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ABB IRB 2600 Series Product Manual Download Page 207

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

Product manual - IRB 2600

207

3HAC035504-001 Revision: Q

© Copyright 2009-2018 ABB. All rights reserved.

4 Repair

4.3.2 Refitting the complete cable harness

Summary of Contents for IRB 2600 Series

Page 1: ...ROBOTICS Product manual IRB 2600 ...

Page 2: ...Trace back information Workspace R18 2 version a18 Checked in 2018 11 20 Skribenta version 5 3 012 ...

Page 3: ...B 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 ...

Page 4: ... 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 ...

Page 5: ...bols 41 1 4 1 Safety signals in the manual 43 1 4 2 Safety symbols on product labels 49 2 Installation and commissioning 49 2 1 Introduction 50 2 2 Unpacking 50 2 2 1 Pre installation procedure 54 2 2 2 Working range and type of motion 59 2 2 3 Risk of tipping stability 60 2 3 On site installation 60 2 3 1 Lifting robot with roundslings 63 2 3 2 Lifting and turning a suspended mounted robot 64 2 3...

Page 6: ...the oil axis 1 gearbox on suspended robots 163 3 4 4 Changing the oil axis 2 gearbox 167 3 4 5 Changing the oil axis 3 gearbox 171 3 4 6 Changing the oil axis 4 gearbox 175 3 4 7 Changing oil axes 5 and 6 gearboxes 179 3 4 8 Replacing SMB battery 184 3 5 Cleaning 184 3 5 1 Cleaning the IRB 2600 IRB 2600 ID 187 4 Repair 187 4 1 Introduction 188 4 2 General procedures 188 4 2 1 Performing a leak dow...

Page 7: ...unters 403 5 4 Calibrating with Axis Calibration method 403 5 4 1 Description of Axis Calibration 406 5 4 2 Calibration tools for Axis Calibration 408 5 4 3 Installation locations for the calibration tools 412 5 4 4 Axis Calibration Running the calibration procedure 420 5 5 Calibrating with Calibration Pendulum method 421 5 6 Verifying the calibration 422 5 7 Checking the synchronization position ...

Page 8: ...447 10 Circuit diagram 447 10 1 Circuit diagrams 449 Index 8 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved Table of contents ...

Page 9: ...ation 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 Contents Chapter Safety information that must be read through before performing any...

Page 10: ...manual IRC5 IRC5 with main computer DSQC 639 3HAC047136 001 Product manual IRC5 IRC5 with main computer DSQC1000 3HAC027098 001 Operating manual Emergency safety information 3HAC050941 001 Operating manual IRC5 with FlexPendant 3HAC020738 001 Operating manual Troubleshooting IRC5 3HAC16578 1 Operating manual Calibration Pendulum 3HAC050944 001 Operating manual Service Information System 3HAC042927...

Page 11: ...ss 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 Maint...

Page 12: ...d 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 fitt...

Page 13: ...B 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 ...

Page 14: ...otors 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...

Page 15: ...cting 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 ...

Page 16: ...ioning 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 ...

Page 17: ...s 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 ...

Page 18: ...ompleted 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 Illustration Action Art no is...

Page 19: ...arried 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 respo...

Page 20: ...orking 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...

Page 21: ...view The protective stops and emergency stops are described in the product manual for the controller Product manual IRB 2600 21 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 1 Safety 1 1 2 Protective stop and emergency stop ...

Page 22: ...uishing Note Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the manipulator or controller 22 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 1 Safety 1 2 1 Fire extinguishing ...

Page 23: ... 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 Product manu...

Page 24: ... 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 24 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 1 Safety 1 2 3 Make sure that the main power has been switched off ...

Page 25: ...afety 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 pur...

Page 26: ...odifications 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...

Page 27: ...y stop equipment is cor rectly installed and connected 1 How to use the hold to run function is de scribed in section How to use the hold to run function in the Operating manual IRC5 with FlexPendant Usually the hold to run function is active only in manual full speed mode To in crease safety it is also possible to activate hold to run for manual reduced speed with a system parameter 2 The hold to...

Page 28: ...fore it is powered up 2 Verify that any safety equipment installed to secure the position or restrict the robot motion during service activity is removed 3 Verify that the fixture and work piece are well secured if applicable 4 Install all safety equipment properly 5 Make sure all personnel are standing at a safe distance from the robot and is out of its reach behind safety fences or similar 6 If ...

Page 29: ...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...

Page 30: ...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 pr...

Page 31: ...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 7...

Page 32: ...e 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 32 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 1 Safety 1 3 6 Risks associated with live electric parts Continued ...

Page 33: ...e Action Wrist straps must be tested frequently to ensure that they are not damaged and are operating cor rectly Product manual IRC5 Product manual IRC5 Panel Mounted Controller Use a wrist strap The wrist strap button is located inside the control ler 1 The mat must be grounded through a current limit ing resistor Use an ESD protective floor mat 2 The mat should provide a controlled discharge of ...

Page 34: ... 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 34 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 1 Safety 1 3 8 Ho...

Page 35: ...re 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 a...

Page 36: ...sks 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 36 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 1 Safety 1 3 10 Safety risks with pressure relief valve ...

Page 37: ...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 Product manual IRB 2600 37 3HAC035504 001 Revision Q Cop...

Page 38: ...losion 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 ...

Page 39: ...ion Action Description Warning Make sure that protective gear like goggles and gloves are al ways worn during this activity Changing and draining gearbox oil or grease may require hand ling hot lubricant heated up to 90 C Hot oil or grease Make sure that protective gear like goggles and gloves are al ways worn When working with gearbox lub ricant there is a risk of an allergic reaction Allergic re...

Page 40: ... time to heat up the oil Warm oil drains quicker than cold oil Heat up the oil After filling verify that the level is correct The specified amount of oil or grease is based on the total volume of the gearbox When changing the lubricant the amount refilled may differ from the specified amount depending on how much has previously been drained from the gearbox Specified amount de pends on drained vol...

Page 41: ...e 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 WARNING Warns for electrical hazards which could result in severe personal injury or deat...

Page 42: ...d conditions NOTE Describes where to find additional information or how to do an operation in an easier way TIP 42 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 1 Safety 1 4 1 Safety signals in the manual Continued ...

Page 43: ...lish German and French Symbols on safety labels Description Symbol Warning xx0900000812 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 to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of c...

Page 44: ... Do not disassemble xx0900000815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the robot arm can fall down Continues on next page 44 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights re...

Page 45: ...ip over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page Product manual IRB 2600 45 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 46: ...1 1 06 xx1300001087 Moving robot 1 2 3 4 5 6 xx0900000819 The robot can move unexpectedly xx1000001141 1 2 3 4 xx1500002616 Continues on next page 46 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 47: ...0001242 Lifting of robot xx0900000822 Oil xx0900000823 Can be used in combination with prohibition if oil is not allowed Mechanical stop xx0900000824 Continues on next page Product manual IRB 2600 47 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 48: ...hat this part is pressurized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller Do not step xx1400002648 Warns that stepping on these parts can cause damage to the parts 48 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Contin...

Page 49: ...ely 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 page19 before performing any installation work Note If the IRB 2600 IRB 2600 ID is connected to power always make sure that the robot is conne...

Page 50: ...t as specified in Weight robot on page 50 5 If the robot is not installed directly it must be stored as described in Storage condi tions robot on page 53 6 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 53 7 Before taking the robot to its installation site make sure that the site conforms to Loads on ...

Page 51: ...e 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 Max load emergency stop Endurance lo...

Page 52: ...foundation The table shows the requirements for the foundation where the weight of the installed robot is included Note Value Requirement Flat foundations give better repeatability of the resolver calibration compared to original settings on delivery from ABB 0 5 mm Flatness of foundation surface The value for levelness aims at the circumstance of the anchoring points in the robot base In order to...

Page 53: ...he 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 Value Param...

Page 54: ...working range for a floor mounted robot IRB 2600 Standard xx0900000194 Pos F Pos E Pos D Pos C Pos B Pos A Variant 1653 mm 1353 mm 469 mm 837 mm 993 mm 1948 mm IRB 2600 20 1 65 IRB 2600 12 1 65 IRB 2600 Type C 20 1 65 IRB 2600 Type C 12 1 65 1853 mm 1553 mm 506 mm 967 mm 1174 mm 2148 mm IRB 2600 12 1 85 Continues on next page 54 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018...

Page 55: ...171 mm 2145 mm IRB 2600ID 15 1 85 2000 mm 1700 mm 539 mm 1051 mm 1321 mm 2295 mm IRB 2600ID 8 2 00 Continues on next page Product manual IRB 2600 55 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range and type of motion Continued ...

Page 56: ... 1353 mm 469 mm 837 mm 993 mm 1948 mm IRB 2600 20 1 65 1653 mm 1353 mm 469 mm 837 mm 993 mm 1948 mm IRB 2600 12 1 65 1853 mm 1553 mm 506 mm 967 mm 1174 mm 2148 mm IRB 2600 12 1 85 Continues on next page 56 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range and type of motion Continued ...

Page 57: ...m 2145 mm IRB 2600ID 15 1 85 2000 mm 1700 mm 539 mm 1051 mm 1321 mm 2295 mm IRB 2600ID 8 2 00 Continues on next page Product manual IRB 2600 57 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range and type of motion Continued ...

Page 58: ... 2 00 Robot motion The table specifies the types and ranges of motion in every axes Range of movement Type of motion Location of motion 180 Rotation motion Axis 1 155 95 Arm motion Axis 2 75 180 Arm motion Axis 3 400 Wrist motion Axis 4 IRB 2600 standard 175 Wrist motion Axis 4 IRB 2600ID 120 Bend motion Axis 5 400 Turn motion Axis 6 58 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2...

Page 59: ...pping 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 1 5 45 A 0 xx0900000211 WARNING The robot is likely to be mechanically unstable if not secured...

Page 60: ...g Lengths 2 m 1 5 m Roundslings 2 pcs Lifting Attach the roundslings as shown in the figure A B 1000 1 5 45 C xx0900000236 Roundsling length 2 m put folded in U shape around the upper arm A Roundsling length 1 5 m put folded in U shape around gearbox axis 3 B Lifting lug C Continues on next page 60 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Inst...

Page 61: ...bot versions IRB 2600ID The best pos ition of axis 4 is 90 4 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 5 See the figure in Lifting on page 60 Attach roundsling A to the lifting lug on the frame and put folded in a U shape on either side of the upper arm 6 See the figure in Lifting on page 60 Attach ro...

Page 62: ...the connec tion box at the base of the robot 9 A Area where the connection box can be damaged while lifting Lifting capacity See Required equipment on page 60 Lift the robot with an overhead crane 10 62 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 3 1 Lifting robot with roundslings Continued ...

Page 63: ...cessory 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 Illustratio...

Page 64: ...s 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 Identifica...

Page 65: ...d 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 rob...

Page 66: ...s 0 0 Floor mounted 1 0 785398 45 Tilted 2 1 570796 90 Wall 3 1 570796 90 Wall 4 Note For suspended robots 180 it is recommended to use Gravity Beta instead of Gravity Alpha Continues on next page 66 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 3 3 Setting the system parameters for a suspended or tilted robot Conti...

Page 67: ...new value is detailed in Mounting angles and values on page65 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 Product manual IRB 2600 67 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 3 3 Setting the syste...

Page 68: ...m 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 Note Action xx0800000272 The internal brake release unit is located at the base of the robot 1 The brake release unit is equipped with six buttons for controlling the axes brakes The buttons are numbered accor...

Page 69: ...n cause all brakes to be released simultaneously 1 Connect to connector R1 MP 0V to pin 12 24V to pin 11 The brake release unit is equipped with six buttons for controlling the axes brakes The buttons are numbered accord ing to the numbers of the axes Release the holding brake on a particular axis by pressing the corresponding button on the push button unit and keeping it de pressed 2 See the prev...

Page 70: ...ke will be released imme diately when the power is switched on This may cause some unexpected robot movements 1 See chapter Circuit diagram on page447 Axes 1 2 and 3 Pos 2 24 V Pos 5 0 V xx1400001984 Connect an external 24 VDC power supply to the motor according to the figures Note Be careful not to interchange the 24V and 0V pins If they are mixed up damage can be caused to the intergrated quench...

Page 71: ...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 Center axis 1 A Note Only the three outer holes are used to secure the robot Continues on next page Product manual IRB 2600 71 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commi...

Page 72: ...700001492 3x common zone C Position of the front of the robot E M16 3 pcs F Guide bushings 2 pcs G 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 Note Dimension Securing parts Facts 3 pcs M16 x 60 Securing screws oiled 200 Nm Quality 8 8 3 pcs 17 x 30 x 3 Washers Continues on next page 72 Pr...

Page 73: ...les 2 CAUTION The IRB 2600 IRB 2600 ID robot weighs 280 kg All lifting accessories used must be sized accordingly 3 CAUTION When the robot is put down after being lifted or transported there is a risk of it tipping if not properly secured 4 How to lift the robot is described in sec tion Lifting robot with roundslings on page 60 Lift the robot to its installation site 5 Fit two guide bushings to th...

Page 74: ...ttachment point front no guide sleeve A Manipulator base B Screw M16x120 C Plain washer D Guide sleeve E Isolator F Nut M16 G 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 74 Product...

Page 75: ... 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 65 291 B 323 190 6 255 7 255 7 C 238 4 A Axis 1 C L 700 445 115 795 150 1382 1019 275 676 85 A xx0900000481 Description Pos R 337 Minimum turning radius of axis 1 A R 98 Minimum turning radius of axis 4 B Cont...

Page 76: ...RB 2600 12 1 85 xx0900000680 Description Pos For all other dimensions see IRB 2600 20 12 1 65 B Continues on next page 76 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 3 6 Fitting equipment on robot Continued ...

Page 77: ...ensions see IRB 2600 X 1 85 A R 172 Minimum turning radius for axis 4 B Continues on next page Product manual IRB 2600 77 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 3 6 Fitting equipment on robot Continued ...

Page 78: ...ensions see IRB 2600 X 1 85 A R 172 Minimum turning radius for axis 4 B Continues on next page 78 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 3 6 Fitting equipment on robot Continued ...

Page 79: ... 2600 1 65 700 IRB 2600 1 85 900 xx0900000189 Max load D Max load A C Max load C Max load B Max load A Variant 35 kg 10 kg 10 kg 1 kg 10 kg IRB 2600 20 1 65 IRB 2600 Type C 20 1 65 IRB 2600 12 1 85 35 kg 15 kg 15 kg 1 kg 15 kg IRB 2600 12 1 65 IRB 2600 Type C 12 1 65 Continues on next page Product manual IRB 2600 79 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installati...

Page 80: ...g 10 kg IRB 2600ID 15 1 85 35 kg 15 kg 15 kg 1 kg 15 kg IRB 2600ID 8 2 00 Note Maximum loads must never be exceeded Continues on next page 80 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 3 6 Fitting equipment on robot Continued ...

Page 81: ...ment on the base and frame of the robot IRB 2600 Standard ID xx0900000227 Attachment holes on base A Center axis 2 B Continues on next page Product manual IRB 2600 81 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 3 6 Fitting equipment on robot Continued ...

Page 82: ... equipment on the lower and upper arms of the robot IRB 2600 standard xx0900000234 Center axis 4 A Center axis 3 B Continues on next page 82 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 3 6 Fitting equipment on robot Continued ...

Page 83: ...4 diameter 50 A Center axis 3 B 2x M8 through C Continues on next page Product manual IRB 2600 83 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 3 6 Fitting equipment on robot Continued ...

Page 84: ...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 84 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 3 6 Fitting equipment on robot Continued ...

Page 85: ... 2 pcs A Holes on other side symmetrical to A 2 pcs B Continues on next page Product manual IRB 2600 85 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 3 6 Fitting equipment on robot Continued ...

Page 86: ... IRB 2600 standard 79 2x M6 110 6 12 5 12 2x M 25 A R98 D B B C 0 05 C 0 3 D 5 0 30 6x M6 6 0 6 H7 8 P P B P P C 7 31 5 H8 63 h8 10 xx0800000278 Smallest circumscribed radius axis 4 A Note Use attachment screws M6 quality 12 9 and 10 mm used thread length Continues on next page 86 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commi...

Page 87: ...gh axis 6 diameter 50 mm B See table below C C mm Variant 135 IRB 2600ID 15 1 85 200 IRB 2600ID 8 2 00 Product manual IRB 2600 87 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 3 6 Fitting equipment on robot Continued ...

Page 88: ... 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 88 P...

Page 89: ...his 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 sto...

Page 90: ...ng 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 Note Art no Equipment etc Includes two additional stop lugs attachment screws washers and instruction See Spare part l...

Page 91: ...600 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 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 Attachment screws D Washers E Continues on next page Product manual IRB 2600 91 3HAC035504 001 Revision Q...

Page 92: ...uidance Determine the position of the stop lugs 1 Specified in Required equipment on page 90 Fit the stop lugs firmly with attachment screws and washers according to the figure Additional stops on page 91 2 Tightening torque 82 Nm 92 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 2 Mechanically restricting the work...

Page 93: ...ing fans The fans are installed on the motors axes 1 or 2 as shown in the figure below xx0900000232 Fan motor axis 1 A Fan motor axis 2 B Protection cover C Continues on next page Product manual IRB 2600 93 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 5 1 Installation of cooling fan for motors option ...

Page 94: ...3 Used for the three tightening screws Locking liquid Content is defined in section Standard tools on page 441 Standard toolkit See chapter Circuit diagram on page447 Circuit diagram These procedures include references to the tools required Other tools and procedures may be required See refer ences to these procedures in the step by step instruc tions below Continues on next page 94 Product manual...

Page 95: ...ox 4 See the figure in Cooling fan on page 94 Tip 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 5 Align the upper part of the fan with the lower part of the connection box A B C xx1000000124 Push the fanbox in line with the connection box 6 Parts A Connection box B Position where the fan shall be aligned with...

Page 96: ...406 After fitting the motor cover fit the protection cover using two attachment screws for the motor cover 9 Parts A Protection cover B Fan Secure the fan cable to the protection cover with a cable strap 10 96 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 5 1 Installation of cooling fan for motors option Continued ...

Page 97: ...unt 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 Cover A Attachment screw M6x16 quality 8 8 A2F 5 pcs B Oil expansion container with cover C Base D O ring D220x5 E Attachment screw M5x20 quality 8 8 A2F and washer 2 2 pcs F O ring D1 9 5 D2 1 6 G Oil plug to be removed H Co...

Page 98: ... and place it in suspended position with the base free for installation work 1 Remove the cover and the o ring from the base 2 xx1500001958 Remove the two existing attachment screws 3 The screws must be replaced with longer screws Remove the oil plug from the base 4 Apply some grease on the small o ring and place it in the recess on the expansion con tainer 5 xx1500001956 Fit a plastic plug in the...

Page 99: ...ening torque 6 Nm Check the o ring used on the cover Replace it if damaged 10 Refit the cover on the base with its attach ment screws 11 Turn the robot so it is not suspended 12 Turn the robot to suspended position 13 See procedure for suspended robot In specting oil level axis 1 gearbox on page 119 Inspect the oil level 14 Product manual IRB 2600 99 3HAC035504 001 Revision Q Copyright 2009 2018 A...

Page 100: ...00 are available in English German French Spanish and Italian and can be found on the DVD delivered with the Cable guard article number 3HAC035933 001 100 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 5 3 Installation of Foundry Plus Cable guard option no 908 1 ...

Page 101: ...on 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 Product manual IRB 2600 101 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 5 4 Signal lamp option ...

Page 102: ...lic pressure supply air pressure supply to the robot before entering the robot work ing area 1 CAUTION Before approaching the potentially hot robot component observe the safety information in section Hot parts may cause burns on page 34 2 Note Before opening the oil plug make certain that the oil plug is above the oil level Place the robot accordingly 3 Tip Hold a cloth or some paper over the oil ...

Page 103: ...e speed can be regulated with the RAPID instruction VelSet Start the robot with its normal program but with reduced speed 1 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 Speed velocity AccSet Work cycles v100 10...

Page 104: ...ual for the controller see document number in References on page 10 Handles power supply to and control of the external axes motors as well as feedback from the servo system External axes cables option 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 com...

Page 105: ...ter for static floor cables A B xx1600002016 Diameter A Diameter x10 B 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 Continues on next page Product manual IRB 2600 105 3HAC035504 001 Revision Q Copyright 2009 2018 ABB Al...

Page 106: ...se 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 106 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 8 1 Robot cabling and connection points Continued ...

Page 107: ... in section Installation of cooling fan for motors option on page 93 Product manual IRB 2600 107 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 8 1 Robot cabling and connection points Continued ...

Page 108: ... 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 Air M16x1 5 24 cone sealing A R2 CP B R2 CS C R2 ETHERNET D Continues on next page 108 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and comm...

Page 109: ...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 Content Art no Connector Connection set Sockets for cable area of 0 14 2 5 mm Hood foundry Hinged frame hood Multicontact module female 3HAC16667 1 R1 CP CS PROC1 on...

Page 110: ...m Bottle shaped shrinking hose Angle shaped shrinking hose 3HAC025396 001 R2 CP R2 CS R2 CP R2 CS 110 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 8 2 Customer connection on robot Continued ...

Page 111: ...s on upper arm Customer Contact on robot base cable between robot and controller not supplied Customer Contact on Upper arm R2 Customer Ter minal Controller Signal name R1 CP CS d1 R2 CP A XP6 1 CPA R1 CP CS d6 R2 CP B XP6 2 CPB R1 CP CS d3 R2 CP C XP6 3 CPC R1 CP CS d4 R2 CP D XP6 4 CPD R1 CP CS d1 R2 CP E XP6 1 CPE R1 CP CS d6 R2 CP F XP6 2 CPF R2 CP G Earth CPG Continues on next page Product ma...

Page 112: ... CSE R1 CP CS b6 R2 CS F XP5 2 4 CSF R1 CP CS b7 R2 CS G XP5 1 9 CSG R1 CP CS b8 R2 CS H XP5 1 10 CSH R1 CP CS b9 R2 CS J XP5 1 11 CSJ R1 CP CS b10 R2 CS K XP5 1 12 CSK R1 CP CS b11 R2 CS L XP5 1 3 CSL R1 CP CS b12 R2 CS M XP5 1 4 CSM R1 CP CS b13 R2 CS N XP5 1 5 CSN R1 CP CS b14 R2 CS P XP5 1 6 CSP R1 CP CS b15 R2 CS R XP5 3 1 CSR R1 CP CS b16 R2 CS S XP5 3 2 CSS R1 CP CS b18 R2 CS T XP5 3 3 CST ...

Page 113: ...ns 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...

Page 114: ... 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...

Page 115: ...ity Cleaning the IRB 2600 IRB 2600 ID on page 184 Robot Cleaning Every 12 months Oil level in axis 1 gearbox Inspection Every 12 months Oil level in axis 2 gearbox Inspection Every 12 months Oil level in axis 3 gearbox Inspection Every 12 months Oil level in axis 4 gearbox Inspection Every 12 months Oil level in axis 5 gearbox Inspection ID Every 12 months Oil level in axis 5 6 gearbox Inspection ...

Page 116: ...ith 2 pole battery contact e g DSQC633A Replacement 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 t...

Page 117: ...rate documents Note Interval Equipment Maintenance activity Every Signal lamp Inspection 12 months Every Additional mechanical stop axis 1 Inspection 12 months Inspect the fan for contam ination that could hinder the air supply Clean if ne cessary Every 12 months Motor fan Inspection Product manual IRB 2600 117 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 2...

Page 118: ... 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 SI...

Page 119: ... 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 rob...

Page 120: ...B 2600 12 1 65 IRB 2600 12 1 85 IRB 2600ID 15 1 85 IRB 2600ID 8 2 0 A B xx1200000883 Oil plug inspection with sealing washer A Oil plug B 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 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 3...

Page 121: ...n 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 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 can contain an excess of pressure...

Page 122: ... 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 floo...

Page 123: ...gearbox 4 xx1100000008 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 5 How to fill oil is described in section Changing the oil axis 1 gearbox on suspended robots on page 158 Add oil if required 6 Tightening torque 3 8 Nm Refit the oil plug Note Before refitting the oil plug in the gearbox always replace the oil plug sealing washer...

Page 124: ... 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 Oil plug inspection when robot is floor mounted A Oil plug inspection when robot is suspended Quick connect fitting B Required equipment Note Equipment 3HAC029646 001 Oil plug sealing washer gearbox See section Type...

Page 125: ...e that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 3 See the figure in Location of axis 2 gearbox on page 124 Open the oil plug inspection location de pends on how the robot is mounted Note Always open the oil plug on top depending how the robot is mounted 4 Measure the oil level at the oil plug hole 5 Required oil level 42 mm 5 mm below the lower edge of ...

Page 126: ...il plug in the gearbox always replace the oil plug sealing washer with a new one If not there is a risk of leakage 7 126 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 3 2 Inspecting the oil level axis 2 gearbox Continued ...

Page 127: ...rbox not visible in this figure B Required equipment Note Equipment See section Type of lubrication in gearboxes on page 148 Lubrication oil Content is defined in section Standard tools on page 441 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues ...

Page 128: ...e 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 See the figure in Location of axis 3 gearbox on page 127 Open the upper oil plug 5 Measure the oil level at the oil plug hole 6 Required oil level IRB 2600 45 5 mm from the upper edge of oil plug hole IRB 2600ID 70 ...

Page 129: ...ion in gearboxes on page 148 Lubrication oil Content is defined in section Standard tools on page 441 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page Product manual IRB 2600 129 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All r...

Page 130: ...re 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 See the figure in Location of axis 4 gearbox on page 129 Open the oil plug 5 Measure the oil level at the oil plug hole 6 Required oil level IRB 2600 15 3 mm below the oil plug flange IRB 2600ID 30 5 mm below the o...

Page 131: ... procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the 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 Note Action IRB 2600 Move the robot to a position where the upper arm is close to horizontal and axis 4 in the calibration position...

Page 132: ...d 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 5 How to fill oil is described in section Changing oil axes 5 and 6 gear boxes on page 175 If necessary refill oil 6 Tightening ...

Page 133: ...cket upper arm G Required equipment Note Equipment Content is defined in section Standard tools on page 441 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below See chapter Circuit diagram on page 447 Circuit diagram Continues on next page Product manual IRB 26...

Page 134: ...ke an overall visual inspection of the cable harness in order to detect wear or damage 2 Check the connectors at the base 3 Check the connectors at the armhouse 4 Check all brackets and straps are properly attached to the robot 5 How to replace the cable harness is de scribed in Repair on page 187 Replace the cable harness if wear cracks or damage is detected 6 134 Product manual IRB 2600 3HAC0355...

Page 135: ...Calibration G Label Suspended robot H Required equipment Note Spare part number Equipment See Spare part lists on page 445 Labels Inspecting labels Use this procedure to inspect the labels on the robot Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 1 Continues on next page Product manual IRB 2...

Page 136: ...formation labels on page 135 Check all labels 2 Replace any missing or damaged labels 3 136 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 3 7 Inspecting information labels Continued ...

Page 137: ...t lists on page 445 Mechanical stop pin axis 1 Content is defined in section Standard tools on page 441 Standard toolkit These procedures include references to the tools re quired Other tools and procedures may be required See refer ences to these procedures in the step by step instructions below Continues on next page Product manual IRB 2600 137 3HAC035504 001 Revision Q Copyright 2009 2018 ABB A...

Page 138: ...ed in any other way 2 How to replace the stop pin is described in section Replacing stop pin axis 1 on page 286 Note 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 3 Check that the mechanical stop pin is prop erly attached 4 ...

Page 139: ...p pin can move freely in both directions and the bracket works as it is supposed to 5 Product manual IRB 2600 139 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 3 8 Inspecting the mechanical stop pin axis 1 Continued ...

Page 140: ...00 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 Attachment screws D Washers E Required equipment Note Equipment etc Includes Stop Attachment screws plus washers Document for movable mechanical stop Fo...

Page 141: ...supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 1 See the figure in Location of additional mechanical stops on page 140 Check the additional mechanical stops on axis 1 for damage 2 Tightening torque 82 Nm Make sure the stops are properly attached 3 Attachment screws M12x40 quality 8 8 A3F 2 pcs stop lug If any damage on stops or attachment ...

Page 142: ...D A Dampers axis 3 IRB 2600 Standard and ID B Damper axis 5 only on IRB 2600 Standard C Required equipment Note Spare part no Equipment See Spare part lists on page 445 Damper Content is defined in section Standard tools on page 441 Standard toolkit Continues on next page 142 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 3 10 Inspecti...

Page 143: ...g area 1 See the figure in Location of dampers on page 142 Check all dampers for damage or cracks 2 Check all dampers for existing impressions larger than 2 3 mm 3 Check attachment screws for deformation 4 If any damage is detected the damper must be replaced 5 Product manual IRB 2600 143 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 3 10 Inspecting dampers ...

Page 144: ...re to inspect the pressure relief valve Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 1 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 2 Continues on next page 144 Product manua...

Page 145: ...ontam inated or covered with litter 3 Clean if necessary Note Use a cloth or a brush 4 Product manual IRB 2600 145 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 3 11 Inspecting the pressure relief valve Continued ...

Page 146: ... page 441 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the 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 Note Action Check that the signal lamp is lit when motors...

Page 147: ... the cable connections 5 24V Measure the voltage in connectors motor axis 3 6 Check the cabling If a fault is detected re place 7 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 8 Product manual IRB 2600 147 3HAC035504 001 Revision Q Copyri...

Page 148: ...iness 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 ge...

Page 149: ...600 12 1 85 IRB 2600ID 15 1 85 IRB 2600ID 8 2 0 Nipple for quick connect fitting with o ring Used on the axis 1 and axis 2 gearboxes IRB 2600 Type C 20 1 65 IRB 2600 Type C 12 1 65 Used when the robot is fitted in a suspended position Expansion container gearbox axis 1 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 3HAC0...

Page 150: ...d 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 t...

Page 151: ...rboxes on page 148 Lubricating oil The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel One example of oil dispenser can be found in section Type of lubrication in gearboxes on page 148 Oil dispenser Content is defined in section Standard tools on page 441 Standard toolkit Continues on next page Product manual IRB 2600 151 3HAC035504 001 Revision Q...

Page 152: ...please read the safety information in the section Safety risks during work with gearbox lubricants oil or grease on page 39 2 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 3 xx1800001136 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 connec...

Page 153: ...he temperature of the oil One example of oil dispenser can be found in section Type of lubrication in gearboxes on page 148 Different position due to design differ ences xx1800001137 Remove the plug from the vent hole 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 6 xx1800001139 Suck out the oil with the oil ...

Page 154: ...ing torque 3 8 Nm xx1800001138 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 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 11 Continues on next page 154 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All...

Page 155: ...upply air pressure supply to the robot before entering the robot working area 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 Continues on next page Product manual IRB 2600 155 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reser...

Page 156: ... 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 5 Different position due to design differ ences xx1800001137 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 Open the oil plug filling 6 xx1800001139 Continues on next page 156 Product manual IRB 2600 3HAC03550...

Page 157: ... level is de scribed in section Inspecting oil level axis 1 gearbox on page 119 Inspect the oil level 8 xx1800001136 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 9 Tightening torque 24 Nm Refit the oil plug 10 Different position due to design differ ences xx1800001137 xx1800001139 Product manual IRB 2600 157 3HAC0355...

Page 158: ...he 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 A B xx1200000883 Oil plug venting A Oil plug draining and filling B Required equipment Note Equipment 3HAC029646 001 Oil plug sealing washer gearbox See section Type of lubrication in gearboxes on page 148 Lubricating oil The capacity of the vessel must be sufficient to take...

Page 159: ...area 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 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 3 See Required equipment on page 158 xx180000...

Page 160: ... Make a note how much oil was drained The same amount shall later be refilled Let the oil drain until the gearbox is empty Note There will be some oil left in the gearbox after draining Measure the volume of the drained oil in the vessel 10 Remove the hose and clean it 11 Filling oil axis 1 gearbox Use this procedure to fill the gearbox with oil Note Action DANGER Turn off all electric power suppl...

Page 161: ...the oil plug for venting 5 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 148 Prepare oil change equipment with the same amount of lubrication oil that was drained Note The amount of oil to be filled depends on the amount previously being drained 6 How to inspect the oil level is de scribed in section Inspecting oil level axis 1 gearbox on pag...

Page 162: ... container for oil must be fitted on gearbox axis 1 xx0900000129 Expansion container A 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 3HAC035...

Page 163: ...he manipulator is being taken down when changing oil Required equipment Note Equipment 3HAC029646 001 Oil plug sealing washer gearbox Information about the oil is found in Technical reference manual Lubrication in gearboxes Lubricating oil See Type and amount of oil in gearboxes on page 148 The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel To be...

Page 164: ...excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 3 See the figure in Location of oil plugs on page 163 Either connect a nipple to the quick connect fitting in the hole for draining or remove the quick connect fitting 4 See the figure in Location of oil plugs on page 163 Note Drainage will be quicker if the oil plug filling is removed Ope...

Page 165: ...ower supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 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 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the ...

Page 166: ...t the oil level is described in section Inspecting the oil level axis 2 gearbox on page 124 Inspect the oil level 6 Tightening torque 24 Nm Refit oil plug 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 7 166 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 3 M...

Page 167: ...rboxes Lubricating oil See Type and amount of oil in gearboxes on page 148 The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel One example of oil dispenser can be found in section Type of lubrication in gearboxes on page 148 Oil dispenser xx1200000862 Funnel Content is defined in section Standard tools on page 441 Standard toolkit Continues on nex...

Page 168: ... 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 See the figure in Location of oil plugs on page167 Open the oil plug armhouse 5 See the figure in Location of oil plugs on page167 Open the oil plug ...

Page 169: ...n xx0800000329 Move the upper arm to a position where the wrist is pointing towards the floor as shown in the figure 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...

Page 170: ...l in gearboxes on page 148 Refill the gearbox with lubricating oil Tip Use a funnel 6 Note The amount of oil to be filled depends on the amount previously being drained How to inspect oil is described in section Inspecting the oil level axis 3 gearbox on page 127 Inspect the oil level 7 Tightening torque in armhouse 10 Nm in gearbox 3 Nm Refit the oil plug 8 170 Product manual IRB 2600 3HAC035504 ...

Page 171: ...he gear box see section Type of lubrication in gear boxes on page 148 Lubricating oil The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel Used for venting the gearbox during draining A suitable hose would be a hose normally used for compressed air Plastic hose Length minimum 300 mm Diameter 5 mm xx1200000862 Funnel Content is defined in section St...

Page 172: ...n 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 See the figure in Location of oil plugs on page 171 Open oil plug draining 5 Note Draining is time consuming Elapsed time varies depending on the temperature of the oil Drain the gearbox oil using an oil collecting vessel Tip Insert a compre...

Page 173: ...ure 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 Continues on next page Product manual IRB 2600 17...

Page 174: ...to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 148 Refill the gearbox with lubricating oil Tip Use a funnel 6 Note The amount of oil to be filled depends on the amount previously being drained Tightening torque 10 Nm Refit the oil plug 7 174 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3...

Page 175: ... 12 20 kg xx0900000139 Oil plug tilthouse A Oil plug wrist also used as air inlet when draining from oil plug A B Wrist IRB 2600ID shown in position for filling xx1000000987 Oil plug filling A Oil plug draining B Continues on next page Product manual IRB 2600 175 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 4 7 Changing oil axes 5 and 6 gearboxes ...

Page 176: ...cess pressure Note Action Move the upper arm to a horizontal position 1 Turn axis 4 to the calibration position 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 duri...

Page 177: ...g please read the safety information in the section Safety risks during work with gearbox lubricants oil or grease on page 39 4 See in figure Location of oil plugs on page 175 Open the oil plug tilthouse 5 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 148 Refill the gearbox with lubrication oil Note The amount of oil to be filled depends on t...

Page 178: ...n Tightening torque 10 Nm Refit the oil plugs 9 178 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 4 7 Changing oil axes 5 and 6 gearboxes Continued ...

Page 179: ...6 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 r...

Page 180: ...x0800000322 SMB battery 2 pole battery contact A Battery cover B Attachment screws C SMB battery cable D How to arrange the battery cable E Continues on next page 180 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 4 8 Replacing SMB battery Continued ...

Page 181: ...ttery includes protection circuits Replace it only with given spare part no or an ABB approved equivalent SMB battery pack See Spare part lists on page 445 Content is defined in section Standard tools on page 441 Standard toolkit See chapter Circuit diagram on page 447 Circuit diagram Removing SMB battery Use this procedure to remove the SMB battery Note Action This is done in order to facilitate ...

Page 182: ...ure in Location of SMB battery on page 180 Disconnect the battery cable and remove the bat tery 6 How to dispose of the used SMB battery see chapter Decommissioning on page 423 7 Refitting SMB battery Use this procedure to refit the SMB battery Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 E...

Page 183: ...its attachment screws 5 Detailed in Updating revolution counters on page 399 Update the revolution counter 6 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 7 Product manual IRB 2600 183 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 3 Maintenan...

Page 184: ...ection 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 tha...

Page 185: ...ctions 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 m2 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 minI I Typical t...

Page 186: ... 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 186 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 5 1 Cleaning the IRB 2600 IRB 2600 ID Continued ...

Page 187: ...m 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 r...

Page 188: ...he pressure must under no circumstance be higher than 0 25 bar 20 25 kPa Also during the time when the pressure is raised 3 0 2 0 25 bar 20 25 kPa Disconnect the compressed air supply 4 If the compressed air is signific antly colder or warmer than the gearbox to be tested a slight pressure increase or decrease may occur This is quite normal Wait for approximately 8 10 minutes and make sure that no...

Page 189: ...o any stresses during the assembly work 3 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 Note Action Tension the bearing gradually until the...

Page 190: ...arted 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 190 Product manual IRB 2...

Page 191: ... correct type provided with cutting edge There is no damage to the sealing edge feel with a fingernail 1 Inspect the sealing surface before mounting If scratches or damage are found the seal must be replaced since it may result in future leakage 2 Article number is specified in Equipment on page191 Lubricate the seal with grease just before fitting Not too early there is a risk of dirt and foreign...

Page 192: ...nly when fastening the flange joint 4 O rings The following procedure describes how to fit o rings Note Action Ensure that the correct o ring size is used 1 Defective o rings including damaged or deformed o rings may not be used Check the o ring for surface defects burrs shape accuracy or deformation 2 Defective o rings may not be used Check the o ring grooves 3 The grooves must be geometrically c...

Page 193: ...52 001 Touch up paint Standard Foundry Plus ABB Orange Removing Description Action xx0900000121 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 1 Carefully grind the paint edge that is left on the structure to a smooth surface 2 Product manual IRB 2600 193 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights re...

Page 194: ...e to the robot Elimination To eliminate the danger after service work has been performed inside the SMB recess follow the procedure below Action Make sure the power is turned off 1 Remove the push button guard if necessary 2 Verify that the push buttons of the brake release unit are working by pressing them down one by one 3 Make sure none of the buttons are jammed in the tube If a button gets jam...

Page 195: ...able 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 arm...

Page 196: ...harness base and frame xx0900000009 Cover base A Bracket B Cable harness C Axis 1 motor cable D Axis 2 motor cable E Axis 2 motor F Axis 1 motor G Continues on next page 196 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 3 1 Removing the complete cable harness Continued ...

Page 197: ...on socket Content is defined in section Standard tools on page 441 Standard toolkit These procedures include references to the tools required Other tools and procedures may be re quired See references to these procedures in the step by step instructions below Continues on next page Product manual IRB 2600 197 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 3 1 Remo...

Page 198: ...t Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 404 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the...

Page 199: ...ver base has been removed 3 Parts A R1 CP CS B R1 MP C Air hose connector D Position of R1 ETHERNET if used E R1 SMB A B C xx0800000456 A Base B Cover base C Attachment screws Remove the cover base 4 Disconnect connectors on the brake release unit X8 X9 X10 5 Continues on next page Product manual IRB 2600 199 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 3 1 Remo...

Page 200: ...hin 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 similar xx1200000888 8 Unscrew the nut for the air connection on the inside of the bracket 9 Continues on next page 200 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 3 1 Removing the compl...

Page 201: ...en performing this procedure in order not to damage cables or other components 11 Parts A Bracket at a 90 angle B Base A B C D xx1200000890 A R1 CP CS B R1 MP C Air hose connector D R1 SMB Remove connectors and air hose connector completely from the bracket R1 CP CS R1 MP R1 SMB Air hose connector R1 ETHERNET if used 12 How to remove the SMB unit is described in section Removing the SMB unit on pa...

Page 202: ...ections of R1 SMB1 2 R1 SMB2 6 15 Parts A Screen connection 4 pcs xx0900000015 Disconnect the earth cables 16 Parts A Earth B Distance screws Continues on next page 202 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 3 1 Removing the complete cable harness Continued ...

Page 203: ... frame Tip Before starting this procedure first remove the cable harness in the base See Removing the complete cable harness on page 195 Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 How to remove the motor cables is de scribed in section Removing motors on page 301 Disconnect the motor cabl...

Page 204: ...e Use caution when performing this proced ure in order not to damage cables or other components 6 How to remove the cable package from the lower arm and armhouse is described in section Removing cable harness in lower arm and armhouse on page 204 Continue the removal of the cable package from the lower arm and armhouse 7 Removing cable harness in lower arm and armhouse Use this procedure to remove...

Page 205: ...ess on page196 Cable harness lower arm Cut the cable strap on the lower arm 2 A B C D xx0900000020 Remove the brackets on the lower arm 3 Parts A Bracket lower arm B Bracket lower arm C Bracket armhouse D Cable bracket Continues on next page Product manual IRB 2600 205 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 3 1 Removing the complete cable harness Continued...

Page 206: ...e removal of the cable package by disconnecting the motor cables of the axis 3 axis 4 axis 5 and axis 6 motors 7 How to remove the motor cables from motors axes 3 and 4 see section Removing motors on page 301 IRB 2600ID Continue the removal of the cable package by disconnecting the motor cables of mo tors axes 3 and 4 8 See section Replacing the cable harness in the upper arm IRB 2600ID on page222...

Page 207: ...ll 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 armhou...

Page 208: ...arness base and frame xx0900000009 Cover base A Bracket B Cable harness C Axis 1 motor cable D Axis 2 motor cable E Axis 2 motor F Axis 1 motor G Continues on next page 208 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 3 2 Refitting the complete cable harness Continued ...

Page 209: ...ep well hexagon socket Content is defined in section Standard tools on page 441 Standard toolkit These procedures include references to the tools required Other tools and procedures may be re quired See references to these procedures in the step by step instructions below Shell Alvania WR2 Cable grease Continues on next page Product manual IRB 2600 209 3HAC035504 001 Revision Q Copyright 2009 2018...

Page 210: ...and base are presented below Chose one of the methods 3 A C E F B D 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 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 Tip In order to protect the connectors...

Page 211: ...orming 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 Note Check that cables and air hose are placed as shown in the figure above Use this procedure when fitting a new cable harness Without removing the plastic arou...

Page 212: ...0016 Secure the cover to the frame with its attach ment screws 9 Parts A Frame B Hole in frame C Cover How to refit the motor cables is described in section Refitting motors on page 313 Connect the axis 1 and axis 2 motor cables 10 Continues on next page 212 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 3 2 Refitting the complete cable har...

Page 213: ...he cable harness in the base 12 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 Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot ...

Page 214: ...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 3 Parts A Base B Attachment screws 2 pcs C Bracket Continues on next page 214 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 3 2 Refitting the co...

Page 215: ...nit on page 238 Refit the SMB unit 6 A xx0900000035 Refit the cables with the screen connec tions 7 Parts A Screen connections 4 pcs xx0900000013 Tip When refitting connectors on the bracket put it at a 90 angle 8 Parts A Bracket B Base Continues on next page Product manual IRB 2600 215 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 3 2 Refitting the complete cabl...

Page 216: ...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 10 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 216 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights re...

Page 217: ...or 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 xx1200000888 13 Refit the air hose connector on the bracket Note Check that there is no leakage from the air hose 14 Reconnect the battery cable 15 Continues on next page Product manual IRB 2600 217 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights re...

Page 218: ...ss on page 208 Refit the bracket on the frame 19 See the figure in Location of the cable harness on page 208 Refit the cable straps securing the cable harness to the frame 20 How to refit the cable harness on the lower arm and armhouse is described in section Refitting the cable harness in the lower arm and armhouse on page 219 Continue the refitting of the cable package on lower arm and armhouse ...

Page 219: ... air pressure supply to the robot before entering the robot working area 1 A B C D xx0900000020 Secure the brackets on the lower arm 2 Parts A Bracket lower arm B Bracket lower arm C Bracket armhouse D Cable bracket See the figure in Location of the cable harness on page208 Cable harness lower arm Refit the cable straps securing the cable harness to the lower arm 3 Push the cable harness carefully...

Page 220: ...otors on page 313 IRB 2600 Standard Reconnect the axis 3 axis 4 axis 5 and axis 6 motor cables 7 How to connect the axis 3 and axis 4 mo tor cables see section Refitting motors on page 313 IRB 2600ID Reconnect the axis 3 and axis 4 motor cables 8 See section Replacing the cable harness in the upper arm IRB 2600ID on page222 IRB 2600ID Refit the cable package in the upper arm 9 Continues on next pa...

Page 221: ...alibration on page 391 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 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 12 Product manual IRB 2600 221 3HAC035504 001 Revision Q Copyright 200...

Page 222: ...acing 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 Bracket inside armhouse A Cover B Cable harness C Connectors motor axis 6 2 pcs D Bracket securing cable harness to arm tube E Continues on next page 222 Product manual IRB 2600 3HAC035504 001 Revis...

Page 223: ...al cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calib...

Page 224: ... crane or similar 5 Remove the cover on the arm house 6 A B C D xx1000000991 Disconnect the cables to motors axes 3 4 5 and 6 7 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 See section Removing the wrist unit on page343 Note No need to remove the axis 6 motor Only the motor cables need to be discon...

Page 225: ...p C O ring D Distance ring E Bracket F Cover xx1000000934 Remove the two VK covers covering the attachment screws securing the cable har ness to the arm tube 10 Parts A VK covers 2 pcs Continues on next page Product manual IRB 2600 225 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 ...

Page 226: ...e of the arm house a little enough to be able to disconnect cables to the axis 5 motor 14 How to remove the motor cables see Replacing motor axis 5 IRB 2600ID on page 329 Note No need to remove motor axis 5 Disconnect connectors to motor axis 5 15 CAUTION Pull the cable harness out carefully The space in the armhouse is cramp Pull carefully out the cable harness off the arm house at the same time ...

Page 227: ...s Use this procedure to refit the cable harness Information Action xx1000000996 Push carefully in the cables to the connect ors for motors axes 3 4 5 and 6 through the hole in the arm house 1 Part A Hole for cables Continues on next page Product manual IRB 2600 227 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 ...

Page 228: ...ness spiral at this point 2 Parts A Cable harness spiral B Attachment screws 8 pcs M8x25 quality Steel 12 9 Gleitmo xx1000001006 Apply flange sealant on the surface where the cover shall be fitted See figure 3 Part A Flange sealant Loctite 574 12340011 116 Continues on next page 228 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 3 3 Replaci...

Page 229: ...rane or similar and lift the upper arm tube almost all the way into its position 5 Push the motor cables for the axis 6 motor through the upper arm tube 6 xx1000000998 Connect the connectors to the axis 5 mo tor 7 Fit the bracket A to the arm house 8 Parts A Bracket B Attachment screws 2 pcs C Connectors motor axis 5 D Motor axis 5 Continues on next page Product manual IRB 2600 229 3HAC035504 001 ...

Page 230: ...itted correctly Check that axis 4 is in the same position as it was when the cable harness was re moved 10 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 11 xx1000001004 Hold the cable harness with one hand and cut the ...

Page 231: ...nt 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 14 Parts A Surface where Sikaflex 521FC shall be applied B Surface where Loctite 574 shall be applied Tightening torque 35 Nm Secure the upper arm tube with its attach ment screws 15 See section Refitting the wrist on page 348 Refit the wrist 16 Cont...

Page 232: ...he o ring and the mechanical stop D with one screw 20 A B C D xx1000000991 Connect the connectors to motors axes 3 4 5 and 6 in the arm house 21 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 Tightening torque 14 Nm Refit the cover on the arm house with its attachment screws 22 Continues on next page...

Page 233: ... is described in Calibrating with Axis Calibration method on page 403 General calibration information is included in section Calibration on page 391 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 25 Product manual IRB 2600 233 3HAC035504 001 Revision Q Copyright 2009 ...

Page 234: ...e 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 Note Equipment Content is defined in section Standard tools on page 441 Standard toolkit Continues on next page 234 Produ...

Page 235: ...s reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 404 If no previous reference values exist and no new reference values can be c...

Page 236: ...cs Cut the cable straps securing the battery cable 4 xx0900000100 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 5 Parts A Screw to be removed B Screws to be unscrewed a little 3 pcs Continues on next page 236 Product manual IRB 2600 3HAC035504 001 Revision...

Page 237: ...ct cable clamps 7 Parts A Cable clamps See the figure in Location of SMB unit on page 234 Unscrew the attachment screws securing the SMB unit just enough to be able to re move the SMB unit 8 Remove the SMB unit 9 xx1700000993 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 10 See the figure in Location of SM...

Page 238: ...n Location of SMB unit on page 234 Place the SMB unit on its attachment screws 3 Secure the SMB unit with its attachment screws 4 A xx0900000035 Refit the cable clamps 5 Parts A Cable clamps See the figure in Location of SMB unit on page 234 Put back the cable harness in the base and refit the bracket on the distance screws Note Use caution when performing this procedure order not to damage cables...

Page 239: ...ion Pendulum enclosed with the calibration tools Recalibrate the robot 10 Axis Calibration is described in Calibrating with Axis Calibration method on page403 General calibration information is included in section Calibration on page 391 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 d...

Page 240: ...1 Brake release board A Connectors on push button board The connectors X8 X9 and X10 are placed on the push button board as shown in the figure below X9 X8 X10 xx1700000978 Continues on next page 240 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 3 5 Replacing the brake release board ...

Page 241: ...anual spare parts IRB 2600 Includes brake release board and harness Removing the brake release board Use this procedure to remove the brake release board Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the s...

Page 242: ...X10 xx1700000978 Disconnect connectors X8 X9 and X10 from the brake release board 6 Remove the nuts securing the brake release board 7 Remove the brake release board 8 Refitting the brake release board Use this procedure to refit the brake release board Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working...

Page 243: ...wn properly 4 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 5 A B C xx0800000456 Use caution when pushing the base cover into position while at the same time checking t...

Page 244: ...6 one at a time to make sure that the buttons are moving freely and do not stay in any locked position 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 11 244 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 3 5...

Page 245: ...the figure The figure shows IRB 2600 Standard but is also valid for IRB 2600ID A B xx1100000947 Upper arm A Attachment screws M8x40 quality steel 12 9 gleitmo 12 pcs B Continues on next page Product manual IRB 2600 245 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 4 1 Replacing the complete upper arm ...

Page 246: ...ew in the rotating lifting point to bottom 3 pcs Roundslings Lengths 1 5 m 1 pc run around the wrist unit 2 m 2 pcs Lifting capacity 500 kg 2 pcs Used to prevent the roundsling at the wrist from sliding Screws Dimension M6 Length 70 mm Quality 8 8 M8 2 pcs Guide pins Content is defined in section Standard tools on page 441 Standard toolkit These procedures include references to the tools required ...

Page 247: ...s possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 404 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be calibrated wi...

Page 248: ...f 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 6 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 7 How to disconnect cables from motors is detailed in sections Removing motors on page 301 Disconnect all...

Page 249: ...cket Using caution pull the cable package out of the hole where the cable bracket was fit ted 12 See the figure in 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 Remove the attachment screws securing the upper arm to the lower arm 13 Continues on next page Product manual IRB 2600 249 3HAC035504 001 Revision Q Cop...

Page 250: ...ment on page 246 Fit two rotating lifting points to the attachment holes in the arm house see the figure Secure the lifting point tightly against the arm house but at the same time mak ing sure that the screw does not bottom Use an extra washer if the screw does bottom 2 The figures show IRB 4600 but the same attachment holes are used also for IRB 2600 xx1100000565 Tightening torque 30 Nm xx110000...

Page 251: ...oundslings 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 A C B D xx1100000567 Screws to prevent the roundsling from sliding 2 pcs A Rotating lifting point 2 pcs B Roundsling around wrist unit C Length 1 5 m Roundsling attached to arm house 2 pcs D Length 2 m Continues on...

Page 252: ...h the lifting accessories to the upper arm 4 Specified in Required equipment on page 246 Fit guide pins to the upper arm 5 Lift the upper arm to the robot using an overhead crane 6 Release the brakes of the axis 3 motor 7 See the figure in Location of the complete upper arm on page 245 Tightening torque 35 Nm Refit the upper arm to the lower arm with its attachment screws It may be necessary to tu...

Page 253: ...bles is detailed in sections Refitting motors on page 313 Reconnect all motor cables 11 xx0800000335 Refit the bracket on the tubular shaft unit 12 Parts A Tubular shaft unit B Attachment screws M6x16 qual ity 8 8 A2F 2 pcs C Bracket Refit the signal lamp if used 13 Continues on next page Product manual IRB 2600 253 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 4...

Page 254: ...n page403 General calibration information is included in section Calibration on page 391 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 page28 15 254 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 4 1 Replacing the com...

Page 255: ...Tubular shaft unit D Wrist E Required equipment Note Equipment 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 2 pcs Dimension M8 Guide pins Isopropanol Cleaning agent Loctite 574 Sealing liquid Content is defined in section Standard tools on page 441 Standard toolkit Continues on next page Product manual IRB 2600 255 3HAC035504...

Page 256: ...e val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 404 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about r...

Page 257: ... 8 A2F 2 pcs C Bracket Place the cable package in a way that it will not be damaged in the continued removal procedure 6 How to remove motors is described in section Removing motors on page 301 Remove motors axes 4 5 and 6 7 How to remove the wrist unit is detailed in section Removal of wrist unit on page 263 Tip If only the tubular shaft unit shall be re placed it is a good idea to remove the wri...

Page 258: ...bular shaft unit 11 Note There are two parallel pins guiding the tubular shaft unit into its place See figure in Replacing complete tubular shaft unit on page 255 Remove the tubular shaft unit using caution The tubular shaft unit is fitted with Loctite CAUTION Do not damage the gears when removing the tubular shaft unit 12 CAUTION Remaining oil will drain out from the gear box cavity when the tubu...

Page 259: ... used must be sized accordingly 4 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 s...

Page 260: ...lar shaft unit B Attachment screws M6x16 qual ity 8 8 A2F 2 pcs C Bracket How to refit the wrist unit is detailed in section Refitting of wrist unit on page 265 If the wrist unit has been removed from the tubular shaft unit refit it now 12 How to refill oil in gearbox is described in section Changing the oil axis 4 gearbox on page 171 Refill gearbox axis 4 with oil 13 Pendulum Calibration is descr...

Page 261: ... the first test run These are further detailed in the section First test run may cause injury or damage on page28 15 Product manual IRB 2600 261 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 4 2 Replacing complete tubular shaft unit Continued ...

Page 262: ...ing washer conical 8 4x18x2 quality steel mZn12c 5 pcs C Gears D Wrist unit E O ring Placed on the wrist Not visible here F Guide pin G only available for robots that are calibrated with Axis Calibration not available on IRB 2600ID Required equipment Note Equipment For spare parts no see Spare parts Upper arm 2 05 2 50 2 55 in Product manual spare parts IRB 2600 Wrist unit For spare parts no see S...

Page 263: ...t is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 404 If no previo...

Page 264: ...Safety risks during work with gearbox lubricants oil or grease on page 39 4 CAUTION The robot wrist unit weighs 15 kg All lifting accessories used must be sized ac cordingly 5 See the figure in Location of wrist unit on page 262 Remove the attachment screws and carefully remove the wrist unit CAUTION Do not damage gears 6 WARNING The wrist unit is filled with oil Perform removal with care See the ...

Page 265: ...ion method 2 xx1600000689 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 3 Verify that the parallel pin sticks out from the wrist according to the meas urement given below 4 0 0 5 xx1600000...

Page 266: ...ge gears 8 CAUTION Make sure that the o ring stays in place on the wrist unit xx1000000223 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 page313 9 Parts A Gears on drive shaft unit axes 5 6 B Gears on the wrist See the figure in Location o...

Page 267: ...on page 175 Refill oil in gearbox axes 5 6 13 Pendulum Calibration is described in Operating manual Calibration Pendu lum enclosed with the calibration tools Recalibrate the robot 14 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 DANGER Make sure all safety requirements are met w...

Page 268: ...s to the tools re quired Other tools and procedures may be required See references to these procedures in the step by step instructions below Measurement axis 5 The procedure below details how to measure the play of axis 5 Information Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Move the robot t...

Page 269: ...rection as shown in the figure to the right 6 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 The maximum play allowed at the given 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 Remove the load and measure the play by reading the dial indicator 7 Product manual IRB 2600 269 3HAC035504 001 Revision Q Copyrig...

Page 270: ...ces to these procedures in the step by step instructions below Measurement axis 6 The procedure below details how to measure the play in axis 6 Information Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Article number is specified in Required equipment on page 270 Fit the measuring tool play to th...

Page 271: ...figure to the right 6 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 The maximum play allowed at the given 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 Remove the load and measure the play by reading the dial indicator 7 Product manual IRB 2600 271 3HAC035504 001 Revision Q Co...

Page 272: ...eferences to the tools re quired Other tools and procedures may be required See references to these procedures in the step by step instructions below Measurement axis 5 Use this procedure to measure the play of axis 5 Information Action Move the robot to calibration position Turn axis 4 to 90 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot bef...

Page 273: ... of the measuring tool shaft 7 Distance from the center line of axis 5 IRB 2600ID 15 1 85 A 235 mm IRB 2600ID 8 2 00 A 300 mm Verify that axis 5 is put in calibration posi tion 8 F A xx1100000691 A 140 mm Apply load F 30N with a dynamometer at the distance A from the turning disk 9 Remove the load and set the dial indicator to zero 10 Continues on next page Product manual IRB 2600 273 3HAC035504 0...

Page 274: ...D 15 1 85 0 25 mm IRB 2600ID 8 2 00 0 32 mm Remove the load and measure the play by reading the dial indicator 12 Turn axis 5 to 90 13 Repeat step 9 to step 12 14 Turn axis 5 to 90 15 Repeat step 9 to step 12 16 274 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 4 6 Measuring the play axis 5 ID upper arm Continued ...

Page 275: ...ferences to the tools re quired Other tools and procedures may be required See references to these procedures in the step by step instructions below Measurement axis 6 Use this procedure to measure the play of axis 6 Information Action Move the robot to calibration position Turn axis 4 to 90 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot befo...

Page 276: ...om the rotation center of axis 6 A 100 mm Verify that axis 6 is put in calibration posi tion 8 A F B xx1100000692 A 100 mm dial indicator B 140 mm 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 9 Remove the load and set the dial indicator to zero 10 Continues on next page 276 Product manual IRB 2600 3HAC0...

Page 277: ...maximum play allowed is IRB 2600ID 15 1 85 0 20 mm IRB 2600ID 8 2 00 0 22 mm Remove the load and measure the play by reading the dial indicator 12 Turn axis 6 to 180 13 Repeat step 9 to step 12 14 Product manual IRB 2600 277 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 4 7 Measuring the play axis 6 ID upper arm Continued ...

Page 278: ... C D E F G H J xx0800000360 Upper arm A Gearbox axis 3 B Lower arm C Washer 12 pcs D Attachment screws M8x40 quality Steel 12 9 Gleitmo 12 pcs E Frame F Gearbox axis 2 G Washer 17 pcs H Attachment screws M8x40 quality Steel 12 9 Gleitmo 17 pcs J Continues on next page 278 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the lowe...

Page 279: ...chment screws M8x40 quality Steel 12 9 Gleitmo 12 pcs E Frame F Gearbox axis 2 G Washer 3 pcs H Attachment screws M10x40 12 9 Gleitmo 603 Geo500 15 pcs J Continues on next page Product manual IRB 2600 279 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the lower arm Continued ...

Page 280: ...on routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis C...

Page 281: ...cept in the base 4 Secure the upper arm with a roundsling in an overhead crane 5 How to remove the complete upper arm is described in section Removing the complete upper arm on page 247 Remove the complete upper arm and put it on a loading pallet 6 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 2...

Page 282: ...2600ID 15 1 85 IRB 2600ID 8 2 0 xx1800000935 Remove the attachment screws and wash ers that secure the lower arm to the axis 2 gearbox 9 Valid for IRB 2600 Type C 20 1 65 IRB 2600 Type C 12 1 65 xx1800000934 Remove the lower arm 10 Continues on next page 282 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the lower arm Continue...

Page 283: ...00ID 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 2 xx0800000379 Fit a lifting lug in one of the upper holes in the lower arm for the attachment screws 3 Parts A Lifting lug Secure the lower arm with a roundsling in an overhead crane and lift it to the robot 4 Continues on next page Product manual IRB 2600 283...

Page 284: ...ue 50 Nm 5 Nm and 90 angle 10 xx1800000934 Secure the complete upper arm with round slings in an overhead crane and lift it to the robot 6 How to refit the complete upper arm is described in section Refitting the complete upper arm on page 252 Refit the complete upper arm 7 How to refit the cable package in frame lower arm and armhouse is described in sections Refitting the cable harness in the fr...

Page 285: ...od on page 403 General calibration information is included in section Calibration on page 391 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 page28 10 Product manual IRB 2600 285 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing th...

Page 286: ...sed if bracket D is installed C Bracket D Stop pin E Required equipment Note Equipment For spare parts number see Spare parts Frame and base in Product manual spare parts IRB 2600 Stop pin Content is defined in section Standard tools on page 441 Standard toolkit Continues on next page 286 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 6 1 R...

Page 287: ...hment screws securing the bracket and stop pin 2 See the figure in Location of stop pin axis 1 on page 286 Remove the bracket and stop pin 3 Refitting the stop pin axis 1 Use this procedure to refit the stop pin axis 1 Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 See the figure in Location ...

Page 288: ...D on the frame with its attachment screws Use Locking liquid 4 Tightening torque 10 Nm See the figure in Location of stop pin axis 1 on page 286 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 page28 5 288 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 A...

Page 289: ...nd the complete arm system is shown in the figure The figure shows IRB 2600 Standard but is also valid for IRB 2600ID xx0900000320 Base A Frame B Lower arm C Arm house part of complete upper arm D Tubular shaft part of complete upper arm E Wrist unit part of complete upper arm F Continues on next page Product manual IRB 2600 289 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved...

Page 290: ...lid for IRB 2600 Type C 20 1 65 IRB 2600 Type C 12 1 65 Lifting eye M12 3 pcs Content is defined in section Standard tools on page 441 Standard toolkit These procedures include refer ences to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Included with spare part base 3 pcs 3HAC065190 001 Gasket Loctite 7063 C...

Page 291: ...ires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 404 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be calibrated...

Page 292: ...ower arm of the robot Tip Wrap up the cabling against the frame to keep it undamaged during the remaining work 5 Dimensions are specified in Required equipment on page 290 A B xx1800001211 A Roundsling 1 5 m B Roundsling 2 m Secure the robot with roundslings in an overhead crane Stretch the roundslings so that the robot weight is secured when removing founda tion bolts in next step 6 CAUTION The I...

Page 293: ... underneath the robot Keep the lifting accessories stretched for extra safety precautions 9 xx1800000875 Lower the robot and secure the support legs to the foundation using bolts and washers 10 xx1800000879 Remove the cover plate at the bottom of the base 11 xx1800000881 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 ...

Page 294: ...IRB 2600ID 8 2 0 Fit two guide pins in opposite holes in the axis 1 gearbox 14 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 CAUTION The arm system and axis 1 gearbox weighs 235 kg together All lifting accessories must be sized accord ingly 15 Continues on next page 294 Product manual...

Page 295: ...0 12 1 65 IRB 2600 12 1 85 IRB 2600ID 15 1 85 IRB 2600ID 8 2 0 Fit three lifting eyes to the base and secure with roundslings in an overhead crane or similar 18 Lifting eye M8 Valid for IRB 2600 Type C 20 1 65 IRB 2600 Type C 12 1 65 Lifting eye M12 xx1800000931 xx1800000885 Remove the support legs attachments screws and remove the base from the sup port legs 19 Continues on next page Product manu...

Page 296: ...ifting eye M8 Valid for IRB 2600 Type C 20 1 65 IRB 2600 Type C 12 1 65 Lifting eye M12 xx1800000885 Fit the new base to the support legs and secure with the attachment screws 3 Tip Use Loctite 7063 or similar for cleaning 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 residues of old Loctite and other contaminations from surfaces before app...

Page 297: ...800000797 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 6 CAUTION The arm system and axis 1 gearbox weighs 235 kg together All lifting accessories must be sized accord ingly 7 Lift the arm system to the mounting site 8 Continues on next page Product manual IRB 2600 297 3HAC035504 001 Revision Q Copy...

Page 298: ...RB 2600 12 1 85 IRB 2600ID 15 1 85 IRB 2600ID 8 2 0 Lower the arm system against the base and secure with the attachment screws and washers 10 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 ...

Page 299: ...s xx1800000879 Refit the cover plate at the bottom of the base with its attachment screws 13 xx1800000875 Remove the screws that secure the support legs to the foundation DANGER Stretch the roundslings to make sure that the robot weight is secured 14 xx1800000874 Lift the complete robot and remove the support legs from the base 15 Continues on next page Product manual IRB 2600 299 3HAC035504 001 R...

Page 300: ...s described in Calibrating with Axis Calibration method on page403 General calibration information is included in section Calibration on page 391 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 page28 18 300 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018...

Page 301: ...d 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 Attachment screws M5x16 quality Steel 8 A2F 7 pcs A Motor cover B 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 32...

Page 302: ...f each motor A 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 B Axis 3 motor C Axis 4 motor D Axis 5 motor E Axis 6 motor F O ring axis 4 axis 5 and axis 6 G Armhouse H Continues on next page 302 Product manual IRB 2600 3HAC...

Page 303: ...hment screws 4 pcs F Connectors motors axes 3 6 The figures shows the connectors in the armhouse IRB 2600 Standard Axes 3 6 IRB 2600ID Axes 3 4 Continues on next page Product manual IRB 2600 303 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 7 1 Removing motors Continued ...

Page 304: ...type B MP3 MP4 MP5 MP6 FB3 6 FB4 MP3 6 FB5 FB6 FB3 xx1400002568 Continues on next page 304 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 7 1 Removing motors Continued ...

Page 305: ...B 2600 Standard motor type A xx0900000367 Continues on next page Product manual IRB 2600 305 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 7 1 Removing motors Continued ...

Page 306: ...acement M6 length minimum 160 mm Extended reach hex bit socket head Content is defined in section Standard tools on page 441 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page 306 Product manual IRB 2600 3HAC035504 001 Revision Q Copyri...

Page 307: ... in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about refe...

Page 308: ... axis 2 to be sure that the lower arm rests in the end position 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 Note Actio...

Page 309: ...cedure 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 Note Action Decide which calibration routine to use and take actions accordingly prior to beginning the repair procedure 1 See Removing motors on page 301 Position of robot on page 308 Move the robot to the rec...

Page 310: ... applicable to axis 1 and axis 2 motors Remove the motor cover 7 See the figure in Location of axis 1 and axis 2 motors on page 301 Only applicable to axis 1 and axis 2 motors Remove the cable gland cover 8 See the figure in Location of axis 1 and axis 2 motors on page 301 Only applicable to axis 1 and axis 2 motors Remove the connection box Note Only needed if the motor shall be replaced with a n...

Page 311: ...r R2 MP5 Axis 6 motor R2 MP6 Connect to pins In order to release the brakes of the motor to be removed connect the 24 VDC power supply to the motor Only applicable to motors axes 2 and 3 Release the brake of axis 2 untill the lower arm firmly rests on the damper 12 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 ...

Page 312: ... the motor flange 15 CAUTION Lift the motor gently in order not to damage pinion or gears Remove the motor 16 See the figure in Location of axis 1 and axis 2 motors on page 301 Only applicable to motor axis 1 Cover the hole if replacement of motor axis 1 is not immediate in order to avoid contamina tion 17 See the figure in Location of axis 1 and axis 2 motors on page 301 Only applicable to motors...

Page 313: ...ID 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 Attachment screws M5x16 quality Steel 8 A2F 7 pcs A Motor cover B Axis 1 motor Attachment screws 4 pcs washers See Tightening torques and attachment...

Page 314: ...ifying the position of each motor A 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 B Axis 3 motor C Axis 4 motor D Axis 5 motor E Axis 6 motor F O ring axis 4 axis 5 and axis 6 G Armhouse H Continues on next page 314 Pro...

Page 315: ...ment screws 4 pcs F Connectors motors axes 3 6 The figures shows the connectors in the armhouse IRB 2600 Standard Axes 3 6 IRB 2600ID Axes 3 4 Continues on next page Product manual IRB 2600 315 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 7 2 Refitting motors Continued ...

Page 316: ...B6 FB3 xx1400002568 Note On IRB 2600 standard motor type B the connector FB6 shall be fitted in a 30 angle Continues on next page 316 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 7 2 Refitting motors Continued ...

Page 317: ...B 2600 Standard motor type A xx0900000367 Continues on next page Product manual IRB 2600 317 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 7 2 Refitting motors Continued ...

Page 318: ...ndard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below For art no see Reference information Lifting tool axis 2 For art no see Reference information Lifting tool axis 3 For spare part no see Spare part lists on page 445 Motors Continues on next page 318 Product manu...

Page 319: ... 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 xx1100000548 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 Axis 3 motor Mo...

Page 320: ... has not been drained 4 Tightening torques and attachment screws The table shows the tightening torques for all motors Tightening torque Quality Attachment screw Motor 22 Nm 8 8 A2F M8x25 Motor axis 1 22 Nm 8 8 A2F M8x25 Motor axis 2 22 Nm 8 8 A2F M8x25 Motor axis 3 10 Nm 8 8 A2F M6x25 Motor axis 4 10 Nm 8 8 A2F M6x25 Motor axis 5 10 Nm Standard 8 8 A2F M6x25 Standard Motor axis 6 6 Nm IRB 2600ID ...

Page 321: ... new o ring if damaged Connectors 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 In order to release the brakes connect the 24 VDC power supply 7 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 con...

Page 322: ...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 Information Action See Refitting motors on page 313 Preparations before the refitting of motors on page 320 Note Before starting the refitting of the motor first make the necessary preparations 1 Note Whenever parting mating mo...

Page 323: ...A Wire exit hole motor axis 3 xx0900000375 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 6 Parts A Wire exit hole motor axis 3 Continues on next page Product manual IRB 2600 323 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 7 2 Refitting motors Continued ...

Page 324: ...hole motor axis 4 E Signal cable exit hole motor axis 4 xx1000000992 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 8 Parts A Wire exit hole motor axis 3 B Motor axis 3 C Motor axis 4 D Wire exit hole motor axis 4 Continues on next page 324 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All ...

Page 325: ...Only applicable to motors axes 4 5 and 6 Adjust the play of the motor 11 Tightening torque and attachment screws are specified in the table Tightening torques and attach ment screws on page 320 Secure the motor with its attachment screws and washers Note Apply the correct tightening torque 12 Disconnect the brake release voltage 13 See the figure in Location of axis 1 and axis 2 motors on page 313...

Page 326: ... 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 xx1400002569 IRB 2600 Standard motor type B Note Connection bracket for FB6 shall be fitted in a 30 angle See figure 16 Continues on next page 326 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 7 2 Refitting...

Page 327: ...and and motor covers Make sure that the o ring is in place 19 How to fill oil in the gearbox is de scribed in sections Changing the oil axis 2 gearbox on page 163 Changing the oil axis 3 gearbox on page 167 Applicable to motors axis 2 Refill gearbox oil 20 If the gasket is damaged it need to be replaced Applicable to motors axes 3 4 5 and 6 Make sure that the gasket on the cover on the armhouse is...

Page 328: ...lum Calibration is described in Operating manual Calibration Pendu lum enclosed with the calibration tools Recalibrate the robot 23 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 DANGER Make sure all safety requirements are met when performing the first test run These are further...

Page 329: ...is located inside the upper arm tube as shown in the figure xx1000000877 Motor axis 6 A Motor axis 5 B Required equipment Note Art no Equipment 3HAC026759 001 Sikaflex 521FC Content is defined in section Standard tools on page 441 Standard toolkit These procedures include references to the tools re quired Other tools and procedures may be required See refer ences to these procedures in the step by...

Page 330: ...new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 404 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is t...

Page 331: ...rder to be able to discon nect cables to motor axis 6 6 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 d...

Page 332: ...ver See figure above Remove the bracket 9 See figure above Remove the cover on the upper arm tube 10 xx1000000934 Remove the two VK covers covering the attachment screws securing the cable har ness to the arm tube 11 Parts A VK covers 2 pcs Continues on next page 332 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 7 3 Replacing motor axis 5 ...

Page 333: ... armhouse 13 Parts A Attachment screws 8 pcs xx1000000939 Unscrew the attachment screws securing the cable harness bracket to the upper arm tube Note The arm tube is not shown 14 Parts A Motor axis 5 B Cover C Bracket inside armhouse D Attachment screws 2 pcs E Bracket upper arm tube Continues on next page Product manual IRB 2600 333 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights res...

Page 334: ... axis 5 17 Parts A Bracket B Attachment screws 2 pcs C Connectors motor axis 5 D Motor axis 5 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 18 Remove the upper arm tube 19 xx1000000938 Secure the upper arm tube with motor axis 5 pointing upwards This is done in order to avoid draining the oil when ...

Page 335: ...xx1000000937 Tighten the attachment screws just enough to still be able to move the motor 2 Parts A Upper arm tube B Motor axis 5 Adjust the play by finding the smallest play 3 Tightening torque 10 Nm Secure the motor with its attachment screws 4 Lift the upper arm tube to the robot 5 Continues on next page Product manual IRB 2600 335 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights re...

Page 336: ...nnectors to motor axis 5 8 Parts A Bracket B Attachment screws 2 pcs C Connectors to motor axis 5 D Motor axis 5 xx1000001006 Apply flange sealing Loctite 574 on the surface where the cover shall be fitted See figure 9 Part A Flange sealing Loctite 574 Continues on next page 336 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 7 3 Replacing m...

Page 337: ...acket B Attachment screws 2 pcs C Connectors motor axis 5 D Motor axis 5 See section Replacing the cable harness in the upper arm IRB 2600ID on page222 Check that the spiral of the cable harness is fitted correctly 12 Tightening torque 35 Nm A xx1000000936 Secure the upper arm tube with its attach ment screws 13 Parts A Attachment screws 8 pcs Continues on next page Product manual IRB 2600 337 3HA...

Page 338: ... Surface where Loctite 574 shall be applied xx1000000879 Refit the cover with two inner attachment screws 15 Parts A Attachment screws 5 pcs B Mechanical stop C O ring D Distance ring E Bracket F Cover See figure above Refit the bracket with the remaining attach ment screws 16 Continues on next page 338 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4...

Page 339: ...st unit IRB 2600ID on page 341 Refit the wrist 21 Pendulum Calibration is described in Op erating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 22 Axis Calibration is described in Calibrating with Axis Calibration method on page403 General calibration information is included in section Calibration on page 391 Continues on next page Product manual IRB 2600 33...

Page 340: ...orming the first test run These are further detailed in the section First test run may cause injury or damage on page28 23 340 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 7 3 Replacing motor axis 5 IRB 2600ID Continued ...

Page 341: ...are part number see Spare part lists on page 445 Wrist unit ID Always replace with a new when removed For spare part number see Spare part lists on page 445 VK cover One VK cover at the axis 5 flexible coupling One VK cover underneath the arm tube Loctite 574 Locking liquid Content is defined in section Standard tools on page 441 Standard toolkit These procedures include references to the tools re...

Page 342: ...libration for Axis Calibration in Reference calibration routine on page 404 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be calibrated with fine calibration Remove all external cable packages Dress...

Page 343: ...en the wrist is pulled out from the arm tube with the axis 6 motor connect ors still connected 2 xx1000000873 Remove the VK cover 3 A B A B xx1000000874 Open the flexible coupling that secures the axis 5 motor on the side facing the wrist 4 Parts A Coupling B Attachment screw Continues on next page Product manual IRB 2600 343 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 ...

Page 344: ...e If opened in the wrong place oil will spill out 6 Parts A Wrist B Cover glued with Loctite to the wrist C Division point D Upper arm tube xx1000000876 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 7 Continues on next page 344 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009...

Page 345: ... Information Action 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 1 xx1000000931 Remove the cable protection by removing the nuts securing it 2 Parts A Cable protection B Nuts 2 pcs C Connector motor axis 6 Continues on next page Product manual IRB 2600 345 3HAC035504 0...

Page 346: ... 6 motor and remove the motor Note Do not remove the attachment screws se curing the motor bracket 4 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 346 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...

Page 347: ...cs D Cylindrical pins 2 pcs E Motor axis 6 Tightening torque 6 Nm Secure the motor with its attachment screws 2 Tightening torque 15 Nm A B C xx1000000930 Secure the motor axis with the flexible coupling with its attachment screw 3 Parts A Attachment screw coupling B Flexible coupling C Motor axis 6 Continues on next page Product manual IRB 2600 347 3HAC035504 001 Revision Q Copyright 2009 2018 AB...

Page 348: ...e wrist with the axis 6 motor fitted a little into the upper arm tube 2 R4 MP6 R4 FB6 xx1400002575 Reconnect the cables R4 MP6 and R4 FB6 to the axis 6 motor 3 xx1000000932 Remove the short screws temporarily used to secure from leakage from the wrist 4 Parts A Short screws 2 pcs Continues on next page 348 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserve...

Page 349: ...e hole for the VK cover when fitting the axis into the flexible coup ling of motor axis 5 6 Parts A Flexible coupling axis 5 B Attachment screw Tightening torque 35 Nm A xx1000000875 Secure the wrist with its attachment screws and washers 7 Parts A Attachment screws 4 pcs Continues on next page Product manual IRB 2600 349 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repa...

Page 350: ...f 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 11 Article number is specified in Required equipment on page 341 xx1600001486 Fit a new VK cover 12 Continu...

Page 351: ...thod on page403 General calibration information is included in section Calibration on page 391 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 page28 2 Product manual IRB 2600 351 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 7 4 Replacing mo...

Page 352: ...352 Tool for adjusting play in mo tors Content is defined in section Standard tools on page 441 Standard toolkit These procedures include references to the tools re quired Other tools and procedures may be required See refer ences to these procedures in 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 t...

Page 353: ...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 2 CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 3 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 ...

Page 354: ...djusting the play on the axis in question 6 Release the brakes on the motor 7 A B xx1200000093 Push the motor firmly in the direction of the gear as shown in figure Note Do not use too much force 8 Parts A Motor pinion B Gear Continues on next page 354 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 7 5 Adjusting the play Continued ...

Page 355: ...ist back and forth with the other 11 The figure shows how to do this on the ax is 4 motor 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 12 If no play can be felt in the tool fitted on the motor axis it means that the play is adjus ted correctly When the play is adjusted correct...

Page 356: ...peat steps 7 to 10 Then check the play again starting with step 11 15 xx1200000100 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 16 If motor and gear is not running smoothly or if unnormal noice comes from the gears the play must be readjust...

Page 357: ...inted 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 Product manual IRB 2600 357 3HAC035504 001 Revision Q Co...

Page 358: ...B 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 Frame A Radial sealing B O ring C Gearbox axis 1 D Washer 21 pcs E Attachment screws M8x80 quality Steel 12 9 Gleitmo 21 pcs F Continues on next page 358 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 8 1 Replacing gearbox axis 1...

Page 359: ... 65 IRB 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 3HAC068109 001 Guide for reduction gear Used to guide axis 1 gear and frame during refit ting Content is defined in section Standard tools on page 441 Standard toolkit These procedures include references to the tools required Other tools and procedures may be r...

Page 360: ...reating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 404 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the ro...

Page 361: ...bot 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 4 See Removing motors on page 301 Remove the axis 1 motor 5 See Removing the base on page 291 xx1800000593 Remove the complete arm system from the base and lay down the robot on its side 6 Continu...

Page 362: ...ssories used must be sized accordingly 8 Secure the gearbox in an overhead crane or similar 9 See the figure in Location of gearbox on page 358 Remove the attachment screws securing the gearbox 10 xx1800000788 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 11 Guide pin M8x100 3HAC15520 1 Always use guide pins in pairs Cont...

Page 363: ...ent screws and washers 13 Note Whenever parting mating motor and gear box the gears may be damaged if excessive force is used 14 Note There will be some excess oil running out of the gearbox when it is removed Use some absorbent material to catch the oil 15 Continues on next page Product manual IRB 2600 363 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 8 1 Replac...

Page 364: ...o refit the gearbox Refitting the gearbox to the frame Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 xx1800000794 Check the radial sealing in the frame Replace if damaged 2 Continues on next page 364 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserve...

Page 365: ...figure The oil plugs shall be placed in the openings in the frame not valid for IRB 2600 Type C 20 1 65 IRB 2600 Type C 12 1 65 4 A Opening for oil plug in frame B Oil plug See the figure in Location of gearbox on page 358 Replace o ring if damaged Apply grease on the o ring 5 Clean all assembly surfaces 6 Remove any painting from the assembly surfaces with a knife Continues on next page Product m...

Page 366: ...00795 Fit the guide for the gear on top of the pro tection tube It protects the radial sealing from being damaged during refitting 9 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 10 Continues on next page 366 Product ...

Page 367: ...g for oil plug in frame B Oil plug xx1800000790 Secure the gearbox with its attachment screws and washers 12 Remove the guide pins from the frame and secure the remaining two screws 13 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...

Page 368: ...o the base The gaskets are included with the gearbox spare part 1 See Refitting the base on page 296 Refit the complete arm system to the base 2 See Refitting motors on page 313 Refit the axis 1 motor 3 See Replacing gearbox axis 1 on page357 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 arm...

Page 369: ...escribed in Calibrating with Axis Calibration method on page403 General calibration information is included in section Calibration on page 391 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 page28 7 Product manual IRB 2600 369 3HAC035504 001 Revision Q Copyright 2009 2018 ABB...

Page 370: ...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 Attachment screws M8x80 quality steel 12 9 Gleitmo 17 p...

Page 371: ...ool Roundslings Lifting accessories 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 3HAC15520 2 Guide pin M8x150 Always use guide pins in pairs Valid for IRB 2600 Type C 20 1 65 IRB 2600 Type C 12 1 65 3HAC15521 2 Guide pin M10x150 Always use guide pins in pairs Continues on next page Product manual IRB 2600 371 3HAC035504 001 Revision Q Copyright 2...

Page 372: ...al ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 404 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about refe...

Page 373: ...pressure supply air pressure supply to the robot before entering the robot working area 3 How to drain the gearbox is described in sec tion Changing the oil axis 2 gearbox on page 163 Drain the gearbox 4 Continues on next page Product manual IRB 2600 373 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing gearbox axis 2 Continued ...

Page 374: ...rm house 7 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 8 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 9 Continues on next page 374 Product...

Page 375: ...ame WARNING The cable harness is still installed on the robot Make sure not to damage the cables or the cable brackets on the robot 11 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 12 Continues on next page Product ma...

Page 376: ...Gearbox axis 2 B Lifting lug C Holes for attachment screws that se cure the lower arm to the axis 2 gearbox Secure the gearbox with a roundsling in an overhead crane or similar 14 Continues on next page 376 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing gearbox axis 2 Continued ...

Page 377: ...rbox to the frame shown in the figure 15 Valid for IRB 2600 Type C 20 1 65 IRB 2600 Type C 12 1 65 xx1800000939 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 Fit guide pins to help guiding the gearbox out from the frame 16 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 us...

Page 378: ...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 2 A B C xx0800000445 Fit a lifting lug in the uppermost hole for the attachment screws securing the lower arm to the gearbox 3 Parts A Gearbox axis 2 B Lifting lug C Holes for attachment screws securing the lower arm to gearbox ax...

Page 379: ...pins in opposite holes in the frame 6 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 Secure the gearbox with a roundsling in an overhead crane or similar 7 Release the brakes of the axis 2 motor 8 Article number is specified in Required equipment on page 371 Lift the gearbox onto the guide pins and...

Page 380: ...C 12 1 65 Attachment screws M10x40 12 9 Gleitmo 603 Geo500 16 pcs Tightening torque 68 Nm xx1800000939 See Performing a leak down test on page 188 Perform a leak down test 11 Fit the guide pins to the gearbox 12 CAUTION The weight of the complete upper and lower arm together is 100 kg All lifting accessories used must be sized accordingly 13 Continues on next page 380 Product manual IRB 2600 3HAC0...

Page 381: ...ers to secure the lower arm to the axis 2 gear box 15 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...

Page 382: ...lum enclosed with the calibration tools Recalibrate the robot 18 Axis Calibration is described in Calibrating with Axis Calibration method on page403 General calibration information is included in section Calibration on page 391 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 383: ...el 12 9 Gleitmo 16 pcs D Required equipment Note Art no Equipment See Spare part lists on page 445 Gearbox 2 pcs dimension M6 2 pcs dimen sion M8 Guide pins Used to guide the gearbox and the upper arm during removal refitting 3HAB7887 1 Rotation tool Content is defined in section Standard tools on page 441 Standard toolkit Continues on next page Product manual IRB 2600 383 3HAC035504 001 Revision ...

Page 384: ...f the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 404 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pend...

Page 385: ...ap 5 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 6 See Attaching the lifting accessories to the upper arm on page 250 Attach the lifting accessories to the upper arm 7 Connect the 24 VDC power supply to the axi...

Page 386: ...o rise the front end of the upper arm a little before removing the attachment screws securing the upper arm 12 CAUTION The gearbox weighs 6 kg All lifting accessories used must be sized accordingly 13 Always use guide pins in pairs Remove two attachment screws diagonally located and insert guide pins 14 See the figure in Location of gearbox axis 3 on page 383 Remove the remaining attachment screws...

Page 387: ...ouse cover 6 Attach the rotation tool on the axis 3 motor 7 Release the brakes of the axis 3 motor 8 Lift the gearbox onto the guide pins 9 Note Whenever parting mating motor and gear box the gears may be damaged if excessive force is used 10 Article number for the rotation tool is specified in Required equipment on page 383 Slide the gearbox into position while rotating the motor pinion to find t...

Page 388: ...on page 245 Tightening torque 35 Nm Refit the upper arm to the lower arm with its attachment screws 18 Remove the guide pins and replace with the remaining attachment screws 19 Remove the 24 VDC power supply 20 Tightening torque 14 Nm Refit the upper armhouse cover with its at tachment screws and washers WARNING The cover on the armhouse must be fitted when the robot is running It is a vital part ...

Page 389: ...ndulum enclosed with the calibration tools Recalibrate the robot 24 Axis Calibration is described in Calibrating with Axis Calibration method on page403 General calibration information is included in section Calibration on page 391 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 ...

Page 390: ...This page is intentionally left blank ...

Page 391: ...at is used for calibration of the robot Calibration position A generic term for all calibration methods that aim to move the robot to calibration position Standard calibration A calibration routine that generates a new zero posi tion of the robot Fine calibration A calibration routine that in the first step generates a reference to current zero position of the robot The same calibration routine ca...

Page 392: ...rdinate system for the robot Absolute accuracy calibration option al 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 a...

Page 393: ...tions 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 ca...

Page 394: ...unter 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 co...

Page 395: ...on 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 Synchronization mark axis 1 A Synchronization mark axis 2 B Synchronization mark axis 3 C Continues on next page Product manual IRB 2600 395 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchr...

Page 396: ...8 2 00 A B C xx1000000445 Synchronization mark axis 4 A Synchronization mark axis 5 B Synchronization mark axis 6 C Continues on next page 396 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchronization position for axes Continued ...

Page 397: ...5 xx0800000321 Synchronization mark axis 6 F Product manual IRB 2600 397 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchronization position for axes Continued ...

Page 398: ...nes 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 398 Product manual IRB 2600 3HAC035504 001 Rev...

Page 399: ...motion mode 1 See Synchronization marks and synchron ization position for axes on page 395 Jog the manipulator to align the synchron ization marks 2 Step 2 Updating the revolution counter with the FlexPendant on page 400 When all axes are positioned update the revolution counter 3 Correct calibration position of axis 4 and 6 When jogging the manipulator to synchronization position it is extremely ...

Page 400: ... 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 On the ABB menu tap Calibration xx1500000942 1 Continues on next page 400 ...

Page 401: ...RobotWare 6 02 and later 3 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 Continues on next page Product manual IRB 2600 401 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 5 Calibration 5 3 Updating revolution counters Continued ...

Page 402: ...s 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 7 CAUTION If a revolution counter is incorrectly updated it will cause incorrect manipulator posi tioning which in turn ma...

Page 403: ...vable 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 inse...

Page 404: ...hen 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 a...

Page 405: ...ot 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 Product manual IRB 2600 405 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 5 Calibration 5 4 1 Description of Axis Calibration Continued ...

Page 406: ...nd or personnel Note Article number Equipment etc Delivered as a set of calibration tools 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 3HAC062326 001 Calibration tool box Axis Calibration Examining the calibration tool Check prior to usage Before using the calibration tool make sure tha...

Page 407: ... should be checked Outer diameter within Ø12g4 mm Ø8g4 mm or Ø6g5 mm depending on calibration tool size Straightness within 0 005 mm xx1500000951 Outer diameter A Product manual IRB 2600 407 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 5 Calibration 5 4 2 Calibration tools for Axis Calibration Continued ...

Page 408: ...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 Cont...

Page 409: ...00ID xx1600000521 Continues on next page Product manual IRB 2600 409 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 5 Calibration 5 4 3 Installation locations for the calibration tools Continued ...

Page 410: ...x1600000522 Continues on next page 410 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 5 Calibration 5 4 3 Installation locations for the calibration tools Continued ...

Page 411: ...ew if needed Note Article number Spare part Contains replacement calibration pin covers and protective plugs for the bushing 3HAC059487 001 Protection cover and plug set Replace if damaged or missing 3HAC057676 001 IRB 2600ID Protective plug on turning disc 3HAC057511 001 IRB 2600 Product manual IRB 2600 411 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 5 Calibration 5 4 3 ...

Page 412: ...e bushing 3HAC059487 001 Protection cover and plug set Replace if damaged or missing 3HAC057676 001 IRB 2600ID Protective plug on turning disc 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...

Page 413: ...forms 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 da...

Page 414: ...n cloth Wipe the calibration tool clean Note The calibration method is exact Dust dirt or color flakes will affect the calibration value 2 Starting the calibration procedure Use this procedure to call for the Axis Calibration method on the FlexPendant Note Action On the ABB menu tap Calibration xx1500000942 1 Continues on next page 414 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 20...

Page 415: ...n the FlexPendant is given in Overview of the calibra tion procedure on the FlexPendant on page 412 Follow the instructions given on the FlexPendant 4 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 Action Situation Press and...

Page 416: ...alibration 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 Note Action SafeMove generates the message Safety control ler not sync...

Page 417: ... Unsynchronized time limit expired SafeMove message anytime during Axis Calibration routine Note Action SafeMove generates the message Unsynchron ized time limit expired anytime xx1500002482 1 Press OK to continue Axis Calibration procedure 2 Restart Axis Calibration procedure by pressing Play 3 Continues on next page Product manual IRB 2600 417 3HAC035504 001 Revision Q Copyright 2009 2018 ABB Al...

Page 418: ... and plug set 3HAC059487 001 xx1500000952 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 3 Protection cover and plug set 3HAC059487 001 Continues on next page 418 Product manual IRB 2600 3HAC035504 001 Revision Q Copyri...

Page 419: ...he calibration tool box 4 IRB 2600ID xx1700000411 IRB 2600 xx1700000901 Remove the tool from the protection plug 5 IRB 2600ID xx1700000902 Product manual IRB 2600 419 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 5 Calibration 5 4 4 Axis Calibration Running the calibration procedure Continued ...

Page 420: ...ndulum Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools 420 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 5 Calibration 5 5 Calibrating with Calibration Pendulum method ...

Page 421: ...change the position of the robot axes after running the program 1 This is detailed in section Synchronization marks and synchronization position for axes on page 395 Adjust the synchronization marks when the calibration is done if necessary 2 Write down the values on a new label and stick it on top of the calibration label 3 The label is located on the lower arm Remove any calibration equipment fr...

Page 422: ... page 395 and Updating revolution counters on page 399 Check that the synchronization marks for the axes align correctly If they do not update the revolu tion counters 6 Using the jogging window Use this procedure to jog the robot to the synchronization position of all axes Note Action On the ABB menu tap Jogging 1 Tap Motion mode to select group of axes to jog 2 Tap to select the axis to jog axis...

Page 423: ... 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 robo...

Page 424: ...Base lower arm upper arm Cast iron nodular iron Gears screws base frame and so on Steel Brakes motors Neodymium Cables connectors drive belts and so on Plastic rubber Gearboxes Oil grease Covers synchronization brackets Aluminium Turning disc foundry Nickel Oil and grease Where possible arrange for oil and grease to be recycled Dispose of via an authorized person contractor in accordance with loca...

Page 425: ...o organisms Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination Product manual IRB 2600 425 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 6 Decommissioning 6 2 Environmental information Continued ...

Page 426: ...attery 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 426 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All r...

Page 427: ...ilable It only affects two variants of the robot IRB 2600ID IRB 2600 standard variants motor type A motor type A Initial version Axis 1 5 change to motor type B Axis 2 changes gearbox IRB 2600 Type A Axis 6 keeps motor type A Axis 1 6 change to motor type B IRB 2600 Type B Axis 1 and 2 have two versions of gearboxes described below IRB 2600 Type C only IRB 2600 Type C 20 1 65 IRB 2600 Type C 12 1 ...

Page 428: ...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 Continues on next page 428 Product ...

Page 429: ... the Type C variant of the robot informing that the robot is a Type C variant xx1800002211 Continues on next page Product manual IRB 2600 429 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 7 Robot description 7 2 Non compatible versions of axis 1 and axis 2 gearboxes Continued ...

Page 430: ... below the motor flange A The bushing for the calibration tool is loc ated to the right on the base The bushing for the calibration tool is centered on the base The oil plug for drainage is located in front of the gearbox when robot is standing in synchronization position The oil plug for drainage is located on the left side of the gearbox and visible through an opening in the frame when robot is ...

Page 431: ...ance regarding which gearbox versions are installed on the robot if needed Article number axis 2 gear box Article number axis 1 gear box Robot variant 3HAC039109 001 3HAC028837 001 IRB 2600 20 1 65 3HAC043134 001 3HAC043130 001 IRB 2600 Type C 20 1 65 3HAC039109 001 3HAC028837 001 IRB 2600 12 1 65 3HAC043134 001 3HAC043130 001 IRB 2600 Type C 12 1 65 Product manual IRB 2600 431 3HAC035504 001 Revi...

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Page 433: ...pter includes general information complementing the more specific information in the different procedures in the manual Product manual IRB 2600 433 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 8 Reference information 8 1 Introduction ...

Page 434: ...015i Ergonomics of the thermal environment Part 1 EN ISO 13732 1 2008 EMC Generic emission EN 61000 6 4 2007 A1 2011 IEC 61000 6 4 2006 A1 2010 option 129 1 EMC Generic immunity EN 61000 6 2 2005 IEC 61000 6 2 2005 Arc welding equipment Part 1 Welding power sources EN IEC 60974 1 2012ii Arc welding equipment Part 10 EMC requirements EN IEC 60974 10 2014ii Safety of machinery Electrical equipment o...

Page 435: ...R15 06 Safety standard for robots and robotic equipment ANSI UL 1740 Industrial robots and robot Systems General safety require ments CAN CSA Z 434 14 Product manual IRB 2600 435 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 8 Reference information 8 2 Applicable standards Continued ...

Page 436: ...39 37 in 3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume 436 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 8 Reference information 8 3 Unit conversion ...

Page 437: ...e 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 dimen...

Page 438: ...pair maintenance or installation procedure overrides the standard torque Tightening torque Nm Class 12 9 oil lubric ated Tightening torque Nm Class 10 9 oil lubric ated Tightening torque Nm Class 8 8 oil lubricated Dimension 6 M5 10 M6 40 34 24 M8 80 67 47 M10 140 115 82 M12 340 290 200 M16 670 560 400 M20 1150 960 680 M24 Lubricated screws Molycote Gleitmo or equivalent with allen head screws The...

Page 439: ...ning 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 Tightening torque Nm Max Tightening torque Nm Min Tightening torque Nm Nominal Dimension 15 8 12 1 8 20 10 15 1 4 25 15 20 3 8 50 30 40 1 2 90 55 70 3 4 Product manual IRB 2600 439 3HAC035504 001 Rev...

Page 440: ...sory 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 Note Action CAUTION The robot weighs 280 kg All lifting accessories used must be sized accord ingly 440 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB ...

Page 441: ...of the standard toolkit and any tools listed in the instruction Contents standard toolkit Tool Qty 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 ...

Page 442: ... Levelmeter alternative method The following table specifies the calibration equipment required when calibrating the robot with the alternative method Levelmeter Calibration Note Art no Description 68080011 LP Angle bracket 3HAC13908 9 Calibration bracket 3HAC13908 4 Calibration tool ax1 Includes one sensor 6369901 347 Levelmeter 2000 kit 3HAC13908 5 Measuring pin 68080011 GM Sensor fixture 3HAC03...

Page 443: ...as a set of calibration tools 3HAC062326 001 Calibration tool box Axis Cal ibration 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 Note Art no Descript...

Page 444: ...ting 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 444 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 8 Reference information 8 8 Lifting accessories and lifting ...

Page 445: ...ews are not included in the manual but delivered as a separate document for registered users on myABB Business Portal www mypo rtal abb com Product manual IRB 2600 445 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 9 Spare part lists 9 1 Spare part lists and illustrations ...

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Page 447: ...B 140 type C 3HAC025611 001 Circuit diagram IRB 260 3HAC028647 009 Circuit diagram IRB 360 3HAC036446 005 Circuit diagram IRB 460 3HAC025691 001 Circuit diagram IRB 660 3HAC025691 001 Circuit diagram IRB 760 3HAC046307 003 Circuit diagram IRB 1200 3HAC2800 3 Circuit diagram IRB 1410 3HAC021351 003 Circuit diagram IRB 1600 1660 3HAC039498 007 Circuit diagram IRB 1520 3HAC6670 3 Circuit diagram IRB ...

Page 448: ... 6650S 3HAC025744 001 3HAC025744 001 Circuit diagram IRB 6660 3HAC029940 001 3HAC043446 005 Circuit diagram IRB 6700 3HAC13347 1 Circuit diagram IRB 7600 3HAC025744 001 3HAC050778 003 Circuit diagram Product ProductName 3HAC056159 002 Circuit diagram IRB 910SC 448 Product manual IRB 2600 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved 10 Circuit diagram 10 1 Circuit diagrams ...

Page 449: ...4 climbing on robot 25 Cold environments 103 connecting the robot and controller cabling 104 connection external safety devices 26 copper disposal 424 D danger levels 41 direction of axes 398 E enabling device 30 environmental information 424 ESD damage elimination 33 sensitive equipment 33 expansion container installing 97 expected life 118 external safety devices 26 F fire extinguishing 22 FlexP...

Page 450: ... axes 23 signal lamp 101 signals 41 signals in manual 41 symbols 41 symbols on robot 43 test run 28 working range 29 safety fence 20 safety risk electric parts 31 hot parts 34 hydraulic system 35 installation 25 oil change 39 operational disturbance 25 pneumatic system 35 pressure relief valve 36 service work 25 voltage 31 safety signals in manual 41 safety standards 434 safety zones 20 scales on ...

Page 451: ...usting 103 verifying calibration 421 W wall mounting 64 weight 50 base 295 296 robot 61 73 258 259 264 266 281 283 292 362 366 375 378 386 387 440 upper and lower arm 374 380 upper arm complete 248 252 Z zero position checking 422 Product manual IRB 2600 451 3HAC035504 001 Revision Q Copyright 2009 2018 ABB All rights reserved Index ...

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Page 454: ...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 ...

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