Note
5 Valid for IRB 2600-20/1.65, IRB 2600-
12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0:
Apply Loctite 574 around the screw holes
on the axis-1 gearbox as shown in the fig-
ure.

xx0800000353

Parts
A Loctite 574
B Screw hole in axis-1 gearbox
C Axis-1 gearbox
6 Valid for IRB 2600 Type C-20/1.65, IRB
2600 Type C-12/1.65:
Fit three new gaskets to the base. The gas-
kets are included with the gearbox spare
part.

xx1800000797

7
CAUTION

The arm system and axis-1 gearbox weighs

235 kg together.
All lifting accessories must be sized accord-
ingly.

8 Lift the arm system to the mounting site.

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4.6.2 Replacing the base
Continued

Action Note
9 Fit two guide pins in opposite holes in the Valid for IRB 2600-20/1.65, IRB 2600-
axis-1 gearbox. 12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0:
Guide pin, M8x150: 3HAC15520-2
Valid for IRB 2600 Type C-20/1.65, IRB
2600 Type C-12/1.65:
Guide pin, M12x150: 3HAC13056-2
Always use guide pins in pairs.

xx1800000932

10 Lower the arm system against the base and Valid for IRB 2600-20/1.65, IRB 2600-
secure with the attachment screws and 12/1.65, IRB 2600-12/1.85, IRB 2600ID-
washers. 15/1.85, IRB 2600ID-8/2.0:
Attachment screws: M8x40 quality Steel
12.9 Gleitmo and washers (24+24 pcs).
Tightening torque: 35 Nm.

xx1800000882

Valid for IRB 2600 Type C-20/1.65, IRB

2600 Type C-12/1.65:
Attachment screws: M12x50 12.9 Gleitmo
603 and washers (12+12 pcs).
Tightening torque: 110 Nm.

xx1800000880

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Continued

Action Note
11 Valid for IRB 2600-20/1.65, IRB 2600-
12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0:
Refit the expansion container, if available.

xx1800000881

12 Apply some grease to the o-ring and refit

the o-ring between the cover and base.
13 Refit the cover plate at the bottom of the Attachment screws: M6x16 quality 8.8-
base with its attachment screws. A2F (5 pcs)

xx1800000879

14 Remove the screws that secure the support

legs to the foundation.

DANGER

Stretch the roundslings to make sure that

the robot weight is secured.

xx1800000875

15 Lift the complete robot and remove the

support legs from the base.

xx1800000874

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4 Repair
4.6.2 Replacing the base
Continued

Action Note
16 Lower the robot and secure it to the found- See Orienting and securing the robot on
ation. page 71.
17 Recalibrate the robot. Pendulum Calibration is described in Op-
erating manual - Calibration Pendulum,
enclosed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 403.
General calibration information is included
in section Calibration on page 391.
18
DANGER

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 28.

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 4 Repair
4.7.1 Removing motors

4.7 Motors

4.7.1 Removing motors

Introduction
This procedure describes how to remove motors on all axes of the robot.

Note

For IRB 2600ID this section describes motors axes 1, 2, 3 and 4. Motors axes 5
and 6 are described in sections:
• Motor axis 5, section Replacing motor axis 5 - IRB 2600ID on page 329
• Motor axis 6, section Replacing motor axis 6 and wrist unit - IRB 2600ID on
page 341.

Location of axis-1 and axis-2 motors

The axis-1 and axis-2 motors are located as shown in the figure.
Motors:
(1) = Axis-1 motor
(2) = Axis-2 motor

xx0900000302

A Attachment screws M5x16, quality Steel 8-A2F (7 pcs)

B Motor cover
C Attachment screws, axis-1 motor (4 pcs) + washers. See Tightening torques and
attachment screws on page 320
C Attachment screws, axis-2 motor (4 pcs) + washers. See Tightening torques and
attachment screws on page 320
D Connection box
E Axis-1 motor
E Axis-2 motor

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4 Repair
4.7.1 Removing motors
Continued

F O-ring
G Hole
H Cable gland cover

Location of axis-3, axis-4, axis-5 and axis-6 motors

The axis-3, axis-4, axis-5 and axis-6 motors are located as shown in the figures.
IRB 2600 Standard.
Motors: (3) = Axis-3 motor. (4) = Axis-4, axis-5 and axis-6 motors.

xx0900000303

A Markings inside armhouse, identifying the position of each motor

B Attachment screws, axis-3 motor (4 pcs) + washers. See Tightening torques and
attachment screws on page 320
B Attachment screws, axis-4, axis-5 and axis-6 motors (3x4 pcs) + washers.
Tightening torques and attachment screws on page 320
C Axis-3 motor
D Axis-4 motor
E Axis-5 motor
F Axis-6 motor
G O-ring (axis-4, axis-5 and axis-6)
H Armhouse

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Continued

IRB 2600ID

xx1000000990

A Attachment screws (4 pcs)

B Motor axis 3
C O-ring
D O-ring
E Motor axis 4
F Attachment screws (4 pcs)

Connectors, motors axes 3 - 6

The figures shows the connectors in the armhouse.
• IRB 2600 Standard: Axes 3-6
• IRB 2600ID: Axes 3-4

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4 Repair
4.7.1 Removing motors
Continued

IRB 2600 Standard, motor type B

MP5 FB5 MP4 FB4

FB6

MP6

FB3

MP3

MP3-6 FB3-6
xx1400002568

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 4 Repair
4.7.1 Removing motors
Continued

IRB 2600 Standard, motor type A

xx0900000367

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4 Repair
4.7.1 Removing motors
Continued

IRB 2600ID

R2.FB6
R2.FB5
R2.MP6
R2.FB4 R2.MP5
R2.MP4

R2.FB3

R2.MP3

xx1400002578

Required equipment

Equipment Note
Threaded bar 2 pcs. Dimension: M8.
Used for pressing out the axis-1 and axis-2
motors.
Extended reach hex bit socket head Required for:
• Axis-2 motor replacement: M6, length
minimum 260 mm.
• Axis-3 motor replacement: M6, length
minimum 160 mm.
Standard toolkit Content is defined in section Standard tools
on page 441.
Other tools and procedures may be required. These procedures include references to the
See references to these procedures in the tools required.
step-by-step instructions below.

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 4 Repair
4.7.1 Removing motors
Continued

Weights
The motors for the different axes weighs according to the table:
Motor Weight in kg
Axis-1 motor 13 kg
Axis-2 motor 13 kg
Axis-3 motor 8 kg
Axis-4 motor 6.5 kg
Axis-5 motor 6.5 kg
Axis-6 motor 6.5 kg

CAUTION

All lifting equipment must be sized accordingly!

Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Action Note
1 Decide which calibration routine to use for
calibrating the robot.
• Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
• Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
If the robot is to be calibrated with refer- Follow the instructions given in the refer-
ence calibration: ence calibration routine on the FlexPendant
Find previous reference values for the axis to create reference values.
or create new reference values. These val- Creating new values requires possibility to
ues are to be used after the repair proced- move the robot.
ure is completed, for calibration of the ro- Read more about reference calibration for
bot. Axis Calibration in Reference calibration
If no previous reference values exist, and routine on page 404.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

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4 Repair
4.7.1 Removing motors
Continued

Position of robot
Use this procedure to place the robot in the position recommended in order to
facilitate replacement of motors.
Action Information
Axis-1, axis-4, axis-5 and axis-6 motor (IRB
2600 Standard)
Axis-1 and axis-4 motors (IRB 2600ID)
• Move the robot to a position where the
wrist is pointing to the floor, as shown in
the figure. This will make it possible to
remove the motors without draining the
oil from the gearbox.

xx0800000388

Axis-2 motor
• Move the robot to a position where the
lower arm rests firmly on the damper of
axes 2 and 3. Release the brake of axis
2 to be sure that the lower arm rests in
the end position.

xx1100000548

Axis-3 motor
• Move axis-2 to 0° and axis-3 to maximal
+. Release the brake of axis-3 to be sure
that the upper arm is completely vertical
and rests against the damper of axis-2
and axis-3.

Draining gearbox
Use this procedure to drain gearboxes, if needed.

Note

Draining of gearbox is only needed when removing the axes 2 and 3 motors.

Action Note
1 Axis-1 motor: -
• Draining of gearbox is not needed.
2 Axis-2 motor: How to drain the gearbox is described
• The gearbox has to be drained before in section:
removing the motor. • Changing the oil, axis-2 gearbox
on page 163

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 4 Repair
4.7.1 Removing motors
Continued

Action Note
3 Axis-3 motor: How to drain the gearbox is described
• The gearbox has to be drained before in section:
removing the motor. • Changing the oil, axis-3 gearbox
on page 167
4 IRB 2600 - axes 4, 5, 6: -
• Draining of gearbox is not needed if ro-
bot is positioned as recommended.
IRB 2600ID - axis 4:
• Draining of gearbox is not needed if ro-
bot is positioned as recommended.

Removing motors
Use this procedure to remove the axis-1, axis-2, axis-3, axis-4, axis-5 and axis-6
motors.

Note

How to replace motors axes 5 and 6 on IRB 2600ID is described in sections:

• Replacing motor axis 5 - IRB 2600ID on page 329
• Replacing motor axis 6 and wrist unit - IRB 2600ID on page 341

Note

The procedure contains information how to remove motors on all axes of the
robot. Some steps are only applicable to a certain motor. Follow the steps
carefully in order not to miss vital information!

Action Note
1 Decide which calibration routine to use, and
take actions accordingly prior to beginning the
repair procedure.
2 Move the robot to the recommended position See Removing motors on page 301.
for the motor that shall be removed. • Position of robot on page 308
3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

4 Check if the gearbox needs to be drained. See Removing motors on page 301.
• Draining gearbox on page 308

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4 Repair
4.7.1 Removing motors
Continued

Action Note
5 Only applicable to axis-3, axis-4, axis-5 and
axis-6 motors!
Remove the cover in the back of the arm house.
B
WARNING

The robot must never be run without the cover

in the armhouse fitted! It is a vital supporting
part of the robot.

A
xx0800000389

Parts:
• A: Cover
• B: Attachment screws (8 pcs) +
washers.
6 Only applicable to motors on axes 1 and 2 How to remove the fan is detailed in
with fan fitted! section:
Remove the fan before starting the removal! • Installation of cooling fan for
motors (option) on page 93
7 Only applicable to axis-1 and axis-2 motors! See the figure in:
Remove the motor cover. • Location of axis-1 and axis-2
motors on page 301
8 Only applicable to axis-1 and axis-2 motors! See the figure in:
Remove the cable gland cover. • Location of axis-1 and axis-2
motors on page 301
9 Only applicable to axis-1 and axis-2 motors! See the figure in:
Remove the connection box. • Location of axis-1 and axis-2
motors on page 301
Note

Only needed if the motor shall be replaced with

a new one.

10 Disconnect the motor cables.

Note

When removing motors 4,5 or 6 the

cables of motor axis 3 must be discon-
nected too. This must be done in order
to be able to remove the bracket on
top of motors axes 4, 5 and 6.

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4.7.1 Removing motors
Continued

Action Note
11 Only applicable to motors axes 3, 4, 5 and 6 The figure shows IRB 2600 Standard.
on IRB 2600 Standard and axes 3 and 4 on
IRB 2600ID! G
Remove the bracket to reach the attachment A
screws of the motors.
F
E

B
C

D
xx0900000372

Parts:
• A: Attachment screws, M6x16
quality 8.8-A2F (2 pcs)
• B: Bracket
• C: Clamp
• D: Cable straps
• E: Connection bracket
• F: Connection bracket
• G: Hexagon nut, M5 quality
steel 8-A2F
12 In order to release the brakes of the motor to Connectors:
be removed, connect the 24 VDC power supply • Axis-1 motor: R2.MP1
to the motor. • Axis-2 motor: R2.MP2
Only applicable to motors axes 2 and 3!
• Axis-3 motor: R2.MP3
Release the brake of axis 2 untill the lower arm
• Axis-4 motor: R2.MP4
firmly rests on the damper.
• Axis-5 motor: R2.MP5
• Axis-6 motor: R2.MP6
Connect to pins:
Axes 1, 2 and 3:
• + : pin 2
• -: pin 5
Axes 4 and 5:
• + : pin 4
• - : pin 6
Axis 6 IRB 2600:
• + : pin 4
• - : pin 6
Axis 6 IRB 2600ID:
• + : pin 7
• -: pin 8

CAUTION

The connections for the motor brakes

(24 VDC connection) are phase de-
pendent. If the connection on the pins
is switched, it can cause severe dam-
age to vital parts.

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4 Repair
4.7.1 Removing motors
Continued

Action Note
13
Note

Whenever parting/mating motor and gearbox,

the gears may be damaged if excessive force
is used!

14 Remove the attachment screws securing the See the figure in:
motor. • Location of axis-1 and axis-2
If needed use a 300 mm extension for bits 1/2" motors on page 301
(Motor axis 1).
15 If required, press the motor out of position by
fitting two threaded bars in the threaded holes Note
in the motor flange.
Always use removal tools in pairs diag-
onal to each other.

16 Remove the motor!

CAUTION

Lift the motor gently in order not to

damage pinion or gears.

17 Only applicable to motor axis 1! See the figure in:

Cover the hole if replacement of motor axis 1 • Location of axis-1 and axis-2
is not immediate, in order to avoid contamina- motors on page 301
tion.
18 Only applicable to motors axes 4, 5 and 6! See the figure in:
Check that the o-ring also is removed. It might • Location of axis-1 and axis-2
stay in the armhouse when the motor is re- motors on page 301
moved.

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 4 Repair
4.7.2 Refitting motors

4.7.2 Refitting motors

Introduction
This procedure describes how to refit motors on all axes of the robot.

WARNING

When a motor is replaced, make sure to use the correct type of new motor. Motors
of different types may not be compatible. See the Spare parts manual on myABB
business portal (www.myportal.abb.com).

Note

For IRB 2600ID this section describes motors axes 1, 2, 3 and 4. Motors axes 5
and 6 are described in sections:
• Motor axis 5, see section Replacing motor axis 5 - IRB 2600ID on page 329
• Motor axis 6, see section Replacing motor axis 6 and wrist unit - IRB 2600ID
on page 341.

Location of axis-1 and axis-2 motors

The axis-1 and axis-2 motors are located as shown in the figure.
Motors:
(1) = Axis-1 motor
(2) = Axis-2 motor

xx0900000302

A Attachment screws M5x16, quality Steel 8-A2F (7 pcs)

B Motor cover
C Axis-1 motor: Attachment screws(4 pcs) + washers. See Tightening torques
and attachment screws on page 320
C Axis-2 motor: Attachment screw (4 pcs) + washers. See Tightening torques and
attachment screws on page 320

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4 Repair
4.7.2 Refitting motors
Continued

D Connection box
E Axis-1 motor
E Axis-2 motor
F O-ring
G Hole
H Cable gland cover

Location of axis-3, axis-4, axis-5 and axis-6 motors

The axis-3, axis-4, axis-5 and axis-6 motors are located as shown in the figures.
IRB 2600 Standard.
Motors:
(3) = Axis-3 motor
(4) = Axis-4, axis-5 and axis-6 motors

xx0900000303

A Markings inside armhouse, identifying the position of each motor

B Attachment screws, axis-3 motor, (4 pcs) + washers. See Tightening torques
and attachment screws on page 320
B Attachment screws, axis-4, axis-5 and axis-6 motors, (3x4 pcs) + washers. See
Tightening torques and attachment screws on page 320
C Axis-3 motor
D Axis-4 motor
E Axis-5 motor
F Axis-6 motor
G O-ring (axis-4, axis-5 and axis-6)
H Armhouse

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Continued

IRB 2600ID

xx1000000990

A Attachment screws (4 pcs)

B Axis-3 motor
C O-ring
D O-ring
E Axis-4 motor
F Attachment screws (4 pcs)

Connectors, motors axes 3 - 6

The figures shows the connectors in the armhouse:
• IRB 2600 Standard: Axes 3-6
• IRB 2600ID: Axes 3-4.

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4 Repair
4.7.2 Refitting motors
Continued

IRB 2600 Standard, motor type B

MP5 FB5 MP4 FB4

FB6

MP6

FB3

MP3

MP3-6 FB3-6
xx1400002568

Note

On IRB 2600 standard, motor type B the connector FB6 shall be fitted in a 30°
angle.

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Continued

IRB 2600 Standard, motor type A

xx0900000367

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4.7.2 Refitting motors
Continued

IRB 2600ID

R2.FB6
R2.FB5
R2.MP6
R2.FB4 R2.MP5
R2.MP4

R2.FB3

R2.MP3

xx1400002578

Required equipment

Equipment Note
Extended reach hex bit socket head Required for:
• Axis-2 motor replacement: M6, length
minimum 260 mm.
• Axis-3 motor replacement: M6, length
minimum 160 mm.
Standard toolkit Content is defined in section Standard tools
on page 441.
Other tools and procedures may be required. These procedures include references to the
See references to these procedures in the tools required.
step-by-step instructions below.
Lifting tool, axis-2 For art. no. see Reference information.
Lifting tool, axis-3 For art. no. see Reference information.
Motors For spare part no. see Spare part lists on
page 445.

Continues on next page

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 4 Repair
4.7.2 Refitting motors
Continued

Weights
The motors for the different axes weighs according to the table:
Motor Weight in kg
Axis-1 motor 13 kg
Axis-2 motor 13 kg
Axis-3 motor 8 kg
Axis-4 motor 6.5 kg
Axis-5 motor 6.5 kg
Axis-6 motor 6.5 kg

CAUTION

All lifting equipment must be sized accordingly!

Position of robot
Use this procedure to place the robot in the position recommended in order to
facilitate replacement of motors.
Action Information
Axis-1, axis-4, axis-5 and axis-6 motors (IRB
2600 Standard)
Axis-1 and axis-4 motors (IRB 2600ID)
• Move the robot to a position where the
wrist is pointing to the floor, as shown in
the figure. This will make it possible to
remove the motors without draining the
oil from the gearbox.

xx0800000388

Axis-2 motor
• Move the robot to a position where the
lower arm rests firmly on the axis-3
damper. Release the axis-2 brake to be
sure that the lower arm rests in the end
position.

xx1100000548

Axis-3 motor
• Move axis-2 to 0° and axis-3 to maximal
+. Release the axis-3 brake to be sure
that the upper arm is completely vertical
and rests against the damper.

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4 Repair
4.7.2 Refitting motors
Continued

Filling oil in gearbox

Use this procedure to fill oil in gearbox, if needed.

Note

Filling oil in the gearbox is only needed when refitting motors axes 2 and 3.

Action Note
1 Axis-1 motor: -
• Filling gearbox oil not needed.
2 Axis-2 motor: How to fill oil in gearbox is described
• Refill oil in gearbox after refitting. in section:
• Changing the oil, axis-2 gear-
box on page 163
3 Axis-3 motor: How to fill oil in gearbox is described
• Refill oil in gearbox after refitting. in section:
• Changing the oil, axis-3 gear-
box on page 167
4 IRB 2600 Standard - axes 4, 5, 6: -
• Filling oil not needed, provided it has not
been drained.
IRB 2600ID - axes 4:
• Filling oil not needed, provided it has not
been drained.

Tightening torques and attachment screws

The table shows the tightening torques for all motors.
Motor Attachment screw Quality Tightening torque
Motor, axis 1 M8x25 8.8-A2F 22 Nm
Motor, axis 2 M8x25 8.8-A2F 22 Nm
Motor, axis 3 M8x25 8.8-A2F 22 Nm
Motor, axis 4 M6x25 8.8-A2F 10 Nm
Motor, axis 5 M6x25 8.8-A2F 10 Nm
Motor, axis 6 M6x25 (Standard) 8.8-A2F 10 Nm (Standard)
M5x25 (IRB 2600ID) 6 Nm (IRB 2600ID)

Preparations before the refitting of motors

Use this procedure to make necessary preparations before refitting motors.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

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 4 Repair
4.7.2 Refitting motors
Continued

Action Note
2 Grind the paint on the surface carefully to get
a smoth surface.
3 Clean the surface from contamination such as
oil and dirt.
Remove any painting from the assembly sur-
faces, with a knife.
4 Make sure that the motor and the pinion are
not damaged or scratched.
5 Lightly lubricate the o-ring with grease.
6 Make sure the o-ring on the flange of the motor
is seated properly.

xx0900000082

Parts:
• A: Correct position of o-ring
• B: Incorrect position of o-ring !
Replace with a new o-ring if damaged!
7 In order to release the brakes, connect the 24 Connectors:
VDC power supply. • Motor axis 1: R2.MP1
• Motor axis 2: R2.MP2
• Motor axis 3: R2.MP3
• Motor axis 4: R2.MP4
• Motor axis 5: R2.MP5
• Motor axis 6: R2.MP6
Connect to pins:
Axes 1, 2 and 3:
• + : pin 2
• -: pin 5
Axes 4 and 5:
• + : pin 4
• - : pin 6
Axis 6 IRB 2600:
• + : pin 4
• - : pin 6
Axis 6 IRB 2600ID:
• + : pin 7
• -: pin 8

CAUTION

The connections for the motor brakes

(24 VDC connection) are phase de-
pendent. If the connection on the pins
is switched, it can cause severe dam-
age to vital parts.

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4 Repair
4.7.2 Refitting motors
Continued

Note

A fan is recommended to be used to avoid overheating of motor and gear in

applications with intensive motion (high average torque and/or short wait time)
of axes 1 and 2. IP54 is valid for cooling fan.
A fan is also recommended to be used if the environmental temperature is high.
How to install a fan is described in section Installation of cooling fan for motors
(option) on page 93.

Refitting motors
Use this procedure to refit motors axes 1, 2, 3, 4, 5 and 6.

Note

How to refit motors axes 5 and 6 on IRB 2600ID is described in sections:

• Replacing motor axis 5 - IRB 2600ID on page 329
• Replacing motor axis 6 and wrist unit - IRB 2600ID on page 341.

Note

The procedure contains information how to refit motors on all axes of the robot.
Some steps are only applicable to a certain motor. Follow the steps carefully in
order not to miss vital information!

Action Information
1 See Refitting motors on page 313.
Note • Preparations before the refitting
of motors on page 320
Before starting the refitting of the motor, first
make the necessary preparations!

2
Note

Whenever parting/mating motor and gearbox,

the gears may be damaged if excessive force
is used!

3 Place the motor carefully in the gearbox.

4 Fit the motor, making sure the motor pinion is Make sure that:
properly mated to the gear in the gearbox. • the motor is turned the correct
way
• the pinion or gear of the motor
does not get damaged!

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 4 Repair
4.7.2 Refitting motors
Continued

Action Information
5 IRB 2600 standard, motor type B
Applicable to motor axis 3!
Make sure that the wire exit holes of motor axis
3 is in the correct position. See illustration!

xx1400002570

Parts:
• A: Wire exit hole, motor axis 3
6 IRB 2600 standard, motor type A
Applicable to motor axis 3!
Make sure that the wire exit holes of motor axis
3 is in the correct position. See illustration!

xx0900000375

Parts:
• A: Wire exit hole, motor axis 3

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4 Repair
4.7.2 Refitting motors
Continued

Action Information
7 IRB 2600ID, motor type B
Make sure that the wire exit holes of motors D E
axes 3 and 4 are in the correct position. See il-
lustration!

xx1400002573

Parts:
A Wire exit hole, motor axis 3
B Motor axis 3
C Motor axis 4
D Power wire exit hole, motor axis
4
E Signal cable exit hole, motor
axis 4
8 IRB 2600ID, motor type A
Make sure that the wire exit holes of motors
axes 3 and 4 are in the correct position. See il-
lustration!

xx1000000992

Parts:
A Wire exit hole, motor axis 3
B Motor axis 3
C Motor axis 4
D Wire exit hole, motor axis 4

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 4 Repair
4.7.2 Refitting motors
Continued

Action Information
9 IRB 2600 standard, motor type B B

Applicable to motors axes 4, 5 and 6!

Make sure that the orientation of the motor is
in the correct position! See illustration! A

A
A

B B
xx1400002571

Parts:
• A: Wire exits of motors axes 4,
5 and 6
10 IRB 2600 standard, motor type A
Applicable to motors axes 4, 5 and 6!
Make sure that the orientation of the motor is
in the correct position! See illustration!

xx0900000376

Parts:
• A: Wire exits of motors axes 4,
5 and 6
11 Only applicable to motors axes 4, 5 and 6! See Adjusting the play on page 352.
Adjust the play of the motor.
12 Secure the motor with its attachment screws Tightening torque and attachment
and washers. screws are specified in the table:
• Tightening torques and attach-
Note ment screws on page 320

Apply the correct tightening torque!

13 Disconnect the brake release voltage.

14 Only applicable to motors axes 1 and 2! See the figure in:
Refit the connection box (if it has been re- • Location of axis-1 and axis-2
moved). motors on page 313

Note

Make sure that the o-ring is in place!

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4 Repair
4.7.2 Refitting motors
Continued

Action Information
15 IRB 2600 Standard, motor type A G
Applicable to motors axes 3, 4, 5 and 6!
A
Refit the bracket in the armhouse on top of
motors axes 4, 5 and 6. F
E

B
C

D
xx0900000372

Parts:
A Attachment screws, M6x16
quality 8.8-A2F (2 pcs)
B Bracket
C Clamp
D Cable straps
E Connection bracket
F Connection bracket
G Hexagon nut, M5 quality steel
8-A2F
16 IRB 2600 Standard, motor type B

Note

Connection bracket for FB6 shall be fitted in a

30° angle. See figure!

xx1400002569

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 4 Repair
4.7.2 Refitting motors
Continued

Action Information
17 IRB 2600ID IRB 2600ID
Refit the bracket in the armhouse with its attach- R2.FB6
ment screws. R2.FB5
R2.MP6
R2.FB4 R2.MP5
R2.MP4

R2.FB3

R2.MP3

xx1400002578

18 Reconnect the motor cables.

19 Applicable to motor axes 1 and 2! See the figure in:
Refit the cable gland and motor covers. • Location of axis-1 and axis-2
motors on page 313
Make sure that the o-ring is in place!

Note

Make sure that the cover is tightly

sealed!

20 Applicable to motors axis 2! How to fill oil in the gearbox is de-

Refill gearbox oil. scribed in sections:
• Changing the oil, axis-2 gearbox
on page 163
• Changing the oil, axis-3 gearbox
on page 167
21 Applicable to motors axes 3, 4, 5 and 6! If the gasket is damaged, it need to be
Make sure that the gasket on the cover on the replaced.
armhouse is intact.

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4 Repair
4.7.2 Refitting motors
Continued

Action Information
22 Applicable to motors axes 3, 4, 5 and 6! Make sure that the cover is tightly
Refit the cover in the back of the armhouse sealed.
with its attachment screws and washers.

WARNING
B
The cover on the armhouse must be fitted when
the robot is running. It is a vital part for the
stability of the robot.

A
xx0800000389

Parts:
• A: Cover
• B: Attachment screws M6x25,
quality 8.8-A2F (8 pcs)
Tightening torque:
• 14 Nm
23 Recalibrate the robot. Pendulum Calibration is described in
Operating manual - Calibration Pendu-
lum, enclosed with the calibration
tools.
Axis Calibration is described in Calib-
rating with Axis Calibration method on
page 403.
General calibration information is in-
cluded in section Calibration on
page 391.
24
DANGER

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 28.

328 Product manual - IRB 2600

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 4 Repair
4.7.3 Replacing motor axis 5 - IRB 2600ID

4.7.3 Replacing motor axis 5 - IRB 2600ID

Introduction
This procedure describes how to replace motor axis 5 on IRB 2600ID.

WARNING

When a motor is replaced, make sure to use the correct type of new motor. Motors
of different types may not be compatible. See the Spare parts manual delivered
as a separate document on myABB business portal (www.myportal.abb.com).

Location of motor axis 5

Motor axis 5 is located inside the upper arm tube as shown in the figure.

xx1000000877

A Motor axis 6
B Motor axis 5

Required equipment

Equipment Art. no. Note

Sikaflex 521FC 3HAC026759-001
Standard toolkit - Content is defined in section
Standard tools on page 441.
Other tools and procedures These procedures include
may be required. See refer- references to the tools re-
ences to these procedures in quired.
the step-by-step instructions
below.

Continues on next page

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4 Repair
4.7.3 Replacing motor axis 5 - IRB 2600ID
Continued

Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Action Note
1 Decide which calibration routine to use for
calibrating the robot.
• Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
• Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
If the robot is to be calibrated with refer- Follow the instructions given in the refer-
ence calibration: ence calibration routine on the FlexPendant
Find previous reference values for the axis to create reference values.
or create new reference values. These val- Creating new values requires possibility to
ues are to be used after the repair proced- move the robot.
ure is completed, for calibration of the ro- Read more about reference calibration for
bot. Axis Calibration in Reference calibration
If no previous reference values exist, and routine on page 404.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Removing motor axis 5

Use this procedure to remove motor axis 5.
Action Information
1 Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.
2 Rotate the upper arm in order to access the
two inner attachment screws securing the
cover and remove them.

xx1000000961

Parts:
• A: Inner attachment screws (2 pcs)
• B: Directions of rotation

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 4 Repair
4.7.3 Replacing motor axis 5 - IRB 2600ID
Continued

Action Information
3 Move the upper arm to sync. position.

xx1000001007

4
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

5 Remove all extra equipment fitted on the

upper arm and wrist.
6 Remove the wrist. How to remove the wrist see section:
This is done in order to be able to discon- • Replacing motor axis 6 and wrist
nect cables to motor axis 6. unit - IRB 2600ID on page 341

7
Note

Make a note of the position of axis 4 before

continueing the removal process.
It is important to refit the mechanical stop
and cable harness spiral, with axis 4 in the
same position as it was before the removal.
If axis 4 has been moved, it must be re-
turned to the position it was when the
mechanical stop was removed.
This is due to risk of damage to the cable
harness.

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4 Repair
4.7.3 Replacing motor axis 5 - IRB 2600ID
Continued

Action Information
8 Remove the mechanical stop.

Note

Don’t loose the o-ring and distance ring in

the removal process!

xx1000000879

Parts:
• A: Attachment screws (5 pcs)
• B: Mechanical stop
• C: O-ring
• D: Distance ring
• E: Bracket
• F: Cover
9 Remove the bracket. See figure above!
10 Remove the cover on the upper arm tube. See figure above!
11 Remove the two VK-covers, covering the
attachment screws securing the cable har-
ness to the arm tube.

xx1000000934

Parts:
• A: VK-covers (2 pcs)

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 4 Repair
4.7.3 Replacing motor axis 5 - IRB 2600ID
Continued

Action Information
12 Remove the attachment screws (A) securing
the cover (B) on the armhouse.

xx1000001001

Parts:
A Attachment screws (6 pcs)
B Cover
C Attachment screws (8 pcs) securing
arm tube
13 Remove the attachment screws (8 pcs) se-
curing the tube of the armhouse.

A
xx1000000936

Parts:
• A: Attachment screws (8 pcs)
14 Unscrew the attachment screws securing
the cable harness bracket to the upper arm
tube.

Note

The arm tube is not shown.

xx1000000939

Parts:
• A: Motor axis 5
• B: Cover
• C: Bracket (inside armhouse)
• D: Attachment screws (2 pcs)
• E: Bracket (upper arm tube)

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4 Repair
4.7.3 Replacing motor axis 5 - IRB 2600ID
Continued

Action Information
15 Pull carefully out the upper arm tube a little.
Not more than it is possible to reach the
connectors for motor axis 5.

CAUTION

Be careful not to damage the cable harness

in the process. The space is cramp.

16 IRB 2600ID, motor type B: R4.FB5

Disconnect connectors R4.MP5 and R4.FB5
to motor axis 5.

R4.MP5

xx1400002576

17 IRB 2600ID, motor type A

Disconnect the connectors to motor axis 5.

xx1000000998

Parts:
A Bracket
B Attachment screws (2 pcs)
C Connectors motor axis 5
D Motor axis 5
18 Pull out the cable harness from motor axis
6 through the upper arm tube and secure
the cable harness with a roundsling or sim-
ilar to the armhouse.
19 Remove the upper arm tube.
20 Secure the upper arm tube with motor axis
5 pointing upwards.
This is done in order to avoid draining the
oil when motor axis 5 is removed.

xx1000000938

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 4 Repair
4.7.3 Replacing motor axis 5 - IRB 2600ID
Continued

Action Information
21 Remove motor axis 5 by unscrewing its at-
tachment screws.
B

xx1000000937

Parts:
• A: Upper arm tube
• B: Motor axis 5

Refitting motor axis 5

Use this procedure to refit motor axis 5.
Action Information
1 Place motor axis 5 in the upper arm tube.
2 Tighten the attachment screws just enough
to still be able to move the motor.
B

xx1000000937

Parts:
• A: Upper arm tube
• B: Motor axis 5
3 Adjust the play by finding the smallest play.
4 Secure the motor with its attachment Tightening torque: 10 Nm.
screws.
5 Lift the upper arm tube to the robot.

Continues on next page

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4 Repair
4.7.3 Replacing motor axis 5 - IRB 2600ID
Continued

Action Information
6 Push the cables to motor axis 6 into the
upper arm tube.
7 IRB 2600, motor type B R4.FB5
Connect connectors R4.MP5 and R4.FB5
to motor axis 5.

R4.MP5

xx1400002576

8 IRB 2600, motor type A

Connect the connectors to motor axis 5.

xx1000000998

Parts:
A Bracket
B Attachment screws (2 pcs)
C Connectors to motor axis 5
D Motor axis 5
9 Apply flange sealing (Loctite 574) on the
surface where the cover shall be fitted. See
figure!

xx1000001006

Part:
A Flange sealing (Loctite 574)

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 4 Repair
4.7.3 Replacing motor axis 5 - IRB 2600ID
Continued

Action Information
10 Secure the cover with its attachment Tightening torque: 10 Nm.
screws.

xx1000001001

Parts:
A Attachment screws (6 pcs) M6x20
quality 8.8-A2F
B Cover
C Attachment screws (8 pcs) M8x25
quality Steel 12.9 Gleitmo
11 Secure the cable harness with its attach-
ment screws to the upper armtube.

xx1000000998

Parts:
A Bracket
B Attachment screws (2 pcs)
C Connectors motor axis 5
D Motor axis 5
12 Check that the spiral of the cable harness See section
is fitted correctly. • Replacing the cable harness in the
upper arm - IRB 2600ID on page 222
13 Secure the upper arm tube with its attach- Tightening torque: 35 Nm.
ment screws.

A
xx1000000936

Parts:
A Attachment screws (8 pcs)

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4 Repair
4.7.3 Replacing motor axis 5 - IRB 2600ID
Continued

Action Information
14 Apply flange sealing (Loctite 574) on the
surface shown in the figure.

Note

Do not apply flange sealing on the surfaces

where Sikaflex 521FC shall be applied!
See figure!

xx1000001003

Parts:
A Surface where Sikaflex 521FC shall
be applied
B Surface where Loctite 574 shall be
applied.
15 Refit the cover with two inner attachment
screws.

xx1000000879

Parts:
A Attachment screws (5 pcs)
B Mechanical stop
C O-ring
D Distance ring
E Bracket
F Cover
16 Refit the bracket with the remaining attach- See figure above.
ment screws.

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 4 Repair
4.7.3 Replacing motor axis 5 - IRB 2600ID
Continued

Action Information
17 Apply Sikaflex 521FC on the surfaces
shown in the figure.

xx1000001002

Parts:
A Sikaflex 521FC
B Cover
C Surface where to apply Sikaflex
521FC
18 Connect the cable to motor axis 6.
19 Refit the mechanical stop.
20 Fit new VK-covers.

xx1000000934

Parts:
A VK cover (2 pcs)
21 Refit the wrist. See section
• Replacing motor axis 6 and wrist
unit - IRB 2600ID on page 341
22 Recalibrate the robot. Pendulum Calibration is described in Op-
erating manual - Calibration Pendulum,
enclosed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 403.
General calibration information is included
in section Calibration on page 391.

Continues on next page

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4 Repair
4.7.3 Replacing motor axis 5 - IRB 2600ID
Continued

Action Information
23
DANGER

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 28.

340 Product manual - IRB 2600

3HAC035504-001 Revision: Q
© Copyright 2009-2018 ABB. All rights reserved.
 4 Repair
4.7.4 Replacing motor axis 6 and wrist unit - IRB 2600ID

4.7.4 Replacing motor axis 6 and wrist unit - IRB 2600ID

Introduction
This procedure describes how to replace the axis-6 motor on IRB 2600ID.
The replacement of the motor also contains the procedure for how to remove and
refit the wrist unit on IRB 2600ID

Location of motor axis 6

Motor axis 6 is located inside the upper arm tube, as shown in the figure.

xx1000000877

A Motor axis 6
B Motor axis 5

Required equipment

Equipment Art. no. Note

Motor, axis 6 For spare part number, see:
• Spare part lists on
page 445
Wrist unit, ID For spare part number, see:
• Spare part lists on
page 445
VK cover For spare part number, see: Always replace with a new
• Spare part lists on when removed.
page 445 One VK cover at the axis-5
flexible coupling.
One VK cover underneath the
arm tube.
Locking liquid - Loctite 574
Standard toolkit Content is defined in section
Standard tools on page 441.
Other tools and procedures These procedures include
may be required. See refer- references to the tools re-
ences to these procedures in quired.
the step-by-step instructions
below.

Continues on next page

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© Copyright 2009-2018 ABB. All rights reserved.
4 Repair
4.7.4 Replacing motor axis 6 and wrist unit - IRB 2600ID
Continued

Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Action Note
1 Decide which calibration routine to use for
calibrating the robot.
• Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
• Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
If the robot is to be calibrated with refer- Follow the instructions given in the refer-
ence calibration: ence calibration routine on the FlexPendant
Find previous reference values for the axis to create reference values.
or create new reference values. These val- Creating new values requires possibility to
ues are to be used after the repair proced- move the robot.
ure is completed, for calibration of the ro- Read more about reference calibration for
bot. Axis Calibration in Reference calibration
If no previous reference values exist, and routine on page 404.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Removing axis-6 motor and wrist unit

Use this procedure to remove the axis-6 motor and the wrist unit.

Preparations before removing the wrist unit

Action Information
1 Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.
2 Move the upper arm to synchronization po-
sition.
3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

4 Remove all extra equipment fitted on the

upper arm.

Continues on next page

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 4 Repair
4.7.4 Replacing motor axis 6 and wrist unit - IRB 2600ID
Continued

Removing the wrist unit

Action Information
1 Remove the VK cover.

xx1600001486

2 Pull out the cabling from the upper arm

cavity through the VK cover hole and re-
lease the cable loop by straightening the
cables.
This is done in order not to damage the
cabling when the wrist is pulled out from
the arm tube with the axis-6 motor connect-
ors still connected.
xx1600001487

3 Remove the VK cover.

xx1000000873

4 Open the flexible coupling that secures the

axis-5 motor, on the side facing the wrist.

xx1000000874

Parts:
A Coupling
B Attachment screw

Continues on next page

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4 Repair
4.7.4 Replacing motor axis 6 and wrist unit - IRB 2600ID
Continued

Action Information
5 Remove the attachment screws that secure
the wrist.

A
xx1000000875

Part:
A Attachment screws (4 pcs)
6 Separate wrist and upper arm tube at the
marked division point (along the dotted line
in the figure).

Note

There is oil inside the wrist. The cover is

only secured with Loctite. If opened in the
wrong place oil will spill out.

xx1000000933

Parts:
A Wrist
B Cover (glued with Loctite to the
wrist)
C Division point
D Upper arm tube
7 Pull the wrist carefully out a little, in order
to be able to disconnect the motor cables
to the axis-6 motor.

Note

The wrist is fitted on cylindrical pins.

xx1000000876

Continues on next page

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 4 Repair
4.7.4 Replacing motor axis 6 and wrist unit - IRB 2600ID
Continued

Action Information
8 Fit two short screws in the holes for the at-
tachment screws in order to temporarily
secure that the cover is not opened.

xx1000000932

Parts:
A Short screws (2 pcs)
9 Disconnect the cables R4.MP6 and R4.FB6 R4.MP6
to the axis-6 motor.

R4.FB6

xx1400002575

10 Put the wrist on a work bench.

Removing the axis-6 motor

Action Information
1
Note

Do not move the gears in the wrist when the

motor is removed! When refitting the motor
the gears in the wrist shall be in the same
position as they were before the removal.

2 Remove the cable protection by removing

the nuts securing it.

xx1000000931

Parts:
A Cable protection
B Nuts (2 pcs)
C Connector motor axis 6

Continues on next page

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4 Repair
4.7.4 Replacing motor axis 6 and wrist unit - IRB 2600ID
Continued

Action Information
3 Open the flexible coupling securing motor
axis 6.

B
A C
xx1000000930

Parts:
A Attachment screw, coupling
B Flexible coupling
C Motor, axis 6
4 Remove the attachment screws that secure
the axis-6 motor and remove the motor.

Note

Do not remove the attachment screws se-

curing the motor bracket.

xx1000000929

Parts:
A Attachment screws, bracket
B Flexible coupling
C Attachment screws, motor (3 pcs)
D Cylindrical pins (2 pcs)
E Motor axis 6

Continues on next page

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 4 Repair
4.7.4 Replacing motor axis 6 and wrist unit - IRB 2600ID
Continued

Refitting axis-6 motor and wrist unit

Use this procedure to refit the axis-6 motor and the wrist unit.

Refitting the motor

Action Information
1 Place the motor axis into the axis-6 flexible
coupling.

xx1000000929

Parts:
A Attachment screws, bracket
B Flexible coupling
C Attachment screws, motor (3 pcs)
D Cylindrical pins (2 pcs)
E Motor axis 6
2 Secure the motor with its attachment Tightening torque: 6 Nm.
screws.
3 Secure the motor axis with the flexible Tightening torque: 15 Nm.
coupling with its attachment screw.

B
A C
xx1000000930

Parts:
A Attachment screw, coupling
B Flexible coupling
C Motor axis 6

Continues on next page

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4 Repair
4.7.4 Replacing motor axis 6 and wrist unit - IRB 2600ID
Continued

Action Information
4 Fit the cable protection with its nuts.

xx1000000931

Parts:
A Cable protection
B Nuts (2 pcs)
C Connector motor axis 6

Refitting the wrist

Action Information
1 Clean all assembly surfaces.
Remove any painting from the assembly
surfaces, with a knife.
2 Place the wrist with the axis-6 motor fitted
a little into the upper arm tube.
3 Reconnect the cables R4.MP6 and R4.FB6 R4.MP6
to the axis-6 motor.

R4.FB6

xx1400002575

4 Remove the short screws temporarily used

to secure from leakage from the wrist.

xx1000000932

Parts:
A Short screws (2 pcs)

Continues on next page

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 4 Repair
4.7.4 Replacing motor axis 6 and wrist unit - IRB 2600ID
Continued

Action Information
5 Apply locking liquid to the assembly surface Specified in Required equipment on
on the upper arm tube. page 341.

xx1200000063

6 Push the wrist and the axis-6 motor into its

position onto the cylindrical pins.

Tip A
Look through the hole for the VK cover
when fitting the axis into the flexible coup-
ling of motor axis 5.

xx1000000874

Parts:
A Flexible coupling axis 5
B Attachment screw
7 Secure the wrist with its attachment screws Tightening torque: 35 Nm.
and washers.

A
xx1000000875

Parts:
A Attachment screws (4 pcs)

Continues on next page

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4 Repair
4.7.4 Replacing motor axis 6 and wrist unit - IRB 2600ID
Continued

Action Information
8 Secure the axis-5 flexible coupling with its Tightening torque: 15 Nm.
attachment screw.
9 Fit a new VK cover. Article number is specified in Required
equipment on page 341.

xx1000000873

10 Pull out the cabling from the upper arm

cavity through the VK cover hole.

xx1600001487

11 Add a cable tie to the middle of the loop.

Then twist the cables into the shape of an
"8", fold the loop and insert the bundle into
the cavity in the upper arm tube, with direc-
tion against the arm house.

WARNING

If placing the cables into the cavity at the

opposite side, with direction against the
wrist, there is a risk of cable damage due
to rotating parts inside the arm tube.

xx1600001515

12 Fit a new VK cover. Article number is specified in Required

equipment on page 341.

xx1600001486

Continues on next page

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 4 Repair
4.7.4 Replacing motor axis 6 and wrist unit - IRB 2600ID
Continued

Concluding procedure

Action Information
1 Recalibrate the robot. Pendulum Calibration is described in Op-
erating manual - Calibration Pendulum,
enclosed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 403.
General calibration information is included
in section Calibration on page 391.
2
DANGER

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 28.

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4 Repair
4.7.5 Adjusting the play

4.7.5 Adjusting the play

Same instruction for all motors

This section describes how to adjust the play in the motors. The method is the
same for all motors. The illustrations show how to adjust the play in the axis-4
motor, but the same method can also be applied when adjusting the play of the
axis-5 and axis-6 motor.

Required equipment

Equipment, etc. Art. no. Note

Rotation tool 3HAB7887-1 M3 screw is included.
Used for feeling the play dur-
ing adjustment
Tool for adjusting play in mo- - See Drawing for adjustment
tors tool on page 352.
Standard toolkit - Content is defined in section
Standard tools on page 441.
Other tools and procedures These procedures include
may be required. See refer- references to the tools re-
ences to these procedures in quired.
the step-by-step instructions
below.

Drawing for adjustment tool

Find or make a tool as described in the figure.
Drill holes in the middle so that they match the existing holes that are used to place
extra equipment at the wrist unit.

500
xx1200000066

Note

Do NOT drill holes in the robot!

Continues on next page

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 4 Repair
4.7.5 Adjusting the play
Continued

Adjusting the play

Use this procedure to adjust the play of the motor. The figures show adjustment
of the axis-4 motor, but the method is also the same for the axis-5 and axis-6
motors.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2 Before fitting the motor, look into the hole

to find the position of the gear. When ad-
justing to the correct play, the motor pinion
is pressed against the gear. How to do this
is detailed further on in this procedure.

xx1200000098

3
CAUTION

Whenever parting/mating motor and gear-

box, the gears may be damaged if excess-
ive force is used!

4 Place the motor carefully in the hole without

damaging the gear or pinion. Put the attach-
ment screws in the holes on the motor and
fit them a few revolutions. Do not tighten
the attachment screws yet!

Continues on next page

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4 Repair
4.7.5 Adjusting the play
Continued

Action Note
5 Fit the rotation tool on the motor axis with
the M3 attachment screw.

xx1200000099

Article number is specified in Required

equipment on page 352.
6 Fit the tool for adjusting the play on the
axis in question.

xx1200000096

7 Release the brakes on the motor.

8 Push the motor, firmly in the direction of A B
the gear, as shown in figure.

Note

Do not use too much force!

xx1200000093

Parts:
• A: Motor pinion
• B: Gear

Continues on next page

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 4 Repair
4.7.5 Adjusting the play
Continued

Action Note
9 Tighten attachment screws number 1 and 1
2 diagonally, alternatingly between the
screws, while at the same time pushing the
motor in the direction of the gear.

2
xx1200000094

10 Secure all four attachment screws.

For tightening torque, see Tightening
torques and attachment screws on page320.
11 Check the play by holding the rotation tool
fitted on the motor with one hand and
moving the tool fitted on the wrist back and
forth with the other.

xx1200000097

The figure shows how to do this on the ax-

is-4 motor.
12 If play is felt in the tool fitted on the motor
axis, unscrew the attachment screws of the
motor and repeat steps 7 to 10. Then check
the play again according to step 11.
If no play can be felt in the tool fitted on the
motor axis, it means that the play is adjus-
ted correctly.
13 When the play is adjusted correctly, rotate
the motor five revolutions and check the
play again.

Continues on next page

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4 Repair
4.7.5 Adjusting the play
Continued

Action Note
14 If no play is detected, continue to rotate the
motor and check the play in steps of five
revolutions until the motor has been rotated
20 revolutions.
(Rotate five revolutions - check play - rotate
five revolutions - check play - and so on)
15 If play is felt in the tool fitted on the motor
axis, unscrew the attachment screws of the
motor and repeat steps 7 to 10. Then check
the play again starting with step 11.
16 Perform a final check of the play by rotating
the motor back and forth with the tool fitted
(in the case of axis-4 motor) on the wrist,
to check that it is running smoothly. There
should be no unnormal noices.

xx1200000100

17 If motor and gear is not running smoothly

or if unnormal noice comes from the gears,
the play must be readjusted.

356 Product manual - IRB 2600

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 4 Repair
4.8.1 Replacing gearbox axis 1

4.8 Gearboxes

4.8.1 Replacing gearbox axis 1

Different versions of the gearbox

There are two different versions of the axis-1 and axis-2 gearboxes. The different
versions affect the mechanical structure of the base, frame and lower arm.
Differences in the mechanical structure are pointed out in the procedure as valid
for different robot version:
• IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-15/1.85,
IRB 2600ID-8/2.0
• IRB 2600 Type C-20/1.65, IRB 2600 Type C-12/1.65
Further information about the differences are given in Non-compatible versions of
axis-1 and axis-2 gearboxes on page 428.

Continues on next page

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4 Repair
4.8.1 Replacing gearbox axis 1
Continued

Location of gearbox
The gearbox is located as shown in the figure. The exploded view only shows the
principle of the assembly. The actual replacing is recommended to be done with
the robot resting on its side.

IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB 2600ID-8/2.0

xx0800000400

Spinea gearbox
A Frame
B Radial sealing
C O-ring
D Gearbox axis 1
E Washer (21 pcs)
F Attachment screws M8x80 quality Steel 12.9 Gleitmo (21 pcs)

Continues on next page

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 4 Repair
4.8.1 Replacing gearbox axis 1
Continued

IRB 2600 Type C-20/1.65, IRB 2600 Type C-12/1.65

xx1800000800

Nabtesco gearbox
A Frame
B Radial sealing
C O-ring
D Gearbox axis 1
E Washer (14 pcs)
F Attachment screws M10x80 quality Steel 12.9 Gle 603+Geo500 (14 pcs)

Required equipment

Equipment Note
Gearbox See Spare part lists on page 445.
Guide pins Guide pin, M8x150: 3HAC15520-2
Used to guide the gearbox during removal/refitting.
Always use guide pins in pairs.
Valid for IRB 2600 Type C-20/1.65, IRB 3HAC15520-1
2600 Type C-12/1.65: Always use guide pins in pairs.
Guide pin, M8x100 Additional pins to guide the gearbox during remov-
al/refitting.
Guide for reduction gear 3HAC068109-001
Used to guide axis-1 gear and frame during refit-
ting.
Standard toolkit Content is defined in section Standard tools on
page 441.
Other tools and procedures may be re- These procedures include references to the tools
quired. See references to these proced- required.
ures in the step-by-step instructions
below.

Continues on next page

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4 Repair
4.8.1 Replacing gearbox axis 1
Continued

Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Action Note
1 Decide which calibration routine to use for
calibrating the robot.
• Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
• Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
If the robot is to be calibrated with refer- Follow the instructions given in the refer-
ence calibration: ence calibration routine on the FlexPendant
Find previous reference values for the axis to create reference values.
or create new reference values. These val- Creating new values requires possibility to
ues are to be used after the repair proced- move the robot.
ure is completed, for calibration of the ro- Read more about reference calibration for
bot. Axis Calibration in Reference calibration
If no previous reference values exist, and routine on page 404.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Illustration of robot put down on its side

The robot is put down on its side for a safe removal of the axis-1 gearbox. Prepare
an area on the floor with cardboard, plastic foam or similar and prepare higher
support for the wrist.
Make sure the cabling brackets on the lower arm are unfastened and moved out
of the way so that the cabling is not getting squeezed.

xx1800000593

Continues on next page

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 4 Repair
4.8.1 Replacing gearbox axis 1
Continued

Removing gearbox axis 1

Use this procedure to remove the gearbox.
Action Note
1 Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.
2 Drain the oil from the gearbox. How to drain the oil from the gearbox is
described in section:
• Changing the oil, axis 1 gearbox
on floor mounted robots on
page 150
3 Jog the robot to:
• Axis 1: 0°
• Axis 2: 0°
• Axis 3: -10°
• Axis 4: 0°
• Axis 5: 0°
• Axis 6: 0°
4
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

5 Remove the axis-1 motor. See Removing motors on page 301.

6 Remove the complete arm system from the See Removing the base on page 291.
base and lay down the robot on its side.

xx1800000593

Continues on next page

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4 Repair
4.8.1 Replacing gearbox axis 1
Continued

Action Note
7 Fit a lifting lug in the uppermost hole for the
base attachment screws.

xx0800000440

A Roundsling
B Lifting lug
C Uppermost base attachment hole
D Axis-1 gearbox
8
CAUTION

The gearbox weighs .

27 kg (IRB 2600-20/1.65, IRB 2600-12/1.65,
IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB
2600ID-8/2.0)
24 kg (IRB 2600 Type C-20/1.65, IRB 2600
Type C-12/1.65)
All lifting accessories used must be sized
accordingly!

9 Secure the gearbox in an overhead crane or

similar.
10 Remove the attachment screws securing the See the figure in:
gearbox. • Location of gearbox on page 358
11 Valid for IRB 2600 Type C-20/1.65, IRB 2600
Type C-12/1.65:
Fit two guide pins to the gearbox through
the holes in the frame.

xx1800000788

Guide pin, M8x100: 3HAC15520-1

Always use guide pins in pairs!

Continues on next page

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 4 Repair
4.8.1 Replacing gearbox axis 1
Continued

Action Note
12 Remove two gearbox attachment screws
opposite to each other and fit two guide pins
into the holes.

xx1800000789

Guide pin, M8x150: 3HAC15520-2

Always use guide pins in pairs!
13 Remove the remaining attachment screws
and washers.

xx1800000790

14
Note

Whenever parting/mating motor and gear-

box, the gears may be damaged if excessive
force is used!

15
Note

There will be some excess oil running out

of the gearbox when it is removed. Use
some absorbent material to catch the oil.

Continues on next page

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4 Repair
4.8.1 Replacing gearbox axis 1
Continued

Action Note
16 Slide the gearbox out onto the guide pins
and lift it away. Note
If necessary use removal tools to remove
the gearbox. Always use removal tools in pairs diagon-
al to each other.

xx1800000791

Refitting gearbox axis 1

Use these procedures to refit the gearbox.

Refitting the gearbox to the frame

Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2 Check the radial sealing in the frame.

Replace if damaged.

xx1800000794

Continues on next page

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 4 Repair
4.8.1 Replacing gearbox axis 1
Continued

Action Note
3 Fit a lifting lug in the uppermost hole for the
base attachment screws.

xx0800000440

A Roundsling
B Lifting lug
C Uppermost base attachment hole
D Axis-1 gearbox
4
Note

Check, when fitting the lifting lug, that both

oil plugs will be placed in the correct posi-
tion after the gearbox is fitted as shown in
the figure. The oil plugs shall be placed in
the openings in the frame. A
(not valid for IRB 2600 Type C-20/1.65, IRB
2600 Type C-12/1.65)
B

xx0800000441

A Opening for oil plug in frame

B Oil plug
5 Apply grease on the o-ring. See the figure in:
• Location of gearbox on page 358
Replace o-ring if damaged.
6 Clean all assembly surfaces.
Remove any painting from the assembly
surfaces, with a knife.

Continues on next page

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4 Repair
4.8.1 Replacing gearbox axis 1
Continued

Action Note
7 Valid for IRB 2600 Type C-20/1.65, IRB
2600 Type C-12/1.65:
Fit two guide pins to the gearbox.

xx1800000792

Guide pin, M8x100: 3HAC15520-1

Always use guide pins in pairs!
8 Fit two guide pins to the frame.

xx1800000793

Guide pin, M8x150: 3HAC15520-2

Always use guide pins in pairs!
9 Fit the guide for the gear on top of the pro- Guide for reduction gear: 3HAC068109-
tection tube. 001.
It protects the radial sealing from being
damaged during refitting.

xx1800000795

10
CAUTION

The gearbox weighs .

27 kg (IRB 2600-20/1.65, IRB 2600-12/1.65,
IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB
2600ID-8/2.0)
24 kg (IRB 2600 Type C-20/1.65, IRB 2600
Type C-12/1.65)
All lifting accessories used must be sized
accordingly!

Continues on next page

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 4 Repair
4.8.1 Replacing gearbox axis 1
Continued

Action Note
11 Lift the gearbox onto the guide pins and
slide it into position, using caution.
Check that the radial sealing in the frame
tube does not get damaged.
Valid for IRB 2600-20/1.65, IRB 2600-
12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0:
Double check that the oil plugs are in the
correct position.

xx1800000791

xx0800000441

A Opening for oil plug in frame

B Oil plug
12 Secure the gearbox with its attachment
screws and washers.
13 Remove the guide pins from the frame and
secure the remaining two screws.

xx1800000790

Valid for IRB 2600-20/1.65, IRB 2600-

12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0:
Tightening torque: 35 Nm.
Valid for IRB 2600 Type C-20/1.65, IRB
2600 Type C-12/1.65:
Tightening torque: 50 Nm.

Continues on next page

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4 Repair
4.8.1 Replacing gearbox axis 1
Continued

Action Note
14 Valid for IRB 2600 Type C-20/1.65, IRB
2600 Type C-12/1.65:
Remove the two guide pins from the gear-
box.

xx1800000788

15 Remove the guide from the protection tube.

xx1800000796

Refitting the arm system to the base

Action Note
1 Valid for IRB 2600 Type C-20/1.65, IRB
2600 Type C-12/1.65:
1 Remove the three gaskets on the
base.
2 Wipe out the oil from the holes in the
base and wipe the sealing surfaces
dry.
3 Fit three new gaskets to the base.
The gaskets are included with the
gearbox spare part.

xx1800000797

2 Refit the complete arm system to the base. See Refitting the base on page 296.
3 Refit the axis-1 motor. See Refitting motors on page 313.
4 Refit the cable harness in the base, the See Replacing gearbox axis 1 on page 357.
frame and the lower arm. • Refitting the cable harness in the
base on page 213
• Refitting the cable harness in the
frame on page 210
• Refitting the cable harness in the
lower arm and armhouse on
page 219
.

Continues on next page

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 4 Repair
4.8.1 Replacing gearbox axis 1
Continued

Action Note
5 Refill oil in the gearbox. See Changing the oil, axis 1 gearbox on
floor mounted robots on page 150.
6 Recalibrate the robot. Pendulum Calibration is described in Op-
erating manual - Calibration Pendulum,
enclosed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 403.
General calibration information is included
in section Calibration on page 391.
7
DANGER

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 28.

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4 Repair
4.8.2 Replacing gearbox axis 2

4.8.2 Replacing gearbox axis 2

Different versions of the gearbox

There are two different versions of the axis-1 and axis-2 gearboxes. The different
versions affect the mechanical structure of the base, frame and lower arm.
Differences in the mechanical structure are pointed out in the procedure as valid
for different robot version:
• IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-15/1.85,
IRB 2600ID-8/2.0
• IRB 2600 Type C-20/1.65, IRB 2600 Type C-12/1.65
Further information about the differences are given in Non-compatible versions of
axis-1 and axis-2 gearboxes on page 428.

Location of gearbox axis 2

The gearbox is located as shown in the figure.

IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB 2600ID-8/2.0

xx0900000380

A Attachment screws M8x80 quality steel 12.9 Gleitmo (17 pcs)

B Washers (17 pcs)
C Gearbox axis 2
D O-ring
E Frame

Continues on next page

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 4 Repair
4.8.2 Replacing gearbox axis 2
Continued

IRB 2600 Type C-20/1.65, IRB 2600 Type C-12/1.65

xx1800000940

A Attachment screws M10x40 12.9 Gleitmo 603+Geo500 (16 pcs)

B Washers (16 pcs)
C Gearbox axis 2
D O-ring
E Frame

Required equipment

Equipment Article number Note

Gearbox See Spare part
lists on page 445.
Rotation tool 3HAB7887-1
Lifting accessories - Roundslings.
Guide pin, M8x150 3HAC15520-2 Valid for IRB 2600-20/1.65, IRB
2600-12/1.65, IRB 2600-12/1.85,
IRB 2600ID-15/1.85, IRB 2600ID-
8/2.0.
Always use guide pins in pairs.
Guide pin, M10x150 3HAC15521-2 Valid for IRB 2600 Type C-20/1.65,
IRB 2600 Type C-12/1.65.
Always use guide pins in pairs.

Continues on next page

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4 Repair
4.8.2 Replacing gearbox axis 2
Continued

Equipment Article number Note

Standard toolkit Content is defined in section
Standard tools on page 441.
Other tools and procedures may be These procedures include refer-
required. See references to these ences to the tools required.
procedures in the step-by-step in-
structions below.

Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Action Note
1 Decide which calibration routine to use for
calibrating the robot.
• Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
• Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
If the robot is to be calibrated with refer- Follow the instructions given in the refer-
ence calibration: ence calibration routine on the FlexPendant
Find previous reference values for the axis to create reference values.
or create new reference values. These val- Creating new values requires possibility to
ues are to be used after the repair proced- move the robot.
ure is completed, for calibration of the ro- Read more about reference calibration for
bot. Axis Calibration in Reference calibration
If no previous reference values exist, and routine on page 404.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Removing gearbox axis 2

Use this procedure to remove the gearbox.

WARNING

The procedure details how to replace the gearbox without removing the cable
harness, only by loosening it. This means that the upper and lower arm will be
separated from the frame but still be connected to the frame through the cabling.
Be careful not to damage the cables!

Action Note
1 Decide which calibration routine to
use, and take actions accordingly prior
to beginning the repair procedure.

Continues on next page

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 4 Repair
4.8.2 Replacing gearbox axis 2
Continued

Action Note
2 Move the robot to the position shown
in the figure.
Upper arm should rest on the axis-3
damper.

xx1200000068

3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

4 Drain the gearbox. How to drain the gearbox is described in sec-

tion:
• Changing the oil, axis-2 gearbox on
page 163

Continues on next page

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4 Repair
4.8.2 Replacing gearbox axis 2
Continued

Action Note
5 Loosen the cabling from the lower arm
by removing two cable brackets and a
cable strap.
B
C

xx1100000946

A Cable bracket
B Cable bracket
C Cable strap
6
CAUTION

The weight of the complete upper and

lower arm together is 100 kg
All lifting accessories used must be
sized accordingly.

7 Attach a roundsling around the upper

arm house.
8 Unload the weight of the lower and
upper arm package by stretching the
roundslings with the overhead crane.
Turn on the power temporarily and re-
lease the brakes of axis 2 to rest the
weight onto the roundslings.
9
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Continues on next page

374 Product manual - IRB 2600
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 4 Repair
4.8.2 Replacing gearbox axis 2
Continued

Action Note
10 Remove the attachment screws and Valid for IRB 2600-20/1.65, IRB 2600-12/1.65,
washers that secure the lower arm to IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB
the axis-2 gearbox. 2600ID-8/2.0:

xx1800000935

Valid for IRB 2600 Type C-20/1.65, IRB 2600

Type C-12/1.65:

xx1800000934

11 Remove the lower and upper arm

package from the frame.

WARNING

The cable harness is still installed on

the robot! Make sure not to damage
the cables or the cable brackets on the
robot.

12
CAUTION

The gearbox weighs

23 kg (IRB 2600-20/1.65, IRB 2600-
12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0)
14 kg (IRB 2600 Type C-20/1.65, IRB
2600 Type C-12/1.65)
All lifting accessories used must be
sized accordingly!

Continues on next page

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4 Repair
4.8.2 Replacing gearbox axis 2
Continued

Action Note
13 Fit a lifting lug in the uppermost hole
for the attachment screws that secure A
the lower arm to the gearbox.

xx0800000445

Parts:
• A: Gearbox axis 2
• B: Lifting lug
• C: Holes for attachment screws that se-
cure the lower arm to the axis-2 gearbox
14 Secure the gearbox with a roundsling
in an overhead crane or similar.

Continues on next page

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 4 Repair
4.8.2 Replacing gearbox axis 2
Continued

Action Note
15 Remove the attachment screws and Valid for IRB 2600-20/1.65, IRB 2600-12/1.65,
washers that secure the gearbox to the IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB
frame. 2600ID-8/2.0:

CAUTION

Valid for IRB 2600-20/1.65, IRB 2600-

12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0:
Notice that there are six screws that
must not be removed! These six
screws keep the gearbox assembled.
Removing these screws would cause
the gearbox to fall apart!
Only remove the screws that secure
the gearbox to the frame, shown in the
figure!

xx1200000086

Valid for IRB 2600 Type C-20/1.65, IRB 2600

Type C-12/1.65:

xx1800000939

16 Fit guide pins to help guiding the Valid for IRB 2600-20/1.65, IRB 2600-12/1.65,
gearbox out from the frame. IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB
2600ID-8/2.0:
Guide pin, M8x150: 3HAC15520-2
Valid for IRB 2600 Type C-20/1.65, IRB 2600
Type C-12/1.65:
Guide pin, M10x150: 3HAC15521-2
Always use guide pins in pairs.
17 If necessary, use removal tools to re-
move the gearbox. Note

Always use removal tools in pairs diagonal to

each other.

Continues on next page

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4 Repair
4.8.2 Replacing gearbox axis 2
Continued

Action Note
18 Remove the gearbox.

CAUTION

Use caution in order not to damage

gearbox or pinion!

Refitting gearbox axis 2

Use this procedure to refit the gearbox.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2
CAUTION

The gearbox weighs

23 kg (IRB 2600-20/1.65, IRB 2600-12/1.65,
IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB
2600ID-8/2.0)
14 kg (IRB 2600 Type C-20/1.65, IRB 2600
Type C-12/1.65)
All lifting accessories used must be sized
accordingly!

3 Fit a lifting lug in the uppermost hole for

A
the attachment screws securing the lower
arm to the gearbox.

xx0800000445

Parts:
• A: Gearbox axis 2
• B: Lifting lug
• C: Holes for attachment screws
securing the lower arm to gearbox
axis 2.

Continues on next page

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 4 Repair
4.8.2 Replacing gearbox axis 2
Continued

Action Note
4 Clean all assembly surfaces.
Remove any painting from the assembly
surfaces, with a knife.
5 Apply some grease on the o-ring before fit- Valid for IRB 2600 Type C-20/1.65, IRB
ting. 2600 Type C-12/1.65:
Valid for IRB 2600 Type C-20/1.65, IRB O-ring: 3HAB3772-106.
2600 Type C-12/1.65: See the figure in:
Replace if damaged. • Location of gearbox axis 2 on
page 370
6 Fit two guide pins in opposite holes in the Valid for IRB 2600-20/1.65, IRB 2600-
frame. 12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0:
Guide pin, M8x150: 3HAC15520-2
Valid for IRB 2600 Type C-20/1.65, IRB
2600 Type C-12/1.65:
Guide pin, M10x150: 3HAC15521-2
Always use guide pins in pairs.
7 Secure the gearbox with a roundsling in an
overhead crane or similar.
8 Release the brakes of the axis 2 motor.
9 Lift the gearbox onto the guide pins and Article number is specified in Required
slide it into position while rotating the motor equipment on page 371.
pinion to find the mating position. Use a ro-
tation tool.

Continues on next page

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4 Repair
4.8.2 Replacing gearbox axis 2
Continued

Action Note
10 Secure the gearbox with its attachment Valid for IRB 2600-20/1.65, IRB 2600-
screws and washers. 12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0:
Attachment screws: M8x80 quality steel
12.9 Gleitmo (17 pcs)
Tightening torque: 35 Nm.

xx1200000086

Valid for IRB 2600 Type C-20/1.65, IRB

2600 Type C-12/1.65:
Attachment screws M10x40 12.9 Gleitmo
603+Geo500 (16 pcs)
Tightening torque: 68 Nm.

xx1800000939

11 Perform a leak-down test. See Performing a leak-down test on

page 188.
12 Fit the guide pins to the gearbox.
13
CAUTION

The weight of the complete upper and lower

arm together is 100 kg
All lifting accessories used must be sized
accordingly.

Continues on next page

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 4 Repair
4.8.2 Replacing gearbox axis 2
Continued

Action Note
14 Lift the upper and lower arms into mounting
position and guide them in place with the
guide pins.
It might be necessary to rotate the motor
pinion with the rotating tool to find the mat-
ing position.
15 Refit the attachment screws and washers Valid for IRB 2600-20/1.65, IRB 2600-
to secure the lower arm to the axis-2 gear- 12/1.65, IRB 2600-12/1.85, IRB 2600ID-
box. 15/1.85, IRB 2600ID-8/2.0:
Attachment screws: M8x40 quality steel
Gleitmo 12.9 (17 pcs)
Washers: 3HAA1001-172 (17 pcs)
Tightening torque: 35 Nm.

xx1800000935

Valid for IRB 2600 Type C-20/1.65, IRB

2600 Type C-12/1.65:
Attachment screws: M10x40 12.9 Gleitmo
603+Geo500 (15 pcs)
Washers: 3HAC043534-001 (3 pcs)
Tightening torque: 50 Nm ± 5 Nm and 90°
angle ± 10°.

xx1800000934

Continues on next page

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4 Repair
4.8.2 Replacing gearbox axis 2
Continued

Action Note
16 Refit the cable brackets and cable strap to
the lower arm.

B
C

xx1100000946

A Cable bracket
B Cable bracket
C Cable strap
17 Refill the gearbox with lubrication oil. How to fill the gearbox with oil is de-
scribed in section:
• Changing the oil, axis-2 gearbox
on page 163
18 Recalibrate the robot. Pendulum Calibration is described in Op-
erating manual - Calibration Pendulum,
enclosed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 403.
General calibration information is included
in section Calibration on page 391.
19
DANGER

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 28.

382 Product manual - IRB 2600

3HAC035504-001 Revision: Q
© Copyright 2009-2018 ABB. All rights reserved.
 4 Repair
4.8.3 Replacing gearbox axis 3

4.8.3 Replacing gearbox axis 3

Location of gearbox axis 3

The gearbox is located as shown in the figure.
The figure shows the standard version of IRB 2600. Assembly is the same for IRB
2600ID.

D
xx0900000381

A Upper arm
B O-ring
C Gearbox, axis 3
D Attachment screws M6x40 quality Steel 12.9 Gleitmo (16 pcs)

Required equipment

Equipment Art. no. Note

Gearbox See Spare part lists on page 445.
Guide pins 2 pcs, dimension: M6. 2 pcs, dimen-
sion: M8.
Used to guide the gearbox and the
upper arm during removal/refitting.
Rotation tool 3HAB7887-1
Standard toolkit Content is defined in section
Standard tools on page 441.

Continues on next page

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4 Repair
4.8.3 Replacing gearbox axis 3
Continued

Equipment Art. no. Note

Other tools and procedures may be These procedures include refer-
required. See references to these ences to the tools required.
procedures in the step-by-step in-
structions below.

Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Action Note
1 Decide which calibration routine to use for
calibrating the robot.
• Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
• Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
If the robot is to be calibrated with refer- Follow the instructions given in the refer-
ence calibration: ence calibration routine on the FlexPendant
Find previous reference values for the axis to create reference values.
or create new reference values. These val- Creating new values requires possibility to
ues are to be used after the repair proced- move the robot.
ure is completed, for calibration of the ro- Read more about reference calibration for
bot. Axis Calibration in Reference calibration
If no previous reference values exist, and routine on page 404.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Removing gearbox axis 3

Use this procedure to remove the gearbox.

WARNING

The procedure details how to replace the gearbox without removing the cable
harness. This means that the upper and lower arm will be separated but still be
connected to eachother through the cabling. Be careful not to damage the cables!

Action Note
1 Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.
2 Drain the gearbox. How to drain the gearbox is described in
section:
• Changing the oil, axis-3 gearbox
on page 167

Continues on next page

384 Product manual - IRB 2600
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© Copyright 2009-2018 ABB. All rights reserved.
 4 Repair
4.8.3 Replacing gearbox axis 3
Continued

Action Note
3 Move the robot to the position shown in the
figure.

xx0800000336

4
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

5 Unscrew the attachment screws securing

the cable harness to the lower arm by the
the two cable brackets and a cable strap.
B
C

xx1100000946

A Cable bracket
B Cable bracket
C Cable strap
6 Loosen the cabling from the lower arm by
unhooking the two cable brackets.

CAUTION

The cable harness is still mounted in other

parts of the robot. Make sure not to damage
the cable harness or any cable brackets in
the continued removal.

7 Attach the lifting accessories to the upper See Attaching the lifting accessories to
arm. the upper arm on page 250
8 Connect the 24 VDC power supply to the
axis-3 motor and release the brakes.

Continues on next page

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4 Repair
4.8.3 Replacing gearbox axis 3
Continued

Action Note
9 Releasing the brakes of the axis-3 motor
unloads the weight of the upper arm by
stretching the roundslings.
10 Remove the attachment screws that secure See the figure in:
the upper arm to the lower arm. • Location of the complete upper arm
on page 245
Note

Do not remove the attachment screws se-

curing the gearbox axis 3 to the armhouse!

11
CAUTION

The robot upper arm weighs 65 kg.

All lifting accessories used must be sized
accordingly!

12 Remove the upper arm from the lower arm

and leave it hanging in the air. WARNING

CAUTION The cable harness is still installed on the

robot! Make sure not to damage the cable
When the upper arm no longer is attached harness or the cable brackets on the ro-
to the robot, the armhouse has a tendency bot.
to drop down a little. In order to prevent this
is to rise the front end of the upper arm a
little before removing the attachment screws
securing the upper arm.

13
CAUTION

The gearbox weighs 6 kg.

All lifting accessories used must be sized
accordingly!

14 Remove two attachment screws diagonally Always use guide pins in pairs!
located and insert guide pins.
15 Remove the remaining attachment screws See the figure in:
that secures the gearbox. • Location of gearbox axis 3 on
page 383
16
Note

There will be some surplus oil in the gear-

box. Place some absorbant cloth or similar
under the gearbox.

17 Slide the gearbox carefully out onto the

guide pins and lift it away. Note
If necessary, use a pair of screws to push
out the gearbox. Always use removal tools in pairs diagon-
al to each other.
CAUTION

Remaining oil will drain out from the gear-

box cavity when the gearbox is lifted out.

Continues on next page

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 4 Repair
4.8.3 Replacing gearbox axis 3
Continued

Refitting the gearbox axis 3

Use this procedure to refit the gearbox.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2
CAUTION

The gearbox weighs 6 kg.

All lifting accessories used must be sized
accordingly!

3 Clean all assembly surfaces.

Remove any painting or other contamination
from the assembly surfaces, with a knife.
4 Apply some grease on the o-ring before fit- See the figure in:
ting it to the gearbox. • Location of gearbox axis 3 on
page 383
5 Fit two guide pins in two opposite screw Always use guide pins in pairs!
holes in the upper arm.
6 Remove the arm house cover.
7 Attach the rotation tool on the axis-3 motor.
8 Release the brakes of the axis 3 motor.
9 Lift the gearbox onto the guide pins.
10
Note

Whenever parting/mating motor and gear-

box, the gears may be damaged if excessive
force is used!

11 Slide the gearbox into position while rotating Article number for the rotation tool is
the motor pinion to find the mating position. specified in Required equipment on
Use a rotation tool. page 383.

Tip

Two persons are required for this step since

the upper arm is hanging freely in the air.
One person needs to hold the upper arm
still while the other fits the gearbox into the
upper arm.

12 Rotate the motor pinion and slide the gear-

box into position.

Continues on next page

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4 Repair
4.8.3 Replacing gearbox axis 3
Continued

Action Note
13 Secure the gearbox with its attachment See the figure in:
screws. • Location of gearbox axis 3 on
page 383
Tightening torque: 17 Nm.
14 Remove the guide pins and replace them
with the remaining attachment screws.
15 Perform a leak-down test. See Performing a leak-down test on
page 188.
16 Fit guide pins in the upper arm. Specified in Required equipment on
page 383.
17 Move the upper arm to its mounting posi-
tion.
(With the brakes of the axis 3 motor still re-
leased.)
18 Refit the upper arm to the lower arm with See the figure in:
its attachment screws. • Location of the complete upper arm
on page 245
Tightening torque:
• 35 Nm
19 Remove the guide pins and replace with the
remaining attachment screws.
20 Remove the 24 VDC power supply.
21 Refit the upper armhouse cover with its at- Tightening torque: 14 Nm.
tachment screws and washers. Make sure that the cover is tightly sealed.

WARNING

The cover on the armhouse must be fitted B

when the robot is running. It is a vital part
for the stability of the robot.

A
xx0800000389

Parts:
• A: Cover
• B: Attachment screws M6x25,
quality 8.8-A2F (8 pcs)

Continues on next page

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 4 Repair
4.8.3 Replacing gearbox axis 3
Continued

Action Note
22 Refit the two cable brackets and a cable
strap to the lower arm.

B
C

xx1100000946

A Cable bracket
B Cable bracket
C Cable strap
23 Refill the gearbox with lubrication oil. How to fill the gearbox with oil is de-
scribed in section:
• Changing the oil, axis-3 gearbox
on page 167
24 Recalibrate the robot. Pendulum Calibration is described in Op-
erating manual - Calibration Pendulum,
enclosed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 403.
General calibration information is included
in section Calibration on page 391.
25
DANGER

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 28.

Product manual - IRB 2600 389

3HAC035504-001 Revision: Q
© Copyright 2009-2018 ABB. All rights reserved.
This page is intentionally left blank
 5 Calibration
5.1.1 Introduction and calibration terminology

5 Calibration
5.1 Introduction to calibration

5.1.1 Introduction and calibration terminology

Calibration information
This chapter includes general information about the recommended calibration
methods and also the detailed procedures for updating the revolution counters,
checking the calibration position etc.
Detailed instructions of how to perform Axis Calibration are given on the
FlexPendant during the calibration procedure. To prepare calibration with Axis
Calibration method, see Calibrating with Axis Calibration method on page 403.
Detailed instructions of how to perform Pendulum Calibration are given in the
documentation enclosed with the calibration tools.

Calibration terminology

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.
Calibration position Known position of the complete robot that is used
for calibration of the robot.
Standard calibration A generic term for all calibration methods that aim
to move the robot to calibration position.
Fine calibration A calibration routine that generates a new zero posi-
tion of the robot.
Reference calibration A calibration routine that in the first step generates
a reference to current zero position of the robot. The
same calibration routine can later on be used to re-
calibrate the robot back to the same position as when
the reference was stored.
This routine is more flexible compared to fine calib-
ration and is used when tools and process equipment
are installed.
Requires that a reference is created before being
used for recalibrating the robot.
Requires that the robot is dressed with the same
tools and process equipment during calibration as
during creation of the reference values.
Update revolution counter A calibration routine to make a rough calibration of
each manipulator axis.
Synchronization mark Visual marks on the robot axes. When marks are
aligned, the robot is in synchronization position.

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5 Calibration
5.1.2 Calibration methods

5.1.2 Calibration methods

Overview
This section specifies the different types of calibration and the calibration methods
that are supplied by ABB.

Types of calibration

Type of calibration Description Calibration method

Standard calibration The calibrated robot is positioned at calibration Axis Calibration or Cal-
position. ibration Pendulum i
Standard calibration data is found on the SMB
(serial measurement board) or EIB in the robot.
For robots with RobotWare 5.04 or older, the
calibration data is delivered in a file, calib.cfg,
supplied with the robot at delivery. The file
identifies the correct resolver/motor position
corresponding to the robot home position.
Absolute accuracy Based on standard calibration, and besides CalibWare
calibration (option- positioning the robot at synchronization posi-
al) tion, the Absolute accuracy calibration also
compensates for:
• Mechanical tolerances in the robot
structure
• Deflection due to load
Absolute accuracy calibration focuses on pos-
itioning accuracy in the Cartesian coordinate
system for the robot.
Absolute accuracy calibration data is found
on the SMB (serial measurement board) in the
robot.
For robots with RobotWare 5.05 or older, the
absolute accuracy calibration data is delivered
in a file, absacc.cfg, supplied with the robot at
delivery. The file replaces the calib.cfg file and
identifies motor positions as well as absolute
accuracy compensation parameters.
A robot calibrated with absolute accuracy has
a sticker next to the identification plate of the
robot.
To regain 100% absolute accuracy perform-
ance, the robot must be recalibrated for abso-
lute accuracy!

xx0400001197

i The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory. Always use
the same calibration method as used at the factory.
Information about valid calibration method is found on the calibration label or in the calibration
menu on the FlexPendant.
If no data is found related to standard calibration, Calibration Pendulum is used as default.

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 5 Calibration
5.1.2 Calibration methods
Continued

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:
• Calibration Pendulum II
• Reference calibration
The calibration equipment for Calibration Pendulum is delivered as a complete
toolkit, including the Operating manual - Calibration Pendulum, which describes
the method and the different routines further.

Axis Calibration method

Axis Calibration is a standard calibration method for calibration of IRB 2600/IRB
2600 ID and is the most accurate method for the standard calibration. It is the
recommended method in order to achieve proper performance.
The following routines are available for the Axis Calibration method:
• Fine calibration
• Update revolution counters
• Reference calibration
The calibration equipment for Axis Calibration is delivered as a toolkit.
An introduction to the calibration method is given in this manual, see Calibrating
with Axis Calibration method on page 403.
The actual instructions of how to perform the calibration procedure and what to
do at each step is given on the FlexPendant. You will be guided through the
calibration procedure, step by step.

CalibWare - Absolute Accuracy calibration

To achieve a good positioning in the Cartesian coordinate system, Absolute
Accuracy calibration is used as a TCP calibration. The CalibWare tool guides
through the calibration process and calculates new compensation parameters.
This is further detailed in the Application manual - CalibWare Field 5.0.
If a service operation is done to a robot with the option Absolute Accuracy, a new
absolute accuracy calibration is required in order to establish full performance.
For most cases after motor and transmission replacements that do not include
taking apart the robot structure, standard calibration is sufficient. Standard
calibration also supports wrist exchange.

References
Article numbers for the calibration tools are listed in the section Special tools on
page 442.
The calibration equipment for Calibration Pendulum is delivered as a complete
toolkit, including the Operating manual - Calibration Pendulum, which describes
the method and the different routines further.

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5 Calibration
5.1.3 When to calibrate

5.1.3 When to calibrate

When to calibrate
The system must be calibrated if any of the following situations occur.

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.
The resolver values will change when parts affecting the calibration position are
replaced on the robot, for example motors or parts of the transmission.

The revolution counter memory is lost

If the revolution counter memory is lost, the counters must be updated. See
Updating revolution counters on page 399. This will occur when:
• The battery is discharged
• A resolver error occurs
• The signal between a resolver and measurement board is interrupted
• A robot axis is moved with the control system disconnected
The revolution counters must also be updated after the robot and controller are
connected at the first installation.

The robot is rebuilt

If the robot is rebuilt, for example, after a crash or when the reach ability of a robot
is changed, it needs to be recalibrated for new resolver values.
If the robot has absolute accuracy calibration, it needs to be calibrated for new
absolute accuracy.

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 5 Calibration
5.2.1 Synchronization marks and synchronization position for axes

5.2 Synchronization marks and axis movement directions

5.2.1 Synchronization marks and synchronization position for axes

Introduction
This section shows the position of the synchronization marks and the
synchronization position for each axis.

Synchronization marks, IRB 2600 and 2600ID

IRB 2600-20/1.65, -12/1.65, -12/1.85
IRB 2600 Type C-20/1.65, -12/1.65

xx0800000312

A Synchronization mark, axis 1

B Synchronization mark, axis 2
C Synchronization mark, axis 3

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5 Calibration
5.2.1 Synchronization marks and synchronization position for axes
Continued

IRB 2600 -20/1.65, -12/1.65, -12/1.85

xx0800000320

D Synchronization mark, axis 4

E Synchronization mark, axis 5

IRB 2600ID -15/1.85, -8/2.00

A B

xx1000000445

A Synchronization mark, axis 4

B Synchronization mark, axis 5
C Synchronization mark, axis 6

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 5 Calibration
5.2.1 Synchronization marks and synchronization position for axes
Continued

IRB 2600 -20/1.65, -12/1.65, -12/1.85

xx0800000321

F Synchronization mark, axis 6

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5 Calibration
5.2.2 Calibration movement directions for all axes

5.2.2 Calibration movement directions for all axes

Overview
When calibrating, the axis must consistently be run towards the calibration position
in the same direction in order to avoid position errors caused by backlash in gears
and so on. Positive directions are shown in the graphic below.
Calibration service routines will handle the calibration movements automatically
and these might be different from the positive directions shown below.

Manual movement directions, 6 axes

Note! The graphic shows an IRB 7600. The positive direction is the same for all
6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in the
opposite direction!

xx0200000089

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 5 Calibration
5.3 Updating revolution counters

5.3 Updating revolution counters

Introduction
This section describes how to do a rough calibration of each manipulator axis by
updating the revolution counter for each axis, using the FlexPendant.

Coupled axes
When updating the revolution counters for a coupled axis, also the axis it is coupled
to needs to be at its synchronization position for the update to be correct; i.e. axis
4 needs to be in synchronization position when updating axis 5 and 6.
With reversed coupled joints, the relationship is the opposite, i.e. axis 4 needs to
be in synchronization position to update axis 3.
Coupled axes

IRB 910 SC
IRB 1600ID

IRB 1660ID

IRB 2600ID

IRB 4450S
IRB 1410

IRB 1520

IRB 1600

IRB 2400

IRB 2600

IRB 4400

IRB 4600
IRB 140

Axis 4, 5, 6 x x x x x x x
Axis 5, 6 x x x x x
Axis 4, 3 x

Step 1 - Manually running the manipulator to the synchronization position

Use this procedure to manually run the manipulator to the synchronization position.
Action Note
1 Select axis-by-axis motion mode.
2 Jog the manipulator to align the synchron- See Synchronization marks and synchron-
ization marks. ization position for axes on page 395.
3 When all axes are positioned, update the Step 2 - Updating the revolution counter
revolution counter. with the FlexPendant on page 400.

Correct calibration position of axis 4 and 6

When jogging the manipulator to synchronization position, it is extremely important
to make sure that axes 4 and 6 of the following mentioned manipulators are
positioned correctly. The axes can be calibrated at the wrong turn, resulting in an
incorrect manipulator calibration.
Make sure the axes are positioned according to the correct calibration values, not
only according to the synchronization marks. The correct values are found on a
label, located either on the lower arm, underneath the flange plate on the base or
on the frame.
At delivery the manipulator is in the correct position, do NOT rotate axis 4 or 6 at
power up before the revolution counters are updated.

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5 Calibration
5.3 Updating revolution counters
Continued

If one of the following mentioned axes are rotated one or more turns from its
calibration position before updating the revolution counter, the correct calibration
position will be lost due to non-integer gear ratio. This affects the following
manipulators:
Manipulator variant Axis 4 Axis 6
IRB 2600 No No

If the synchronization marks seem to be wrong (even if the motor calibration data
is correct), try to rotate the axis one turn, update the revolution counter and check
the synchronization marks again (try both directions, if needed).

Step 2 - Updating the revolution counter with the FlexPendant

Use this procedure to update the revolution counter with the FlexPendant (IRC5).
Action
1 On the ABB menu, tap Calibration.

xx1500000942

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 5 Calibration
5.3 Updating revolution counters
Continued

Action
2 All mechanical units connected to the system are shown with their calibration status.
Tap the mechanical unit in question.

xx1500000943

3 This step is valid for RobotWare 6.02 and later.

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

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5 Calibration
5.3 Updating revolution counters
Continued

Action
4 A screen is displayed, tap Rev. Counters.

en0400000771

5 Tap Update Revolution Counters....

A dialog box is displayed, warning that updating the revolution counters may change
programmed robot positions:
• Tap Yes to update the revolution counters.
• Tap No to cancel updating the revolution counters.
Tapping Yes displays the axis selection window.
6 Select the axis to have its revolution counter updated by:
• Ticking in the box to the left
• Tapping Select all to update all axes.
Then tap Update.
7 A dialog box is displayed, warning that the updating operation cannot be undone:
• Tap Update to proceed with updating the revolution counters.
• Tap Cancel to cancel updating the revolution counters.
Tapping Update updates the selected revolution counters and removes the tick from
the list of axes.
8
CAUTION

If a revolution counter is incorrectly updated, it will cause incorrect manipulator posi-

tioning, which in turn may cause damage or injury!
Check the synchronization position very carefully after each update. See Checking
the synchronization position on page 422.

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 5 Calibration
5.4.1 Description of Axis Calibration

5.4 Calibrating with Axis Calibration method

5.4.1 Description of Axis Calibration

Instructions for Axis Calibration procedure given on the FlexPendant

The actual instructions of how to perform the calibration procedure and what to
do at each step is given on the FlexPendant. You will be guided through the
calibration procedure, step by step.
This manual contains a brief description of the method, additional information to
the information given on the FlexPendant, article number for the tools and images
of where to fit the calibration tools on the robot.

Overview of the Axis Calibration procedure

The Axis Calibration procedure applies to all axes, and is performed on one axis
at the time. The robot axes are both manually and automatically moved into position,
as instructed on the FlexPendant.
A fixed calibration pin/bushing is installed on each robot axis at delivery.
The Axis Calibration procedure described roughly:
• A removable calibration tool is inserted by the operator into a calibration
bushing on the axis chosen for calibration, according to instructions on the
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.

• During the calibration procedure, RobotWare moves the robot axis chosen
for calibration so that the calibration tools get into contact. RobotWare records
values of the axis position and repeats the coming-in-contact procedure
several times to get an exact value of the axis position.

WARNING

Risk of pinching! The contact force for large robots can be up to 150 kg.
Keep a safe distance to the robot.

• The axis position is stored in RobotWare with an active choice from the
operator.

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5 Calibration
5.4.1 Description of Axis Calibration
Continued

Routines in the calibration procedure

The following routines are available in the Axis Calibration procedure, given at the
beginning of the procedure on the FlexPendant.

Fine calibration routine

Choose this routine to calibrate the robot when there are no tools, process cabling
or equipment fitted to the robot.

Reference calibration routine

Choose this routine to create reference values and to calibrate the robot when the
robot is dressed with tools, process cabling or other equipment.
Also choose this routine if the robot is wall mounted or suspended.
If calibrating the robot with reference calibration there must be reference values
created before repair is made to the robot, if values are not already available.
Creating new values requires possibility to move the robot. The reference values
contain positions of all axes, torque of axes and technical data about the tool
installed. 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.
Follow the instructions given in the reference calibration routine on the FlexPendant
to create reference values.
When reference calibration is performed, the robot is restored to the status given
by the reference values.

Note

When calibrating the robot with the reference calibration routine, the robot must
be dressed with the same tools, process cabling and any other equipment as
when the reference values were created.

Update revolution counters

Choose this routine to make a rough calibration of each manipulator axis by
updating the revolution counter for each axis, using the FlexPendant.

Validation
In the mentioned routines, it is also possible to validate the calibration data.

Position of robot axes

The axis chosen for calibration is automatically run by the calibration program to
its calibration position during the calibration procedure.
In order for the axis to be able to be moved to calibration position, or in order for
getting proper access to the calibration bushing, other axes might need to be
jogged to positions different from 0 degrees. Information about which axes are
allowed to be jogged will be given on the FlexPendant. These axes are marked
with Unrestricted in the FlexPendant window.

How to calibrate a suspended or wall mounted robot

The IRB 2600/IRB 2600 ID is calibrated floor standing in factory, prior to shipping.

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 5 Calibration
5.4.1 Description of Axis Calibration
Continued

To calibrate a suspended or wall mounted robot, reference calibration must be

used. Reference values for a suspended or a wall mounted robot must be created
with the robot mounted at its working position, not standing on a floor.
To calibrate a suspended or wall mounted robot with the fine calibration routine,
the robot must first be taken down and mounted standing on the floor.

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5 Calibration
5.4.2 Calibration tools for Axis Calibration

5.4.2 Calibration tools for Axis Calibration

Calibration tool set

The calibration tools used for Axis Calibration are designed to meet requirements
for calibration performance, durability and safety in case of accidental damage.
The calibration tool will eventually break from fatigue after longer period of use
and then needs to be replaced. 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 Note

Calibration tool box, 3HAC062326-001 Delivered as a set of calibration tools.
Axis Calibration Required if Axis Calibration is the valid calib-
ration method for the robot.
Contains a removal tool for removing special
protection plugs on the turning disc.

Examining the calibration tool

Check prior to usage
Before using the calibration tool, make sure that the tube insert, the plastic
protection and the steel spring ring are present.

WARNING

If any part is missing or damaged, the tool must be replaced immediately.

xx1500001914

A Tube insert
B Plastic protection
C Steel spring ring

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 5 Calibration
5.4.2 Calibration tools for Axis Calibration
Continued

Periodic check of the calibration tool

If including the calibration tool in a local periodic check system, the following
measures should be checked.
• Outer diameter within Ø12g4 mm, Ø8g4 mm or Ø6g5 mm (depending on
calibration tool size).
• Straightness within 0.005 mm.

xx1500000951

A Outer diameter

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5 Calibration
5.4.3 Installation locations for the calibration tools

5.4.3 Installation locations for the calibration tools

Location of fixed calibration items

This section shows how the robot is equipped with items for installation of
calibration tools for Axis Calibration (fixed calibration pins and/or bushings).
Installed calibration tools are not shown.
A fixed calibration pin and a bushing for the movable calibration tool are located
on each axis as follows.
If there is not enough space on an axis to install a fixed calibration pin, the axis is
equipped with two bushings instead, for installation of two calibration tools when
calibration is carried out. This is shown in the figure.

IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB 2600ID-8/2.0

xx1800000963

IRB 2600 Type C-20/1.65, IRB 2600 Type C-12/1.65

xx1800000964

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 5 Calibration
5.4.3 Installation locations for the calibration tools
Continued

IRB 2600, IRB 2600ID

xx1600000521

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5 Calibration
5.4.3 Installation locations for the calibration tools
Continued

IRB 2600

xx1600000522

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 5 Calibration
5.4.3 Installation locations for the calibration tools
Continued

IRB 2600ID

xx1600000523

Spare parts
When calibration is not being performed, a protective cover and an o-ring should
always be installed on the fixed calibration pin as well as a protective plug, included
a sealing, in the bushing. Replace damaged parts with new, if needed.
Spare part Article number Note
Protection cover and plug set 3HAC059487-001 Contains replacement calibration
pin covers and protective plugs
for the bushing.
Protective plug on turning disc 3HAC057676-001 Replace if damaged or missing.
(IRB 2600ID)
3HAC057511-001
(IRB 2600)

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5 Calibration
5.4.4 Axis Calibration - Running the calibration procedure

5.4.4 Axis Calibration - Running the calibration procedure

Required tools
The calibration tools used for Axis Calibration are designed to meet requirements
for calibration performance, durability and safety in case of accidental damage.

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. Article number Note

Calibration tool box, Axis 3HAC062326-001 Delivered as a set of calibration tools.
Calibration Required if Axis Calibration is the valid
calibration method for the robot.
Contains a removal tool for removing
special protection plugs on the turning
disc.

Required consumables
Consumable Article number Note
Clean cloth -

Spare parts

Spare part Article number Note

Protection cover and plug set 3HAC059487-001 Contains replacement calibration
pin covers and protective plugs
for the bushing.
Protective plug on turning disc 3HAC057676-001 Replace if damaged or missing.
(IRB 2600ID)
3HAC057511-001
(IRB 2600)

Overview of the calibration procedure on the FlexPendant

The actual instructions of how to perform the calibration procedure and what to
do at each step is given on the FlexPendant. You will be guided through the
calibration procedure, step by step.
Use the following list to learn about the calibration procedure before running the
RobotWare program on the FlexPendant. It gives you a brief overview of the
calibration procedure sequence.
After the calibration method has been called for on the FlexPendant, the following
sequence will be run.
1 Choose calibration routine. The routines are described in Routines in the
calibration procedure on page 404.
2 Choose which axis/axes to calibrate.
3 The robot moves to synchronization position.

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 5 Calibration
5.4.4 Axis Calibration - Running the calibration procedure
Continued

4 Validate the synchronization marks.

5 The robot moves to preparation position.
6 Remove the protective cover from the fixed pin and the protection plug from
the bushing, if any, and install the calibration tool.
Use the removal tool included in the calibration tool box to remove the special
protection plug(s) on the turning disc.
IRB 2600

xx1700000407 xx1700000408

IRB 2600ID

xx1700000410 xx1700000411

When calibrating axis 6, push in the calibration tool into the turning disc until
the snap ring engages, no further.
7 The robot performs a measurement sequence by rotating the axis back and
forth.
8 Remove the calibration tool and reinstall the protective cover on the fixed
pin and the protection plug in the bushing, if any.
Refit the protection plug(s) to the turning disc, push until the steel spring ring
snaps into place.
9 The robot moves to verify that the calibration tool is removed.
10 Choose whether to save the calibration data or not.
Calibration of the robot is not finished until the calibration data is saved, as last
step of the calibration procedure.
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5 Calibration
5.4.4 Axis Calibration - Running the calibration procedure
Continued

Preparation prior to calibration

The calibration procedure is described in the FlexPendant while conducting it.
Action Note
1
DANGER

While conducting the calibration, the robot needs

to be connected to power.
Make sure that the robots working area is empty,
as the robot can make unpredictable movements.

2 Wipe the calibration tool clean. Use a clean cloth.

Note

The calibration method is exact. Dust, dirt or color

flakes will affect the calibration value.

Starting the calibration procedure

Use this procedure to call for the Axis Calibration method on the FlexPendant.
Action Note
1 On the ABB menu, tap Calibration.

xx1500000942

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 5 Calibration
5.4.4 Axis Calibration - Running the calibration procedure
Continued

Action Note
2 All mechanical units connected to the system are
shown with their calibration status.
Tap the mechanical unit in question.

xx1500000943

3 Calibration method used at factory for each axis The FlexPendant will give all inform-
is shown, as well as calibration method used for ation needed to proceed with Axis
the robot during last field calibration. Calibration.
Tap Run Calibration Method. The software will
automatically call for the procedure for the valid
calibration method.

xx1500000944

4 Follow the instructions given on the FlexPendant. A brief overview of the sequence
that will be run on the FlexPendant
is given in Overview of the calibra-
tion procedure on the FlexPendant
on page 412.

Restarting an interrupted calibration procedure

If the Axis Calibration procedure is interrupted before the calibration is finished,
the RobotWare program needs to be started again. Use this procedure to take
required action.
Situation Action
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.

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5 Calibration
5.4.4 Axis Calibration - Running the calibration procedure
Continued

Situation Action
The RobotWare program is terminated with Remove the calibration tool, if it is installed,
PP to Main. and restart the calibration procedure from
the beginning. See Starting the calibration
procedure on page 414.
If the calibration tool is in contact the robot
axis needs to be jogged in order to release
the calibration tool. Jogging the axis in wrong
direction will cause the calibration tool to
break. Directions of axis movement is shown
in Calibration movement directions for all
axes on page 398

Axis Calibration with SafeMove option

To be able to run Axis Calibration SafeMove needs to be unsynchronized. The Axis
Calibration routine recognizes if the robot is equipped with SafeMove and will force
SafeMove to unsynchronize automatically.
However, SafeMove may generate other warning messages anytime during the
Axis Calibration routine.

Safety controller not synchronized - SafeMove message

Action Note
1 SafeMove generates the message "Safety control-
ler not synchronized".

xx1500002480

2 Confirm unsynchronized state by pressing Ac-

knowledge to continue Axis Calibration proced-
ure.
3 Restart Axis Calibration procedure by pressing
Play.

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 5 Calibration
5.4.4 Axis Calibration - Running the calibration procedure
Continued

Unsynchronized speed exceeded - SafeMove message while saving robot data

Action Note
1 SafeMove generates the message "Unsynchron-
ized speed exceeded" while saving robot data.

xx1500002481

2 Press Acknowledge to continue Axis Calibration

procedure.
3 Restart Axis Calibration procedure by pressing
Play.

Unsynchronized time limit expired - SafeMove message anytime during Axis Calibration routine

Action Note
1 SafeMove generates the message "Unsynchron-
ized time limit expired" (anytime).

xx1500002482

2 Press OK to continue Axis Calibration procedure.

3 Restart Axis Calibration procedure by pressing
Play.

Continues on next page

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5 Calibration
5.4.4 Axis Calibration - Running the calibration procedure
Continued

After calibration

Action Note
1 Check the o-ring on the fixed calibration pin.
Replace if damaged or missing.
2 Reinstall the protective cover on the fixed calibra-
tion pin on each axis, directly after the axis has
been calibrated.
Replace the cover with new spare part, if missing
or damaged.

xx1600002102

Protection cover and plug set:

3HAC059487-001.
3 Reinstall the protective plug and sealing in the
bushing on each axis, directly after the axis has
been calibrated. 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:

3HAC059487-001.

Continues on next page

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 5 Calibration
5.4.4 Axis Calibration - Running the calibration procedure
Continued

Action Note
4 Refit the special protection plug to the turning IRB 2600
disc using the tool included in the calibration tool
box.

xx1700000408

IRB 2600ID

xx1700000411

5 Remove the tool from the protection plug. IRB 2600

xx1700000901

IRB 2600ID

xx1700000902

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5 Calibration
5.5 Calibrating with Calibration Pendulum method

5.5 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.

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 5 Calibration
5.6 Verifying the calibration

5.6 Verifying the calibration

Introduction
Always verify the results after calibrating any robot axis to verify that all calibration
positions are correct.

Verifying the calibration

Use this procedure to verify the calibration result.
Action Note
1 Run the calibration home position program twice. See Checking the synchron-
Do not change the position of the robot axes after running ization position on page 422.
the program!
2 Adjust the synchronization marks when the calibration is This is detailed in section
done, if necessary. Synchronization marks and
synchronization position for
axes on page 395.
3 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.
4 Remove any calibration equipment from the robot.

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5 Calibration
5.7 Checking the synchronization position

5.7 Checking the synchronization position

Introduction
Check the synchronization position of the robot before beginning any programming
of the robot system. This may be done:
• Using a MoveAbsJ instruction with argument zero on all axes.
• Using the Jogging window on the FlexPendant.

Using a MoveAbsJ instruction

Use this procedure to create a program that runs all the robot axes to their
synchronization position.
Action Note
1 On ABB menu tap Program editor.
2 Create a new program.
3 Use MoveAbsJ in the Motion&Proc menu.
4 Create the following program:
MoveAbsJ [[0,0,0,0,0,0],
[9E9,9E9,9E9,9E9,9E9,9E9]]
\NoEOffs, v1000, fine, tool0

5 Run the program in manual mode.

6 Check that the synchronization marks for the axes See Synchronization marks and
align correctly. If they do not, update the revolu- synchronization position for axes on
tion counters. page 395 and Updating revolution
counters on page 399.

Using the jogging window

Use this procedure to jog the robot to the synchronization position of all axes.
Action Note
1 On the ABB menu, tap Jogging.
2 Tap Motion mode to select group of axes
to jog.
3 Tap to select the axis to jog, axis 1, 2, or
3.
4 Manually run the robots axes to a position
where the axis position value read on the
FlexPendant, is equal to zero.
5 Check that the synchronization marks for See Synchronization marks and synchron-
the axes align correctly. If they do not, up- ization position for axes on page 395 and
date the revolution counters. Updating revolution counters on page 399.

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 6 Decommissioning
6.1 Introduction

6 Decommissioning
6.1 Introduction

Introduction
This section contains information to consider when taking a product, robot or
controller, out of operation.
It deals with how to handle potentially dangerous components and potentially
hazardous materials.

General
All used grease/oils and dead batteries must be disposed of in accordance with
the current legislation of the country in which the robot and the control unit are
installed.
If the robot or the control unit is partially or completely disposed of, the various
parts must be grouped together according to their nature (which is all iron together
and all plastic together), and disposed of accordingly. These parts must also be
disposed of in accordance with the current legislation of the country in which the
robot and control unit are installed.

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6 Decommissioning
6.2 Environmental information

6.2 Environmental information

Symbol
The following symbol indicates that the product must not be disposed of as common
garbage. Handle each product according to local regulations for the respective
content (see table below).

xx1800000058

Hazardous material
The table specifies some of the materials in the product and their respective use
throughout the product.
Dispose components properly according to local regulations to prevent health or
environmental hazards.
Material Example application
Batteries, NiCad or Lithium Serial measurement board
Copper Cables, motors
Cast iron/nodular iron Base, lower arm, upper arm
Steel Gears, screws, base, frame, and so on.
Neodymium Brakes, motors
Plastic/rubber Cables, connectors, drive belts, and so on.
Oil, grease Gearboxes
Aluminium Covers, synchronization brackets
Nickel Turning disc (foundry)

Oil and grease

Where possible, arrange for oil and grease to be recycled. Dispose of via an
authorized person/contractor in accordance with local regulations. Do not dispose
of oil and grease near lakes, ponds, ditches, down drains, or onto soil. Incineration
must be carried out under controlled conditions in accordance with local regulations.

Continues on next page

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 6 Decommissioning
6.2 Environmental information
Continued

Also note that:

• 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.

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6 Decommissioning
6.3 Scrapping of robot

6.3 Scrapping of robot

Important when scrapping the robot

DANGER

When a robot is disassembled while being scrapped, it is very important to

remember the following before disassembling starts, in order to prevent injuries:
• Always remove all batteries. If a battery is exposed to heat, for example
from a blow torch, it will explode.
• Always remove all oil/grease in gearboxes. If exposed to heat, for example
from a blow torch, the oil/grease will catch fire.
• When motors are removed from the robot, the robot will collapse if it is not
properly supported before the motor is removed.

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 7 Robot description
7.1 Robot types

7 Robot description
7.1 Robot types

Robot types
There are different variants of the IRB 2600, Type A and Type B, and they may
have different motor types; i.e the silver label says it is a Type A robot, but it may
use Type B motors. The following table explains the differences.
From release 19.1 it is also another variant called Type C available. It only affects
two variants of the robot.
IRB 2600 (standard IRB 2600ID
variants)
Initial version motor type A motor type A
IRB 2600 Type A Axis 2 changes Axis 1-5 change to motor type B
gearbox Axis 6 keeps motor type A
IRB 2600 Type B Axis 1-6 change to
motor type B
IRB 2600 Type C - only IRB 2600 Axis 1 and 2 have
Type C-20/1.65, IRB 2600 Type C- two versions of
12/1.65. gearboxes described
below.

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7 Robot description
7.2 Non-compatible versions of axis-1 and axis-2 gearboxes

7.2 Non-compatible versions of axis-1 and axis-2 gearboxes

Gearboxes from different suppliers are not compatible

There are two different versions of the axis-1 and axis-2 gearboxes for robot variants
IRB 2600-20/1.65 and IRB 2600-12/1.65.
• Version 1 for IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB
2600ID-15/1.85, IRB 2600ID-8/2.0.
• Version 2 for IRB 2600 Type C-20/1.65, IRB 2600 Type C-12/1.65.
The different versions affect the surrounding mechanical structure of the robot.
Following parts are unique for each version of the gearbox.
• Axis-1 gearbox
• Axis-2 gearbox
• Frame
• Base
• Lower arm
• Axis-1 motor pinion
• Axis-2 motor pinion
• Cable harness
The listed parts are not interchangeable.
The gearbox oils are not interchangeable.

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 7 Robot description
7.2 Non-compatible versions of axis-1 and axis-2 gearboxes
Continued

Designation label on lower arm

At delivery there is a designation label fitted to the lower arm of the Type C variant
of the robot, informing that the robot is a Type C variant.

xx1800002211

Continues on next page

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7 Robot description
7.2 Non-compatible versions of axis-1 and axis-2 gearboxes
Continued

Identifying the gearbox version visually

The mechanical structure of the robot differs depending on which axis-1 and axis-2
gearbox the robot is equipped with. Some of the differences are visible, as shown
in the table.
Identification of gearbox - mechanical Identification of gearbox - mechanical
structure structure
IRB 2600-20/1.65, IRB 2600-12/1.65, IRB IRB 2600 Type C-20/1.65, IRB 2600 Type
2600-12/1.85, IRB 2600ID-15/1.85, IRB C-12/1.65
2600ID-8/2.0

xx1800001133
xx1800000551

xx1800001134
xx1800000554

A The fixed calibration pin for Axis Calibra- The fixed calibration pin for Axis Calibra-
tion is located straight below the motor tion is located on a casted arm on the
flange. motor flange.
The bushing for the calibration tool is The bushing for the calibration tool is loc-
centered on the base. ated to the right on the base.
B The oil plug for drainage is located on the The oil plug for drainage is located in front
left side of the gearbox and visible through of the gearbox (when robot is standing in
an opening in the frame (when robot is synchronization position).
standing in synchronization position).
C The cable cover shape is triangular. The cable cover shape is rectangular.
D Hole pattern for 17 screws that fasten the Hole pattern for 16 screws that fasten the
lower arm to the gearbox. lower arm to the gearbox.

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 7 Robot description
7.2 Non-compatible versions of axis-1 and axis-2 gearboxes
Continued

Identifying the gearbox version by article number

Only robot variants IRB 2600-20/1.65 and IRB 2600-12/1.65 are affected by different
gearbox suppliers.
Use the table to identify which gearbox versions are installed on the robot, by
article number. The article numbers specified are found in WebConfig.
Contact ABB Service for further assistance regarding which gearbox versions are
installed on the robot, if needed.
Robot variant Article number, axis-1 gear- Article number, axis-2 gear-
box box
IRB 2600-20/1.65 3HAC028837-001 3HAC039109-001
IRB 2600 Type C-20/1.65 3HAC043130-001 3HAC043134-001
IRB 2600 - 12/1.65 3HAC028837-001 3HAC039109-001
IRB 2600 Type C-12/1.65 3HAC043130-001 3HAC043134-001

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 8 Reference information
8.1 Introduction

8 Reference information
8.1 Introduction

General
This chapter includes general information, complementing the more specific
information in the different procedures in the manual.

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8 Reference information
8.2 Applicable standards

8.2 Applicable standards

Note

The listed standards are valid at the time of the release of this document. Phased
out or replaced standards are removed from the list when needed.

Standards, EN ISO
The product is designed in accordance with the requirements of:
Standard Description
EN ISO 12100:2010 Safety of machinery - General principles for design - Risk as-
sessment and risk reduction
EN ISO 13849-1:2015 Safety of machinery, safety related parts of control systems -
Part 1: General principles for design
EN ISO 13850:2015 Safety of machinery - Emergency stop - Principles for design
EN ISO 10218-1:2011 Robots for industrial environments - Safety requirements -Part
1 Robot
ISO 9787:2013 Robots and robotic devices -- Coordinate systems and motion
nomenclatures
ISO 9283:1998 Manipulating industrial robots, performance criteria, and related
test methods
EN ISO 14644-1:2015 i Classification of air cleanliness
EN ISO 13732-1:2008 Ergonomics of the thermal environment - Part 1
EN 61000-6-4:2007 + EMC, Generic emission
A1:2011
IEC 61000-6-4:2006 +
A1:2010
(option 129-1)
EN 61000-6-2:2005 EMC, Generic immunity
IEC 61000-6-2:2005
EN IEC 60974-1:2012 ii Arc welding equipment - Part 1: Welding power sources
EN IEC 60974-10:2014 ii Arc welding equipment - Part 10: EMC requirements
EN IEC 60204-1:2006 Safety of machinery - Electrical equipment of machines - Part
1 General requirements
IEC 60529:1989 + A2:2013 Degrees of protection provided by enclosures (IP code)
i Only robots with protection Clean Room.
ii Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.

European standards

Standard Description
EN 614-1:2006 + A1:2009 Safety of machinery - Ergonomic design principles - Part 1:
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

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 8 Reference information
8.2 Applicable standards
Continued

Other standards

Standard Description
ANSI/RIA R15.06 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

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8 Reference information
8.3 Unit conversion

8.3 Unit conversion

Converter table
Use the following table to convert units used in this manual.
Quantity Units
Length 1m 3.28 ft. 39.37 in
Weight 1 kg 2.21 lb.
Weight 1g 0.035 ounces
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.225 lbf
Moment 1 Nm 0.738 lbf-ft
Volume 1L 0.264 US gal

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 8 Reference information
8.4 Screw joints

8.4 Screw joints

General
This section describes how to tighten the various types of screw joints on the IRB
2600/IRB 2600 ID.
The instructions and torque values are valid for screw joints comprised of metallic
materials and do not apply to soft or brittle materials.

UNBRAKO screws
UNBRAKO is a special type of screw recommended by ABB for certain screw joints.
It features special surface treatment (Gleitmo as described below) and is extremely
resistant to fatigue.
Whenever used, this is specified in the instructions, and in such cases, no other
type of replacement screw is allowed. Using other types of screws will void any
warranty and may potentially cause serious damage or injury.

Gleitmo treated screws

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

Screws lubricated in other ways

Screws lubricated with Molycote 1000 should only be used when specified in the
repair, maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1 Apply lubricant to the screw thread.
2 Apply lubricant between the plain washer and screw head.
3 Screw dimensions of M8 or larger must be tightened with a torque wrench.
Screw dimensions of M6 or smaller may be tightened without a torque wrench
if this is done by trained and qualified personnel.
Lubricant Article number
Molycote 1000 (molybdenum disulphide grease) 3HAC042472-001

Tightening torque
Before tightening any screw, note the following:
• Determine whether a standard tightening torque or special torque is to be
applied. The standard torques are specified in the following tables. Any
special torques are specified in the repair, maintenance or installation
procedure descriptions. Any special torque specified overrides the standard
torque!
• Use the correct tightening torque for each type of screw joint.
• Only use correctly calibrated torque keys.

Continues on next page

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8 Reference information
8.4 Screw joints
Continued

• Always tighten the joint by hand, and never use pneumatic tools.
• Use the correct tightening technique, that is do not jerk. Tighten the screw
in a slow, flowing motion.
• Maximum allowed total deviation from the specified value is 10%!

Oil-lubricated screws with slotted or cross-recess head screws

The following table specifies the recommended standard tightening torque for
oil-lubricated screws with slotted or cross-recess head screws.

Note

A special torque specified in the repair, maintenance or installation procedure

overrides the standard torque.

Oil-lubricated screws with allen head screws

The following table specifies the recommended standard tightening torque for
oil-lubricated screws with allen head screws.

Note

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)
Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric-
ated ated
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340
M20 400 560 670
M24 680 960 1150

Lubricated screws (Molycote, Gleitmo or equivalent) with allen head screws

The following table specifies the recommended standard tightening torque for
screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head
screws.

Note

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 i Class 12.9, lubricated i
M8 28 35

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 8 Reference information
8.4 Screw joints
Continued

Dimension Tightening torque (Nm) Tightening torque (Nm)

Class 10.9, lubricated i Class 12.9, lubricated i
M10 55 70
M12 96 120
M16 235 280
M20 460 550
M24 790 950
i Lubricated with Molycote 1000, Gleitmo 603 or equivalent

Water and air connectors

The following table specifies the recommended standard tightening torque for
water and air connectors when one or both connectors are made of brass.

Note

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.
1/8 12 8 15
1/4 15 10 20
3/8 20 15 25
1/2 40 30 50
3/4 70 55 90

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8 Reference information
8.5 Weight specifications

8.5 Weight specifications

Definition
In installation, repair, and maintenance procedures, weights of the components
handled are sometimes specified. 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.

Example
Following is an example of a weight specification in a procedure:
Action Note

CAUTION

The robot weighs 280 kg.

All lifting accessories used must be sized accord-
ingly.

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 8 Reference information
8.6 Standard tools

8.6 Standard tools

General
All service (repairs, maintenance, and installation) procedures contains lists of
tools required to perform the specified activity.
All special tools required are listed directly in the procedures while all the tools
that are considered standard are gathered in the standard toolkit and defined in
the following table.
This way, the tools required are the sum of the standard toolkit and any tools listed
in the instruction.

Contents, standard toolkit

Qty Tool
1 Ring-open-end spanner 8-19 mm
1 Socket head cap 2.5-17 mm
1 Torx socket no: 20-60
1 Small screwdriver
1 Plastic mallet
1 Ratchet head for torque wrench 1/2"
1 Socket head cap no: 5, socket 1/2" bit L 20 mm
1 Socket head cap no: 6, socket 1/2" bit L 20 mm
1 Socket head cap no: 8, socket 1/2" bit L 20 mm
1 Small cutting plier
1 T-handle with ball head

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8 Reference information
8.7 Special tools

8.7 Special tools

General
All service instructions contain lists of tools required to perform the specified
activity. The required tools are a sum of standard tools, defined in the section
Standard tools on page 441, and of special tools, listed directly in the instructions
and also gathered in this section.

Measuring tools, play

The tools listed for measuring the play are used after service work on axes 5 and
6.
Description Robot variant Art. no.
Measuring tool, play IRB 2600 - 20/1.65, -12/1.65, 12/1.85 3HAB6337-1
Measuring tool, play IRB 2600ID 3HAB9238-1
Turning disk adapter IRB 2600ID 3HAC027717-020
Measuring bracket IRB 2600ID 3HAC032976-001
Rotation tool IRB 2600, IRB 2600ID 3HAB7887-1
(Used on motor axis. M3
screw is included.)
Tool for adjusting play in IRB 2600, IRB 2600ID See Drawing for ad-
motors justment tool on
page 352.

Calibration equipment, Levelmeter (alternative method)

The following table specifies the calibration equipment required when calibrating
the robot with the alternative method, Levelmeter Calibration.
Description Art. no. Note
Angle bracket 68080011-LP
Calibration bracket 3HAC13908-9
Calibration tool ax1 3HAC13908-4
Levelmeter 2000 kit 6369901-347 Includes one sensor.
Measuring pin 3HAC13908-5
Sensor fixture 68080011-GM
Sensor plate 3HAC0392-1
Sync. adapter 3HAC13908-1

Calibration equipment, Calibration Pendulum

The following table specifies the calibration equipment needed when calibrating
the robot with the Calibration Pendulum method.
The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory.
Always use the same calibration method as used at the factory.
Information about valid calibration method is found on the calibration label or in
the calibration menu on the FlexPendant.

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 8 Reference information
8.7 Special tools
Continued

If no data is found related to standard calibration, Calibration Pendulum is used

as default.
Description Art. no. Note
Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes operating
manual.

Calibration equipment, Axis Calibration

The following table specifies the calibration equipment needed when calibrating
the robot with the Axis Calibration method.
The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory.
Always use the same calibration method as used at the factory.
Information about valid calibration method is found on the calibration label or in
the calibration menu on the FlexPendant.
If no data is found related to standard calibration, Calibration Pendulum is used
as default.
Description Art. no. Note
Calibration tool box, Axis Cal- 3HAC062326- Delivered as a set of calibration tools.
ibration 001 Required if Axis Calibration is the valid
calibration method for the robot.
Contains a removal tool for removing
special protection plugs on the turning
disc.

Turning tool for suspended mounting

The following table specifies the lifting tool required when fitting the robot in a
suspended position.
Description Art. no. Note
Turning tool (includes lifting instruction) 3HAC034766-001
Turning tool (includes lifting instruction 3HAC048502-001
3HAC051688-001)

Special tools
This table specifies the special tools required during several of the service
procedures. The tools are specified directly in concerned instructions.
Description Qty Article no.
Guide for reduction gear 1 3HAC068109-001
Used to guide axis-1 gear and frame
during refitting.

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8 Reference information
8.8 Lifting accessories and lifting instructions

8.8 Lifting accessories and lifting instructions

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

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 9 Spare part lists
9.1 Spare part lists and illustrations

9 Spare part lists

9.1 Spare part lists and illustrations

Location
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.

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 10 Circuit diagram
10.1 Circuit diagrams

10 Circuit diagram
10.1 Circuit diagrams

Overview
The circuit diagrams are not included in this manual, but are available for registered
users on myABB Business Portal, www.myportal.abb.com.
See the article numbers in the tables below.

Controllers

Product Article numbers for circuit diagrams

Circuit diagram - IRC5 3HAC024480-011
Circuit diagram - IRC5 Compact 3HAC049406-003
Circuit diagram - IRC5 Panel Mounted Con- 3HAC026871-020
troller
Circuit diagram - Euromap 3HAC024120-004
Circuit diagram - Spot welding cabinet 3HAC057185-001

Robots

Product Article numbers for circuit diagrams

Circuit diagram - IRB 120 3HAC031408-003
Circuit diagram - IRB 140 type C 3HAC6816-3
Circuit diagram - IRB 260 3HAC025611-001
Circuit diagram - IRB 360 3HAC028647-009
Circuit diagram - IRB 460 3HAC036446-005
Circuit diagram - IRB 660 3HAC025691-001
Circuit diagram - IRB 760 3HAC025691-001
Circuit diagram - IRB 1200 3HAC046307-003
Circuit diagram - IRB 1410 3HAC2800-3
Circuit diagram - IRB 1600/1660 3HAC021351-003
Circuit diagram - IRB 1520 3HAC039498-007
Circuit diagram - IRB 2400 3HAC6670-3
Circuit diagram - IRB 2600 3HAC029570-007
Circuit diagram - IRB 4400/4450S 3HAC9821-1
Circuit diagram - IRB 4600 3HAC029038-003
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

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© Copyright 2009-2018 ABB. All rights reserved.
10 Circuit diagram
10.1 Circuit diagrams
Continued

Product Article numbers for circuit diagrams

Circuit diagram - IRB 6620 3HAC025090-001
Circuit diagram - IRB 6620 / IRB 6620LX 3HAC025090-001
Circuit diagram - IRB 6640 3HAC025744-001
Circuit diagram - IRB 6650S 3HAC13347-1
3HAC025744-001
Circuit diagram - IRB 6660 3HAC025744-001
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

448 Product manual - IRB 2600

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© Copyright 2009-2018 ABB. All rights reserved.
 Index

Index D
danger levels, 41
direction of axes, 398
A
Absolute Accuracy, calibration, 393 E
aluminum enabling device, 30
disposal, 424 environmental information, 424
ambient humidity ESD
operation, 53 damage elimination, 33
storage, 53 sensitive equipment, 33
ambient temperature expansion container
operation, 53 installing, 97
storage, 53 expected life, 118
assembly instructions, 49 external safety devices, 26
assessment of hazards and risks, 20
Axis Calibration, 403 F
calibration tool fire extinguishing, 22
article number, 406, 412 FlexPendant
examining, 406 jogging to calibration position, 422
installation position, 408 MoveAbsJ instruction, 422
overview of method, 403 updating revolution counters, 400
procedure on FlexPendant, 412 foundation
protective cover and protection plug, 408, 412 requirements, 52
B G
batteries gearboxes
disposal, 424 location of, 148
handling, 38 Gravity Alpha, 65
battery pack Gravity Beta, 64
replacing, interval, 116 grease
brakes disposal, 424
testing function, 37
H
C hanging
cabinet lock, 25, 31 installed hanging, 25
cabling, robot, 104 hazardous material, 424
cabling between robot and controller, 104 height
calibrating installed at a height, 25
robot, 403 hold-to-run, 30
roughly, 399 HRA, 20
calibrating robot, 403 humidity
calibration operation, 53
Absolute Accuracy type, 392 storage, 53
rough, 399
standard type, 392 I
verification, 421 instructions for assembly, 49
when to calibrate, 394 integrator responsibility, 19
calibration, Absolute Accuracy, 393 intervals for maintenance, 115
calibration manuals, 393
calibration marks, 395 L
calibration position labels
jogging to, 422 robot, 43
scales, 395 leak-down test, 188
calibration scales, 395 lifting
CalibWare, 392 accessory, 63
carbon dioxide extinguisher, 22 lifting accessory, 440
cast iron limitation of liability, 19
disposal, 424 Lithium
cleaning, 184 disposal, 424
climbing on robot, 25 loads on foundation, 51
Cold environments, 103 lubrication
connecting the robot and controller, cabling, 104 amount in gearboxes, 148
connection type of lubrication, 148
external safety devices, 26
copper M
disposal, 424 magnesium
disposal, 424

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© Copyright 2009-2018 ABB. All rights reserved.
Index

maintenance schedule, 115 signal lamp, 101

MoveAbsJ instruction, 422 signals, 41
signals in manual, 41
N symbols, 41
nation specific regulations, 19 symbols on robot, 43
negative directions, axes, 398 test run, 28
neodymium working range, 29
disposal, 424 safety fence, 20
NiCad safety risk
disposal, 424 electric parts, 31
nodular iron hot parts, 34
disposal, 424 hydraulic system, 35
installation, 25
O oil change, 39
oil operational disturbance, 25
amount in gearboxes, 148 pneumatic system, 35
disposal, 424 pressure relief valve, 36
type of oil, 148 service work, 25
oil change voltage, 31
axis 1, floor mounted robots, 150 safety signals
axis 1, suspended robots, 158 in manual, 41
axis 2, 163 safety standards, 434
axis 3, 167 safety zones, 20
axis 4, 171 scales on robot, 395
axis 5, 175 schedule for maintenance, 115
axis 6, 175 screw joints, 437
safety risks, 39 signal lamp, 101
operating conditions, 53 signals
options safety, 41
expansion container, 97 special tools, 442
speed
P adjusting, 103
pedestal stability, 59
installed on pedestal, 25 standards, 434
plastic ANSI, 435
disposal, 424 CAN, 435
positive directions, axes, 398 EN, 434
product standards, 434 EN IEC, 434
protection classes, 53 EN ISO, 434
protection type, 53 start of robot in cold environments, 103
protective equipment, 26 steel
protective wear, 26 disposal, 424
R storage conditions, 53
region specific regulations, 19 suspended mounting, 64
release brakes, 23 symbols
requirements on foundation, 52 safety, 41
responsibility and validity, 19 synchronization position, 399
revolution counters sync marks, 395
storing on FlexPendant, 400 system integrator requirements, 19
updating, 399 system parameter
risk of tipping, 59 Gravity Alpha, 65
robot Gravity Beta, 64
labels, 43
T
protection class, 53 temperatures
protection types, 53 operation, 53
symbols, 43 storage, 53
rubber testing
disposal, 424 brakes, 37
S three-position enabling device, 30
safety tilted mounting, 64
brake testing, 37 tools
ESD, 33 Axis Calibration, 443
fire extinguishing, 22 calibration equipment, Levelmeter, 442
moving robots, 27 Calibration Pendulum, 442
release robot axes, 23 for service, 442
torques on foundation, 51

450 Product manual - IRB 2600

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© Copyright 2009-2018 ABB. All rights reserved.
 Index

troubleshooting W
oil spills, 184 wall mounting, 64
turning weight, 50
accessory, 63 base, 295–296
robot, 61, 73, 258–259, 264, 266, 281, 283, 292, 362,
U 366, 375, 378, 386–387, 440
updating revolution counters, 399 upper and lower arm, 374, 380
upper arm, complete, 248, 252
V
validity and responsibility, 19 Z
velocity zero position
adjusting, 103 checking, 422
verifying calibration, 421

Product manual - IRB 2600 451

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© Copyright 2009-2018 ABB. All rights reserved.
ABB AB, Robotics
Robotics and Motion
S-721 68 VÄSTERÅS, Sweden
Telephone +46 (0) 21 344 400

ABB AS, Robotics

Robotics and Motion
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000

ABB Engineering (Shanghai) Ltd.

Robotics and Motion
No. 4528 Kangxin Highway
PuDong District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666

ABB Inc.
Robotics and Motion
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000

abb.com/robotics
3HAC035504-001, Rev Q, en

© Copyright 2009-2018 ABB. All rights reserved.

Specifications subject to change without notice.