ABB IRB 2600 Series User manual

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
9Overview of this manual ...................................................................................................................
16Product documentation ....................................................................................................................
18How to read the product manual ......................................................................................................
191 Safety
191.1 General safety information ..................................................................................
191.1.1 Limitation of liability .................................................................................
211.1.2 Protective stop and emergency stop ...........................................................
221.2 Safety actions ...................................................................................................
221.2.1 Fire extinguishing ....................................................................................
231.2.2 Emergency release of the robot axes ..........................................................
241.2.3 Make sure that the main power has been switched off ....................................
251.3 Safety risks ......................................................................................................
251.3.1 Safety risks during installation and service work on robots ..............................
271.3.2 Moving robots are potentially lethal ............................................................
281.3.3 First test run may cause injury or damage ....................................................
291.3.4 Work inside the working range of the robot ..................................................
301.3.5 Enabling device and hold-to-run functionality ...............................................
311.3.6 Risks associated with live electric parts .......................................................
331.3.7 The unit is sensitive to ESD .......................................................................
341.3.8 Hot parts may cause burns .......................................................................
351.3.9 Safety risks related to pneumatic/hydraulic systems ......................................
361.3.10 Safety risks with pressure relief valve .........................................................
371.3.11 Brake testing ..........................................................................................
381.3.12 Safety risks during handling of batteries ......................................................
391.3.13 Safety risks during work with gearbox lubricants (oil or grease) .......................
411.4 Safety signals and symbols .................................................................................
411.4.1 Safety signals in the manual ......................................................................
431.4.2 Safety symbols on product labels ...............................................................
492 Installation and commissioning
492.1 Introduction ......................................................................................................
502.2 Unpacking .......................................................................................................
502.2.1 Pre-installation procedure .........................................................................
542.2.2 Working range and type of motion ..............................................................
592.2.3 Risk of tipping/stability .............................................................................
602.3 On-site installation ............................................................................................
602.3.1 Lifting robot with roundslings ....................................................................
632.3.2 Lifting and turning a suspended mounted robot ............................................
642.3.3 Setting the system parameters for a suspended or tilted robot .........................
682.3.4 Manually releasing the brakes ...................................................................
712.3.5 Orienting and securing the robot ................................................................
752.3.6 Fitting equipment on robot ........................................................................
882.3.7 Loads fitted to the robot, stopping time and braking distances .........................
892.4 Restricting the working range ..............................................................................
892.4.1 Axes with restricted working range .............................................................
902.4.2 Mechanically restricting the working range of axis 1 ......................................
932.5 Installing options ...............................................................................................
932.5.1 Installation of cooling fan for motors (option) ................................................
972.5.2 Installing an expansion container ...............................................................
1002.5.3 Installation of Foundry Plus Cable guard (option no. 908-1) .............................
1012.5.4 Signal lamp (option) .................................................................................
1022.6 Robot in hot environments ..................................................................................
1022.6.1 Start of robot in hot environments ..............................................................
1032.7 Robot in cold environments .................................................................................
1032.7.1 Start of robot in cold environments ............................................................
Product manual - IRB 2600 5
3HAC035504-001 Revision: Q
© Copyright 2009-2018 ABB. All rights reserved.
Table of contents

1042.8 Electrical connections ........................................................................................
1042.8.1 Robot cabling and connection points ..........................................................
1082.8.2 Customer connection on robot ...................................................................
1112.8.3 Customer connections on upper arm ..........................................................
1133 Maintenance
1133.1 Introduction ......................................................................................................
1143.2 Maintenance schedule and expected component life ...............................................
1143.2.1 Specification of maintenance intervals ........................................................
1153.2.2 Maintenance schedule .............................................................................
1183.2.3 Expected component life .........................................................................
1193.3 Inspection activities ...........................................................................................
1193.3.1 Inspecting oil level, axis-1 gearbox .............................................................
1243.3.2 Inspecting the oil level, axis 2 gearbox ........................................................
1273.3.3 Inspecting the oil level, axis 3 gearbox ........................................................
1293.3.4 Inspecting the oil level, axis 4 gearbox ........................................................
1313.3.5 Inspecting oil level, gearbox axes 5 - 6 ........................................................
1333.3.6 Inspecting the cable harness .....................................................................
1353.3.7 Inspecting information labels .....................................................................
1373.3.8 Inspecting the mechanical stop pin, axis 1 ...................................................
1403.3.9 Inspecting additional mechanical stops .......................................................
1423.3.10 Inspecting dampers .................................................................................
1443.3.11 Inspecting the pressure relief valve ............................................................
1463.3.12 Inspecting Signal lamp (option) ..................................................................
1483.4 Replacement / Changing activities ........................................................................
1483.4.1 Type of lubrication in gearboxes ................................................................
1503.4.2 Changing the oil, axis 1 gearbox on floor mounted robots ...............................
1583.4.3 Changing the oil, axis-1 gearbox on suspended robots ...................................
1633.4.4 Changing the oil, axis-2 gearbox ................................................................
1673.4.5 Changing the oil, axis-3 gearbox ................................................................
1713.4.6 Changing the oil, axis-4 gearbox ................................................................
1753.4.7 Changing oil, axes-5 and -6 gearboxes ........................................................
1793.4.8 Replacing SMB battery .............................................................................
1843.5 Cleaning ..........................................................................................................
1843.5.1 Cleaning the IRB 2600/IRB 2600 ID .............................................................
1874 Repair
1874.1 Introduction ......................................................................................................
1884.2 General procedures ...........................................................................................
1884.2.1 Performing a leak-down test ......................................................................
1894.2.2 Mounting instructions for bearings .............................................................
1914.2.3 Mounting instructions for seals ..................................................................
1934.2.4 Cut the paint or surface on the robot before replacing parts ............................
1944.2.5 The brake release buttons may be jammed after service work .........................
1954.3 Complete robot .................................................................................................
1954.3.1 Removing the complete cable harness ........................................................
2074.3.2 Refitting the complete cable harness ..........................................................
2224.3.3 Replacing the cable harness in the upper arm - IRB 2600ID ............................
2344.3.4 Replacing SMB unit .................................................................................
2404.3.5 Replacing the brake release board .............................................................
2454.4 Upper arm .......................................................................................................
2454.4.1 Replacing the complete upper arm .............................................................
2554.4.2 Replacing complete tubular shaft unit .........................................................
2624.4.3 Replacing wrist unit .................................................................................
2684.4.4 Measuring the play, axis 5 .........................................................................
2704.4.5 Measuring the play, axis 6 .........................................................................
2724.4.6 Measuring the play, axis 5 (ID upper arm) ....................................................
2754.4.7 Measuring the play, axis 6 (ID upper arm) ....................................................
6 Product manual - IRB 2600
3HAC035504-001 Revision: Q
© Copyright 2009-2018 ABB. All rights reserved.
Table of contents

2784.5 Lower arm .......................................................................................................
2784.5.1 Replacing the lower arm ...........................................................................
2864.6 Frame and base ................................................................................................
2864.6.1 Replacing stop pin axis 1 ..........................................................................
2894.6.2 Replacing the base ..................................................................................
3014.7 Motors ............................................................................................................
3014.7.1 Removing motors ....................................................................................
3134.7.2 Refitting motors ......................................................................................
3294.7.3 Replacing motor axis 5 - IRB 2600ID ...........................................................
3414.7.4 Replacing motor axis 6 and wrist unit - IRB 2600ID ........................................
3524.7.5 Adjusting the play ...................................................................................
3574.8 Gearboxes .......................................................................................................
3574.8.1 Replacing gearbox axis 1 ..........................................................................
3704.8.2 Replacing gearbox axis 2 ..........................................................................
3834.8.3 Replacing gearbox axis 3 ..........................................................................
3915 Calibration
3915.1 Introduction to calibration ...................................................................................
3915.1.1 Introduction and calibration terminology ......................................................
3925.1.2 Calibration methods .................................................................................
3945.1.3 When to calibrate ...................................................................................
3955.2 Synchronization marks and axis movement directions .............................................
3955.2.1 Synchronization marks and synchronization position for axes .........................
3985.2.2 Calibration movement directions for all axes ................................................
3995.3 Updating revolution counters ...............................................................................
4035.4 Calibrating with Axis Calibration method ...............................................................
4035.4.1 Description of Axis Calibration ..................................................................
4065.4.2 Calibration tools for Axis Calibration ...........................................................
4085.4.3 Installation locations for the calibration tools ...............................................
4125.4.4 Axis Calibration - Running the calibration procedure ......................................
4205.5 Calibrating with Calibration Pendulum method ........................................................
4215.6 Verifying the calibration ......................................................................................
4225.7 Checking the synchronization position ..................................................................
4236 Decommissioning
4236.1 Introduction ......................................................................................................
4246.2 Environmental information ..................................................................................
4266.3 Scrapping of robot .............................................................................................
4277 Robot description
4277.1 Robot types .....................................................................................................
4287.2 Non-compatible versions of axis-1 and axis-2 gearboxes ..........................................
4338 Reference information
4338.1 Introduction ......................................................................................................
4348.2 Applicable standards .........................................................................................
4368.3 Unit conversion .................................................................................................
4378.4 Screw joints ....................................................................................................
4408.5 Weight specifications .........................................................................................
4418.6 Standard tools ..................................................................................................
4428.7 Special tools ....................................................................................................
4448.8 Lifting accessories and lifting instructions ..............................................................
4459 Spare part lists
4459.1 Spare part lists and illustrations ...........................................................................
Product manual - IRB 2600 7
3HAC035504-001 Revision: Q
© Copyright 2009-2018 ABB. All rights reserved.
Table of contents

44710 Circuit diagram
44710.1 Circuit diagrams ................................................................................................
449Index
8 Product manual - IRB 2600
3HAC035504-001 Revision: Q
© Copyright 2009-2018 ABB. All rights reserved.
Table of contents

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:
ContentsChapter
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.
Safety
Required information about lifting and installation of the robot.Installation and commis-
sioning
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.
Maintenance
Continues on next page
Product manual - IRB 2600 9
3HAC035504-001 Revision: Q
© Copyright 2009-2018 ABB. All rights reserved.
Overview of this manual

ContentsChapter
Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.
Repair
Calibration procedures and general information about calibration.Calibration
Environmental information about the robot and its components.Decommissioning
Useful information when performing installation, maintenance
or repair work. Includes lists of necessary tools, additional doc-
uments, safety standards etc.
Reference information
Complete spare part list and complete list of robot components,
shown in exploded views.
Spare part / part list
Detailed illustrations of the robot with reference numbers to the
part list.
Exploded views
Reference to the circuit diagram for the robot.Circuit diagram
References
Document IDReference
3HAC035959-001Product specification - IRB 2600
3HAC029570-007Circuit diagram - IRB 2600
3HAC049106-001Product manual, spare parts - IRB 2600
3HAC031045-001Operating manual - General safety information i
3HAC021313-001Product manual - IRC5
IRC5 with main computer DSQC 639.
3HAC047136-001Product manual - IRC5
IRC5 with main computer DSQC1000.
3HAC027098-001Operating manual - Emergency safety information
3HAC050941-001Operating manual - IRC5 with FlexPendant
3HAC020738-001Operating manual - Troubleshooting IRC5
3HAC16578-1Operating manual - Calibration Pendulum
3HAC050944-001Operating manual - Service Information System
3HAC042927-001Technical reference manual - Lubrication in gearboxes
3HAC050948-001Technical reference manual - System parameters
3HAC051016-001Application manual - Additional axes and stand alone controller
3HAC050996-001Application manual - Electronic Position Switches
3HAC030421-001Application manual - CalibWare Field 5.0
iThis manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Revisions
DescriptionRevision
First edition-
The following updates and additions have been made in this revision:A
• Variant IRB 2600ID added throughout the manual.
• Safety symbols updated throughout the manual.
Continues on next page
10 Product manual - IRB 2600
3HAC035504-001 Revision: Q
© Copyright 2009-2018 ABB. All rights reserved.
Overview of this manual
Continued

DescriptionRevision
•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.
The following updates and additions have been made in this revision:B
• 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.
Continues on next page
Product manual - IRB 2600 11
3HAC035504-001 Revision: Q
© Copyright 2009-2018 ABB. All rights reserved.
Overview of this manual
Continued

DescriptionRevision
• 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.
The following updates and changes have been made in this revision:C
• 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.
Continues on next page
12 Product manual - IRB 2600
3HAC035504-001 Revision: Q
© Copyright 2009-2018 ABB. All rights reserved.
Overview of this manual
Continued

DescriptionRevision
• 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.
The following updates and changes have been made in this revision:D
• 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.
Continues on next page
Product manual - IRB 2600 13
3HAC035504-001 Revision: Q
© Copyright 2009-2018 ABB. All rights reserved.
Overview of this manual
Continued

DescriptionRevision
• 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.
The following updates and changes have been made in this revision:E
• 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.
The following updates have been made in this revision:F
• 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.
The following updates have been made in this revision:G
• 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.
The following updates have been made in this revision:H
• 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.
The following updates have been made in this revision:J
• Information about expansion container added.
• Updated number of screws and sizes of screws in Replacing the lower
arm.
Published in release R16.2. The following updates are done in this revision:K
• 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.
Published in release R17.1. The following updates are done in this revision:L
• 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.
Continues on next page
14 Product manual - IRB 2600
3HAC035504-001 Revision: Q
© Copyright 2009-2018 ABB. All rights reserved.
Overview of this manual
Continued

DescriptionRevision
• Clarification for types of motors, Motors on page 301.
Published in release R17.2. The following updates are done in this revision:M
• 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.
Published in release R18.1. The following updates are done in this revision:N
•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.
Published in release R18.2. The following updates are done in this revision:P
• Updates related to mechanical stop pin.
• Changed the method for replacing the axis-1 gearbox and the base.
Published in release R18.2. The following updates are done in this revision:Q
• Updated reference.
Product manual - IRB 2600 15
3HAC035504-001 Revision: Q
© Copyright 2009-2018 ABB. All rights reserved.
Overview of this manual
Continued

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
16 Product manual - IRB 2600
3HAC035504-001 Revision: Q
© Copyright 2009-2018 ABB. All rights reserved.
Product documentation

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.
Product manual - IRB 2600 17
3HAC035504-001 Revision: Q
© Copyright 2009-2018 ABB. All rights reserved.
Product documentation
Continued

How to read the product manual
Reading the procedures
The procedures contain references to figures, tools, material, and so on. The
references are read as described below.
References to figures
The procedures often include references to components or attachment points
located on the manipulator/controller. The components or attachment points are
marked with italic text in the procedures and completed with a reference to the
figure where the current component or attachment point is shown.
The denomination in the procedure for the component or attachment point
corresponds to the denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a
procedure.
Note/IllustrationAction
Shown in the figure Location of
gearbox on page xx.
Remove the rear attachment screws, gearbox.8.
References to required equipment
The procedures often include references to equipment (spare parts, tools, etc.)
required for the different actions in the procedure. The equipment is marked with
italic text in the procedures and completed with a reference to the section where
the equipment is listed with further information, that is article number and
dimensions.
The designation in the procedure for the component or attachment point
corresponds to the designation in the referenced list.
The table below shows an example of a reference to a list of required equipment
from a step in a procedure.
Note/IllustrationAction
Art. no. is specified in Required
equipment on page xx.
Fit a new sealing, axis 2 to the gearbox.3.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 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.
18 Product manual - IRB 2600
3HAC035504-001 Revision: Q
© Copyright 2009-2018 ABB. All rights reserved.
How to read the product manual

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
Product manual - IRB 2600 19
3HAC035504-001 Revision: Q
© Copyright 2009-2018 ABB. All rights reserved.
1 Safety
1.1.1 Limitation of liability

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.
20 Product manual - IRB 2600
3HAC035504-001 Revision: Q
© Copyright 2009-2018 ABB. All rights reserved.
1 Safety
1.1.1 Limitation of liability
Continued