ABB IRB 2600 Series User manual

Product manual
IRB 2600

Trace back information:
Workspace R15-1 version a3
Checked in 2015-03-25
Skribenta version 4.1.349

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
M2004
Document ID: 3HAC035504-001
Revision: G
© Copyright 2009-2015 ABB. All rights reserved.

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.
Additional copies of this manual may be obtained from ABB.
The original language for this publication is English. Any other languages that are
supplied have been translated from English.
© Copyright 2009-2015 ABB. All rights reserved.
ABB AB
Robotics Products
Se-721 68 Västerås
Sweden

Table of contents
9Overview of this manual ...................................................................................................................
15Product documentation, IRC5 ..........................................................................................................
17How to read the product manual ......................................................................................................
191 Safety
191.1 Introduction to safety information ......................................................................... 201.2 General safety information .................................................................................. 201.2.1 Introduction to general safety information .................................................... 211.2.2 Safety in the robot system ........................................................................ 221.2.3 Safety risks ............................................................................................ 221.2.3.1 Safety risks during installation and service work on robots .................. 251.2.3.2 CAUTION - Hot parts may cause burns! ........................................... 261.2.3.3 Safety risks related to tools/work pieces .......................................... 271.2.3.4 Safety risks related to pneumatic/hydraulic systems .......................... 281.2.3.5 Safety risks with pressure relief valve .............................................. 291.2.3.6 Safety risks during operational disturbances ..................................... 301.2.3.7 Risks associated with live electric parts ........................................... 321.2.4 Safety actions ......................................................................................... 321.2.4.1 Safety fence dimensions ............................................................... 331.2.4.2 Fire extinguishing ........................................................................ 341.2.4.3 Emergency release of the robot arm ............................................... 351.2.4.4 Brake testing .............................................................................. 361.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" ........................ 371.2.4.6 Safe use of the jogging device ....................................................... 381.2.4.7 Work inside the working range of the robot ....................................... 391.2.4.8 Signal lamp (optional) ................................................................... 401.2.5 Safety stops ........................................................................................... 401.2.5.1 What is an emergency stop? .......................................................... 421.3 Safety related instructions .................................................................................. 421.3.1 Safety signals in the manual ...................................................................... 441.3.2 Safety symbols on product labels ............................................................... 491.3.3 DANGER - Moving robots are potentially lethal! ............................................ 501.3.4 DANGER - First test run may cause injury or damage! ................................... 511.3.5 WARNING - The brake release buttons may be jammed after service work ........ 521.3.6 DANGER - Make sure that the main power has been switched off! .................... 531.3.7 WARNING - The unit is sensitive to ESD! ..................................................... 541.3.8 WARNING - Safety risks during handling of batteries ..................................... 551.3.9 WARNING - Safety risks during work with gearbox lubricants (oil or grease) ......
572 Installation and commissioning
572.1 Introduction ...................................................................................................... 582.2 Unpacking ....................................................................................................... 582.2.1 Pre-installation procedure ......................................................................... 622.2.2 Working range and type of motion .............................................................. 672.2.3 Risk of tipping/stability ............................................................................. 682.3 On-site installation ............................................................................................ 682.3.1 Lifting robot with roundslings .................................................................... 712.3.2 Lifting and turning a suspended mounted robot ............................................ 722.3.3 Setting the system parameters for a suspended or tilted robot ......................... 752.3.4 Manually releasing the brakes ................................................................... 782.3.5 Orienting and securing the robot ................................................................ 822.3.6 Fitting equipment on robot ........................................................................ 942.3.7 Loads fitted to the robot, stopping time and braking distances ......................... 952.4 Restricting the working range .............................................................................. 952.4.1 Introduction ............................................................................................ 962.4.2 Mechanically restricting the working range of axis 1 ......................................
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982.5 Installing options ............................................................................................... 982.5.1 Installation of cooling fan for motors (option) ................................................ 1022.5.2 Installing an expansion container ............................................................... 1042.5.3 Installation of Foundry Plus Cable guard (option no. 908-1) ............................. 1052.5.4 Installation of signal lamp (option) .............................................................. 1062.6 Robot in hot environments .................................................................................. 1062.6.1 Start of robot in hot environments .............................................................. 1072.7 Robot in cold environments ................................................................................. 1072.7.1 Start of robot in cold environments ............................................................. 1082.8 Electrical connections ........................................................................................ 1082.8.1 Robot cabling and connection points .......................................................... 1102.8.2 Customer connection on robot ................................................................... 1122.8.3 Customer connections on upper arm ..........................................................
1153 Maintenance
1153.1 Introduction ...................................................................................................... 1163.2 Maintenance schedule and expected component life ............................................... 1163.2.1 Specification of maintenance intervals ........................................................ 1173.2.2 Maintenance schedule ............................................................................. 1203.2.3 Expected component life ......................................................................... 1213.3 Inspection activities ........................................................................................... 1213.3.1 Inspecting oil level, axis-1 gearbox ............................................................ 1283.3.2 Inspecting the oil level, axis 2 gearbox ........................................................ 1303.3.3 Inspecting the oil level, axis 3 gearbox ........................................................ 1323.3.4 Inspecting the oil level, axis 4 gearbox ........................................................ 1343.3.5 Inspecting oil level, gearbox axes 5 - 6 ........................................................ 1363.3.6 Inspecting the cable harness ..................................................................... 1383.3.7 Inspecting information labels ..................................................................... 1403.3.8 Inspecting the mechanical stop pin, axis 1 ................................................... 1433.3.9 Inspecting additional mechanical stops ....................................................... 1453.3.10 Inspecting dampers ................................................................................. 1473.3.11 Inspecting the pressure relief valve ............................................................ 1493.3.12 Inspecting Signal lamp (option) .................................................................. 1513.4 Replacement / Changing activities ........................................................................ 1513.4.1 Type of lubrication in gearboxes ................................................................ 1533.4.2 Changing the oil, axis 1 gearbox on floor mounted robots ............................... 1583.4.3 Changing the oil, axis-1 gearbox on suspended robots ................................... 1643.4.4 Changing the oil, axis-2 gearbox ................................................................ 1683.4.5 Changing the oil, axis-3 gearbox ................................................................ 1723.4.6 Changing the oil, axis-4 gearbox ................................................................ 1763.4.7 Changing oil, axes-5 and -6 gearboxes ........................................................ 1803.4.8 Replacing SMB battery ............................................................................. 1853.5 Cleaning .......................................................................................................... 1853.5.1 Cleaning the IRB 2600 ..............................................................................
1894 Repair
1894.1 Introduction ...................................................................................................... 1904.2 General procedures ........................................................................................... 1904.2.1 Performing a leak-down test ...................................................................... 1914.2.2 Mounting instructions for bearings ............................................................. 1934.2.3 Mounting instructions for seals .................................................................. 1954.3 Complete robot ................................................................................................. 1954.3.1 Removing the complete cable harness ........................................................ 2064.3.2 Refitting the complete cable harness .......................................................... 2214.3.3 Replacing the cable harness in the upper arm - IRB 2600ID ............................ 2324.3.4 Replacing SMB unit ................................................................................. 2374.3.5 Replacing the brake release unit ................................................................ 2414.3.6 Replacing the base ..................................................................................
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2494.4 Upper arm ....................................................................................................... 2494.4.1 Replacing the complete upper arm ............................................................. 2584.4.2 Replacing complete tubular shaft unit ......................................................... 2644.4.3 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) .................................................... 2784.5 Lower arm ....................................................................................................... 2784.5.1 Replacing the lower arm ........................................................................... 2834.6 Frame and base ................................................................................................ 2834.6.1 Replacing stop pin axis 1 .......................................................................... 2864.7 Motors ............................................................................................................ 2864.7.1 Removing motors .................................................................................... 2984.7.2 Refitting motors ...................................................................................... 3144.7.3 Replacing motor axis 5 - IRB 2600ID ........................................................... 3254.7.4 Replacing motor axis 6 and wrist unit - IRB 2600ID ........................................ 3344.7.5 Adjusting the play ................................................................................... 3394.8 Gearboxes ....................................................................................................... 3394.8.1 Replacing gearbox axis 1 .......................................................................... 3454.8.2 Replacing gearbox axis 2 .......................................................................... 3544.8.3 Replacing gearbox axis 3 ..........................................................................
3615 Calibration information
3615.1 Introduction ..................................................................................................... 3625.2 Calibration methods ........................................................................................... 3645.3 Calibration scale and correct axis position ............................................................. 3675.4 Calibration movement directions for all axes .......................................................... 3685.5 Updating revolution counters ............................................................................... 3705.6 Checking the zero position ..................................................................................
3716 Decommissioning
3716.1 Introduction ...................................................................................................... 3726.2 Environmental information .................................................................................. 3736.3 Scrapping of robot .............................................................................................
3757 Reference information
3757.1 Introduction ...................................................................................................... 3767.2 Applicable safety standards ................................................................................ 3787.3 Unit conversion ................................................................................................. 3797.4 Screw joints .................................................................................................... 3827.5 Weight specifications ......................................................................................... 3837.6 Standard tools .................................................................................................. 3847.7 Special tools .................................................................................................... 3867.8 Lifting accessories and lifting instructions ..............................................................
3878 Spare part lists
3878.1 Spare part lists and illustrations ...........................................................................
3899 Circuit diagram
3899.1 Circuit diagrams ................................................................................................
391Index
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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
A maintenance/repair/installation craftsman working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
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
Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.
Repair
Procedures that do not require specific calibration equipment.
General information about calibration.
Calibration information
Environmental information about the robot and its components.Decommissioning
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Overview of this manual

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

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.
•Section Safety signals in the manual on page 42 added in Safety chapter.
• Section Safety risks with pressure relief valve on page 28 added in
Safety chapter.
• Force and Torque loads updated in section Pre-installation procedure
on page 58.
• Section Installing an expansion container on page 102 added.
• Interval for inspection of Signal lamp added in section Maintenance
schedule on page 117.
• New design of frame added in sections Inspecting oil level, axis-1
gearbox on page 121 and Changing the oil, axis 1 gearbox on floor
mounted robots on page 153.
•Required oil level updated in section Inspecting oil level, axis-1 gearbox
on page 121.
• Required oil level updated in section Inspecting the oil level, axis 3
gearbox on page 130.
• Required oil level updated in section Inspecting the oil level, axis 4
gearbox on page 132.
• Required oil level updated in section Inspecting oil level, gearbox axes
5 - 6 on page 134.
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 58.
• Figure and describing text edited for the stress forces. See Loads on
foundation, robot on page 59.
• Removed Foundry from table with protection classes. See Protection
classes, robot on page 61.
• Text added for the maximum levelness. See Requirements, foundation
on page 60.
• Length of roundslings for lifting the robot is changed from 4 m to 2 m.
See Lifting robot with roundslings on page 68.
• Note about fan cabling added in the cable list. See Robot cabling and
connection points on page 108.
• Minor editorial changes made throughout the maintenance chapter.
•Note about ambient temperature deleted from the maintenance schedule.
See Maintenance schedule on page 117.
• Added figure of suspended robot in maintenance sections for axis 1
gearbox. See Inspecting oil level, axis-1 gearbox on page 121 and
Changing the oil, axis 1 gearbox on floor mounted robots on page 153.
• A new block, about general illustrations, added in section How to read
the product manual on page 17.
• Figure of axis 1 stop pin is updated. See Replacing stop pin axis 1 on
page 283.
• Figure of axis 1 gearbox is updated. See Replacing gearbox axis 1 on
page 339.
• Figure with movement directions of axes added. See Calibration
movement directions for all axes on page 367.
• Figure of suspended robot added. See Lifting and turning a suspended
mounted robot on page 71.
Continues on next page
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Continued

DescriptionRevision
• Warning of heavy weight is changed to include the complete robot in-
stead of only the arm system, section Replacing the base on page 241.
• Separated robot dimensions and mounting hole measurements in
drawings. See Fitting equipment on robot on page 82.
• Added section Setting the system parameters for a suspended or tilted
robot on page 72.
• 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 221.
• 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 241.
• Changed information about the robot position when removing motor.
See Removing motors on page 286.
• 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 339. 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 253.
• Additional information in the procedure for replacing the base with im-
proved lifting instruction etc., see Replacing the base on page 241.
•Added a second roundsling to the lifting instruction for the complet robot,
see Lifting robot with roundslings on page 68.
•Changed type of oil in axes 1, 2 and 4 gearboxes. See Type of lubrication
in gearboxes on page 151.
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 249.
• 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 249,Replacing gearbox axis 3 on page 354
and Replacing gearbox axis 2 on page 345.
• 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 354 and Replacing gearbox axis 2 on page 345.
• Added safety information about preventing roundslings from sliding
when lifting the upper arm tube, see Replacing complete tubular shaft
unit on page 258.
• Added information about removing painting, if any, from assembly sur-
faces when replacing gearboxes and motors.
Continues on next page
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Continued

DescriptionRevision
• 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 172.
• Corrected data for which motor pins to connect when releasing the
brakes, see Removing motors on page 286 and Refitting motors on
page 298.
• Added information about o-ring and made other minor improvements
to the instruction for replacing wrist unit, see Replacing wrist unit on
page 264.
•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 168.
• 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 130.
• Changed instruction for replacing the wrist unit so that the wrist do not
need to be drained, see Replacing wrist unit on page 264.
• Added Profibus to the section about connections to extra equipment,
see Customer connection on robot on page 110.
•New section added to the manual, see Installation of Foundry Plus Cable
guard (option no. 908-1) on page 104.
•Some general tightening torques have been changed/added, see updated
values in Screw joints on page 379.
• 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 286
and Refitting motors on page 298.
• 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 325, 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 334.
• Added WARNING - Safety risks during handling of batteries on page 54.
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.
Continues on next page
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Continued

DescriptionRevision
•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.
• 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 373.
•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 79.
• Term "Guide sleeves" changed to "Guide bushings", see Dimension,
mounting surface and guide bushing on page 79.
• Information in 2.3.4 Manually releasing the brakes has been updated
and two figures are added.
• Motors Type B (IRB 2600) and Type A (IRB 2600ID) added.
• 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.
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Continued

Product documentation, IRC5
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 listed can be ordered from ABB on a DVD. The documents listed
are valid for IRC5 robot systems.
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 exploded views (or references to separate spare parts
lists).
• Circuit diagrams (or references to circuit diagrams).
Technical reference manuals
The technical reference manuals describe reference information for robotics
products.
•Technical reference manual - Lubrication in gearboxes: Description of types
and volumes of lubrication for the manipulator gearboxes.
•Technical reference manual - RAPID overview: An overview of the RAPID
programming language.
•Technical reference manual - RAPID Instructions, Functions and Data types:
Description and syntax for all RAPID instructions, functions, and data types.
•Technical reference manual - RAPID kernel: A formal description of the
RAPID programming language.
•Technical reference manual - System parameters: Description of system
parameters and configuration workflows.
Continues on next page
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Product documentation, IRC5

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, DVD with PC software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and trouble shooters.
The group of manuals includes (among others):
•Operating manual - Emergency safety information
•Operating manual - General safety information
•Operating manual - Getting started, IRC5 and RobotStudio
•Operating manual - Introduction to RAPID
•Operating manual - IRC5 with FlexPendant
•Operating manual - RobotStudio
•Operating manual - Trouble shooting IRC5, for the controller and manipulator.
16 Product manual - IRB 2600
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Product documentation, IRC5
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.
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© Copyright 2009-2015 ABB. All rights reserved.
How to read the product manual

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1 Safety
1.1 Introduction to safety information
Overview
The safety information in this manual is divided into two categories:
• General safety aspects, important to attend to before performing any service
work on the robot. These are applicable for all service work and are found
in General safety information on page 20.
• Specific safety information, pointed out in the procedures. How to avoid and
eliminate the danger is either described directly in the procedure, or in specific
instructions in the section Safety related instructions on page 42.
Product manual - IRB 2600 19
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© Copyright 2009-2015 ABB. All rights reserved.
1 Safety
1.1 Introduction to safety information

1.2 General safety information
1.2.1 Introduction to general safety information
Definitions
This section details general safety information for personnel performing installation,
repair and maintenance work.
Sections
The general safety information is divided into the following sections.
ContainingContents
• safety, service
• limitation of liability
• related information
General information
• safety risks during installation or service
• risks associated with live electrical parts
Safety risks lists dangers relevant when
working with the product. The dangers are
split into different categories.
• fire extinguishing
• safe use of the teach pendant or jogging
device
Safety actions describes actions which
may be taken to remedy or avoid dangers.
• stopping functions
• description of emergency stop
• description of safety stop
• description of safeguarding
Safety stops describes different types of
stops.
20 Product manual - IRB 2600
3HAC035504-001 Revision: G
© Copyright 2009-2015 ABB. All rights reserved.
1 Safety
1.2.1 Introduction to general safety information