3HAC035504 PM IRB 2600-En

ROBOTICS
Product manual
IRB 2600
Trace back information:
Workspace 21C version a7
Checked in 2021-10-11
Skribenta version 5.4.005
Product manual
IRB 2600-20/1.65
IRB 2600-12/1.65
IRB 2600-12/1.85
IRB 2600-20/1.65 type C
IRB 2600-12/1.65 type C
IRB 2600ID-15/1.85
IRB 2600ID-8/2.0
IRC5
Document ID: 3HAC035504-001

Revision: AB
© Copyright 2009-2021 ABB. All rights reserved.

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

Table of contents
Table of contents
Overview of this manual ................................................................................................................... 9
Product documentation .................................................................................................................... 18
How to read the product manual ...................................................................................................... 20
1 Safety 21
1.1 Safety information ............................................................................................. 21
1.1.1 Limitation of liability ................................................................................. 21
1.1.2 Requirements on personnel ...................................................................... 22
1.2 Safety signals and symbols ................................................................................. 23
1.2.1 Safety signals in the manual ...................................................................... 23
1.2.2 Safety symbols on manipulator labels ......................................................... 25
1.3 Robot stopping functions .................................................................................... 31
1.4 Installation and commissioning ............................................................................ 32
1.5 Operation ........................................................................................................ 35
1.5.1 Unexpected movement of robot arm ........................................................... 35
1.6 Maintenance and repair ...................................................................................... 36
1.6.1 Maintenance and repair ............................................................................ 36
1.6.2 Emergency release of the robot axes .......................................................... 39
1.6.3 Brake testing .......................................................................................... 40
1.7 Troubleshooting ................................................................................................ 41
1.8 Decommissioning .............................................................................................. 42
2 Installation and commissioning 43

2.1 Introduction to installation and commissioning ....................................................... 43
2.2 Unpacking ....................................................................................................... 44
2.2.1 Pre-installation procedure ......................................................................... 44
2.2.2 Working range and type of motion .............................................................. 48
2.2.3 Risk of tipping/stability ............................................................................. 53
2.2.4 The unit is sensitive to ESD ....................................................................... 54
2.3 On-site installation ............................................................................................ 55
2.3.1 Lifting robot with roundslings .................................................................... 55
2.3.2 Lifting and turning a suspended mounted robot ............................................ 58
2.3.3 Setting the system parameters for a suspended or tilted robot ......................... 59
2.3.4 Manually releasing the brakes ................................................................... 63
2.3.5 Orienting and securing the robot ................................................................ 66
2.3.6 Fitting equipment on robot ........................................................................ 70
2.3.7 Loads fitted to the robot, stopping time and braking distances ......................... 83
2.4 Restricting the working range .............................................................................. 84
2.4.1 Axes with restricted working range ............................................................. 84
2.4.2 Mechanically restricting the working range of axis 1 ...................................... 85
2.5 Installing options ............................................................................................... 88
2.5.1 Installation of cooling fan for motors (option) ................................................ 88
2.5.2 Installing an expansion container ............................................................... 92
2.5.3 Installation of Foundry Plus Cable guard (option no. 908-1) ............................. 97
2.5.4 Signal lamp (option) ................................................................................. 98
2.6 Robot in hot environments .................................................................................. 99
2.6.1 Start of robot in hot environments .............................................................. 99
2.7 Robot in cold environments ................................................................................. 100
2.7.1 Start of robot in cold environments ............................................................ 100
2.8 Electrical connections ........................................................................................ 101
2.8.1 Robot cabling and connection points .......................................................... 101
2.8.2 Customer connection on robot ................................................................... 105
3 Maintenance 111
3.1 Introduction ...................................................................................................... 111
Product manual - IRB 2600 5

3HAC035504-001 Revision: AB
Table of contents
3.2 Maintenance schedule and expected component life ............................................... 112

3.2.1 Specification of maintenance intervals ........................................................ 112
3.2.2 Maintenance schedule ............................................................................. 113
3.2.3 Expected component life ......................................................................... 116
3.3 Inspection activities ........................................................................................... 117
3.3.1 Inspecting oil level, axis-1 gearbox ............................................................. 117
3.3.2 Inspecting the oil level, axis 2 gearbox ........................................................ 122
3.3.5 Inspecting oil level, gearbox axes 5 - 6 ........................................................ 129
3.3.6 Inspecting the cable harness ..................................................................... 131
3.3.7 Inspecting information labels ..................................................................... 133
3.3.8 Inspecting the mechanical stop pin, axis 1 ................................................... 135
3.3.9 Inspecting additional mechanical stops ....................................................... 138
3.3.10 Inspecting dampers ................................................................................. 140
3.3.11 Inspecting the pressure relief valve ............................................................ 142
3.3.12 Inspecting Signal lamp (option) .................................................................. 144
3.4 Replacement / Changing activities ........................................................................ 146
3.4.1 Type of lubrication in gearboxes ................................................................ 146
3.4.2 Changing the oil, axis 1 gearbox on floor mounted robots ............................... 148
3.4.3 Changing the oil, axis-1 gearbox on suspended robots ................................... 156
3.4.4 Changing the oil, axis-2 gearbox ................................................................ 161
3.4.7 Changing oil, axes-5 and -6 gearboxes ........................................................ 173
3.4.8 Replacing SMB battery ............................................................................. 178
3.5 Cleaning .......................................................................................................... 183
3.5.1 Cleaning the IRB 2600/IRB 2600 ID ............................................................. 183
4 Repair 187
4.1 Introduction ...................................................................................................... 187
4.2 General procedures ........................................................................................... 188
4.2.1 Performing a leak-down test ...................................................................... 188
4.2.2 Mounting instructions for bearings ............................................................. 189
4.2.3 Mounting instructions for sealings .............................................................. 191
4.2.4 Cut the paint or surface on the robot before replacing parts ............................ 194
4.2.5 The brake release buttons may be jammed after service work ......................... 195
4.3 Complete robot ................................................................................................. 196
4.3.1 Removing the complete cable harness ........................................................ 196
4.3.2 Refitting the complete cable harness .......................................................... 208
4.3.3 Replacing the cable harness in the upper arm - IRB 2600ID ............................ 223
4.3.4 Replacing SMB unit ................................................................................. 235
4.3.5 Replacing the brake release board ............................................................. 241
4.4 Upper arm ....................................................................................................... 246
4.4.1 Replacing the complete upper arm ............................................................. 246
4.4.2 Replacing complete tubular shaft unit ......................................................... 256
4.4.3 Replacing wrist unit ................................................................................. 263
4.4.4 Measuring the play, axis 5 ......................................................................... 270
4.4.5 Measuring the play, axis 6 ......................................................................... 272
4.4.6 Measuring the play, axis 5 (ID upper arm) .................................................... 274
4.4.7 Measuring the play, axis 6 (ID upper arm) .................................................... 277
4.5 Lower arm ....................................................................................................... 280
4.5.1 Replacing the lower arm ........................................................................... 280
4.6 Frame and base ................................................................................................ 288
4.6.1 Replacing stop pin axis 1 .......................................................................... 288
4.6.2 Replacing the base .................................................................................. 291
4.7 Motors ............................................................................................................ 303
4.7.1 Removing motors .................................................................................... 303
4.7.2 Refitting motors ...................................................................................... 316
6 Product manual - IRB 2600

Table of contents
4.7.3 Replacing motor axis 5 - IRB 2600ID ........................................................... 332

4.7.4 Replacing motor axis 6 and wrist unit - IRB 2600ID ........................................ 344
4.7.5 Adjusting the play ................................................................................... 355
4.8 Gearboxes ....................................................................................................... 360
4.8.1 Replacing gearbox axis 1 .......................................................................... 360
5 Calibration 393
5.1 Introduction to calibration ................................................................................... 393
5.1.1 Introduction and calibration terminology ...................................................... 393
5.1.2 Calibration methods ................................................................................. 394
5.1.3 When to calibrate ................................................................................... 397
5.2 Synchronization marks and axis movement directions ............................................. 398
5.2.1 Synchronization marks and synchronization position for axes ......................... 398
5.2.2 Calibration movement directions for all axes ................................................ 401
5.3 Updating revolution counters ............................................................................... 402
5.4 Calibrating with Axis Calibration method ............................................................... 406
5.4.1 Description of Axis Calibration .................................................................. 406
5.4.2 Calibration tools for Axis Calibration ........................................................... 409
5.4.3 Installation locations for the calibration tools ............................................... 411
5.4.4 Axis Calibration - Running the calibration procedure ...................................... 415
5.4.5 Reference calibration ............................................................................... 422
5.5 Calibrating with Calibration Pendulum method ....................................................... 424
5.6 Calibrating with Wrist Optimization method ........................................................... 425
5.7 Verifying the calibration ...................................................................................... 427
5.8 Checking the synchronization position .................................................................. 428
6 Decommissioning 429
6.1 Introduction ...................................................................................................... 429
6.2 Environmental information .................................................................................. 430
6.3 Scrapping of robot ............................................................................................. 432
7 Robot description 433

7.1 Robot types ..................................................................................................... 433
7.2 Non-compatible versions of axis-1 and axis-2 gearboxes .......................................... 434
8 Reference information 439

8.1 Introduction ...................................................................................................... 439
8.2 Applicable standards ......................................................................................... 440
8.3 Unit conversion ................................................................................................. 442
8.4 Screw joints .................................................................................................... 443
8.5 Weight specifications ......................................................................................... 446
8.6 Standard tools .................................................................................................. 447
8.7 Special tools .................................................................................................... 448
8.8 Lifting accessories and lifting instructions .............................................................. 450
9 Spare part lists 451

9.1 Spare part lists and illustrations ........................................................................... 451
10 Circuit diagram 453

10.1 Circuit diagrams ................................................................................................ 453
Index 455

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Overview of this manual

About this manual
This manual contains instructions for:
• mechanical and electrical installation of the robot
• maintenance of the robot
• mechanical and electrical repair of the robot.
The manual also contains reference information for all procedures detailed in the
manual.
Usage
This manual should be used during:
• installation, from lifting the robot to its work site and securing it to the
foundation, to making it ready for operation
• maintenance work
• repair work and calibration.
Who should read this manual?

This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
Maintenance/repair/installation personnel working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
Product manual scope

The manual covers covers all variants and designs of the IRB 2600/IRB 2600 ID.
Some variants and designs may have been removed from the business offer and
are no longer available for purchase.
Organization of chapters
The manual is organized in the following chapters:
Chapter Contents
Safety Safety information that must be read through before performing
any installation or service work on the robot. Contains general
safety aspects as well as more specific information on how to
avoid personal injuries and damage to the product.
Installation and commis- Required information about lifting and installation of the robot.
sioning
Maintenance Step-by-step procedures that describe how to perform mainten-
ance of the robot. Based on a maintenance schedule that may
be used to plan periodical maintenance.
Continues on next page

Continued
Chapter Contents
Repair Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.
Calibration Calibration procedures and general information about calibration.
Decommissioning Environmental information about the robot and its components.
Reference information Useful information when performing installation, maintenance
or repair work. Includes lists of necessary tools, additional doc-
uments, safety standards etc.
Spare part / part list Complete spare part list and complete list of robot components,
shown in exploded views.
Exploded views Detailed illustrations of the robot with reference numbers to the
part list.
Circuit diagram Reference to the circuit diagram for the robot.
References
Reference Document ID
Product specification - IRB 2600 3HAC035959-001
Circuit diagram - IRB 2600 3HAC029570-007
Product manual, spare parts - IRB 2600 3HAC049106-001
Safety manual for robot - Manipulator and IRC5 or OmniCore controller 3HAC031045-001
i
Product manual - IRC5 3HAC021313-001

IRC5 with main computer DSQC 639.
Product manual - IRC5 3HAC047136-001
IRC5 with main computer DSQC1000.
Operating manual - Emergency safety information 3HAC027098-001
Operating manual - IRC5 with FlexPendant 3HAC050941-001
Operating manual - Troubleshooting IRC5 3HAC020738-001
Operating manual - Calibration Pendulum 3HAC16578-1
Operating manual - Service Information System 3HAC050944-001
Technical reference manual - Lubrication in gearboxes 3HAC042927-001
Technical reference manual - System parameters 3HAC050948-001
Application manual - Additional axes and stand alone controller 3HAC051016-001
Application manual - Electronic Position Switches 3HAC050996-001
Application manual - CalibWare Field 3HAC030421-001
i This manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Revisions
Revision Description
- First edition
A The following updates and additions have been made in this revision:
• Variant IRB 2600ID added throughout the manual.

Continued
• Safety symbols updated throughout the manual.
• Section Safety signals in the manual on page 23 added in Safety chapter.
• Added information about pressure relief valve in Safety chapter.
• Force and Torque loads updated in section Pre-installation procedure
on page 44.
• Section Installing an expansion container on page 92 added.
• Interval for inspection of signal lamp added in section Maintenance
schedule on page 113.
• New design of frame added in sections Inspecting oil level, axis-1
gearbox on page 117 and Changing the oil, axis 1 gearbox on floor
mounted robots on page 148.
• Required oil level updated in section Inspecting oil level, axis-1 gearbox
on page 117.
• Required oil level updated in section Inspecting the oil level, axis 3
gearbox on page 125.
• Required oil level updated in section Inspecting the oil level, axis 4
gearbox on page 127.
• Required oil level updated in section Inspecting oil level, gearbox axes
5 - 6 on page 129.
B The following updates and additions have been made in this revision:
• The difference in weight between the different robot variants is minor,
therefor the weight specification for the robot is simplified. See Weight,
robot on page 44.
• Figure and describing text edited for the stress forces. See Loads on
foundation, robot on page 45.
• Removed Foundry from table with protection classes. See Protection
classes, robot on page 47.
• Text added for the maximum levelness. See Requirements, foundation
on page 46.
• Length of roundslings for lifting the robot is changed from 4 m to 2 m.
See Lifting robot with roundslings on page 55.
• Note about fan cabling added in the cable list. See Robot cabling and
connection points on page 101.
• Minor editorial changes made throughout the maintenance chapter.
• Note about ambient temperature deleted from the maintenance schedule.
See Maintenance schedule on page 113.
• Added figure of suspended robot in maintenance sections for axis 1
gearbox. See Inspecting oil level, axis-1 gearbox on page 117 and
Changing the oil, axis 1 gearbox on floor mounted robots on page 148.
• A new block, about general illustrations, added in section How to read
the product manual on page 20.
• Figure of axis 1 stop pin is updated. See Replacing stop pin axis 1 on
page 288.
• Figure of axis 1 gearbox is updated. See Replacing gearbox axis 1 on
page 360.
• Figure with movement directions of axes added. See Calibration
movement directions for all axes on page 401.
• Figure of suspended robot added. See Lifting and turning a suspended
mounted robot on page 58.
• Warning of heavy weight is changed to include the complete robot in-
stead of only the arm system, section Replacing the base on page 291.
• Separated robot dimensions and mounting hole measurements in
drawings. See Fitting equipment on robot on page 70.
• Added section Setting the system parameters for a suspended or tilted
robot on page 59.

Continued
• Corrected spare part numbers for axes 3, 4, 5 and 6 motors. See Upper
arm and Upper arm ID.
• Added VK covers to the instruction for upper arm cabling replacement,
IRB 2600ID. See Replacing the cable harness in the upper arm - IRB
2600ID on page 223.
• Changed information about which attachment screws to remove when
removing the base from the robot. Previously the instruction said "Re-
move the attachment screws securing the gearbox to the frame", now
it says "Remove the attachment screws that secure the base to the axis
1 gearbox". See step in the end of the removal procedure in section
Replacing the base on page 291.
• Changed information about the robot position when removing motor.
See Removing motors on page 303.
• Added step about removing/refitting axis 1 motor when replacing the
axis 1 gearbox. Also added information about guide pins. See Replacing
gearbox axis 1 on page 360. Also minor additions concerning the mating
of gearbox and motor, in all such instructions.
• Added information about lifting accessories and how to attach them to
the upper arm of the robot, see Attaching the lifting accessories to the
upper arm on page 251.
• Additional information in the procedure for replacing the base with im-
proved lifting instruction etc., see Replacing the base on page 291.
• Added a second roundsling to the lifting instruction for the complet robot,
see Lifting robot with roundslings on page 55.
• Changed type of oil in axes 1, 2 and 4 gearboxes. See Type of lubrication
in gearboxes on page 146.
C The following updates and changes have been made in this revision:
• Added instructions for how to measure the play of axis 5 and 6 of an ID
upper arm. See sections Measuring the play, axis 5 (ID upper arm) on
page 274 and Required equipment on page 277.
• Deleted the spare part number for harnesses in Spare parts - lower arm
and instead inserted a reference to the Electrical connections.
• Corrected the spare part numbers for cable harnesses, see Electrical
connections.
• Corrected measurement that belong to figure xx0300000187, when fitting
tools for measuring the play of axis 5, see Measuring the play, axis 5
on page 270.
• Corrected faulty information about attachment screws between upper
and lower arm (figure, screw dimension and tightening torque), see
Replacing the complete upper arm on page 246.
• Added information about releasing the motor brakes in order to set the
weight of different axes onto lifting accessories, see Replacing the
complete upper arm on page 246, Replacing gearbox axis 3 on page 386
and Replacing gearbox axis 2 on page 373.
• Changed the instruction for how to replace the axes 2 and 3 gearboxes
without having to remove the cable harness, see Replacing gearbox
axis 3 on page 386 and Replacing gearbox axis 2 on page 373.
• Added safety information about preventing roundslings from sliding
when lifting the upper arm tube, see Replacing complete tubular shaft
unit on page 256.
• Added information about removing painting, if any, from assembly sur-
faces when replacing gearboxes and motors.
• Corrected the specified weight for the tubular shaft unit to 30 kg.
• Added tip to speed up the draining of axis 4 gearbox, see Changing the
oil, axis-4 gearbox on page 169.
• Corrected data for which motor pins to connect when releasing the
brakes, see Removing motors on page 303 and Refitting motors on
page 316.

Continued
• Added information about o-ring and made other minor improvements
to the instruction for replacing wrist unit, see Replacing wrist unit on
page 263.
• Added information about disconnecting the battery cable when removing
the cable harness, see Removing the complete cable harness on
page 196.
• Corrected the figure that shows location of oil plugs of axis 3 gearbox,
added a funnel to equipment list, see Changing the oil, axis-3 gearbox
on page 165.
• Corrected the figure that shows location of oil plugs of axis 3 gearbox
and adjusted the oil level, see Inspecting the oil level, axis 3 gearbox
on page 125.
• Changed instruction for replacing the wrist unit so that the wrist do not
need to be drained, see Replacing wrist unit on page 263.
• Added Profibus to the section about connections to extra equipment,
see Customer connection on robot on page 105.
• New section added to the manual, see Installation of Foundry Plus Cable
guard (option no. 908-1) on page 97.
• Some general tightening torques have been changed/added, see updated
values in Screw joints on page 443.
• The method of changing the axis-1 gearbox oil in suspended robots is
improved, see the new section Changing the oil, axis-1 gearbox on
suspended robots on page 156.
• Corrected the motor connector pin numbers used for releasing the motor
brakes with external power supply, see Removing motors on page 303
and Refitting motors on page 316.
• Complete process wrist for IRB 2600ID is added to the spare part list
and to the service instructions, see Spare partsand Replacing motor
axis 6 and wrist unit - IRB 2600ID on page 344, 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 355.
• Added information about batteries.
D The following updates and changes have been made in this revision:
• Removed faulty information about motors when rebuilding the robot,
see Rebuilding parts.
• Removed faulty information about expansion container for wall mounted
robots, see Changing the oil, axis-1 gearbox on suspended robots on
page 156. Expansion container is not used on wall mounted robots.
• Added ID variants to the information about lower arm when rebuilding
the robot, see Rebuilding parts. Also corrected the ID information in the
spare part list for the lower arm.
• Added correct variant descriptions to the information about IRB 2600ID
upper arms. See Upper arm (IRB 2600ID).
• Mounting angles and values for tilted the variant of the robot added.
• Corrected the spare part numbers for cable harnesses, see Electrical
connections.
• Corrected the spare part number for o-ring pos (5). See Base and frame
unit.
• Spare part number for VK cover, pos 41 was wrong. Has been corrected.
See Upper arm (IRB 2600ID).
• Corrected tightening torque value for oil plugs on axis-1 and axis-2
gearboxes. Correct value is 24 Nm. (Earlier incorrect value: 60 Nm.)
• Information about the type and amount of oil has been removed from
the manual and can now be found in Technical reference manual - Lub-
rication in gearboxes. For article number see References on page 10.

Continued
• Information about sealing washer oil plugs on the axis-1 and axis-2
gearbox changed. Also spare part number is added.
• New frame introduced throughout the manual.
• A new SMB unit and battery is introduced, with longer battery lifetime.
E The following updates and changes have been made in this revision:
• Corrected links to lubrication in gearboxes.
• Spare part numbers in general corrected.
• Added information about risks when scrapping a decommissioned robot,
see Scrapping of robot on page 432.
• Spare parts and exploded views are not included in this document but
delivered as a separate document. See Product manual, spare
parts - IRB 2600.
F The following updates have been made in this revision:
• Illustration changes in Dimension, mounting surface and guide bushing
on page 67.
• Term "Guide sleeves" changed to "Guide bushings", see Dimension,
mounting surface and guide bushing on page 67.
• Information in 2.3.4 Manually releasing the brakes has been updated
and two figures are added.
• Motors Type B added for IRB 2600 and IRB 2600ID.
• A new WARNING! is added in the section about motor replacement,
informing not to mix different motor types.
• Minor corrections.
G The following updates have been made in this revision:
• Information about removing the mech stop bracket added in section
2.4.1
• Illustrations of cable harness and motors in upper arm, improved
throughout the manual.
H The following updates have been made in this revision:
• Turning disk fixture is removed from special tools for Levelmeter calib-
ration.
• Valid serial numbers changed to type designations (Type A and Type
B) in the section "Checking the oil level" to avoid confusion between
different serial number series.
• Oil levels adjusted.
J The following updates have been made in this revision:
• Information about expansion container added.
• Updated number of screws and sizes of screws in Replacing the lower
arm.
K Published in release R16.2. The following updates are done in this revision:
• Corrections due to updates in SAP terminology.
• New standard calibration method is introduced (Axis Calibration). See
Calibration on page 393.
• Clarifications in maintenance schedule.
• Information about grounding point added. See Robot cabling and con-
nection points on page 101.
L Published in release R17.1. The following updates are done in this revision:
• Added information about how to handle cabling in the upper arm tube,
and upper arm housing, during wrist removal and cable replacement,
see Removing the wrist unit on page 346 and Replacing the cable harness
in the upper arm - IRB 2600ID on page 223.
• Changed the tightening torque of the oil plug located on axis-1 gearbox.
• Recommendation about changing oil in axis-2 gearbox in floor standing
position added.

Continued
• Clarification for types of motors, Motors on page 303.
M Published in release R17.2. The following updates are done in this revision:
• Information about coupled axes in Updating revolution counters on
page 402.
• Caution about removing metal residues added in sections about SMB
boards.
• Information added into calibration procedure regarding installation of
calibration tool on turning disc, see Overview of the calibration procedure
on the FlexPendant on page 415.
• Information about minimum resonance frequency added.
• Bending radius for static floor cables added.
• Updated list of applicable standards.
• Article number for the Calibration tool box, Axis Calibration is changed.
• Added text regarding overhaul in section specification of maintenance
intervals.
• Updated the section Start of robot in cold environments on page 100.
• Information about isolating arc welding manipulator added.
• Updated information regarding replacement of brake release board.
• Updated information regarding disconnecting and reconnecting battery
cable to serial measurement board.
• Definition of reference calibration clarified.
N Published in release R18.1. The following updates are done in this revision:
• Information added about fatigue to Axis Calibration tool, see Calibration
tools for Axis Calibration on page 409.
• Added sections in General procedures on page 188.
• Illustration updated in dimension, mounting surface and guide bushing.
• Safety restructured.
• Added information about harness customer ethernet connection.
• Updated spare parts number for Brake release boards.
• Note added to calibration chapter to emphasize the requirement of
equally dressed robot when using previously created reference calibra-
tion values.
• Information about myABB Business Portal added.
• Added Nickel in Environmental information.
P Published in release R18.2. The following updates are done in this revision:
• Updates related to mechanical stop pin.
• Changed the method for replacing the axis-1 gearbox and the base.
Q Published in release R18.2. The following updates are done in this revision:
• Updated reference.
R Published in release 19B. The following updates are made in this revision:
• Added information about IRB 2600-20/1.65 type C, IRB 2600-12/1.65
type C to the manual. NOTE! The Type C robot is not available until
later release.
• New touch up color Graphite White available. See Cut the paint or sur-
face on the robot before replacing parts on page 194.
• New article numbers for manipulator cables in section Robot cabling
and connection points on page 101.
• Levelmeter 2000 kit (6369901-347) no longer available.
S Published in release 19B. The following updates are made in this revision:
• Type C variants (IRB 2600-20/1.65 type C, IRB 2600-12/1.65 type C) are
removed from the manual, due to later sales start.

Continued
T Published in release 19C. The following updates are made in this revision:
• Release date for IRB 2600-20/1.65 type C, IRB 2600-12/1.65 type C is
removed in section Robot description on page 433.
• Note added about need to calibrate if the robot is other than floor
mounted. See When to calibrate on page 397.
• Procedure for changing oil in axis-5/6 gearbox is updated with informa-
tion valid for IRB 2600ID.
U Published in release 19D. The following updates are made in this revision:
• Updated oil level in axis-1 gearbox for robots IRB 2600-20/1.65 type C,
IRB 2600-12/1.65 type C.
• Updated installation procedure for expansion container, see Installing
an expansion container on page 92.
V Published in release 20A. The following updates are made in this revision:
• Added information about IRB 2600-20/1.65 type C, IRB 2600-12/1.65
type C to the manual.
• Replaced article number and name of grease, previously 3HAB3537-1.
• Clarified and added information in mounting instructions for rotating
sealings, see Mounting instructions for sealings on page 191.
• Clarified text about position of robot and added table with dependencies
between axes during Axis Calibration.
W Published in release 20B. The following updates are made in this revision:
• Article number of Calibration tool box, Axis Calibration is changed from
3HAC062326-001 to 3HAC074119-001.
• Added information about Wrist Optimization in calibration chapter.
X Published in release 20C. The following updates are made in this revision:
• Added note about differences in type of oil pre-filled in axis-4 gear
compared to recommended oil for field maintenance.
• Clarified information regarding brake release on motor connectors when
removing motors.
• Updated section about customer connections in regard to Ethernet etc.
See Customer connection on robot on page 105.
• Added illustration of base hole configuration for IRB 2600-20/1.65 type
C, IRB 2600-12/1.65 type C, see Orienting and securing the robot on
page 66.
Y Published in release 20D. The following updates are made in this revision:
• Removed inspection of axis-5 gear oil level from maintenance schedule
(IRB 2600ID).
• Added information about refilling oil in the axis-5 gear after replacing
the axis-5 motor (IRB 2600ID).
• Added tightening torque and inspection step for axis-5 gear oil plug,
after refilling oil during axis-5 motor replacement (IRB 2600ID).
Z Published in release 21A. The following updates are made in this revision:
• Changed grease to Loctite 574 on o-ring when refitting motor axes 1
and 2.
• Note regarding maximum leakage current for attached equipment. See
Customer connection on robot on page 105.
AA Published in release 21B. The following updates are made in this revision:
• Information regarding documentation of Installation of Foundry Plus
Cable guard (option no. 908-1) is changed since DVDs are removed.
See Installation of Foundry Plus Cable guard (option no. 908-1) on
page 97.
• Text regarding fastener quality is updated, see Fastener quality on
page 82.

Continued
AB Published in release 21C. The following updates are made in this revision:
• Information regarding option 224-2 (expansion tank) when in inverted
mounting. See Installing an expansion container on page 92.

Product documentation
Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories.
This listing is based on the type of information in the documents, regardless of
whether the products are standard or optional.
Tip
All documents can be found via myABB Business Portal, www.abb.com/myABB.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.
Technical reference manuals

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

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

How to read the product manual
How to read the product manual

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

The procedures often include references to equipment (spare parts, tools, etc.)
required for the different actions in the procedure. The equipment is marked with
italic text in the procedures and completed with a reference to the section where
the equipment is listed with further information, that is article number and
dimensions.
The designation in the procedure for the component or attachment point
corresponds to the designation in the referenced list.
The table below shows an example of a reference to a list of required equipment
from a step in a procedure.
Action Note/Illustration
3. Fit a new sealing, axis 2 to the gearbox. Art. no. is specified in Required
equipment on page xx.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 21.
Illustrations
The robot is illustrated with general figures that does not take painting or protection
type in consideration.
Likewise, certain work methods or general information that is valid for several robot
models, can be illustrated with illustrations that show a different robot model than
the one that is described in the current manual.

1 Safety
1.1.1 Limitation of liability
1 Safety
1.1 Safety information
1.1.1 Limitation of liability
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial robot will not cause injury or damage even if
all safety instructions are complied with.
The information does not cover how to design, install and operate a robot system,
nor does it cover all peripheral equipment that can influence the safety of the robot
system.
In particular, liability cannot be accepted if injury or damage has been caused for
any of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed.
• Non-authorized design modifications of the robot.
• Repairs on the robot and its spare parts carried out by in-experienced or
non-qualified personnel.
• Foreign objects.
• Force majeure.
Spare parts and equipment

ABB supplies original spare parts and equipment which have been tested and
approved. The installation and/or use of non-original spare parts and equipment
can negatively affect the safety, function, performance, and structural properties
of the robot. ABB is not liable for damages caused by the use of non-original spare
parts and equipment.

1 Safety
1.1.2 Requirements on personnel
1.1.2 Requirements on personnel
General
Only personnel with appropriate training are allowed to install, maintain, service,
repair, and use the robot. This includes electrical, mechanical, hydraulics,
pneumatics, and other hazards identified in the risk assessment.
Persons who are under the influence of alcohol, drugs or any other intoxicating
substances are not allowed to install, maintain, service, repair, or use the robot.
The plant liable must make sure that the personnel is trained on the robot, and on
responding to emergency or abnormal situations.
Personal protective equipment

Use personal protective equipment, as stated in the instructions.

1 Safety
1.2.1 Safety signals in the manual
1.2 Safety signals and symbols
Introduction to safety signals

This section specifies all safety signals used in the user manuals. Each signal
consists of:
• A caption specifying the hazard level (DANGER, WARNING, or CAUTION)
and the type of hazard.
• Instruction about how to reduce the hazard to an acceptable level.
• A brief description of remaining hazards, if not adequately reduced.
Hazard levels
The table below defines the captions specifying the hazard levels used throughout
this manual.
Symbol Designation Significance
DANGER Signal word used to indicate an imminently hazard-
ous situation which, if not avoided, will result in ser-
ious injury.
WARNING Signal word used to indicate a potentially hazardous

situation which, if not avoided, could result in serious
injury.
ELECTRICAL Signal word used to indicate a potentially hazardous

SHOCK situation related to electrical hazards which, if not
avoided, could result in serious injury.
CAUTION Signal word used to indicate a potentially hazardous

situation which, if not avoided, could result in slight
injury.
ELECTROSTATIC Signal word used to indicate a potentially hazardous

DISCHARGE (ESD) situation which, if not avoided, could result in severe
damage to the product.
NOTE Signal word used to indicate important facts and

conditions.

1 Safety
Continued
Symbol Designation Significance

TIP Signal word used to indicate where to find additional
information or how to do an operation in an easier
way.

1 Safety
1.2.2 Safety symbols on manipulator labels
Introduction to symbols
This section describes safety symbols used on labels (stickers) on the manipulator.
Symbols are used in combinations on the labels, describing each specific warning.
The descriptions in this section are generic, the labels can contain additional
information such as values.
Note
The symbols on the labels on the product must be observed. Additional symbols
added by the integrator must also be observed.
Types of symbols
Both the manipulator and the controller are marked with symbols, containing
important information about the product. This is important for all personnel handling
the robot, for example during installation, service, or operation.
The safety labels are language independent, they only use graphics. See Symbols
on safety labels on page 25.
The information labels can contain information in text.
Symbols on safety labels
Symbol Description
Warning!
Warns that an accident may occur if the instructions are not
followed that can lead to serious injury, possibly fatal, and/or
great damage to the product. It applies to warnings that apply
xx0900000812
to danger with, for example, contact with high voltage electrical
units, explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height, etc.
Caution!
Warns that an accident may occur if the instructions are not
followed that can result in injury and/or damage to the product.
It also applies to warnings of risks that include burns, eye injury,
skin injury, hearing damage, crushing or slipping, tripping, im-
xx0900000811 pact, fall from height, etc. Furthermore, it applies to warnings
that include function requirements when fitting and removing
equipment where there is a risk of damaging the product or
causing a breakdown.
Prohibition
Used in combinations with other symbols.
xx0900000839

1 Safety
Continued
Symbol Description
See user documentation
Read user documentation for details.
Which manual to read is defined by the symbol:
• No text: Product manual.
• EPS: Application manual - Electronic Position Switches.
xx0900000813
Before disassembly, see product manual
xx0900000816
Do not disassemble
Disassembling this part can cause injury.
xx0900000815
Extended rotation
This axis has extended rotation (working area) compared to
standard.
xx0900000814
Brake release
Pressing this button will release the brakes. This means that
the robot arm can fall down.
xx0900000808

1 Safety
Continued
Symbol Description
Tip risk when loosening bolts
The robot can tip over if the bolts are not securely fastened.
xx0900000810
xx1500002402
Crush
Risk of crush injuries.
xx0900000817

1 Safety
Continued
Symbol Description
Heat
Risk of heat that can cause burns. (Both signs are used)
xx0900000818
!
3HAC 4431-1/06
xx1300001087
Moving robot
4 6 The robot can move unexpectedly.
3 5
1
xx0900000819
xx1000001141
2 3
xx1500002616

1 Safety
Continued
Symbol Description
Brake release buttons
xx0900000820
xx1000001140
Lifting bolt
xx0900000821
Chain sling with shortener
xx1000001242
Lifting of robot
xx0900000822
Oil
Can be used in combination with prohibition if oil is not allowed.
xx0900000823
Mechanical stop
xx0900000824

1 Safety
Continued
Symbol Description
No mechanical stop
xx1000001144
Stored energy
Warns that this part contains stored energy.
Used in combination with Do not disassemble symbol.
xx0900000825
Pressure
Warns that this part is pressurized. Usually contains additional
text with the pressure level.
xx0900000826
Shut off with handle

Use the power switch on the controller.
xx0900000827
Do not step
Warns that stepping on these parts can cause damage to the
parts.
xx1400002648

1 Safety
1.3 Robot stopping functions
1.3 Robot stopping functions
Protective stop and emergency stop

The protective stops and emergency stops are described in the product manual
for the controller.
For more information see:
• Product manual - IRC5
• Product manual - IRC5 Panel Mounted Controller

1 Safety
1.4 Installation and commissioning
National or regional regulations

The integrator of the robot system is responsible for the safety of the robot system.
The integrator is responsible that the robot system is designed and installed in
accordance with the safety requirements set forth in the applicable national and
regional standards and regulations.
The integrator of the robot system is required to perform a risk assessment.
Layout
The robot integrated to a robot system shall be designed to allow safe access to
all spaces during installation, operation, maintenance, and repair.
If robot movement can be initiated from an external control panel then an emergency
stop must also be available.
If the manipulator is delivered with mechanical stops, these can be used for reducing
the working space.
A perimeter safeguarding, for example a fence, shall be dimensioned to withstand
the following:
• The force of the manipulator.
• The force of the load handled by the robot if dropped or released at maximum
speed.
• The maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the robot.
The maximum TCP speed and the maximum velocity of the robot axes are detailed
in the section Robot motion in the product specification for the respective
manipulator.
Consider exposure to hazards, such as slipping, tripping, and falling.
Hazards due to the working position and posture for a person working with or near
the robot shall be considered.
Consider hazards from other equipment in the robot system, for example, that
guards remain active until identified hazards are reduced to an acceptable level.
Allergenic material
See Environmental information on page 430 for specification of allergenic materials
in the product, if any.
Securing the robot to the foundation

The robot must be properly fixed to its foundation/support, as described in the
respective product manual.
When the robot is installed at a height, hanging, or other than mounted directly on
the floor, there will be additional hazards.
Electrical safety
The mains power must be installed to fulfill national regulations.

1 Safety
Continued
The power supply wiring to the robot must be sufficiently fused and if necessary,
it must be possible to disconnect it manually from the mains power.
The power to the robot must be turned off with the main switch and the mains
power disconnected when performing work inside the controller cabinet. Lock and
tag shall be considered.
Harnesses between controller and manipulator shall be fixed and protected to
avoid tripping and wear.
Wherever possible, power on/off or rebooting the robot controller shall be performed
with all persons outside the safeguarded space.
Note
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot.
Safety devices
The integrator is responsible for that the safety devices necessary to protect people
working with the robot system are designed and installed correctly.
When integrating the robot with external devices to a robot system:
• The integrator of the robot system must ensure that emergency stop functions
are interlocked in accordance with applicable standards.
• The integrator of the robot system must ensure that safety functions are
interlocked in accordance with applicable standards.
Other hazards
WARNING
Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.
A robot may perform unexpected limited movement.
WARNING
Manipulator movements can cause serious injuries on users and may damage
equipment.
The risk assessment should also consider other hazards arising from the
application, such as, but not limited to:
• Water
• Compressed air
• Hydraulics
End-effector hazards require particular attention for applications which involve
close human collaboration with the robot.

1 Safety
Continued
Pressure relief valves

The pressure relief valve prevents too much air pressure being built up inside the
robot. The air pressure must not exceed the rated limit for the manipulator, or there
is a risk of personal injury and mechanical damage.
Pressure relief valves must be kept clean.
Pneumatic or hydraulic related hazards
Note
The pressure in the complete pneumatic or hydraulic systems must be released

before service and maintenance.
All components in the robot system that remain pressurized after switching off
the power to the robot must be marked with clearly visible drain facilities and a
warning sign that indicates the hazard of stored energy.
Loss of pressure in the robot system may cause parts or objects to drop.
Dump valves should be used in case of emergency.
Shot bolts should be used to prevent tools, etc., from falling due to gravity.
All pipes, hoses, and connections have to be inspected regularly for leaks and
damage. Damage must be repaired immediately.
Verify the safety functions

Before the robot system is put into operation, verify that the safety functions are
working as intended and that any remaining hazards identified in the risk
assessment are mitigated to an acceptable level.

1 Safety
1.5.1 Unexpected movement of robot arm
1.5 Operation
1.5.1 Unexpected movement of robot arm
Unexpected movement of robot arm
WARNING
WARNING
equipment.

1 Safety
1.6.1 Maintenance and repair
1.6 Maintenance and repair
General
Corrective maintenance must only be carried out by personnel trained on the robot.
Maintenance or repair must be done with all electrical, pneumatic, and hydraulic
power switched off, that is, no remaining hazards.
Hazards due to stored mechanical energy in the manipulator for the purpose of
counterbalancing axes must be considered before maintenance or repair.
Never use the robot as a ladder, which means, do not climb on the controller,
manipulator, including motors, or other parts. There are hazards of slipping and
falling. The robot might be damaged.
Make sure that there are no loose screws, turnings, or other unexpected parts
remaining after work on the robot has been performed.
When the work is completed, verify that the safety functions are working as
intended.
Hot surfaces
Surfaces can be hot after running the robot, and touching these may result in burns.
Allow the surfaces to cool down before maintenance or repair.
Allergic reaction
Warning Description Elimination/Action

When working with lubricants Make sure that protective gear
there is a risk of an allergic reac- like goggles and gloves are al-
tion. ways worn.
Allergic reaction
Gearbox lubricants (oil or grease)

When handling oil, grease, or other chemical substances the safety information of
the respective manufacturer must be observed.
Note
Take special care when handling hot lubricants.

Changing and draining gearbox Make sure that protective gear
oil or grease may require hand- like goggles and gloves are al-
ling hot lubricant heated up to ways worn during this activity.
90 °C.
Hot oil or grease

1 Safety
Continued

When working with lubricants Make sure that protective gear
there is a risk of an allergic reac- like goggles and gloves are al-
tion. ways worn.
Allergic reaction
When opening the oil or grease Open the plug carefully and keep
plug, there may be pressure away from the opening. Do not
present in the gearbox, causing overfill the gearbox when filling.
lubricant to spray from the
opening.
Possible pressure
build-up in gearbox
Overfilling of gearbox lubricant Make sure not to overfill the
can lead to internal over-pres- gearbox when filling it with oil or
sure inside the gearbox which in grease.
turn may: After filling, verify that the level
• damage seals and gas- is correct.
Do not overfill kets
• completely press out
seals and gaskets
• prevent the robot from
moving freely.
Mixing types of oil may cause When filling gearbox oil, do not
severe damage to the gearbox. mix different types of oil unless
specified in the instructions. Al-
ways use the type of oil specified
for the product.
Do not mix types of oil
Warm oil drains quicker than Run the robot before changing
cold oil. the gearbox oil, if possible.
Heat up the oil

The specified amount of oil or After filling, verify that the level
grease is based on the total is correct.
volume of the gearbox. When
changing the lubricant, the
amount refilled may differ from
the specified amount, depending
Specified amount de- on how much has previously
pends on drained been drained from the gearbox.
volume
For lifetime reasons always drain
as much oil as possible from the
gearbox. The magnetic oil plugs
will gather residual metal chips.
Contaminated oil in
gearboxes
Hazards related to batteries

Under rated conditions, the electrode materials and liquid electrolyte in the batteries
are sealed and not exposed to the outside.

1 Safety
Continued
There is a hazard in case of abuse (mechanical, thermal, electrical) which leads

to the activation of safety valves and/or the rupture of the battery container. As a
result under certain circumstances, electrolyte leakage, electrode materials reaction
with moisture/water or battery vent/explosion/fire may follow.
Do not short circuit, recharge, puncture, incinerate, crush, immerse, force discharge
or expose to temperatures above the declared operating temperature range of the
product. Risk of fire or explosion.
Operating temperatures are listed in Operating conditions, robot on page 47.
See safety instructions for the batteries in Material/product safety data
sheet - Battery pack (3HAC043118-001).
WARNING
WARNING
equipment.
Related information
See also the safety information related to installation and operation.

1 Safety
1.6.2 Emergency release of the robot axes
1.6.2 Emergency release of the robot axes
Description
In an emergency situation, the brakes on a robot axis can be released manually
by pushing a brake release button.
How to release the brakes is described in the section:
• Manually releasing the brakes on page 63.
The robot may be moved manually on smaller robot models, but larger models
may require using an overhead crane or similar equipment.
Increased injury
Before releasing the brakes, make sure that the weight of the manipulator does
not result in additional hazards, for example, even more severe injuries on a trapped
person.
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.

1 Safety
1.6.3 Brake testing
1.6.3 Brake testing
When to test
During operation, the holding brake of each axis normally wears down. A test can
be performed to determine whether the brake can still perform its function.
How to test
The function of the holding brake of each axis motor may be verified as described
below:
1 Run each axis to a position where the combined weight of the manipulator
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 manipulator does not change position as the motors are switched off,
then the brake function is adequate.
Note
It is recommended to run the service routine BrakeCheck as part of the regular

maintenance, see the operating manual for the robot controller.
For robots with the option SafeMove, the Cyclic Brake Check routine is
recommended. See the manual for SafeMove in References on page 10.

1 Safety
1.7 Troubleshooting
1.7 Troubleshooting
General
When troubleshooting requires work with power switched on, special considerations
must be taken:
• Safety circuits might be muted or disconnected.
• Electrical parts must be considered as live.
• The manipulator can move unexpectedly at any time.
DANGER
Troubleshooting on the controller while powered on must be performed by

personnel trained by ABB or by ABB field engineers.
A risk assessment must be done to address both robot and robot system specific
hazards.
WARNING
WARNING
equipment.
Related information
See also the safety information related to installation, operation, maintenance, and
repair.

1 Safety
1.8 Decommissioning
1.8 Decommissioning
General
See section Decommissioning on page 429.
WARNING
WARNING
equipment.

2 Installation and commissioning
2.1 Introduction to installation and commissioning

2.1 Introduction to installation and commissioning
General
This chapter contains assembly instructions and information for installing the IRB
2600/IRB 2600 ID at the working site.
See also the product manual for the robot controller.
The installation must be done by qualified installation personnel in accordance
with the safety requirements set forth in the applicable national and regional
standards and regulations.
Safety information
Before any installation work is commenced, all safety information must be observed.
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 21 before performing any installation
work.
Note
Always connect the IRB 2600/IRB 2600 ID and the robot to protective earth and
residual current device (RCD) before connecting to power and starting any
installation work.

2.2.1 Pre-installation procedure
2.2 Unpacking
Introduction
This section is intended for use when unpacking and installing the robot for the
first time. It also contains information useful during later re-installation of the robot.
Prerequisites for installation personnel

Installation personnel working with an ABB product must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/maintenance/repair work
• conform to all national and local codes.
Checking the pre-requisites for installation
Action
1 Make a visual inspection of the packaging and make sure that nothing is damaged.
2 Remove the packaging.
3 Check for any visible transport damage.
Note
Stop unpacking and contact ABB if transport damages are found.
4 Clean the unit with a lint-free cloth, if necessary.

5 Make sure that the lifting accessory used (if required) is suitable to handle the weight
of the robot as specified in: Weight, robot on page 44
6 If the robot is not installed directly, it must be stored as described in: Storage condi-
tions, robot on page 47
7 Make sure that the expected operating environment of the robot conforms to the
specifications as described in: Operating conditions, robot on page 47
8 Before taking the robot to its installation site, make sure that the site conforms to:
• Loads on foundation, robot on page 45
• Protection classes, robot on page 47
• Requirements, foundation on page 46
9 Before moving the robot, please observe the stability of the robot: Risk of tipping/sta-
bility on page 53
10 When these prerequisites are met, the robot can be taken to its installation site as
described in section: On-site installation on page 55
11 Install required equipment, if any.
• Signal lamp (option) on page 98
Weight, robot
The table shows the weight of the robot.
Robot model Weight
IRB 2600/IRB 2600 ID 280 kg

Continued
Note
The weight does not include tools and other equipment fitted on the robot.
Loads on foundation, robot

The illustration shows the directions of the robots stress forces.
The directions are valid for all floor mounted, suspended and inverted robots.
Txy
Fz
Fxy
Tz
xx1100000521
Fxy Force in any direction in the XY plane

Fz Force in the Z plane
Txy Bending torque in any direction in the XY plane
Tz Bending torque in the Z plane
The table shows the various forces and torques working on the robot during different
kinds of operation.
Note
These forces and torques are extreme values that are rarely encountered during
operation. The values also never reach their maximum at the same time!
WARNING
The robot installation is restricted to the mounting options given in following load
table(s).
Floor mounted
Force Endurance load (in operation) Max. load (emergency stop)

Force xy ±2330 N ±5450 N
Continued

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

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

Force xy ±2250 N i ±5380 N i
Force z -2750 ±1420 N i -2750 ±4280 N i
Torque xy ±3440 Nm i ±7800 Nm i
Torque z ±1110 Nm i ±3050 Nm i
i Only valid for IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB
2600ID-8/2.0.
IRB 2600-20/1.65 type C, IRB 2600-12/1.65 type C is not available for suspended installation.
Requirements, foundation
The table shows the requirements for the foundation where the weight of the
installed robot is included:
Requirement Value Note
Flatness of foundation 0.5 mm Flat foundations give better repeatability of the
surface resolver calibration compared to original settings
on delivery from ABB.
The value for levelness aims at the circumstance
of the anchoring points in the robot base.
In order to compensate for an uneven surface,
the robot can be recalibrated during installation.
If resolver/encoder calibration is changed this
will influence the absolute accuracy.
Maximum tilt 15° The limit for the maximum payload on the robot
is reduced if the robot is tilted from 0°.
Contact ABB for further information about accept-
able loads.

Continued
Requirement Value Note

Minimum resonance 25 Hz The value is recommended for optimal perform-
frequency ance.
Note Due to foundation stiffness, consider robot mass
including equipment. i
It may affect the For information about compensating for founda-
manipulator life- tion flexibility, see Application manual - Control-
time to have a ler software IRC5, section Motion Process Mode.
lower resonance
frequency than
recommended.
i The minimum resonance frequency given should be interpreted as the frequency of the robot
mass/inertia, robot assumed stiff, when a foundation translational/torsional elasticity is added, i.e.,
the stiffness of the pedestal where the robot is mounted. The minimum resonance frequency should
not be interpreted as the resonance frequency of the building, floor etc. For example, if the equivalent
mass of the floor is very high, it will not affect robot movement, even if the frequency is well below
the stated frequency. The robot should be mounted as rigid as possibly to the floor.
Disturbances from other machinery will affect the robot and the tool accuracy. The robot has
resonance frequencies in the region 10 – 20 Hz and disturbances in this region will be amplified,
although somewhat damped by the servo control. This might be a problem, depending on the
requirements from the applications. If this is a problem, the robot needs to be isolated from the
environment.
Storage conditions, robot

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

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

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

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

The illustration shows the unrestricted working range for a floor mounted robot.
IRB 2600 Standard
xx0900000194
Variant Pos. A Pos. B Pos. C Pos. D Pos. E Pos. F

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

Continued
IRB 2600ID
xx1000000300

IRB 2600ID-15/1.85 2145 mm 1171 mm 936 mm 542 mm 1550 mm 1850 mm

Continued
Working range, suspended mounted

This section is only valid for IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85,
IRB 2600ID-15/1.85, IRB 2600ID-8/2.0.
The illustration shows the unrestricted working range for a suspended mounted
robot.
xx0900000195

IRB 2600 - 20/1.65 1948 mm 993 mm 837 mm 469 mm 1353 mm 1653 mm

Continued
xx1000000986


Continued
Turning radius
The turning radius of the robot that is floor or suspended mounted is shown in the
figure.
xx0900000199
Variant Pos. A Pos. B

IRB 2600-20/1.65 R1653 R469
IRB 2600-12/1.65
IRB 2600 Type C-20/1.65
IRB 2600 Type C-12/1.65
IRB 2600-12/1.85 R1853 R506
IRB 2600ID-15/1.85 R1850 R542
IRB 2600ID-8/2.00 R2000 R539
Robot motion,
The table specifies the types and ranges of motion in every axes.
Location of motion Type of motion Range of movement
Axis 1 Rotation motion ±180°
Axis 2 Arm motion +155° / -95°
Axis 3 Arm motion +75° / -180°
Axis 4 (IRB 2600 standard) Wrist motion ±400°
Axis 4 (IRB 2600ID) Wrist motion ±175°
Axis 5 Bend motion ±120°
Axis 6 Turn motion ±400°

2.2.3 Risk of tipping/stability
2.2.3 Risk of tipping/stability
Risk of tipping
Do not change the robot position before securing it to the foundation.
The shipping position is the most stable position.
Shipping and transportation position

This figure shows the robot in its shipping position and transportation position.
The figure shows IRB 2600 but is also valid for IRB 2600ID. Best position of IRB
2600ID axis 4 is ±90°.
The position where part of the lower arm (A) is beginning to show in the hole, is
approximate.
0°
45
°
A
15
°
xx0900000211
WARNING
The robot will be mechanically unstable if not properly secured to the foundation.

2.2.4 The unit is sensitive to ESD
2.2.4 The unit is sensitive to ESD
Description
ESD (electrostatic discharge) is the transfer of electrical static charge between two
bodies at different potentials, either through direct contact or through an induced
electrical field. When handling parts or their containers, personnel not grounded
may potentially transfer high static charges. This discharge may destroy sensitive
electronics.
Safe handling
Use one of the following alternatives:
• Use a wrist strap.
Wrist straps must be tested frequently to ensure that they are not damaged
and are operating correctly.
• Use an ESD protective floor mat.
The mat must be grounded through a current-limiting resistor.
• Use a dissipative table mat.
The mat should provide a controlled discharge of static voltages and must
be grounded.

2.3.1 Lifting robot with roundslings
2.3 On-site installation
Introduction
When lifting the robot use roundslings and an overhead crane.
Required equipment
Equipment Note
Overhead crane Lifting capacity 1 000 kg (Max load at 90°)
Roundslings (2 pcs) • Lifting capacity/roundsling: 1 000 kg
• Lengths: 2 m, 1.5 m
Lifting
Attach the roundslings as shown in the figure.
45°
B
A
1000
°
15
xx0900000236
A Roundsling, length 2 m (put folded in U-shape around the upper arm)

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

Continued
Lifting instructions
Use this procedure to lift the robot in a safe way.
Action Note
1
CAUTION
The IRB 2600/IRB 2600 ID robot weighs 280

kg.
All lifting accessories used must be sized ac-
cordingly!
2
CAUTION
Attempting to lift the robot in any other posi-

tion than that recommended may result in the
robot tipping over and causing severe damage
or injury!
3
WARNING
Personnel must not, under any circumstances,

be present under the suspended load!
4 Move the robot to its most stable position. Detailed in section:

For robot versions IRB 2600ID: The best pos- • Risk of tipping/stability on
ition of axis 4 is ±90°. page 53
5
DANGER
Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.
6 Attach roundsling A to the lifting lug on the See the figure in:
frame, and put folded in a U-shape on either • Lifting on page 55
side of the upper arm.
7 Attach roundsling B at axis 3 gearbox by run- See the figure in:
ning it folded in a U-shape around the gear- • Lifting on page 55
box.
8 Make sure the roundslings do not rub against
any sharp edges.

Continued
Action Note
9 When the robot is lifted the roundslings will
adjust themselves.
CAUTION
When lifting, the robot will tilt slightly back-

wards! Be careful not to damage the connec-
tion box at the base of the robot!
xx0800000291
• A: Area where the connection

box can be damaged while lifting.
10 Lift the robot with an overhead crane. Lifting capacity:
• See Required equipment on
page 55

2.3.2 Lifting and turning a suspended mounted robot
2.3.2 Lifting and turning a suspended mounted robot
Validity of this section

IRB 2600ID-15/1.85, IRB 2600ID-8/2.0.
Introduction
How to lift and turn the robot to a suspended position using the turning accessory
is described in the lifting instruction delivered with the turning accessory. Article
numbers for the accessory and the instruction is specified in Special tools on
page 448. Any additional equipment required is specified in the instruction for the
lifting accessory. Contact ABB for more information.
How to lift and turn the robot into position for wall position: Contact ABB for more
information.
How to lift and turn the robot into position for tilted position: Contact ABB for more
information.
Illustration
xx1500002117

2.3.3 Setting the system parameters for a suspended or tilted robot
General
The robot is configured for mounting parallel to the floor, without tilting, on delivery.
The method for mounting the robot in a suspended (upside down) or tilted position
is basically the same as for floor mounting, but the system parameters that describe
the mounting angle (how the robot is oriented relative to the gravity) must be
re-defined.
Note
IRB 2600-20/1.65 type C, IRB 2600-12/1.65 type C is not available for suspended
installation.
Note
With suspended installation, make sure that the gantry or corresponding structure
is rigid enough to prevent unacceptable vibrations and deflections, so that
optimum performance can be achieved.
Note
The allowed mounting positions are described in the product specification for
the robot. The requirements on the foundation are described in Requirements,
foundation on page 46.
System parameters
Note
The mounting angle must be configured correctly in the system parameters so

that the robot system can control the movements in the best possible way. An
incorrect definition of the mounting angle will result in:
• Overloading the mechanical structure.
• Lower path performance and path accuracy.
• Some functions will not work properly, for example Load Identification and
Collision detection.
Gravity Beta
If the robot is mounted upside down or on a wall (rotated around the y-axis), then
the robot base frame and the system parameter Gravity Beta must be redefined.
Gravity Beta should then be π (+3.141593) if the robot is mounted upside down
(suspended), or ±π/2 (±1.570796) if mounted on a wall.
The Gravity Beta is a positive rotation direction around the y-axis in the base
coordinate system. The value is set in radians.

Continued
Gravity Alpha
If the robot is mounted on a wall (rotated around the x-axis), then the robot base
frame and the system parameter Gravity Alpha must be redefined. The value of
Gravity Alpha should then be ±π/2 (±1.570796).
The Gravity Alpha is a positive rotation direction around the x-axis in the base
coordinate system. The value is set in radians.
Note
The system parameter Gravity Alpha is not supported for all robot types. It is not
supported for IRB 140, IRB 1410, IRB 1600ID, IRB 2400, IRB 4400, IRB 6400R,
IRB 6400 (except for IRB 6400 200/2.5 and IRB 6400 200/2.8), IRB 6600, IRB
6650, IRB 6650S and IRB 7600 (except for IRB 7600 325/3.1).
If the robot does not support Gravity Alpha, then use Gravity Beta along with the
recalibration of axis 1 to define the rotation of the robot around the x-axis.
Note
The parameter is supported for all robots on track when the system parameter
7 axes high performance motion is set, see Technical reference manual - System
parameters.
Gamma Rotation
Gamma Rotation defines the orientation of the robot foot on the travel carriage
(track motion).
Mounting angles and values

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

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

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

The following illustration shows the IRB 120, but the same principle applies for all
robots.
xx1500000532
Pos Mounting angle Gravity Alpha

1 0° (Floor mounted) 0
2 45° (Tilted) 0.785398
3 90° (Wall) 1.570796
4 -90° (Wall) -1.570796
Note
For suspended robots (180°), it is recommended to use Gravity Beta instead of

Gravity Alpha.

Continued
Defining the parameter in the IRC5 software

The value of the system parameters that define the mounting angle must be
redefined when changing the mounting angle of the robot. The parameters belong
to the type Robot, in the topic Motion.
How to calculate a new value is detailed in Mounting angles and values on page 60.
The system parameters are described in Technical reference manual - System
parameters.
The system parameters are configured in RobotStudio or on the FlexPendant.

2.3.4 Manually releasing the brakes
General
The section below describes how to release the holding brakes of each axis' motor.
This can be done in one of three ways:
• using the push-button when the robot is connected to the controller.
• using the push-button on the robot with an external power supply.
• using an external voltage supply directly on the respective brake.
DANGER
When releasing the holding brakes with push-buttons, the robot must be properly
attached!
DANGER
When releasing the holding brakes, the robot axes may move very quickly and
sometimes in unexpected ways!
Make sure no personnel is near or beneath the robot arm!
Using the push-button when the robot is connected to the controller

This procedure details how to release the holding brakes with push-buttons, when
the robot is connected to the controller.
Action Note
1 The internal brake release unit is located
at the base of the robot.
xx0800000272
2 The brake release unit is equipped with

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

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

This procedure details how to release the holding brakes with the push-buttons,
when the robot is not connected to the controller.
Action Note
1 Connect an external 24VDC power supply to
the connector R1.MP on the robot base.
Note
Be careful not to interchange the 24V and 0V

pins!
If they are mixed up, damage can be caused
to the brake release unit and the system
board!
WARNING
Incorrect connections can cause all brakes

to be released simultaneously!
xx0800000269
Connect to connector R1.MP:

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

Continued
Using an external voltage supply directly on the respective brake

This procedure details how to release the holding brake of a specific axis by
supplying external voltage directly on the brake.
Action Note
1 Every axis has a holding brake built into the Make the connection to the current motor
axis motor. This holding brake may be re- according to the Circuit Diagram.
leased by connecting 24VDC power supply See chapter Circuit diagram on page 453.
directly to one of the connectors in the motor.
DANGER
When power is connected directly to the

brake cable, the brake will be released imme-
diately when the power is switched on.
This may cause some unexpected robot
movements!
2 Connect an external 24 VDC power supply Axes 1, 2 and 3:

to the motor, according to the figures. Pos 2: +24 V
Note
Be careful not to interchange the 24V and 0V

pins!
If they are mixed up, damage can be caused Pos 5: 0 V
to the intergrated quenching circuits.
WARNING
Incorrect connections can cause all brakes

to be released simultaneously! xx1400001984
Axes 4, 5 and 6:
Pos 6: 0 V Pos 4: +24 V
xx1400001985

2.3.5 Orienting and securing the robot
Introduction
This section describes how to orient and secure the robot to the foundation or base
plate in order to run the robot safely. The requirements made on the foundation
are shown in sections Loads on foundation, robot on page 45 and Requirements,
foundation on page 46.
Hole configuration, base

The illustration shows the hole configuration used when securing the robot.
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
xx0900000193
A Center axis 1
Note
Only the three outer holes are used to secure the robot!
IRB 2600-20/1.65 type C, IRB 2600-12/1.65 type C

G
12
0°
3x 18,5
0,5 D E G
G +0,039
2x 35 H8 0
G 0,25 D E
20 45
2x 3 D E B
Rmax 0,8 3,2
500
0°
12
SECTION G-G
xx2000001773

Continued
Dimension, mounting surface and guide bushing

The figure shows the dimension of the mounting surface and guide bushings.
E F
Ø60
Ø0.5 AB
C C (3 2.5 25
X12 2x 1x45º
0º
Ø 35 -0.025 f7
) (A)
-0.050
Ø22
1.6
Ø 500
A B B
A
0.5 (C)
Ø35 +0.024 J8
1
-0.015
216.5 2x Ø 90 R
B
(433±0.5)
G 433 ±0.5
G (D)
Ø35 +0.024 J8
-0.015
A (37)
1.6
1x45º
10 10
20 min 20 min 30 min
M16 M16 M16

A-A B-B C-C
xx1700001492
(C) 3x common zone

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

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

Continued
Securing parts/Facts Dimension Note

Guide bushings Article number: 21510024-
169.
Added to the rear bolt holes,
to allow the same robot to be
re-mounted without program
adjustments.
xx1200000885
Level surface requirements
xx0300000251
Orienting and securing the robot

Use this procedure to orient and secure the robot.
Action Note
1 Make sure the installation site for the robot
conforms to the specifications in section Pre-
installation procedure on page 44.
2 Prepare the installation site with attachment Hole configuration of the base is shown
holes. in the figure in:
• Hole configuration, base on
page 66
3
CAUTION

kg.
All lifting accessories used must be sized
accordingly!
4
CAUTION
When the robot is put down after being lifted

or transported, there is a risk of it tipping, if
not properly secured.
5 Lift the robot to its installation site. How to lift the robot is described in sec-
tion:
• Lifting robot with roundslings on
page 55
6 Fit two guide bushings to the rear bolts in the
base.
7 Guide the robot gently, using the attachment Make sure the robot base is correctly fit-
screws while lowering it into its mounting ted onto the guide sleeves.
position.

Continued
Action Note
8 Fit the securing screws and washers in the
attachment holes of the base.
9 Tighten the bolts in a criss-cross pattern to
ensure that the base is not distorted.
Isolating AW manipulator
CAUTION
If the manipulator is used for arc welding and is mounted on a pedestal, make
sure that the manipulator is isolated from the pedestal with isolators.
xx1400000831
A Attachment point, front (no guide sleeve)

B Manipulator base
C Screw M16x120
D Plain washer
E Guide sleeve
F Isolator
G Nut M16
Securing robot on a mounting plate

When bolting a mounting plate or frame to a concrete floor, follow the general
instructions for expansion-shell bolts.
Screw joints must be able to withstand the stress loads defined in section Loads
on foundation, robot on page 45.

2.3.6 Fitting equipment on robot
Introduction
The robot features mounting holes for additional equipment.
Access to any of the following mounting holes may be obstructed by any additional
cabling, equipment, etc., fitted by the robot user. Make sure the required mounting
holes are accessible when planning the robot cell.
Note
All equipment and cables used on the robot, must be designed and fitted not to
damage the robot and/or its parts.
Note
Never drill a hole in the robot without first consulting ABB!
Robot dimensions
Dimensions IRB 2600-20(12)/1.65, IRB 2600 Type C-20(12)/1.65
1019
323
238,4 190,6 795 85
115
700
1382
445
255,7 255,7 CL Axis 1 150

291 A
275
C
676
B
A
xx0900000481
Pos Description
A R 337 Minimum turning radius of axis 1
B R 98 Minimum turning radius of axis 4

Continued
Pos Description
C IRB 2600ID = 281 mm
Other types than Type A (IRB 2600ID) = 276 mm
Dimensions IRB 2600-12/1.85
xx0900000680
Pos Description
B For all other dimensions see IRB 2600-20(12)/1.65

Continued
Dimensions IRB 2600ID-15/1.85
xx1000000962
Pos Description
A For dimensions, see IRB 2600-X/1.85
B R 172 Minimum turning radius for axis 4

Continued
Dimensions IRB 2600ID-8/2.00
xx1000000963
Pos Description
A For dimensions, see IRB 2600-X/1.85
B R 172 Minimum turning radius for axis 4

Continued
Fitting equipment on robot - Load areas

The shaded area indicates the permitted positions (center of gravity) for any extra
equipment fitted in the holes intended for this purpose.
IRB 2600 standard
B
200 180 240 120 200
300
300
250
280 360
A
260
260
C
IRB 2600 -1.65 = 700
IRB 2600 -1.85 = 900
200
380
xx0900000189
Variant Max load A Max load B Max load C Max load Max load D
A+C
IRB 2600-20/1.65 10 kg 1 kg 10 kg 10 kg 35 kg
IRB 2600 Type C-
20/1.65
IRB 2600-12/1.85
IRB 2600-12/1.65 15 kg 1 kg 15 kg 15 kg 35 kg
IRB 2600 Type C-
12/1.65

Continued
IRB 2600ID
xx1000000319
Variant Max load A Max load B Max load C Max load Max load D
A+C
IRB 2600ID-15/1.85 10 kg 1 kg 10 kg 10 kg 35 kg
IRB 2600ID-8/2.00 15 kg 1 kg 15 kg 15 kg 35 kg
Note
Maximum loads must never be exceeded!

Continued
Fitting equipment on base and frame

The illustrations show the fitting holes available for fitting extra equipment on the
base and frame of the robot.
IRB 2600 Standard & ID.
xx0900000227
A Attachment holes on base

B Center axis 2

Continued
Fitting equipment on lower and upper arm

The illustrations show the fitting holes available for fitting extra equipment on the
lower and upper arms of the robot.
IRB 2600 standard
xx0900000234
A Center axis 4
B Center axis 3

Continued
IRB 2600ID
xx1000000707
A Hole through axis 4, diameter 50

B Center axis 3
C 2x M8 through

Continued
Lower arm of IRB 2600 -12/1.85, IRB 2600ID -15/1.85 and -8/2.00
445
xx0900000492
- The uppermost holes for fitting equipment on the lower arm are only applicable
to variant IRB 2600 -12/1.85.
Lower arm of IRB 2600 -20/1.65 and -12/1.65, IRB 2600 Type C-20(12)/1.65
445
xx0900000491

Continued
Upper arm
xx1000000823
A Holes on top of upper arm, 2 pcs

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

Continued
Fitting equipment on wrist and mounting flange IRB 2600/IRB 2600 ID.
The illustration shows the fitting holes available for fitting extra equipment on the
wrist of the robot.
The illustration also shows the mechanical interface for the mounting flange.
IRB 2600 standard
110
6 H7 8
12,5
D
0,05 B C
30°
25
P
50
P-P
60°
2x M6 12 10
C
B
79 (2x M6)
6x M6
63 h8
31,5H8
0,3 B C D
P
7
A = R98
xx0800000278
A Smallest circumscribed radius axis 4
Note
Use attachment screws M6, quality 12.9 and 10 mm used thread length.

Continued
IRB 2600ID
xx1000000822
A Smallest circumscribed radius axis 5

B Hole through axis 6, diameter 50 mm
C See table below!
Variant C mm
IRB 2600ID-15/1.85 135
IRB 2600ID-8/2.00 200
Fastener quality
When fitting tools on the tool flange, only use screws with quality 12.9. For other
equipment use suitable screws and tightening torque for your application.

2.3.7 Loads fitted to the robot, stopping time and braking distances
2.3.7 Loads fitted to the robot, stopping time and braking distances
General
Any loads mounted on the robot must be defined correctly and carefully (with
regard to the position of center of gravity and mass moments of inertia) in order
to avoid jolting movements and overloading motors, gears and structure.
CAUTION
Incorrectly defined loads may result in operational stops or major damage to the
robot.
References
Load diagrams, permitted extra loads (equipment) and their positions are specified
in the product specification. The loads must be defined in the software.
• Operating manual - IRC5 with FlexPendant
Stopping time and braking distances

The performance of the motor brake depends on if there are any loads attached
to the robot. For more information, see product specification for the robot.

2.4.1 Axes with restricted working range
2.4 Restricting the working range
2.4.1 Axes with restricted working range
General
When installing the robot, make sure that it can move freely within its entire working
space. If there is a risk that it may collide with other objects, its working space
should be limited.
The working range of the following axes may be restricted:
• Axis 1, hardware (mechanical stop) and software
• Axis 2, software
• Axis 3, software.
This section describes how to install hardware that restricts the working range.
Note
Adjustments must also be made in the robot configuration software (system

parameters). References to relevant manuals are included in the installation
procedures.
WARNING
Remove the mechancial stop bracket if the robots full working range is from a
mechanical stop to another mechanical stop. Otherwise the mechanical stop pin
will be worn out.
xx1500000253

2.4.2 Mechanically restricting the working range of axis 1
Mechanically restricting the working range

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

changes in the mechanical limitations of the working range. The system
parameters that must be changed (Upper joint bound and Lower joint bound)
are described in Technical reference manual - System parameters.
Required equipment
Equipment, etc. Art. no. Note

Mechanical stop, axis 1 See Spare part Includes two additional stop lugs, attachment
lists on page 451. screws, washers and instruction
Attachment screw See Spare part 2 pcs/stop lug
lists on page 451. Hex socket head cap screw M12x40, quality
8.8-A3F
Washer See Spare part 2 pcs/lug
lists on page 451. 13x24x2.5
Standard toolkit Content is defined in section Standard tools

on page 447.
Other tools and procedures These procedures include references to the
may be required. See refer- tools required.
ences to these procedures
in the step-by-step instruc-
tions below.

Continued
Additional stops
The additional stops are fitted as shown in the figure.
D, E
xx0800000273
A Movable mechanical stop. Limited to:

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

Continued
Fitting, mechanical stop axis 1

How to fit the additional mechanical stop to the base is described in the procedure.
Mounting instructions are also supplied with the kit.
Action Note
1 Determine the position of the stop lugs. See the figure Additional stops on
page 86 for guidance.
2 Fit the stop lugs firmly with attachment Specified in Required equipment on
screws and washers according to the figure page 85.
Additional stops on page 86. Tightening torque: 82 Nm

2.5.1 Installation of cooling fan for motors (option)
2.5 Installing options
General
A cooling fan can be installed on motor axis 1 and/or axis 2!
Location of cooling fans

The fans are installed on the motors, axes 1 or 2, as shown in the figure below.
xx0900000232
A Fan, motor axis 1

B Fan, motor axis 2
C Protection cover

Continued
Cooling fan
The details of the cooling fan are shown in the figure below.
xx0900000137
A Fanbox
B Groove in the connector
C Back plate
D Part of the fanbox that can be removed, if needed. NOTE! Only valid on motor
axis 1!
Required equipment
Equipment Article number Note

Cooling fans axes 1 and 2 - For Spare part no. see chapter Spare
parts:
• Spare part lists on page 451
Locking liquid - Loctite 243. Used for the three tightening
screws.
Standard toolkit - Content is defined in section Standard
tools on page 447.
Circuit diagram - See chapter Circuit diagram on page 453.
Other tools and procedures These procedures include references to
may be required. See refer- the tools required.
tions below.

Continued
Installation, fan on motor axis 1 and 2

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

• electric power supply to the robot
• hydraulic pressure supply to the robot
• air pressure supply to the robot
Before entering the robot working area.
2 Remove the back plate of the fanbox. See the figure in:
• Cooling fan on page 89
3 Place the fanbox around motor axis 1 and 2. See the figure in:
• Cooling fan on page 89
4 Refit the back plate of the fanbox.
5 See the figure in:
Tip • Cooling fan on page 89
Only applicable to fan fitted on axis 1!

If there is a lack of space between motor and
robot, it is possible to remove part of the fanbox.
6 Push the fanbox in line with the connection box. Align the upper part of the fan with the
lower part of the connection box.
A B C
xx1000000124
Parts:
• A: Connection box
• B: Position where the fan shall
be aligned with connection box
• C: Fan
7 Fit the fanbox with two attachment screws
M6x25.

Continued
Action Note
8 Connect the fan connector to motor and fan.
xx0900000405
Parts:
• A: Connector, signal
• B: Connector, power
• C: Fan cable
• D: Connector, fan
• E: Cable gland
• F: Motor cover, with fan cable
9 After fitting the motor cover, fit the protection A
cover using two attachment screws for the
motor cover.
xx0900000406
Parts:
• A: Protection cover
• B: Fan
10 Secure the fan cable to the protection cover
with a cable strap.

2.5.2 Installing an expansion container

IRB 2600ID-15/1.85, IRB 2600ID-8/2.0.
Introduction to the expansion container

The expansion container is needed on suspended robots (IRB 2600-20/1.65, IRB
2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB 2600ID-8/2.0) to make
sure that the amount of oil in gearbox axis 1 covers all important parts. Robots
ordered as suspended robots (Option 224-2) have the expansion container installed
on delivery.
Note
Manipulators delivered for floor mounting must have the option 224-2 added
before changing mounting position to inverted.
IRB2600-20/1.65 type C and IRB2600-12/1.65 type C are not valid for inverted
mounting.

Continued
Expansion container
xx1000000318
A Cover
B Attachment screw M6x16, quality 8.8-A2F (5 pcs)
C Oil expansion container with cover
D Base
E O-ring D220x5
F Attachment screw M5x20, quality 8.8-A2F and washer (2+2 pcs)
G O-ring D1=9.5 D2=1.6
H Oil plug (to be removed)
Required equipment
Equipment Note
Expansion container Kit including oil.
Lifting accessory 3HAC034766-001
Lifting instruction Included with the lifting accessory.
Grease -
Locking liquid 3HAB7116-1
Loctite 243
O-ring for base cover Replace if damaged.

Continued
Installing an expansion container

Use this procedure to install the expansion container.
Action Information
1 Lift the robot using the lifting accessory and See Lifting and turning a suspended
place it in suspended position with the base mounted robot on page 58.
free for installation work.
2 Remove the cover and the o-ring from the
base.
3 Remove two existing attachment screws as
shown in the figure.
xx1500001958
The screws must be replaced with longer

screws.
4 Remove the oil plug from the base.
xx1900001818
5 Fit a plastic plug in the expansion container

drain hole.
xx1500001956
6 Fill the expansion container with oil. Oil volume: 0.4 l

Continued
Action Information
7 Apply locking liquid to the three screw holes Locking liquid: 3HAB7116-1 (Loctite 243).
in the expansion container. Screws: M6x8 (3 pcs).
Knock in the VK-cover with a rubber mallet.
Secure with three screws and washers.
xx1500001957
8 Remove the plastic plug.

9 Apply some grease on the small o-ring and
place it in the recess on the expansion con-
tainer.
xx1500001956
10 Place the expansion container in the base

and place it so the drain holes match.
Tip
Turn and install the container quickly to avoid

oil spill.
11 Secure the expansion container with the at-

tachment screws and washers.
Wipe off any oil residuals before continuing. xx1500001959
Tightening torque 6 Nm.

12 Check the o-ring used on the cover. Replace
it if damaged.
13 Refit the cover on the base with its attach-
ment screws.
xx1900001819

Continued
Action Information
14 Turn the robot so it is not suspended.
15 Turn the robot to suspended position.
16 Inspect the oil level. See procedure for suspended robot, In-
specting oil level, axis-1 gearbox on
page 117.

2.5.3 Installation of Foundry Plus Cable guard (option no. 908-1)
2.5.3 Installation of Foundry Plus Cable guard (option no. 908-1)
Introduction
Separate instructions for IRB 2600, 4600, 6620, 6640, 6650S, 6660 and 7600 are
available in English, German, French, Spanish, and Italian and can be found for
registered users on myABB Business Portal (www.abb.com/myabb) and delivered
with the Cable guard, article number 3HAC035933-001.

2.5.4 Signal lamp (option)
2.5.4 Signal lamp (option)
Description
A signal lamp with a yellow fixed light can be mounted on the robot, as a safety
device.
Installation
See the assembly instruction delivered with the signal lamp.
Function
The lamp is active in MOTORS ON mode.
Further information
Further information about the MOTORS ON/MOTORS OFF mode may be found in
the product manual for the controller.

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

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

to the robot, before entering the robot work-
ing area.
2
CAUTION
Components may be hot.
3
Note
Before opening the oil plug, make certain that

the oil plug is above the oil level. Place the
robot accordingly.
4 Open oil plug filling very carefully!

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

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

2.7.1 Start of robot in cold environments
2.7 Robot in cold environments
2.7.1 Start of robot in cold environments
Introduction
This section describes how to start the robot in a cold environment if it is not starting
the normal way.
Problems with starting the robot

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

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

Depending on how cold the environment is and what program is being used, the
speed might need to be ramped up until reached maximum. The table shows
examples of how to adjust the speed:
Work cycles AccSet Speed/velocity
3 Work cycles 20, 20 v100 (100 mm/s)
5 Work cycles 40, 40 v400 (400 mm/s)
5 Work cycles 60, 60 v600 (600 mm/s)
5 Work cycles 100, 100 v1000 (1000 mm/s)
More than 5 Work cycles 100, 100 Max.
If the program consists of large wrist movements, it is possible that the reorientation
velocity, which is always high in predefined velocities, needs to be included in the
ramping up.

2.8.1 Robot cabling and connection points
2.8 Electrical connections
Introduction
Connect the robot and controller to each other after securing them to the foundation.
The lists below specify which cables to use for each respective application.
CAUTION
Connect the male and female connectors perfectly aligned horizontally to avoid
any kind of tilt or skew.
CAUTION
Verify that the robot serial number is according to the number(s) in the Declaration
of Incorporation (DoI).
Main cable categories

All cables between the robot and controller are divided into the following categories:
Cable category Description
Robot cables Handles power supply to and control of the robot's motors
as well as feedback from the serial measurement board.
Specified in the table Robot cables on page 101.
Fan cables (option) Handles supply to and feedback from any cooling fan on
the robot.
Specified in the table Fan cables (option) on page 103.
Customer cables (option) Handles communication with equipment fitted on the robot
by the customer, low voltage signals and high voltage power
supply + protective ground.
The customer cables also handle databus communication.
See the product manual for the controller, see document
number in References on page 10.
External axes cables (option) Handles power supply to and control of the external axes'
motors as well as feedback from the servo system.
See the Application manual - Additional axes and stand
alone controller (M2004), see document number in Refer-
ences on page 10.
Robot cables
These cables are included in the standard delivery. They are completely
pre-manufactured and ready to plug in.
Cable sub-category Description Connection Connection
point, cabinet point, robot
Robot cable, power Transfers drive power from the XS1 R1.MP
drive units in the control cabinet
to the robot motors.

Continued
Cable sub-category Description Connection Connection

point, cabinet point, robot
Robot cable, signals Transfers resolver data from XS2 R1.SMB
and power supply to the serial
measurement board.
Robot cable, power
Cable Art. no.

Robot cable, power: 7 m 3HAC026787-001
Robot cable, signals
Cable Art. no.

Robot cable signal, shielded: 7 m 3HAC068917-001
Bending radius for static floor cables

The minimum bending radius is 10 times the cable diameter for static floor cables.
A
B
xx1600002016
A Diameter
B Diameter x10
Grounding and bonding point on manipulator

There is a grounding/bonding point on the manipulator base. The grounding/bonding
point is used for potential equalizing between control cabinet, manipulator and any
peripheral devices.

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

2600ID-8/2.0
xx1600001001
xx1800001155
Fan cables (option)

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

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

fan for motors (option) on page 88.

2.8.2 Customer connection on robot
Location of customer connection

For the connection of extra equipment to the robot, cables and air hose are
integrated into the robot´s cabling, and there can be two UTOW71210SH06 and
one UTOW71626SH06 connector on the front part of the upper arm.
Note
The maximum leakage current for attached equipment must not exceed 10mA.
The customer connections are located on the robot as shown in the figure.
Customer connections on upper arm
A B C D
xx2000001657
A R2.PROC1
Air M16x1.5
(24° cone sealing)
B R2.ETHERNET
C R2.CP or R2.CBUS
D R2.CS or R2.CP/CS

Continued
Customer connections on upper arm with signal lamp

The figure shows the customer connections on the upper arm, including the optional
signal lamp that can be fitted to the arm house.
A B C D
xx2000001658
A R2.PROC1
Air M16x1.5
(24° cone sealing)
B R2.ETHERNET
C R2.CP or R2.CBUS
D R2.CS or R2.CP/CS
E Signal lamp
- R3.H1 +, R3.H2 - (inside the arm house, not shown in figure)

Continued
Customer connections base
A B C D
xx2000001636
A R1.CP/CS
B R1.PROC1 (Air M16x1.5)
C R1.ETHERNET
D R1.SMB
Customer connections base with 7th axis
A B E C D
xx2000001637
A R1.CP/CS
B R1.PROC1 (Air M16x1.5)
C R1.ETHERNET
D R1.SMB
E R2.FB7

Continued
Extra equipment connections

Connections to the:
• air hose ( 3/8") is located on the front part of the upper arm and at the base.
Max. 8 bar. Inner diameter of the air hose: 9.5 mm.
Number of signals, customer connections option Parallel&Air (803-1):
• 23 (50V, 0.5A)
• 9 (300V, 2A). 8 are double crimped in R1.CP/CS and 1 is only accessible in
the robot base.
• 1 protective ground
Number of signals, customer connections option Ethernet, Parallel&Air (803-2)
and DeviceNet, Parallel&Air (803-3):
• 8 (50V, 0.5A)
• 3 (300V, 2A)
• 2 DeviceNet
• 4 EtherNet
Number of signals, customer connections option Profibus, Parallel&Air (803-4):
• 8 (50V, 0.5A)
• 2 (300V, 2A)
• 2 Profibus
Connection sets
To connect power and signal conductors to the robot base/upper arm connectors,
the following parts are recommended.
Connection Connector Art. no. Content
set
PROC1 on R1.CP/CS 3HAC16667-1 • Sockets for cable area of 0.14-2.5
base mm²
• Hood foundry
• Hinged frame, hood
• Multicontact-module, female
Connector set R1.ETHER- 3HAC033181-001 • Hose coupling
on base NET • M12 connector, male
R2.CP/R2.CS R2.CP/R2.CS 3HAC025396-001 • Pins for cable area 0.21 - 0.93
mm 2
• Bottle shaped shrinking hose
• Angle shaped shrinking hose
• Hose coupling
Connector set R2.ETHER- 3HAC070439-001 • Pins for cable area 0.21 - 0.93
upper arm NET mm 2
• Bottle shaped shrinking hose
• Angle shaped shrinking hose

Continued
Power supply connections on the robot
Signal name Customer Ter- Customer Contact Customer Contact on robot base
minal Controller on Upper arm, R2 (cable between robot and controller
not supplied)
CPA XP6.1 R2.CP.A R1.CP/CS.d1
CPB XP6.2 R2.CP.B R1.CP/CS.d6
CPC XP6.3 R2.CP.C R1.CP/CS.d3
CPD XP6.4 R2.CP.D R1.CP/CS.d4
CPE XP6.1 R2.CP.E R1.CP/CS.d1
CPF XP6.2 R2.CP.F R1.CP/CS.d6
CPG R2.CP.G (Earth)
CPH - R2.CP.H R1.CP/CS.d7
CPJ XP6.3 R2.CP.J R1.CP/CS.d3
CPK XP6.4 R2.CP.K R1.CP/CS.d4
Signal connection on the robot
not supplied)
CSA XP5.1.1 R2.CS.A R1.CP/CS.b1
CSB XP5.1.2 R2.CS.B R1.CP/CS.b2
CSC XP5.2.1 R2.CS.C R1.CP/CS.b3
CSD XP5.2.2 R2.CS.D R1.CP/CS.b4
CSE XP5.2.3 R2.CS.E R1.CP/CS.b5
CSF XP5.2.4 R2.CS.F R1.CP/CS.b6
CSG XP5.1.9 R2.CS.G R1.CP/CS.b7
CSH XP5.1.10 R2.CS.H R1.CP/CS.b8
CSJ XP5.1.11 R2.CS.J R1.CP/CS.b9
CSK XP5.1.12 R2.CS.K R1.CP/CS.b10
CSL XP5.1.3 R2.CS.L R1.CP/CS.b11
CSM XP5.1.4 R2.CS.M R1.CP/CS.b12
CSN XP5.1.5 R2.CS.N R1.CP/CS.b13
CSP XP5.1.6 R2.CS.P R1.CP/CS.b14
CSR XP5.3.1 R2.CS.R R1.CP/CS.b15
CSS XP5.3.2 R2.CS.S R1.CP/CS.b16
CST XP5.3.3 R2.CS.T R1.CP/CS.b18
CSU XP5.3.4 R2.CS.U R1.CP/CS.b19
CSV XP5.3.5 R2.CS.V R1.CP/CS.b20
CSW XP5.3.6 R2.CS.W R1.CP/CS.b21
CSX XP5.2.9 R2.CS.X R1.CP/CS.b22

Continued
not supplied)
CSY XP5.2.10 R2.CS.Y R1.CP/CS.b23
CSZ XP5.2.11 R2.CS.Z R1.CP/CS.b24

3 Maintenance
3.1 Introduction
3 Maintenance
3.1 Introduction
Structure of this chapter

This chapter describes all the maintenance activities recommended for the IRB
2600/IRB 2600 ID.
It is based on the maintenance schedule found at the beginning of the chapter.
The schedule contains information about required maintenance activities including
intervals, and refers to procedures for the activities.
Each procedure contains all the information required to perform the activity,
including required tools and materials.
The procedures are gathered in different sections and divided according to the
maintenance activity.
Safety information
Observe all safety information before conducting any service work.
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 21 before performing any service
work.
The maintenance must be done by qualified personnel in accordance with the
safety requirements set forth in the applicable national and regional standards and
regulations.
Note
If the IRB 2600/IRB 2600 ID is connected to power, always make sure that the
IRB 2600/IRB 2600 ID is connected to protective earth and a residual current
device (RCD) before starting any maintenance work.
• Robot cabling and connection points on page 101.

3 Maintenance
3.2.1 Specification of maintenance intervals
3.2 Maintenance schedule and expected component life
3.2.1 Specification of maintenance intervals
Introduction
The intervals are specified in different ways depending on the type of maintenance
activity to be carried out and the working conditions of the IRB 2600/IRB 2600 ID:
• Calendar time: specified in months regardless of whether the system is
running or not.
• Operating time: specified in operating hours. More frequent running means
more frequent maintenance activities.
• SIS: specified by the robot's SIS (Service Information System). A typical
value is given for a typical work cycle, but the value will differ depending on
how hard each part is run.
The SIS used in M2004 is further described in the Operating manual - Service
Information System.
Robots with the functionality Service Information System activated can show active
counters in the device browser in RobotStudio, or on the FlexPendant.
Overhaul
Depending on application and operational environment a complete overhaul may
be necessary in average around 40000 hours.
ABB Connected Services and its Assessment tools can help you to identify the
real stress level of your robot, and define the optimal ABB support to maintain your
robot working.
Contact your local ABB Customer Service to get more information.

3 Maintenance
3.2.2 Maintenance schedule
General
The robot must be maintained regularly to ensure proper function. The maintenance
activities and intervals are specified in the following table.
Non-predictable situations also give rise to inspections of the robot. Any damage
must be attended to immediately.
The inspection intervals do not specify the life of each component. Values for these
are specified in the section Expected component life on page 116
Instructions for how to perform the different maintenance activities are found in
sections:
• Inspection activities on page 117
• Replacement / Changing activities on page 146
• Cleaning on page 183
Activities and intervals, standard equipment

The following table specifies the required maintenance activities and intervals.
Maintenance activity Equipment Interval
Cleaning Robot Cleaning the IRB 2600/IRB 2600 ID
on page 183
Inspection Oil level in axis-1 gearbox Every 12 months.
Inspection Oil level in axis-5 gearbox No inspection needed.
(ID)
Inspection Oil level in axis-5-6 gearbox Every 12 months.
Inspection Oil level in axis-5-6 gearbox Every 12 months.
(ID)
Inspection Robot harness Every 12 months i .
Inspection Information labels Every 12 months.
Inspection Dampers Every 12 months.
Inspection Pressure relief valve Every 12 months ii .
Inspection Mechanical stop Every 12 months.
Change Oil in axis-1 gearbox First change when DTC iii reads:
• 6,000 hours
Second change when DTC iii reads:
• 24,000 hours
Following changes:
• Every 24,000 hours.

3 Maintenance
Continued
Maintenance activity Equipment Interval

• 6,000 hours
• 24,000 hours
Following changes:
• 6,000 hours
• 24,000 hours
Following changes:
Change Oil in axis-4 gearbox No change needed.
Change Oil in axis-5 gearbox No change needed.
(ID)
Change Oil in axis-5-6 gearbox First change when DTC iii reads:
• 6,000 hours
• 24,000 hours
Following changes:
Change Oil in axis-5-6 gearbox First change when DTC iii reads:
(ID) • 6,000 hours
• 24,000 hours
Following changes:
Overhaul Robot Every:
• 40,000 hours .
Replacement Battery pack, measurement 36 months or battery low alert iv
system of type RMU101 or
RMU102 (3-pole battery con-
tact)
Replacement Battery pack, measurement Battery low alert v
system with 2-pole battery
contact, e.g. DSQC633A
i Replace when damage or cracks is detected or life limit is approaching that specified in section
Expected component life on page 116.
ii Check more often if the environment is very contaminated.
iii DTC = Duty Time Counter. Shows the operational time of the robot.
iv The battery low alert (38213 Battery charge low) is displayed when the battery needs to be replaced.
The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned
on until the battery is to be replaced.
See the replacement instruction for more details.
v The battery low alert (38213 Battery charge low) is displayed when remaining backup capacity
(robot powered off) is less than 2 months. The typical lifetime of a new battery is 36 months if the
robot is powered off 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime
can be extended with a battery shutdown service routine. See Operating manual - IRC5 with
FlexPendant for instructions.

3 Maintenance
Continued
Activities and intervals, optional equipment

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

3 Maintenance
3.2.3 Expected component life
3.2.3 Expected component life
General
The expected life of a specific component of the robot can vary greatly depending
on how hard it is run.
Expected component life - protection type Standard
Component Expected life Note

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

3 Maintenance
3.3.1 Inspecting oil level, axis-1 gearbox
3.3 Inspection activities
Different versions of the gearbox

There are two different versions of the axis-1 and axis-2 gearboxes. The different
versions affect the mechanical structure of the base, frame and lower arm.
Differences in the mechanical structure are pointed out in the procedure as valid
for different robot version:
• IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-15/1.85,
IRB 2600ID-8/2.0
• IRB 2600-20/1.65 type C, IRB 2600-12/1.65 type C
Further information about the differences are given in Non-compatible versions of
axis-1 and axis-2 gearboxes on page 434.
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 119.
If the robot is suspended, follow the procedures in Inspecting oil level, axis-1
gearbox (suspended robot) on page 120.
Location of oil plugs (floor mounted)

The axis 1 gearbox is located between the frame and base of the robot. The oil
plug for inspection is shown in the figure.
xx0800000304
A Oil plug, inspection

B Oil plug, gearbox, with sealing washer

3 Maintenance
Continued
xx1800001132
A Oil plug, inspection
Location of oil plugs (suspended mounted)

The axis 1 gearbox is located between the frame and base of the robot. The oil
plug for inspection is shown in the figure.
xx1200000883
A Oil plug, inspection, with sealing washer

B Oil plug

installation.

3 Maintenance
Continued
Required equipment
Equipment Note
Oil plug sealing washer, gearbox 3HAC029646-001
Lubrication oil See section Type of lubrication in gearboxes
on page 146.
on page 447.
Other tools and procedures may be required. These procedures include references to the
See references to these procedures in the tools required.
step-by-step instructions below.
Inspecting oil level, axis-1 gearbox (floor mounted)

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

risks, see Gearbox lubricants (oil or grease)
on page 36.
2
DANGER
Turn off all:

to the robot, before entering the robot
working area.
3
CAUTION
The gearbox can contain an excess of

pressure that can be hazardous. Open the
oil plug carefully in order to let out the ex-
cess pressure.
4 Open the oil plug, inspection. See Location of oil plugs (floor mounted)
on page 117.

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

of the oil plug inspection hole.
xx1200001352
Parts:
A Oil level
B Measurement of required oil level
C Oil plug hole inspection
D Gear
6 Add oil if required. How to fill oil is described in section:
• Changing the oil, axis 1 gearbox on
floor mounted robots on page 148
7 Refit the oil plug, inspection. Tightening torque:
• 24 Nm
Inspecting oil level, axis-1 gearbox (suspended robot)

Use this procedure to inspect the oil level in the axis-1 gearbox for IRB 2600-20/1.65,
IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB 2600ID-8/2.0.
installation.
CAUTION
If the robot has the earlier design of the frame, and the robot is filled with an
amount of oil suited for an inverted position, the oil level of the axis-1 gearbox
will be above the oil plug hole when the robot is standing on the floor, which will
result in oil leakage if the plug is opened while robot stands on the floor! The oil
level of axis-1 gearbox can therefore only be inspected when the robot is mounted
in an inverted position!
Action Note
1
WARNING

on page 36.

3 Maintenance
Continued
Action Note
2
DANGER
Turn off all:

working area.
3
CAUTION

cess pressure.
4 Open the oil plug inspection on the axis 1 See the figure in:
gearbox. • Location of oil plugs (suspended
mounted) on page 118
5 Required oil level:
• up to the lower edge of the oil plug
hole.
Note
The oil plugs on gearbox axis 1 are now on

top.
xx1100000008

• Changing the oil, axis-1 gearbox
on suspended robots on page 156
7 Refit the oil plug. Tightening torque:
• 3-8 Nm
Note
Before refitting the oil plug in the gearbox,

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

3 Maintenance
3.3.2 Inspecting the oil level, axis 2 gearbox

• IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB 2600ID-15/1.85,
IRB 2600ID-8/2.0
Location of axis 2 gearbox

The axis 2 gearbox is located in the lower arm rotational center, underneath the
motor attachment. The oil plugs are shown in the figure.
xx0800000305
A Oil plug, inspection, when robot is floor mounted

B Oil plug, inspection, when robot is suspended (Quick connect fitting)
Required equipment
Equipment Note
on page 146.
Oil plug (Quick connect fitting) For article number see Spare part lists on
page 451.
on page 447.

3 Maintenance
Continued
Equipment Note
Inspecting oil level, axis 2 gearbox

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

on page 36.
2
DANGER
Turn off all:

working area.
3
CAUTION

cess pressure.
4 Open the oil plug, inspection (location de- See the figure in:
pends on how the robot is mounted). • Location of axis 2 gearbox on
page 122
Note
Always open the oil plug on top, depending

how the robot is mounted.

Required oil level:
of the oil plug hole (IRB 2600-20/1.65,
IRB 2600-12/1.65, IRB 2600-12/1.85,
IRB 2600ID-15/1.85, IRB 2600ID-
8/2.0).
28 mm ± 3 mm below the lower edge
of the oil plug hole (IRB 2600-20/1.65
type C, IRB 2600-12/1.65 type C).
6 Add oil if required. How to fill oil is described in section
on page 161

3 Maintenance
Continued
Action Note
• 24 Nm
Note

leakage.

3 Maintenance

The axis 3 gearbox is located in the upper arm rotational center, underneath the
motor attachment. The oil plug for inspection is shown in the figure.
The figure shows IRB 2600 Standard but the position of plugs are approximately
the same on IRB 2600ID.
xx0800000306
A Oil plug, armhouse

B Oil plug, gearbox (not visible in this figure)
Required equipment
Equipment Note
on page 146.
on page 447.

3 Maintenance
Continued
Inspecting the oil level, axis 3 gearbox

Action Note
1
WARNING

on page 36.
2 IRB 2600: Move the robot to where the upper

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

ing area.
4
CAUTION
The gearbox can contain an excess of pres-

sure that can be hazardous. Open the oil plug
carefully in order to let out the excess pres-
sure.
5 Open the upper oil plug. See the figure in:

• Location of axis 3 gearbox on
page 125
Required oil level:
• IRB 2600: 45 ± 5 mm from the upper
edge of oil plug hole.
• IRB 2600ID: 70 ± 3 mm from the upper
edge of oil plug hole.
on page 165
• in armhouse: 10 Nm
• in gearbox: 3 Nm

3 Maintenance

The axis 4 gearbox is located in the upper armhouse. The oil plug is shown in the
figure.
xx0800000307
A Oil plug, for filling and draining
Required equipment
Equipment Note
on page 146.
on page 447.
Inspecting the oil level, axis 4 gearbox

Action Note
1
WARNING

on page 36.

3 Maintenance
Continued
Action Note
2 Move the robot to where the upper arm points
straight up and the oil plug hole is on top of
the axis 4 gearbox.
3
DANGER
Turn off all:

ing area.
4
CAUTION

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

• Location of axis 4 gearbox on
page 127
Required oil level:
• IRB 2600: 15 ±3 mm below the oil plug
flange.
IRB 2600ID: 30 ±5 mm below the oil
plug flange.
on page 169
8 Refit the oil plug, filling. Tightening torque:
• 10 Nm

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

The gearbox axes 5-6 is located in the wrist unit. The oil plug is shown in the figure.
xx0900000139
A Oil plug, tilthouse

B Oil plug, wrist (also used as air inlet when draining from oil plug A)
Required equipment
Equipment Note
on page 146.
on page 447.
Inspecting oil level, gearbox axes 5-6 - wrist 12/20 kg

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

3 Maintenance
Continued
Action Note
2
DANGER
Turn off all:

ing area.
3
CAUTION

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

• Location of gearbox, axes 5-6 on
page 129
5 Required oil level:
• IRB 2600: 3 ± 3 mm from the lower
edge of the oil plug in the wrist house.
Open the oil plug in the tilthouse to al-
low the oil level between axis 5 and 6
to level.
• IRB 2600ID: Oil shall be visible in the
rear oil plug hole, almost on its way to
pour out of the hole.
6 If necessary, refill oil. How to fill oil is described in section:
• Changing oil, axes-5 and -6 gear-
boxes on page 173
• 10 Nm

3 Maintenance
3.3.6 Inspecting the cable harness
Location of cable harness

The figure shows the location of the cable harness.
The figure shows IRB 2600 with standard upper arm.
xx0900000384
A Cable harness
B Bracket, lower arm
C Bracket, lower arm
D Cable straps, one not visible here (steel)
E Bracket, frame
F Cable strap, lower arm (plastic)
G Bracket, upper arm
Required equipment
Equipment Note
on page 447.
Circuit diagram See chapter Circuit diagram on page 453.

3 Maintenance
Continued
Inspecting the cable harness

Use this procedure to inspect the cable harness. The inspection points are shown
in the figure Location of cable harness on page 131
Action Note
1
DANGER
Turn off all:

ing area.
2 Make an overall visual inspection of the cable

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

3 Maintenance
3.3.7 Inspecting information labels
Location of information labels

The figure shows the location of the information labels to be inspected.
xx1000000205
A Warning - Symbol of flash (4 pcs)

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

Labels See Spare part lists on
page 451.
Inspecting labels
Use this procedure to inspect the labels on the robot.
Action Note
1
DANGER
Turn off all:

ing area.

3 Maintenance
Continued
Action Note
2 Check all labels. See the figure in Location of information
labels on page 133.
3 Replace any missing or damaged labels.

3 Maintenance
3.3.8 Inspecting the mechanical stop pin, axis 1
Location of mechanical stop pin, axis 1

The mechanical stop pin is located on the frame as shown in the figure.
xx0800000298
A Fixed stop
B Mechanical stop pin, axis 1
Required equipment

Mechanical stop pin axis 1 See Spare part lists on
page 451.
Standard toolkit Content is defined in section
Standard tools on page 447.
Other tools and procedures These procedures include
may be required. See refer- references to the tools re-
ences to these procedures in quired.
the step-by-step instructions
below.

3 Maintenance
Continued
Inspection of mechanical stop pin, axis 1

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

ing area.
2 Regularly check that the mechanical stop pin See the figure in:
is not bent or damaged in any other way. • Location of mechanical stop pin,
axis 1 on page 135
3 How to replace the stop pin is described
Note in section Replacing stop pin axis 1 on
page 288.
If the mechanical stop pin has been deformed
or damaged, all of its mounting parts have to
be replaced.
xx0800000045
Parts:
A Attachment screws
B Bracket
C O-ring (2 pcs) - Not used if bracket (D)
is installed.
D Bracket
E Stop pin
4 Check that the mechanical stop pin is prop-

erly attached.

3 Maintenance
Continued
Action Note
5 Check that the mechanical stop pin can move
freely in both directions and the bracket
works as it is supposed to.
xx1000000222

3 Maintenance
3.3.9 Inspecting additional mechanical stops
Location of additional mechanical stops

The figure shows the location of the additional stops.
D, E
xx0800000273
A Movable mechanical stop. Limited to:

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

Mechanical stop set, axis 1 Includes:
• Stop
• Attachment screws plus washers
• Document for movable mechanical stop
For spare part number see Spare part lists on
page 451.

3 Maintenance
Continued
Equipment etc. Note

Standard toolkit Content is defined in section Standard tools on
page 447.
Other tools and procedures may be re- These procedures include references to the
quired. See references to these procedures tools required.
in the step-by-step instructions below.
Inspecting additional mechanical stops

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

ing area.
2 Check the additional mechanical stops on See the figure in:

axis 1 for damage. • Location of additional mechanical
stops on page 138
3 Make sure the stops are properly attached. Tightening torque:
• 82 Nm
4 If any damage on stops or attachment screws Attachment screws:
etc. is detected, the mechanical stops must • M12x40, quality 8.8-A3F
be replaced! • 2 pcs/stop lug

3 Maintenance
3.3.10 Inspecting dampers
Location of dampers
The figure shows the location of all dampers to be inspected.
The figure shows IRB 2600 with Standard upper arm.
xx0800000297
A Dampers axis 2 (IRB 2600 Standard and ID)

B Dampers axis 3 (IRB 2600 Standard and ID)
C Damper axis 5 (only on IRB 2600 Standard)
Required equipment
Equipment Spare part no. Note

Damper See Spare part lists on
page 451.
Standard toolkit - Content is defined in section

3 Maintenance
Continued
Inspecting dampers
Use this procedure to inspect the dampers.
Action Note
1
DANGER
Turn off all:

ing area.
2 Check all dampers for damage or cracks. See the figure in:
• Location of dampers on page 140
3 Check all dampers for existing impressions
larger than 2-3 mm.
4 Check attachment screws for deformation.
5 If any damage is detected the damper must
be replaced.

3 Maintenance
3.3.11 Inspecting the pressure relief valve
Location of the pressure relief valve

The figure shows the location of the pressure relief valve.
xx0900000131
A Pressure relief valve
Required equipment
Equipment Note
on page 447.
Inspecting pressure relief valve

Use this procedure to inspect the pressure relief valve.
Action Note
1
DANGER
Turn off all:

ing area.
2
DANGER
It is important to keep the pressure relief

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

3 Maintenance
Continued
Action Note
3 Check if the pressure relief valve is contam-
inated or covered with litter.
4 Clean if necessary.
Note
Use a cloth or a brush.

3 Maintenance
3.3.12 Inspecting Signal lamp (option)
Location of signal lamp

Signal lamp is an option.
Located as shown in the figure.
The figure shows IRB 2600 Standard.
B C D
xx0800000290
A Signal lamp
B R3.H1 +, R3.H2 -
C R2.CP
D R2.CS
Required equipment
Equipment Note
Signal lamp For spare parts no. see Spare parts - Spare
parts options in Product manual, spare
parts - IRB 2600.
on page 447.
Inspecting signal lamp

Use this procedure to inspect the function of the signal lamp.
Note
If the signal lamp is damaged, it shall be replaced!
Action Note
1 Check that the signal lamp is lit when motors
are put in operation ("MOTORS ON").

3 Maintenance
Continued
Action Note
2 If the signal lamp is not lit, continue tracing
the fault with the steps below.
3
DANGER
Turn off all:

ing area.
4 Check whether the signal lamp is broken. If

so, replace.
5 Check the cable connections.
6 Measure the voltage in connectors, motor 24V
axis 3.
7 Check the cabling. If a fault is detected, re-
place.
8 Seal and paint the joints that have been
opened. Also repair possible damages of the
special Foundry Prime paint coat of the robot.
See Cut the paint or surface on the robot be-
fore replacing parts on page 194.

3 Maintenance
3.4.1 Type of lubrication in gearboxes
3.4 Replacement / Changing activities
Introduction
This section describes where to find information about the type of lubrication,
article number and the amount of lubrication in the specific gearbox. It also
describes the equipment needed when working with lubrication.
Type and amount of oil in gearboxes

Information about the type of lubrication, article number as well as the amount in
the specific gearbox can be found in Technical reference manual - Lubrication in
gearboxes available for registered users on myABB Business Portal,
www.abb.com/myABB.
Note
The type of oil pre-filled in axis-4 gear differs from the type of oil recommended
for field maintenance, due to differences in factory and customer sites
prerequisites. The two types of oil are fully equal and compatible.
Use the type of oil specified in Technical reference manual - Lubrication in
gearboxes, even though it differs from the oil specified in WebConfig.
Location of gearboxes
The figure shows the location of the gearboxes.
xx0900000312

3 Maintenance
Continued
1 IRB 2600 Standard

2 IRB 2600ID
A Gearbox, axis 1
B Gearbox, axis 2
C Gearbox, axis 3
D Gearbox, axis 4
E Gearbox, axis 5-6
Equipment
Equipment Note
Oil dispenser Includes pump with outlet pipe.
Use the suggested dispenser or a similar one:
• Orion OriCan article number 22590
(pneumatic)
Nipple for quick connect fitting, with o-ring Used on the axis-2 gearbox (IRB 2600-20/1.65,
IRB 2600-12/1.65, IRB 2600-12/1.85, IRB
2600ID-15/1.85, IRB 2600ID-8/2.0).
Used on the axis-1 and axis-2 gearboxes (IRB
2600-20/1.65 type C, IRB 2600-12/1.65 type C).
Expansion container, gearbox axis 1 Used when the robot is fitted in a suspended
position.
(valid for IRB 2600-20/1.65, IRB 2600-12/1.65,
IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB
2600ID-8/2.0)

3 Maintenance
3.4.2 Changing the oil, axis 1 gearbox on floor mounted robots
General
This section describes how to change the axis-1 gearbox oil in a floor mounted
robot.

• 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
Location of oil plugs

The oil plugs are located according to following figures.
xx0800000304
A Oil plug, filling and venting

B Oil plug, draining, with sealing washer

3 Maintenance
Continued
xx1800001135
A Oil plug, filling and draining

B Oil plug, venting
Required equipment
Equipment Note
Oil plug sealing washer, gearbox Valid for IRB 2600-20/1.65, IRB 2600-12/1.65,
IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB
2600ID-8/2.0
3HAC029646-001
Lubricating oil See section Type of lubrication in gearboxes
on page 146.
Oil collecting vessel The capacity of the vessel must be sufficient
to take the complete amount of oil.
Oil dispenser One example of oil dispenser can be found
in section:
• Type of lubrication in gearboxes on
page 146
on page 447.

3 Maintenance
Continued
Draining, axis 1 gearbox

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

working area.
2
WARNING

on page 36.
3
CAUTION

cess pressure.
4 Valid for IRB 2600-20/1.65 type C, IRB

2600-12/1.65 type C:
Remove the protective cap from the oil
nipple and connect the oil dispenser.
xx1800001136

3 Maintenance
Continued
Action Note
5 Valid for IRB 2600-20/1.65, IRB 2600- The capacity of the vessel must be suffi-
12/1.65, IRB 2600-12/1.85, IRB 2600ID- cient to take the complete amount of oil.
15/1.85, IRB 2600ID-8/2.0:
• Put an oil collecting vessel as close
as possible to the draining hole of
the gearbox.
• Replace oil plug draining quickly with
a nipple (M10x1.5) where a draining
hose is fitted and connect the oil
dispenser.
xx1800001138
Note
Draining is time-consuming.
Elapsed time varies depending on the
temperature of the oil.
One example of oil dispenser can be
found in section:
page 146
6 Remove the plug from the vent hole. Different position due to design differ-
ences:
WARNING
If the oil plug for venting is not open when

the oil dispenser is working, there is a risk
of damaging vital parts in the gearbox!
xx1800001137
xx1800001139
7 Suck out the oil with the oil dispenser.
Note
There will be some oil left in the gear after

draining.

3 Maintenance
Continued
Action Note
8
WARNING
Used oil is hazardous material and must be

disposed of in a safe way. See section De-
commissioning on page 429 for more inform-
ation.
9 Remove the oil dispenser.

2600-12/1.65 type C:
Refit the protective cap on the nipple.
xx1800001136
11 Valid for IRB 2600-20/1.65, IRB 2600- Tightening torque: 3-8 Nm

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

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

3 Maintenance
Continued
Action Note
12 Refit the oil plug, venting. Tightening torque: 24 Nm
Different position due to design differ-
ences:
xx1800001137
xx1800001139
Filling oil, axis 1 gearbox

Use this procedure to fill the gearbox with oil.
Action Note
1
DANGER
Turn off all:

area.
2
WARNING

risks, see Gearbox lubricants (oil or grease) on
page 36.

3 Maintenance
Continued
Action Note
3
CAUTION
The gearbox can contain an excess of pressure

that can be hazardous. Open the oil plug care-
fully in order to let out the excess pressure.
4 Valid for IRB 2600-20/1.65 type C, IRB 2600-

12/1.65 type C:
Remove the protective cap from the oil nipple
and connect the oil dispenser.
xx1800001136

12/1.65 type C:
Remove the plug from the vent hole.
Note
The vent hole is opened to let out air during the

filling process.
xx1800001137
6 Valid for IRB 2600-20/1.65, IRB 2600-12/1.65, Different position due to design differ-
IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB ences:
2600ID-8/2.0:
Open the oil plug, filling.
xx1800001137
xx1800001139

3 Maintenance
Continued
Action Note
7 Refill the gearbox with lubrication oil. Where to find type of oil and total
Valid for IRB 2600-20/1.65 type C, IRB 2600- amount is detailed in Type and
12/1.65 type C: amount of oil in gearboxes on
page 146.
Use the oil dispenser.
Note
The amount of oil to be filled depends on the

amount previously being drained.
8 Inspect the oil level. How to inspect the oil level is de-
scribed in section:
• Inspecting oil level, axis-1
gearbox on page 117
12/1.65 type C:
Remove the oil dispenser and refit the protect-
ive cap to the nipple.
xx1800001136
10 Refit the oil plug. Tightening torque: 24 Nm

Different position due to design differ-
ences:
xx1800001137
xx1800001139

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

IRB 2600ID-15/1.85, IRB 2600ID-8/2.0.
General
This section describes how to change the axis-1 gearbox oil in a suspended robot.

The oil plugs in axis 1 gearbox are located according to the following figures
xx1200000883
A Oil plug, venting

B Oil plug, draining and filling
Required equipment
Equipment Note
Lubricating oil See section Type of lubrication in gearboxes
on page 146
in section:
page 146
Oil change equipment
Hose Used with the oil dispenser
on page 447.

3 Maintenance
Continued
Draining, axis-1 gearbox

Tip
In order to save time, a pneumatic oil dispenser can be used to suck the oil out
from the gearbox.
Action Note
1
DANGER
Turn off all:

working area.
2
WARNING

on page 36.
3
CAUTION

cess pressure.
4 Connect the oil dispenser to the oil plug for See Required equipment on page 156.
draining.
xx1800001271
5 Put the end of the hose in an oil collecting The capacity of the vessel must be suffi-
vessel. cient to take the complete amount of oil.
6 Open the end plug of the hose.

3 Maintenance
Continued
Action Note
7 Open the oil plug, venting. See Location of oil plugs on page 156.
xx1800001272
8 Using a low air pressure, start sucking the

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

ation.
10 Let the oil drain until the gearbox is empty.

Tip
Note
Make a note how much oil was drained.
There will be some oil left in the gearbox The same amount shall later be refilled.
after draining. Measure the volume of the
drained oil in the vessel.
11 Remove the hose and clean it.
Filling oil, axis-1 gearbox

Action Note
1
DANGER
Turn off all:

area.
2
WARNING

page 36.

3 Maintenance
Continued
Action Note
3
CAUTION

4 Verify that the hose of the oil change equipment

is clean and then fit the quick connection to the
oil plug for filling.
xx1800001271
5 Open the oil plug for venting.
xx1800001272
6 Prepare oil change equipment with the same Where to find type of oil and total
amount of lubrication oil that was drained. amount is detailed in Type and
amount of oil in gearboxes on
Note page 146.

7 Inspect the oil level. How to inspect the oil level is de-
scribed in section:
• Inspecting oil level, axis-1
gearbox on page 117
8 Disconnect the oil change equipment and put
on the protective hood on the oil plug.
9 Refit the oil plug for venting. Tightening torque:
• 3-8 Nm
Note
Before refitting the oil plug in the gearbox, al-

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

3 Maintenance
Continued
Expansion container axis-1 gearbox, suspended mounted robots

When the robot is fitted in a suspended mounted position, an expansion container
for oil must be fitted on gearbox axis 1.
xx0900000129
A Expansion container
Note
The expansion container is installed on delivery on the robot if ordered as option

suspended/inverted mounted. If a floor mounted robot shall be fitted in a
suspended mounted position, an expansion container must be installed. See
Installing an expansion container on page 92.

3 Maintenance
3.4.4 Changing the oil, axis-2 gearbox

The axis-2 gearbox is located in the lower arm rotational center, underneath the
motor attachment.
Oil plugs are shown in the figure.
xx0800000305
A Oil plug, filling (draining when robot is suspended)

B Oil plug, draining (filling when robot is suspended) (Quick connect fitting)
Note
On a wall-mounted IRB 2600 the oil plugs are rotated into such a position that it
is not possible to drain the oil, or fill the correct amount of oil. Therefore it is
recommended that the manipulator is being taken down when changing oil.
Required equipment
Equipment Note
Lubricating oil Information about the oil is found in Technical
reference manual - Lubrication in gearboxes.
See Type and amount of oil in gearboxes on
page 146.
Nipple (TEMA IF 3820 S06) To be fitted on a hose, and then used for
draining connected to the quick connect fit-
ting.
See Location of oil plugs on page 161.

3 Maintenance
Continued
Equipment Note
on page 447.

Action Note
1
DANGER
Turn off all:

working area.
2
WARNING

on page 36.
3
CAUTION

cess pressure.
4 Either See the figure in:

• connect a nipple to the quick connect • Location of oil plugs on page 161
fitting in the hole for draining
or
• remove the quick connect fitting.
5 Open the oil plug, filling. See the figure in:
• Location of oil plugs on page 161
Note
Drainage will be quicker if the oil plug,

filling is removed.
6 Drain the gearbox oil using an oil collecting

vessel. Note

3 Maintenance
Continued
Action Note
7
WARNING

ation.
8
Note
There will be some oil left in the gearbox

after draining.
9 Refit oil plug. Tightening torque:

• 24 Nm
Note

leakage.

Action Note
1
DANGER
Turn off all:

working area.
2
WARNING

on page 36.
3
CAUTION

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


3 Maintenance
Continued
Action Note
5 Refill the gearbox with lubrication oil. Where to find type of oil and total amount
is detailed in Type and amount of oil in
Note gearboxes on page 146.
The amount of oil to be filled depends on

the amount previously being drained.
6 Inspect the oil level. How to inspect the oil level is described
in section:
• Inspecting the oil level, axis 2
gearbox on page 122
7 Refit oil plug. Tightening torque:
• 24 Nm
Note

leakage.

3 Maintenance

The axis-3 gearbox is located in the upper arm rotational center.
Oil plugs are shown in the figure.
xx0800000306
A Oil plug, armhouse

B Oil plug, gearbox (not visible in this figure)
Required equipment
Equipment Note
Lubricating oil Information about the oil is found in Technical
reference manual - Lubrication in gearboxes.
See Type and amount of oil in gearboxes on
page 146.
in section:
page 146
Funnel
xx1200000862

on page 447.

3 Maintenance
Continued

Action Note
1 Move the robot to an upright position as shown
in the figure.
xx0800000327
• A: Oil collecting vessel

2
DANGER
Turn off all:

area.
3
WARNING

page 36.
4
CAUTION

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

6 Open the oil plug, gearbox and use it as a See the figure in:
ventilation hole. • Location of oil plugs on page 165

3 Maintenance
Continued
Action Note
vessel. Note
8
WARNING

disposed of in a proper way. See section De-
commissioning for more information.
9 Refit oil plugs. Tightening torque:


Action Note
1 Move the upper arm to a position where the
wrist is pointing towards the floor as shown in
the figure.
xx0800000329
2
DANGER
Turn off all:

area.
3
WARNING

page 36.

3 Maintenance
Continued
Action Note
4
CAUTION

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

6 Refill the gearbox with lubricating oil. Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
Tip page 146.
Use a funnel.
Note

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

section:
• Inspecting the oil level, axis 3
gearbox on page 125

3 Maintenance

The axis-4 gearbox is located in the front of the upper armhouse.
The oil plug is shown in the figure.
The figure shows IRB 2600 Standard but the position of oil plug is the same on
IRB2600ID.
xx0900000311
A Oil plug, for filling and draining
Required equipment
Equipment Note
Lubricating oil Where to find information of the type of oil,
article number and the amount in the gear-
box, see section Type of lubrication in gear-
boxes on page 146
Plastic hose Used for venting the gearbox during draining.
A suitable hose would be a hose normally
used for compressed air.
Length: minimum 300 mm. Diameter: 5 mm.
Funnel
xx1200000862

on page 447.

3 Maintenance
Continued
Draining oil
Use this procedure to drain oil from the gearbox.
Action Note
1 Move the robot to the position shown in the
figure.
xx0800000328
• A: Oil collecting vessel

2
DANGER
Turn off all:

working area.
3
WARNING

on page 36.
4
CAUTION

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

vessel. Note
Tip
Insert a compressed air hose approximately
100 mm into the gearbox, to vent the gear-
box.
This speeds up the draining significantly.

3 Maintenance
Continued
Action Note
7
WARNING

ation.
8 Refit the oil plug. Tightening torque: 10 Nm.
Filling oil
Action Note
1 Move the upper arm to the position shown
in the figure.
xx0800000330
2
DANGER
Turn off all:

working area.
3
WARNING

on page 36.
4
CAUTION

cess pressure.

3 Maintenance
Continued
Action Note
5 Open the oil plug, filling. See the figure in:
6 Refill the gearbox with lubricating oil. Where to find type of oil and total amount
gearboxes on page 146.
Tip
Use a funnel.
Note

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

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

The axes-5 and -6 gearboxes are located in the wrist unit.
The oil plug is shown in the figure.
The figure shows wrist variant 12/20 kg
xx0900000139
A Oil plug, tilthouse

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

3 Maintenance
Continued
Wrist IRB 2600ID shown in position for filling.
xx1000000987
A Oil plug, filling

B Oil plug, draining
C Oil plug, venting
Note
The gearboxes for axes-5 and -6 are the same.
Required equipment
Equipment Note
Lubrication oil Where to find information of the type of oil,
article number and the amount in the gear-
box, see section: Type of lubrication in gear-
boxes on page 146
on page 447.

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

Use this procedure to drain oil from the gearbox.
CAUTION
The gearbox can contain an excess of pressure that can be hazardous. Open
the oil plug carefully in order to let out the excess pressure.
Action Note
1 Move the upper arm to a horizontal position.
2 IRB 2600: See the figure in Location of oil plugs on
Turn axis-4 to the calibration position. page 173.
IRB 2600ID:
Turn axis-4 +90° so that the oil plug for
filling is on top.
3
DANGER
Turn off all:

working area.
4
WARNING

on page 36.
5 Remove the oil plugs in the wrist. See the figure in Location of oil plugs on
IRB 2600ID: page 173.
The oil plug, venting can stay seated until
the wrist is rotated.
6 Turn axis-4 through so that the oil plug on
the side of the wrist points downwards.
IRB 2600ID:
Open the oil plug, venting.
7 IRB 2600:
Then turn axis-4 another 90°.
8 IRB 2600:
Let the remaining oil run out through the oil
plug hole, tilthouse.

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

CAUTION
The gearbox can contain an excess of pressure that can be hazardous. Open
the oil plug carefully in order to let out the excess pressure.
Action Note
1 Run the upper arm to a horizontal position.
2 IRB 2600:
Turn axis-4 to the calibration position.
IRB 2600ID:
Turn axis-4 to +90° so that the oil plug for
filling is on top.
3
DANGER
Turn off all:

working area.
4
WARNING

on page 36.
5 IRB 2600: See in figure:

Open the oil plug, tilthouse. • Location of oil plugs on page 173
IRB 2600ID:
Open all oil plugs, also for the venting hole.
6 Refill the gearbox with lubrication oil. Where to find type of oil and total amount
Note gearboxes on page 146.

IRB 2600ID:
The venting hole at the bottom needs to be
open to make the oil run into the axis-6 gear.
If oil starts to run out through the venting
hole, refit the oil plug.
If it is difficult to get oil into the axis-6 gear,
the venting hole can also be used for filling
oil into the gear.
7 Inspect the oil level. How to inspect the oil level is described
in section:
• Inspecting oil level, gearbox axes
5 - 6 on page 129

3 Maintenance
Continued
Action Note
8
Note
If the robot is fitted in a suspended position,

the wrist should be turned 180°.
9 Refit the oil plugs. Tightening torque:

• IRB 2600: 10 Nm
IRB 2600ID: 3 Nm

3 Maintenance
3.4.8 Replacing SMB battery
Note
The battery low alert (38213 Battery charge low) is displayed when the battery
needs to be replaced. The recommendation to avoid an unsynchronized robot
is to keep the power to the controller turned on until the battery is to be replaced.
For an SMB board with 3-pole battery contact (RMU101 3HAC044168-001 or
RMU102 3HAC043904-001), the lifetime of a new battery is typically 36 months.
For an SMB board with 2-pole battery contact, the typical lifetime of a new battery
is 36 months if the robot is powered off 2 days/week or 18 months if the robot is
powered off 16 h/day. The lifetime can be extended for longer production breaks
with a battery shutdown service routine. See Operating manual - IRC5 with
FlexPendant for instructions.
WARNING
See Hazards related to batteries on page 37.

3 Maintenance
Continued
Location of SMB battery

The SMB battery is located at the base of the robot, as shown in the figure.
DSQC 633A
xx0800000322
A SMB battery (2-pole battery contact)

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

3 Maintenance
Continued
RMU 101
A
B
xx1300000339
A SMB battery (3-pole battery contact)

B Battery cover
Required equipment
Note
There are two variants of SMB units and batteries. One with 2-pole battery contact
and one with 3-pole battery contact. The variant with the 3-pole battery contact
has longer lifetime for the battery.
It is important that the SMB unit uses the correct battery. Make sure to order the
correct spare parts. Do not replace the battery contact!
Equipment Note
SMB battery pack Battery includes protection circuits. Replace it only with given
spare part no. or an ABB approved equivalent.
See Spare part lists on page 451.
Standard toolkit Content is defined in section Standard tools on page 447.
Circuit diagram See chapter Circuit diagram on page 453.
Removing SMB battery

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

3 Maintenance
Continued
Action Note
2
DANGER
Turn off all:

to the robot, before entering the robot working area.
3
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the

unit please read the safety information in the section
The unit is sensitive to ESD on page 54
4 Remove the SMB battery cover. See the figure in Location of SMB
battery on page 179.
CAUTION
Clean cover from metal residues before opening.

Metal residues can cause shortage on the boards
which can result in hazardous failures.
5 Pull out the SMB battery. See the figure in Location of SMB
6 Disconnect the battery cable and remove the bat- See the figure in Location of SMB
tery. battery on page 179.
7 How to dispose of the used SMB battery, see
chapter Decommissioning on page 429.
Refitting SMB battery

Use this procedure to refit the SMB battery.
Action Note
1
DANGER
Turn off all:

to the robot, before entering the robot working area.
2
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the

unit please read the safety information in the section
The unit is sensitive to ESD on page 54
3 Reconnect the battery cable to the SMB battery. See the figure in Location of SMB

3 Maintenance
Continued
Action Note
4 Put the battery unit into its recess while arranging See the figure in Location of SMB
the SMB cables as shown in the figure. battery on page 179.
5 Secure the SMB cover with its attachment screws. See the figure in Location of SMB
6 Update the revolution counter. Detailed in Updating revolution
counters on page 402.
7
DANGER
Make sure all safety requirements are met when

performing the first test run.

3 Maintenance
3.5.1 Cleaning the IRB 2600/IRB 2600 ID
3.5 Cleaning
DANGER
Turn off all:

to the robot, before entering the safeguarded space.
General
To secure high uptime it is important that the IRB 2600/IRB 2600 ID is cleaned
regularly. The frequency of cleaning depends on the environment in which the
product works.
Different cleaning methods are allowed depending on the type of protection of the
IRB 2600/IRB 2600 ID.
Note
Always verify the protection type of the robot before cleaning.
Oil spills
Oil spills from gearboxes
Use the following procedure if any oil spills are detected that can be suspected to
originate from a gearbox.
1 Inspect that the oil level in the suspected gearbox is according to the
recommendations, see Inspection activities on page 117.
2 Write down the oil level.
3 Inspect the oil level again after, for example, 6 months.
4 If the oil level is decreased then replace the gearbox.
Special cleaning considerations

This section specifies some special considerations when cleaning the robot.
• Always use cleaning equipment as specified. Any other cleaning equipment
may shorten the life of the robot.
• Always check that all protective covers are fitted to the robot before cleaning.
• Never point the water jet at connectors, joints, sealings, or gaskets.
• Do not use compressed air to clean the robot.
• Never use solvents that are not approved by ABB to clean the robot.
• Do not spray from a distance closer than 0.4 m.

3 Maintenance
Continued
• Do not remove any covers or other protective devices before cleaning the
robot.
Cleaning methods
The following table defines what cleaning methods are allowed depending on the
protection type.
Note
Rinsing with water is not allowed for a robot with integrated dressing (ID variants).
Protection Cleaning method

type
Vacuum Wipe with cloth Rinse with water i High pressure water or
cleaner steam
Standard Yes Yes. With light Yes. It is highly re- No
cleaning deter- commended that
gent. the water contains
a rust-prevention
solution and that
the manipulator is
dried afterwards.
Foundry Plus Yes Yes. With light Yes. It is highly re- Yes ii .
cleaning deter- commended that It is highly recommended
gent or spirit. the water contains that the water and steam
a rust-prevention contains rust preventive,
solution. without cleaning deter-
gents.
i Rinsing with water is not allowed for a robot with integrated dressing (ID variants)!
ii Perform according to section Cleaning with water and steam on page 184.
Cleaning with water and steam

Instructions for rinsing with water
ABB robots with protection types Standard, Foundry Plus, Wash, or Foundry Prime
can be cleaned by rinsing with water (water cleaner). 1
The following list defines the prerequisites:
• Maximum water pressure at the nozzle: 700 kN/m 2 (7 bar) I
• Fan jet nozzle should be used, min. 45° spread

• Minimum distance from nozzle to encapsulation: 0.4 meters
• Maximum flow: 20 liters/min I
I Typical tap water pressure and flow
Instructions for steam or high pressure water cleaning

ABB robots with protection types Foundry Plus, Wash, or Foundry Prime can be
cleaned using a steam cleaner or high pressure water cleaner. 2
The following list defines the prerequisites:
• Maximum water pressure at the nozzle: 2500 kN/m 2 (25 bar)
• Fan jet nozzle should be used, min. 45° spread
1 See Cleaning methods on page 184 for exceptions.
2 See Cleaning methods on page 184 for exceptions.

3 Maintenance
Continued
• Minimum distance from nozzle to encapsulation: 0.4 meters

• Maximum water temperature: 80° C
Cables
Movable cables need to be able to move freely:
• Remove waste material, such as sand, dust and chips, if it prevents cable
movement.
• Clean the cables if they have a crusty surface, for example from dry release
agents.
Cooling fans
Inspect the air supply inlet of the the motor cooling fans. Clean to remove any
contamination that could hinder the air supply.

4 Repair
4.1 Introduction
4 Repair
4.1 Introduction
Structure of this chapter

This chapter describes repair activities for the IRB 2600/IRB 2600 ID. Each
procedure contains the information required to perform the activity, for example
spare parts numbers, required special tools, and materials.
WARNING
Repair activities not described in this chapter must only be carried out by ABB.
Report replaced units
Note
When replacing a part on the IRB 2600/IRB 2600 ID, report to your local ABB the
serial number, the article number, and the revision of both the replaced unit and
the replacement unit.
This is particularly important for safety equipment to maintain the safety integrity
of the installation.
Safety information
Make sure to read through the chapter Safety on page 21 before commencing any
service work.
Note
If the IRB 2600/IRB 2600 ID is connected to power, always make sure that the
IRB 2600/IRB 2600 ID is connected to protective earth and a residual current
device (RCD) before starting any repair work.

4 Repair
4.2.1 Performing a leak-down test
4.2 General procedures
4.2.1 Performing a leak-down test
When to perform a leak-down test

After refitting any motor and gearbox, the integrity of all seals enclosing the gearbox
oil must be tested. This is done in a leak-down test.
Required equipment
Equipment, etc. Article number Note

Leak-down tester -
Leak detection spray -
Performing a leak-down test
Action Note
1 Finish the refitting procedure of the motor or gear in
question.
2 Remove the upper oil plug on the gear and replace
it with the leak-down tester.
Regulators, which are included in the leak-down test,
may be required.
3 Use caution, apply compressed air and raise the Correct value:
pressure with the knob until the correct value is 0.2-0.25 bar (20-25 kPa)
shown on the manometer.
CAUTION
The pressure must under no circumstance be higher

than 0.25 bar (20-25 kPa). Also during the time when
the pressure is raised.
4 Disconnect the compressed air supply.

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

4 Repair
4.2.2 Mounting instructions for bearings
General
This section describes how to mount and grease different types of bearings on the
robot.
Equipment

Grease 3HAC042536-001 Shell Gadus S2
Used to grease the bearings, if not
specified otherwise.
Assembly of all bearings

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

Follow the preceding instructions for the assembly of the bearings when mounting
a tapered bearing on the robot.
In addition to those instructions, the following procedure must be carried out to
enable the roller elements to adjust to the correct position against the race flange.
Action Note
1 Tension the bearing gradually until the recommended pre-tension is achieved.
Note
The roller elements must be rotated a specified number of turns before pre-
tensioning is carried out and also rotated during the pre-tensioning sequence.
2 Make sure the bearing is properly aligned as this will directly affect the durab-
ility of the bearing.
Greasing of bearings
Note
This instruction is not valid for solid oil bearings.

4 Repair
Continued
The bearings must be greased after assembly according to the following

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

4 Repair
4.2.3 Mounting instructions for sealings
General
This section describes how to mount different types of sealings.
Equipment
Consumable Article number Note

Grease 3HAC042536-001 Shell Gadus S2
Rotating sealings
The procedure below describes how to fit rotating sealings.
CAUTION
Please observe the following before commencing any assembly of sealings:

• Protect the sealing during transport and mounting, especially the main lip.
• Keep the sealing in its original wrappings or protect it well before actual
mounting.
• The fitting of sealings and gears must be carried out on clean workbenches.
• Use a protective sleeve for the main lip during mounting, when sliding over
threads, keyways or other sharp edges.
Action Note
1 Check the sealing to ensure that:
• The sealing is of the correct type.
• There is no damage on the main lip.
2 Inspect the shaft surface before mounting. If scratches
or damage are found, the shaft must be replaced since
it may result in future leakage. Do not try to grind or
polish the shaft surface to get rid of the defect.
3 Lubricate the sealing with grease just before fitting. Article number is specified in
(Not too early - there is a risk of dirt and foreign Equipment on page 191.
particles adhering to the sealing.)
Fill 2/3 of the space between the dust lip and the main
lip with grease. If the sealing is without dust lip, just
lubricate the main lip with a thin layer of grease.
A B C
xx2000000071
A Main lip
B Grease
C Dust lip

4 Repair
Continued
Action Note
4 Mount the sealing correctly with a mounting tool. A
Never hammer directly on the sealing as this may
result in leakage.
xx2000000072
A Gap
Flange sealings and static sealings

The following procedure describes how to fit flange sealings and static sealings.
Action
1 Check the flange surfaces. They must be even and free from pores.
It is easy to check flatness using a gauge on the fastened joint (without sealing com-
pound).
If the flange surfaces are defective, the parts may not be used because leakage could
occur.
2 Clean the surfaces properly in accordance with the recommendations of ABB.
3 Distribute the sealing compound evenly over the surface, preferably with a brush.
4 Tighten the screws evenly when fastening the flange joint.
O-rings
The following procedure describes how to fit o-rings.
Action Note
1 Ensure that the correct o-ring size is used.
2 Check the o-ring for surface defects, burrs, Defective o-rings, including damaged
shape accuracy, or deformation. or deformed o-rings, may not be used.

4 Repair
Continued
Action Note
3 Check the o-ring grooves.
The grooves must be geometrically correct and
should be free of pores and contamination.
4 Lubricate the o-ring with grease.
5 Tighten the screws evenly while assembling.
6 Check that the o-ring is not squashed outside
the o-ring groove.

4 Repair
4.2.4 Cut the paint or surface on the robot before replacing parts
4.2.4 Cut the paint or surface on the robot before replacing parts
General
Follow the procedures in this section whenever breaking the paint of the robot
during replacement of parts.
Required equipment
Equipment Spare parts Note

Cleaning agent Ethanol
Knife
Lint free cloth
Touch up paint Standard/Foundry 3HAC067974-001 Graphite White
Plus
Touch up paint Standard/Foundry 3HAC037052-001 ABB Orange
Plus
Removing
Action Description
1 Cut the paint with a knife in the joint between
the part that will be removed and the struc-
ture, to avoid that the paint cracks.
xx0900000121
2 Carefully grind the paint edge that is left on

the structure to a smooth surface.

4 Repair
4.2.5 The brake release buttons may be jammed after service work
4.2.5 The brake release buttons may be jammed after service work
Description
The brake release unit has push-buttons for the brake release of each axis motor.
When service work is performed inside the SMB recess that includes removal and
refitting of the brake release unit, the brake release buttons may be jammed after
refitting.
DANGER
If the power is turned on while a brake release button is jammed in depressed

position, the affected motor brake is released. This may cause serious personal
injuries and damage to the robot.
Elimination
To eliminate the danger after service work has been performed inside the SMB
recess, follow the procedure below.
Action
1 Make sure the power is turned off.
2 Remove the push-button guard, if necessary.
3 Verify that the push-buttons of the brake release unit are working by pressing them
down, one by one.
Make sure none of the buttons are jammed in the tube.
4 If a button gets jammed in the depressed position, the alignment of the brake release
unit must be adjusted so that the buttons can move freely in their tubes.

4 Repair
4.3.1 Removing the complete cable harness
4.3 Complete robot
Introduction
This procedure describes how to remove the cable harness on the different variants
of IRB 2600:
• IRB 2600 Standard: Axes 1, 2, 3, 4, 5 and 6
• IRB 2600ID: Axes 1, 2, 3 and 4. How to remove the cable harness on axes 5
and 6 is described in section Replacing the cable harness in the upper arm
- IRB 2600ID on page 223.
How to refit the cable harness is described in section Refitting the complete cable
harness on page 208.
The removal procedure is presented in the order the work is recommended to be
performed. Therefore the order is different in the two procedures removal and
refitting of the cable harness. Cross references will make it easy to find what is
needed to know as the work continues.
The section Removing the complete cable harness consists of the following parts
presented in the order the work is recommended to be performed:
• Removal in the base Removing cable harness in base on page 199
• Removal in the frame Removing cable harness in frame on page 204
• Removal in lower arm and armhouse Removing cable harness in lower arm
and armhouse on page 205.
How to replace the SMB unit, brake release unit and motors can be found in:
• SMB unit Removing the SMB unit on page 236
• Brake release unit Removing the brake release board on page 242
• Motors Removing motors on page 303

4 Repair
Continued
Location of the cable harness

The location of the cable harness in the base, frame and lower arm is shown in the
figures.
Cable harness, base and frame.
xx0900000009
A Cover base
B Bracket
C Cable harness
D Axis-1 motor cable
E Axis-2 motor cable
F Axis-2 motor
G Axis-1 motor

4 Repair
Continued
xx0900000384
A Cable harness
E Bracket, frame
F Cable strap, lower arm (plastic)
Required equipment
Equipment Note
Deep well hexagon socket Width 30 mm
on page 447.

4 Repair
Continued
Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Action Note
1 Decide which calibration routine to use for
calibrating the robot.
• Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
• Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
If the robot is to be calibrated with refer- Follow the instructions given in the refer-
ence calibration: ence calibration routine on the FlexPendant
Find previous reference values for the axis to create reference values.
or create new reference values. These val- Creating new values requires possibility to
ues are to be used after the repair proced- move the robot.
ure is completed, for calibration of the ro- Read more about reference calibration for
bot. Axis Calibration in Reference calibration
If no previous reference values exist, and routine on page 407.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
Removing cable harness in base

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

working area.

4 Repair
Continued
Action Note
3 Disconnect the following connectors on the
base cover:
• R1.CP/CS
• R1.MP
• R1.ETHERNET (if used)
Tip
xx0900000014
Do not remove the R1.SMB-connector and
air hose connector at this stage. It will be Parts:
easier to remove these two when the cover • A: R1.CP/CS
base has been removed. • B: R1.MP
• C: Air hose connector
• D: Position of R1.ETHERNET (if
used)
• E: R1.SMB
4 Remove the cover base.
C
xx0800000456
A Base
B Cover base
C Attachment screws
5 Disconnect connectors on the brake release
unit:
• X8
• X9
• X10

4 Repair
Continued
Action Note
6 Cut the cable straps securing the battery
cable.
xx0900000099
Parts:
• A: Cable straps (2 pcs)
7 Disconnect the battery cable.
8 Unscrew the thin nut securing the R1.SMB
connector on the outside of the bracket.
Tip
Use a deep well hexagon socket, width 30

mm (like the ones used for spark plugs, or A
similar).
xx1200000888 D
C
B
xx1200000889
A Thin nut, width 30 mm

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

4 Repair
Continued
Action Note
10 Remove the screw that secures the bracket
and unscrew the three other screws a little
just enough to be able to slide the bracket
sideways.
xx0900000100
Parts:
• A: Screw to be removed
• B: Screws to be unscrewed (3 pcs)
11 Remove the bracket by sliding it off the re-
maining three attachment screws and put
it at a 90° angle from the base.
Putting the bracket at a 90° angle facilitates
the disconnecting of cables from the
bracket.
Note xx0900000013
Use caution when performing this procedure Parts:

in order not to damage cables or other • A: Bracket at a 90° angle
components! • B: Base
12 Remove connectors and air hose connector

completely from the bracket:
• R1.CP/CS
• R1.MP
• R1.SMB
• Air hose connector
A
B
C
D
xx1200000890
A R1.CP/CS
B R1.MP
C Air hose connector
D R1.SMB
13 Remove the SMB unit from its attachment How to remove the SMB unit is described
screws. in section:
Leave the screws in the base. • Removing the SMB unit on page 236

4 Repair
Continued
Action Note
14 Disconnect connectors on the SMB unit:
• R1.SMB1-2
• R1.SMB2-6
• R2.SMB
15 Disconnect the screen connections of:
• R1.SMB1-2
• R1.SMB2-6
A
xx0900000035
Parts:
• A: Screen connection (4 pcs)
16 Disconnect the earth cables.
xx0900000015
Parts:
• A: Earth
• B: Distance screws

4 Repair
Continued
Action Note
17 Remove the bracket securing the cable
package inside the base on the left side, by
following these steps:
• Unscrew the attachment screws just
enough to be able to remove the
bracket.
• Lift the bracket off the screws.
xx0900000018
Parts:
• A: Base
• B: Attachment screws
• C: Bracket
18 Continue removal of the cable package from How to remove the cable package from
the frame. the frame is described in section
• Removing cable harness in frame
on page 204
Removing cable harness in frame

Use this procedure to remove the cable harness in the frame.
Tip
Before starting this procedure, first remove the cable harness in the base. See
Removing the complete cable harness on page 196.
Action Note
1
DANGER
Turn off all:

working area.
2 Disconnect the motor cables on the axis-1 How to remove the motor cables is de-
and axis-2 motors. scribed in section:
• Removing motors on page 303
3 Remove the bracket securing the cable See the figure in:
package to the frame. • Location of the cable harness on
page 197

4 Repair
Continued
Action Note
4 Cut the cable straps securing the cable See the figure in:
harness to the frame and lower arm. • Location of the cable harness on
page 197
5 Prepare the end of the cable package in the
base with tape as shown in the figure.
Tip
A
In order to protect the connectors from
getting residual grease on the cable har-
ness, put some plastic over them prior to F
pushing it through the hole in the frame.
C
B
xx1200000886
A Tape
B Connectors to SMB unit and Brake
release unit
C R1.CP/CS
D Air hose
E R1.MP
F R1.SMB (Connector bent and taped
upwards)
6 Pull out the cable package through the hole
in the frame.
Note
Use caution when performing this proced-

ure in order not to damage cables or other
components!
7 Continue the removal of the cable package How to remove the cable package from
from the lower arm and armhouse. the lower arm and armhouse is described
in section:
• Removing cable harness in lower
arm and armhouse on page 205
Removing cable harness in lower arm and armhouse

Use this procedure to remove the cable harness in the lower arm and armhouse.
Tip
Before starting this procedure, first remove the cable harness in the base
Removing the complete cable harness on page 196 and frame Removing the
complete cable harness on page 196.

4 Repair
Continued
Action Note
1
DANGER
Turn off all:

working area.
2 Cut the cable strap on the lower arm. See the figure in:
• Location of the cable harness on
page 197 (Cable harness, lower arm)
3 Remove the brackets on the lower arm.
D
C
xx0900000020
Parts:
• A: Bracket, lower arm
• B: Bracket, lower arm
• C: Bracket, armhouse
• D: Cable bracket

4 Repair
Continued
Action Note
4 Remove the bracket on the armhouse.
xx0800000335
Parts:
• A: Tubular shaft unit
5 Remove the cable cover on the armhouse.
xx0800000338
Parts:
• A: Signal lamp
• B: Bracket
• C: Cable cover, armhouse
6 Remove signal lamp if used.
7 IRB 2600 Standard: How to remove the motor cables from the
Continue the removal of the cable package axis-3, axis-4, axis-5 and axis-6 motors
by disconnecting the motor cables of the see section:
axis-3, axis-4, axis-5 and axis-6 motors. • Removing motors on page 303
8 IRB 2600ID: How to remove the motor cables from

Continue the removal of the cable package motors axes 3 and 4 see section:
by disconnecting the motor cables of mo- • Removing motors on page 303
tors axes 3 and 4.
9 IRB 2600ID: See section
Remove the cable package in the upper • Replacing the cable harness in the
arm. upper arm - IRB 2600ID on page 223

4 Repair
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 223.
How to remove the cable harness is described in Removing the complete cable
harness on page 196.
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 211
• Refitting in the base Refitting the cable harness in the base on page 214
• Refitting in the lower arm and armhouse Refitting the cable harness in the
lower arm and armhouse on page 220.
How to refit the SMB unit, brake release unit and motors can be found in:
• SMB unit Refitting the SMB unit on page 239
• Brake release unit Refitting the brake release board on page 243
• Motors Refitting motors on page 316

4 Repair
Continued
Location of the cable harness

The location of the cable harness in the base, frame and lower arm is shown in the
figures.
Cable harness, base and frame.
xx0900000009
A Cover base
B Bracket
C Cable harness
D Axis-1 motor cable
E Axis-2 motor cable
F Axis-2 motor
G Axis-1 motor

4 Repair
Continued
The figure shows IRB 2600 Standard but is also valid for IRB 2600ID.
xx0900000384
A Cable harness
E Bracket, frame
F Cable strap (plastic)
Required equipment
Equipment Note
Deep well hexagon socket Width 30 mm
on page 447.
Cable grease 3HAC042536-001 (Shell Gadus S2)

4 Repair
Continued
Refitting the cable harness in the frame

Use this procedure to refit the cable harness in the frame.
Action Note
1
DANGER
Turn off all:

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

• cable guide inside the hole • Required equipment on page 210
• the part of the cable harness that
runs through the cable guide.
3
Note
Two alternative methods to insert the cable

package in frame and base are presented
below. Chose one of the methods.
4 Use this procedure when replacing the old

cable harness:
Method 1, step 1:
Prepare the end of the cable package in the
base with tape as shown in the figure.
A
Tip
F
In order to protect the connectors from get-

ting residual grease on the cable harness,
put some plastic over them prior to pushing E
it through the hole in the frame.
C
B
xx1200000886
A Tape
B Connectors to SMB unit and Brake
release unit
C R1.CP/CS
D Air hose
E R1.MP
F R1.SMB (Connector bent and taped
upwards)

4 Repair
Continued
Action Note
cable harness:
Method 1, step 2:
Push the cable package carefully in through
the base and up through the hole in the
frame.
Note
Use caution when performing this procedure

in order not to damage cables or other
components!

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

components!
Tip
In order to protect the connectors from get-

ting residual grease on the cable harness,
put some plastic over them prior to pushing
it through the hole in the frame.
7 Use this procedure when fitting a new cable

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

components!

4 Repair
Continued
Action Note
8
Note
It is vital that the position of the air hose is

correct, as shown in the figure!
xx0900000096
Parts:
• A: Cables
• B: Air hose
• C: Hole in frame
• D: Cable guide
• E: Position of the front of the robot
9 Secure the cover to the frame with its attach-
ment screws.
xx0900000016
Parts:
• A: Frame
• B: Hole in frame
• C: Cover
10 Connect the axis-1 and axis-2 motor cables. How to refit the motor cables is described
in section:
• Refitting motors on page 316

4 Repair
Continued
Action Note
11 Sort out the different cables the way they
later will be fit on the bracket in the base.
xx0900000017
Connections:
• A: Earth cables
• B: R1.SMB1-2
• C: R1.SMB3-6
• D: R2.SMB
• E: R1.CP/CS
• F: R1.MP
• G: Air hose
• H: Position of R1.ETHERNET (if
used)
• J: R1.SMB
12 Continue the refitting of the cable harness How to refit the cable harness in the base
in the base. is described in section:
• Refitting the cable harness in the
base on page 214
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 208
Action Note
1
DANGER
Turn off all:

to the robot, before entering the safe-
guarded space.

4 Repair
Continued
Action Note
2 Attach the cable harness to the bracket.
xx0900000098
Parts:
• A: Attachment screw and nut
• B: Bracket
• C: Cable harness
3 Secure the bracket on its attachment screws
in the base.
Tip
Perform this in the following order:

• Put the attachment screws in the
holes but do not tighten them yet (if
they have been removed earlier).
• Place the bracket on the attachment
screws.
• Secure the bracket with its attach-
ment screws.
xx0900000018
Parts:
• A: Base
• B: Attachment screws (2 pcs)
• C: Bracket

4 Repair
Continued
Action Note
4 Refit the earth cables.
xx0900000015
Parts:
• A: Earth
• B: Distance screws
5 Connect the contacts on the SMB unit:
• R1.SMB1-2
• R1.SMB3-6
• R2.SMB
6 Refit the SMB unit. How to refit the SMB unit is described in
section:
• Refitting the SMB unit on page 239
7 Refit the cables with the screen connec-
tions.
A
xx0900000035
Parts:
• A: Screen connections (4 pcs)
8
Tip
When refitting connectors on the bracket,

put it at a 90° angle.
xx0900000013
Parts:
• A: Bracket
• B: Base

4 Repair
Continued
Action Note
9 Before refitting the connectors on the
bracket, arrange cables and connectors as
A B C
xx1200000857
A R1.CP/CS
B R1.MP
C Air hose
10 Refit the connectors and air hose on the
bracket:
• R1.CP/CS
• R1.MP
Tip
Do not refit the R1.SMB-connector and air

hose at this stage. It will be easier to refit
these two when the bracket has been fitted
to the distance screws.
xx0900000017
Connectors:
• A: Earth cables
• B: R1.SMB1-2
• C: R1.SMB3-6
• D: R2.SMB
• E: R1.CP/CS
• F: R1.MP
• G: Air hose
• H: Position of R1.ETHERNET (if
used)
• J: R1.SMB

4 Repair
Continued
Action Note
11 Secure the bracket on the distance screws.
B
C
D
xx1200000887
A Base
B Distance screw
C Attachment screw
D Bracket
12 Reconnect connectors on the brake release
unit:
• X8
• X9
• X10
13 Refit the R1.SMB-connector on the bracket.
Tip
Use a deep well hexagon socket, width 30

mm (like the ones used for spark plugs, or
similar). A
xx1200000888
D
C
B
xx1200000889
A Thin nut, width 30 mm

B R1.SMB
C Bracket
D Air connector
14 Refit the air hose connector on the bracket.
Note
Check that there is no leakage from the air

hose.
15 Reconnect the battery cable.

4 Repair
Continued
Action Note
16 Secure the battery cable with cable straps.
xx0900000099
Parts:
• A: Cable straps (2 pcs)
17 Use caution when pushing the base cover
into position while at the same time check-
ing that no cables are damaged.
C
xx0800000456
Parts:
• A: Base
• B: Base cover
• C: Attachment screws (6 pcs)
18 Secure the base cover with its attachment
screws.
19 Refit the bracket on the frame. See the figure in:
• Location of the cable harness on
page 209
20 Refit the cable straps securing the cable See the figure in:
harness to the frame. • Location of the cable harness on
page 209
21 Continue the refitting of the cable package How to refit the cable harness on the
on lower arm and armhouse. lower arm and armhouse is described in
section:
lower arm and armhouse on
page 220

4 Repair
Continued
Refitting the cable harness in the lower arm and armhouse

Use this procedure to refit the cable harness in the lower arm and armhouse.
Tip
Before starting this procedure, first refit the cable harness in the frame and base.
See:
Action Note
1
DANGER
Turn off all:

working area.
2 Secure the brackets on the lower arm.
D
C
xx0900000020
Parts:
• A: Bracket, lower arm
• B: Bracket, lower arm
• D: Cable bracket
3 Refit the cable straps securing the cable See the figure in:
harness to the lower arm. • Location of the cable harness on
page 209 (Cable harness, lower arm)
4 Push the cable harness carefully into the
armhouse.

4 Repair
Continued
Action Note
5 Secure the bracket, armhouse with its at-
tachment screws.
xx0800000335
Parts:
6 Secure the bracket to the armhouse with
its attachment screws.
xx0800000338
Parts:
• A: Signal lamp
• B: Bracket, armhouse
• C: Cable bracket
7 IRB 2600 Standard: How to connect the axis-3, axis-4, axis-5
Reconnect the axis-3, axis-4, axis-5 and and axis-6 motor cables, see:
axis-6 motor cables. • Refitting motors on page 316
8 IRB 2600ID: How to connect the axis-3 and axis-4 mo-

Reconnect the axis-3 and axis-4 motor tor cables, see section:
cables. • Refitting motors on page 316
9 IRB 2600ID: See section

Refit the cable package in the upper arm. • Replacing the cable harness in the
upper arm - IRB 2600ID on page 223

4 Repair
Continued
Action Note
10 Recalibrate the robot. Pendulum Calibration is described in Op-
erating manual - Calibration Pendulum,
enclosed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 406.
General calibration information is included
in section Calibration on page 393.
11
WARNING
The cover on the armhouse must be fitted

when the robot is running. It is a vital part
for the stability of the robot.
12
DANGER
Make sure all safety requirements are met

when performing the first test run.

4 Repair
4.3.3 Replacing the cable harness in the upper arm - IRB 2600ID
Introduction
This procedure describes how to replace the cable harness in the upper arm on
IRB 2600ID.
Note
In order to perform this procedure it is necessary to follow instructions in these

sections as well:
• Replacing motor axis 5 - IRB 2600ID on page 332
• Replacing motor axis 6 and wrist unit - IRB 2600ID on page 344
Location of the cable harness in the upper arm - IRB 2600ID

The location of the cable harness in the upper arm is shown in the figure.
xx1000001000
A Bracket (inside armhouse)

B Cover
C Cable harness
D Connectors motor axis 6 (2 pcs)
E Bracket (securing cable harness to arm tube)

4 Repair
Continued
Required equipment
Equipment Note
VK cover 2 pcs.
Art. no. is specified in Spare part lists on
page 451.
Sikaflex 521FC Art. no. 3HAC026759-001
Flange sealant -
Loctite 574
Grease 3HAC042536-001
Shell Gadus S2
For lubrication of the cable spiral.
Standard toolkit Content is defined in section Standard
tools on page 447.
Other tools and procedures may be required. These procedures include references to
See references to these procedures in the step- the tools required.
by-step instructions below.

Action Note
calibration:

4 Repair
Continued
Removing the cable harness

Use this procedure to remove the cable harness.
Action Information
2 Move the robot to synchronization position.
3
DANGER
Turn off all:

working area.
4 Remove all extra equipment fitted on the

upper arm and wrist.
5 Secure the upper arm with roundslings in
an overhead crane or similar.
6 Remove the cover on the arm house.
7 Disconnect the cables to motors axes 3, 4,
5 and 6. D
A B C
xx1000000991
Parts:
A Motor axis 4
B Motor axis 3
C MP connectors axes 3, 4, 5 and 6
(see markings for axis)
D FP connectors axes 3, 4, 5 and 6
8 Remove the wrist. See section
(This is done in order to be able to discon- • Removing the wrist unit on page 346
nect the motor cables of motor axis 6)
Note
No need to remove the axis-6 motor. Only

the motor cables need to be disconnected.

4 Repair
Continued
Action Information
9 Remove the mechanical stop, bracket and See section
cover . • Replacing motor axis 5 - IRB
2600ID on page 332
xx1000000879
Parts:
A Attachment screws (5 pcs)
B Mechanical stop
C O-ring
D Distance ring
E Bracket
F Cover
10 Remove the two VK-covers, covering the
attachment screws securing the cable har-
ness to the arm tube.
xx1000000934
Parts:
A VK-covers (2 pcs)

4 Repair
Continued
Action Information
11 Remove the attachment screws (2 pcs),
securing the cable harness bracket to the
arm tube.
Note
The arm tube is not shown here.
xx1000000998
Parts:
A Bracket
B Attachment screws (2 pcs)
C Connectors motor axis 5
D Motor axis 5
12 Remove the attachment screws (A) securing
the cover (B) on the arm house.
13 Remove the attachment screws (C) (8 pcs)
securing the arm tube.
xx1000001001
Parts:
A Attachments screws (6 pcs)
B Cover
C Attachment screws (8 pcs) securing
arm tube
14 Pull out the tube of the arm house a little,
enough to be able to disconnect cables to
the axis-5 motor.
15 Disconnect connectors to motor axis 5. How to remove the motor cables, see:
• Replacing motor axis 5 - IRB
2600ID on page 332
Note
No need to remove motor axis 5!
16 Pull carefully out the cable harness off the

arm house at the same time as the tube of CAUTION
the arm house is pulled out.
Pull the cable harness out carefully! The
space in the armhouse is cramp.
17 Place the upper arm tube somewhere safe.

4 Repair
Continued
Action Information
18 Pull carefully out the cables off the hole in
the arm house from the arm house where
the connectors are.
xx1000000996
Part:
A Hole in arm house
19 Remove the cable harness.
Refitting cable harness

Use this procedure to refit the cable harness.
Action Information
1 Push carefully in the cables to the connect-
ors for motors axes 3, 4, 5 and 6 through
the hole in the arm house.
xx1000000996
Part:
A Hole for cables

4 Repair
Continued
Action Information
2 Place the cable harness spiral into its pos- Grease: Shell Gadus S2, 3HAC042536-001.
ition in the arm house.
Lubricate the cables in the spiral with
grease.
Note
Do not cut the strap used as transport

protection of the cable harness spiral at
this point!
xx1000001005
Parts:
A Cable harness spiral
B Attachment screws (8 pcs) M8x25
quality Steel 12.9 Gleitmo
3 Apply flange sealant on the surface where
the cover shall be fitted. See figure!
xx1000001006
Part:
A Flange sealant: Loctite 574, -

4 Repair
Continued
Action Information
4 Secure the cover with its attachment Tightening torque: 10 Nm.
screws.
xx1000001001
Parts:
A Attachment screws (6 pcs) M6x20
quality 8.8-A2F
B Cover
C Attachment screws (8 pcs) M8x25
5 Use an overhead crane (or similar) and lift
the upper arm tube almost all the way into Note
its position.
It must still be possible to reach inside the
armtube for the remaining assembly inside.
6 Push the motor cables for the axis-6 motor

through the upper arm tube.
7 Connect the connectors to the axis-5 mo-
tor.
8 Fit the bracket (A) to the arm house.
xx1000000998
Parts:
A Bracket
D Motor axis 5

4 Repair
Continued
Action Information
9 For IRB 2600ID - 8/2.0: cut the cable tie
that holds the harness loop together to
loosen the cabling and make it longer.
Fasten the cabling to the MP5 cable.
Tighten the cable ties gently with hand
force.
For IRB 2600ID - 15/1.85: remake the har-
ness loop if it is missing. Fasten the loop
to the MP5 cable. Tighten the cable ties
gently with hand force. Diameter of the loop
should be approximately Ø40 mm.
xx1600001494
10 Check that axis 4 is in the same position

as it was when the cable harness was re- Note
moved.
If axis 4 is being moved in the continued
refitting process it must be returned to the
position it was when the mechanical stop
was removed in order to get the cable har-
ness spiral fitted correctly.
11
CAUTION
When the spiral of the cable harness is ar-

ranged check that:
• none of the cables are twisted
• the two cables running in the spiral
runs parallel to each other all the
way
• the cables are not arranged too tight
or too loose.
12 Hold the cable harness with one hand and

cut the cable strap used as transport pro-
tection.
CAUTION
When the cable strap is cut, the spiral of

the cable harness can unwind and the
cables can start to cross each other.
xx1000001004
Part:
A Cable strap used as transport protec-
tion

4 Repair
Continued
Action Information
13 Check that the cable harness is fitted cor-
rectly by releasing the brakes on the axis- Note
4 motor and manually moving axis 4 very
carefully all the way to each end position. If axis 4 is not running correctly the spiral
of the cable harness must be refitted.
CAUTION
Too much force when turning axis 4 can

result in damage to the cable harness!
14 Apply flange sealant Loctite 574 on the

surface B, shown in the figure.
Note
Do not apply flange sealant on the surfaces

where Sikaflex 521FC shall be applied!
See figure!
xx1000001003
Parts:
A Surface where Sikaflex 521FC shall
be applied
B Surface where Loctite 574 shall be
applied.
15 Secure the upper arm tube with its attach- Tightening torque: 35 Nm.
ment screws.
16 Refit the wrist. See section
• Refitting the wrist on page 351

4 Repair
Continued
Action Information
17 Refit the cover (A) with two screws (B).
18 Refit the bracket (C) with two screws.
19 Apply Sikaflex 521FC on the surfaces A
xx1600001557
Parts:
A Cover
B Attachment screws for the cover (2
A pcs of totally 5 pcs)
C Bracket (including 2 cover attach-
ment screws)
D Mechanical stop (including o-ring
and one cover attachment screw)
xx1600001558
20 Refit the o-ring and the mechanical stop

(D) with one screw.
21 Connect the connectors to motors axes 3,
4, 5 and 6 in the arm house.
D
A B C
xx1000000991
Parts:
A Motor axis 4
B Motor axis 3
C MP connectors axes 3, 4, 5 and 6
D FP connectors axes 3, 4, 5 and 6
22 Refit the cover on the arm house with its Tightening torque: 14 Nm.
attachment screws.

4 Repair
Continued
Action Information
23 Fit new VK covers to the arm tube.
xx1000000934
Parts:
A VK-covers (2 pcs). See article num-
ber in section Spare part lists on
page 451.
24 Recalibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
25
DANGER


4 Repair
4.3.4 Replacing SMB unit
Location of SMB unit

The SMB unit (SMB = Serial measurement board) is located in the base below the
brake release unit, as shown in the figure.
xx0800000466
A R1.SMB3-6
B R1.SMB1-2
C R2.SMB
D SMB unit
E Attachment screws M6x16 quality 8.8-A2F (2 pcs)
F Brake release unit
G Bracket
Required equipment
Note
There are different variants of SMB units and batteries. The variant with the
3-pole battery contact (RMU) has longer lifetime for the battery.
It is important that the SMB unit uses the correct battery. Make sure to order the
correct spare parts. Do not replace the battery contact!
Equipment Note
on page 447.

4 Repair
Continued
Equipment Note
SMB unit For spare part no. see chapter Spare parts,
section:
• Spare part lists on page 451

Action Note
calibration:
Removing the SMB unit

Use this procedure to remove the SMB unit.
Action Note
2
DANGER
Turn off all:

working area.

4 Repair
Continued
Action Note
3 Remove the base cover.
CAUTION
C
Clean cover from metal residues before
opening.
Metal residues can cause shortage on the
boards which can result in hazardous fail-
ures.
A
xx0900000103
Parts:
B Base cover
C Cable straps, securing the battery
cable (2 pcs)
4 Cut the cable straps securing the battery
cable.
5 Remove the screw that secures the bracket
and unscrew the three other screws a little
just enough to be able to slide the bracket
sideways.
Note
It is not needed to remove these three

screws.
xx0900000100
Parts:
A Screw to be removed
B Screws to be unscrewed a little (3
pcs)

4 Repair
Continued
Action Note
6 Remove the bracket by sliding it off the re- Cable harness can stay connected to all
maining three attachment screws and put connectors except to the SMB unit.
it at a 90° angle from the base.
Putting the bracket at a 90° angle facilitates
the disconnecting of cables from the
bracket.
Note
Use caution when performing this procedure xx0900000013

order not to damage cables or other com-
ponents! Parts:
A Bracket at a 90° angle
B Base
7 Disconnect cable clamps.
A
xx0900000035
Parts:
A Cable clamps
8 Unscrew the attachment screws securing See the figure in:
the SMB unit just enough to be able to re- • Location of SMB unit on page 235
move the SMB unit.
9 Remove the SMB unit.
10 Disconnect the battery cable by pressing
down the upper lip of the R1.G connector
to release the lock while pulling the connect-
or upwards.
xx1700000993
11 Disconnect the remaining connectors on See the figure in:

the SMB unit: • Location of SMB unit on page 235
• R1.SMB1-2
• R1.SMB3-6
• R2.SMB

4 Repair
Continued
Refitting the SMB unit

Use this procedure to refit the SMB unit.
Action Note
1
DANGER
Turn off all:

working area.
2 Reconnect contacts on the SMB unit:

• R1.SMB1-2
• R1.SMB3-6
• R2.SMB
• Battery cable R1.G (X3) Make sure
the lock snaps into place during refit-
ting.
xx1700000994
3 Place the SMB unit on its attachment See the figure in:
screws. • Location of SMB unit on page 235
4 Secure the SMB unit with its attachment
screws.
5 Refit the cable clamps.
A
xx0900000035
Parts:
A Cable clamps
6 Put back the cable harness in the base and See the figure in:
refit the bracket on the distance screws. • Location of SMB unit on page 235
Note

order not to damage cables or other com-
ponents!

4 Repair
Continued
Action Note
7 Secure the battery cable with cable straps.
into position while at the same time check-
ing that no cables are damaged.
9 Secure the base cover with the attachment
screws.
C
xx0800000456
Parts:
B Base cover
C Base
11
DANGER


4 Repair
4.3.5 Replacing the brake release board
Location of brake release board

The brake release board is located as shown in the figure.
xx0900000101
A Brake release board
Connectors on push-button board

The connectors X8, X9 and X10 are placed on the push-button board as shown in
the figure below.
X8
X10
X9
xx1700000978

4 Repair
Continued
Required equipment
Equipment Note
Brake release board 3HAC065020-001 i DSQC1050
3HAC062021-001 ii DSQC1052
Other tools and procedures These procedures include refer-
may be required. See references to the tools required.
tions below.
i Valid for robots that are equipped with motors of Type A and Type B (see Product manual, spare
parts - IRB 2600).
Includes brake release board and harness.
ii Valid for robots that are equipped with motors of Type B (see Product manual, spare parts - IRB
2600).
Includes brake release board and harness.
Removing the brake release board

Use this procedure to remove the brake release board.
Action Note
1
DANGER
Turn off all:

working area.
2
ELECTROSTATIC DISCHARGE
(ESD)
The unit is sensitive to ESD. Before handling

the unit read the safety information in sec-
tion The unit is sensitive to ESD on page 54.
3 Remove the push button guard from the The guard must be removed to ensure a
SMB cover. correct refitting of the brake release
board.

4 Repair
Continued
Action Note
4 Remove the base cover.
CAUTION
Clean cover from metal residues before

opening.
Metal residues can cause shortage on the
boards which can result in hazardous fail- A
ures.
C
xx0800000456
Parts:
A Base
B Base cover
C Attachment screws M6x16 quality
8.8-A2F (6 pcs)
5 Take a picture or make notes of how the
robot cabling is positioned in regard to the
brake release board.
6 Disconnect connectors X8, X9 and X10 from
the brake release board.
X8
X10
X9
xx1700000978
7 Remove the nuts securing the brake release

board.
8 Remove the brake release board.
Refitting the brake release board

Use this procedure to refit the brake release board.
Action Note
1
DANGER
Turn off all:

area.

4 Repair
Continued
Action Note
2
ELECTROSTATIC DISCHARGE
(ESD)
The unit is sensitive to ESD. Before handling

the unit read the safety information in section
The unit is sensitive to ESD on page 54.
3 Secure the brake release board to the bracket Maximum tightening torque: 5 Nm.
with its nuts with flange. See the figure in:
• Location of brake release board
on page 241
4 Reconnect connectors X8, X9 and X10 to the
brake release board.
Be careful not to damage the sockets or pins.
Make sure the connector and its locking arms X8
X10
are snapped down properly. X9
xx1700000978
5 Verify that the robot cabling is positioned

correctly, according to previously taken pic-
ture/notes.
WARNING
Screened cables must not get in contact with

the brake release board after installation.
Eliminate all risks of contact between
screened cables and the brake release board.

into position while at the same time checking
that no cables are damaged.
C
xx0800000456
Parts:
A Base
B Base cover
C Attachment screws M6x16 quality
8.8-A2F (6 pcs)
7 Secure the base cover with its attachment
screws.

4 Repair
Continued
Action Note
8
WARNING
Before continuing any service work, follow

the safety procedure in section The brake
release buttons may be jammed after service
work on page 195!
9 Refit the push button guard to the SMB cover.

10 Press the push buttons 1 to 6, one at a time,
to make sure that the buttons are moving
freely and do not stay in any locked position.
11
DANGER


4 Repair
4.4.1 Replacing the complete upper arm
4.4 Upper arm
Location of the complete upper arm

The complete upper arm is located as shown in the figure.
xx1100000947
A Upper arm
B Attachment screws M8x40, quality steel 12.9 gleitmo (12 pcs)

4 Repair
Continued
Required equipment
Equipment Note
Armhouse For spare parts no. see Spare parts - Upper arm
(2.05/2.50/2.55) in Product manual, spare
parts - IRB 2600.
Tubular shaft unit For spare parts no. see Spare parts - Upper arm
parts - IRB 2600.
Rotating lifting point 2 pcs. Dimension: M8.
Example: Gunnebo RLP GrabiQ M8-10.
xx1100000564
Washer Required if the screw in the rotating lifting point

bottoms.
Inner diameter: 12 mm. Outer diameter: min. 23
mm. Thickness: enough to prevent the screw in
the rotating lifting point to bottom.
Roundslings 3 pcs.
Lengths: 1.5 m (1 pc, run around the wrist unit),
2 m (2 pcs).
Lifting capacity: 500 kg.
Screws 2 pcs. Used to prevent the roundsling at the wrist
from sliding.
Dimension:
• M6. Length: 70 mm. Quality: 8.8.
Guide pins M8 (2 pcs)
page 447.
Other tools and procedures may be re- These procedures include references to the tools
quired. See references to these proced- required.
ures in the step-by-step instructions be-
low.

4 Repair
Continued

Action Note
calibration:
Removing the complete upper arm

Use this procedure to remove the complete upper arm. This procedure can be
done without draining the axis 3 gearbox.
Action Note
2 Run the robot to the position shown in the
figure.
The robot must be floor mounted and the
upper arm must be horizontally positioned.
xx0800000336

4 Repair
Continued
Action Note
3
DANGER
Turn off all:

working area.
4
CAUTION
The weight of the complete upper arm (in-

cluding the wrist) is 65 kg
accordingly.
5 Attach the lifting accessories to the upper See Attaching the lifting accessories to
arm. the upper arm on page 251.
6 Unload the weight of the upper arm by
stretching the roundslings.
Tip
Turn on the power temporarily and release

the brakes of axis 3 to rest the weight onto
the roundslings.
7
DANGER
Turn off all:

working area.
8 Disconnect all motor cables from motors How to disconnect cables from motors is
axes 3, 4, 5 and 6. detailed in sections:

4 Repair
Continued
Action Note
9 Remove the bracket fitted on the tubular
shaft unit.
xx0800000335
Parts:
• B: Attachment screws M6x16 qual-
ity 8.8-A2F (2 pcs)
• C: Bracket
10 Remove the signal lamp, if used.
11 Remove the cable bracket on the armhouse.
xx0800000338
Parts:
• A: Signal lamp
• B: Bracket
12 Using caution, pull the cable package out
of the hole where the cable bracket was fit-
ted.
13 Remove the attachment screws securing See the figure in:
the upper arm to the lower arm. • Location of the complete upper arm
on page 246
Note
Do not remove the attachment screws

securing the gearbox axis 3 to the arm-
house!

4 Repair
Continued
Action Note
14 Remove the complete upper arm.
Attaching the lifting accessories to the upper arm

Attaching the lifting accessories
Action Note
1 Fit two screws in the wrist unit. Dimension is specified in Required equipment on
The purpose of these screws is page 247.
to prevent the roundsling from
sliding.
The wrist unit of IRB 2600ID looks
a bit different. Either run the
roundsling around the ID wrist in
such a way that the sling can not
slide, or remove the mechanical xx1100000581
stop at the wrist temporarily and
use the attachment holes to fit the
screws to prevent the sling from
sliding.
2 Fit two rotating lifting points to the Dimension is specified in Required equipment on
attachment holes in the arm page 247.
house, see the figure. Secure the The figures show IRB 4600 but the same attachment
lifting point tightly against the arm holes are used also for IRB 2600.
house, but at the same time mak-
ing sure that the screw does not
bottom. Use an extra washer if
the screw does bottom.
Tightening torque: 30 Nm.
xx1100000565
xx1100000566
3 Run a roundsling through each Dimension is specified in Required equipment on

rotating lifting point and fasten page 247.
both ends at the lifting hook. See figure Attaching the roundslings to the upper
Use the longest roundslings (2 arm on page 252.
m).

4 Repair
Continued
Action Note
4 Make a loop of the third round- Dimension is specified in Required equipment on
sling, running it around the wrist page 247.
unit. Run the roundsling on both See figure Attaching the roundslings to the upper
sides of the screws and fasten the arm on page 252.
free end of the roundsling to the
lifting hook.
Use the shortest roundsling (1.5
m).
Attaching the roundslings to the upper arm

The figure shows IRB 4600 but the principle is the same for IRB 2600. Make sure
the roundsling looped around the wrist unit is run on both sides of the screws.
xx1100000567
A Screws to prevent the roundsling from sliding, 2 pcs

B Rotating lifting point, 2 pcs
C Roundsling around wrist unit
Length: 1.5 m.
D Roundsling attached to arm house, 2 pcs
Length: 2 m

4 Repair
Continued
Refitting the complete upper arm

Use this procedure to refit the complete upper arm.
Action Note
1
DANGER
Turn off all:

working area.
2
CAUTION
The weight of the complete upper arm (in-

cluding the wrist) is 65 kg
accordingly.
3 Clean all assembly surfaces.

arm. the upper arm on page 251.
5 Fit guide pins to the upper arm. Specified in Required equipment on
page 247.
6 Lift the upper arm to the robot using an
overhead crane.
7 Release the brakes of the axis 3 motor.
8 Refit the upper arm to the lower arm with See the figure in:
its attachment screws. • Location of the complete upper arm
It may be necessary to turn the gear by ro- on page 246
tating the motor pinion with a rotation tool, Tightening torque :
motor beneath the motor cover. • 35 Nm

4 Repair
Continued
Action Note
9 Using caution, push the cable package
through the hole where the cable bracket
will be fitted.
xx0800000338
Parts:
• A: Signal lamp
• B: Bracket
10 Refit the cable bracket with its attachment
screws.
11 Reconnect all motor cables. How to connect motor cables is detailed
in sections:
12 Refit the bracket on the tubular shaft unit.
xx0800000335
Parts:
ity 8.8-A2F (2 pcs)
• C: Bracket
13 Refit the signal lamp, if used.

4 Repair
Continued
Action Note
15
DANGER


4 Repair
4.4.2 Replacing complete tubular shaft unit
Introduction
This section is not valid for IRB 2600ID.
Location of tubular shaft unit

The tubular shaft unit is located as shown in the figure.
xx0900000385
A Armhouse
B Parallel pin, hardened M8x16 m6 (2 pcs)
C Attachment screws M8x35 quality 8.8-A2F and washers (6+6 pcs)
D Tubular shaft unit
E Wrist
Required equipment
Equipment Note
Tubular shaft unit For spare parts no. see Spare parts - Upper arm
parts - IRB 2600.
Guide pins 2 pcs. Dimension: M8.
Cleaning agent Isopropanol
Sealing liquid Loctite 574
page 447.

4 Repair
Continued
Equipment Note
ures in the step-by-step instructions be-
low.

Action Note
calibration:
Removing complete tubular shaft unit

Use this procedure to remove the complete tubular shaft unit.
Action Note
2 Drain oil from gearbox axis 4. How to drain the oil from the gearbox is
described in section:
on page 169

4 Repair
Continued
Action Note
figure.
xx0800000336
4
DANGER
Turn off all:

working area.
5 Remove the bracket securing the cable

package to the tubular shaft unit by remov-
ing its attachment screws.
xx0800000335
Parts:
ity 8.8-A2F (2 pcs)
• C: Bracket
6 Place the cable package in a way that it will
not be damaged in the continued removal
procedure.
7 Remove motors axes 4, 5 and 6. How to remove motors is described in
section:
8 How to remove the wrist unit is detailed
Tip in section:
• Removal of wrist unit on page 265
If only the tubular shaft unit shall be re-
placed, it is a good idea to remove the wrist
unit at this stage.

4 Repair
Continued
Action Note
9
CAUTION
The robot arm tube weighs 30 kg.

accordingly.
10 Secure the tubular shaft unit with round-

slings in an overhead crane.
CAUTION
Prevent the slings from sliding!

For example a small plate can be fitted to
the lower attachment hole for the cable
bracket (removed in a previous step). The
plate should be fitted so it points down-
wards and functions as a mechanical stop
for the roundsling.
At the other end of the tubular shaft unit, a
shackle can be fitted if the wrist unit is re-
moved.
11 Remove the attachment screws that secure See the figure in:
the tubular shaft unit. • Location of tubular shaft unit on
page 256
12 Remove the tubular shaft unit using caution.
The tubular shaft unit is fitted with Loctite. Note
There are two parallel pins guiding the

CAUTION
tubular shaft unit into its place. See figure
in Replacing complete tubular shaft unit
Do not damage the gears when removing on page 256.
the tubular shaft unit.
CAUTION
Remaining oil will drain out from the gear-

box cavity when the tubular shaft is lifted
out.
Refitting complete tubular shaft unit

Use this procedure to refit the tubular shaft unit.
Action Note
1
DANGER
Turn off all:

working area.

4 Repair
Continued
Action Note
2 Remove residues of old Loctite and other
contaminations from the assembly surfaces.
Remove any painting from the assembly
surfaces, with a knife.
3 Apply sealing liquid (Loctite 574) on the A
surface between the tubular shaft unit and
the armhouse. B C
Make sure to apply the sealing liquid in
circles around each of the attachment holes.
xx0800000457
Parts:
A Armhouse
applied
C Tubular shaft unit
D Cylindrical pin (2 pcs)
4
CAUTION
The robot arm tube weighs 30 kg.

accordingly!
5 Secure the tubular shaft unit with a round-

sling in an overhead crane.
CAUTION
Prevent the slings from sliding!

For example a small plate can be fitted to
the lower attachment hole for the cable
bracket (removed in a previous step). The
plate should be fitted so it points down-
wards and functions as a mechanical stop
for the roundsling.
At the other end of the tubular shaft unit, a
shackle can be fitted if the wrist unit is re-
moved.
6 Fit guide pins in the upper arm house. Specified in Required equipment on
page 256.

4 Repair
Continued
Action Note
7 Refit the tubular shaft unit, using caution.
Note
CAUTION
There are two parallel pins guiding the
Do not damage the gears when refitting the tubular shaft unit into its place.
tubular shaft unit.
8 Secure the tubular shaft unit with its attach- See the figure in:
ment screws. • Location of tubular shaft unit on
page 256
Tightening torque: 22 Nm
9 Refit motors axes 4, 5 and 6. How to refit motors is described in sec-
tion:
10 Perform a leak-down test. See Performing a leak-down test on
page 188.
11 Refit the bracket securing the cable package
to the tubular shaft unit, with its attachment
screws.
xx0800000335
Parts:
ity 8.8-A2F (2 pcs)
• C: Bracket
12 If the wrist unit has been removed from the How to refit the wrist unit is detailed in
tubular shaft unit, refit it now. section:
• Refitting of wrist unit on page 266
13 Refill gearbox axis 4 with oil. How to refill oil in gearbox is described in
section:
on page 169

4 Repair
Continued
Action Note
15
DANGER


4 Repair
4.4.3 Replacing wrist unit
Introduction
This section describes how to replace the wrist on IRB 2600 Standard.
How to remove and refit the wrist unit on IRB 2600ID is described in section
Replacing motor axis 6 and wrist unit - IRB 2600ID on page 344.
Location of wrist unit

The wrist unit is located in the upper arm as shown in the figures.
There are two versions of the wrist, one with an o-ring and one with a sealing. Make
sure to order the correct spare parts.
A
B
C
D
G
E
xx0800000341
xx1800003343
A Upper arm
B Attachment screw M8x40, quality steel 12.9 Gleitmo (5 pcs)

4 Repair
Continued
C Spring washer, conical 8.4x18x2, quality steel-mZn12c (5 pcs)

D Gears
E Wrist unit
F O-ring (Placed on the wrist, not visible)
Sealing (lower image)
G Guide pin
(only available for robots that are calibrated with Axis Calibration)
(not available on IRB 2600ID)
Required equipment
Equipment Note
Wrist unit For spare parts no. see Spare parts - Upper
arm (2.05/2.50/2.55) in Product manual, spare
parts - IRB 2600.
O-ring For spare parts no. see Spare parts - Upper
arm (2.05/2.50/2.55) in Product manual, spare
Sealing parts - IRB 2600.
on page 447.

Action Note
calibration:

4 Repair
Continued
Removal of wrist unit

Use this procedure to remove the wrist unit.
Action Note
take actions accordingly prior to beginning the
repair procedure.
2 Move the upper arm to a position where the
wrist is pointing towards the floor as shown in
the figure.
This way the wrist can be removed without
drainage.
xx0800000329
3
DANGER
Turn off all:

area.
4
WARNING

page 36.
5
CAUTION
The robot wrist unit weighs 15 kg.

cordingly!
6 Remove the attachment screws and carefully See the figure in:
remove the wrist unit. • Location of wrist unit on
page 263
CAUTION
Do not damage the gears.
WARNING
The wrist unit is filled with oil. Perform removal

with care.

4 Repair
Continued
Action Note
7 Pour out the oil from the wrist unit. See the figure in
• Location of wrist unit on
page 263
Refitting of wrist unit

Use this procedure to refit the wrist unit.
Action Note
1
DANGER
Turn off all:

area.
2 Check if there is a parallel pin hole in the upper

arm tube.
The hole is available on robots that are calib-
rated with the Axis Calibration method.
xx1600000690

4 Repair
Continued
Action Note
3 If there is a hole, fit the parallel pin into the
corresponding hole in the wrist (enclosed with
the new wrist spare part).
Note
If the parallel pin is not installed on a robot cal-

ibrated with Axis Calibration, the calibration
result will be affected negatively.
xx1600000689
Verify that the parallel pin sticks out

from the wrist according to the meas-
urement given below.
0
4 -0,5
xx1600000703

Remove any painting from the assembly sur-
faces with a knife.

4 Repair
Continued
Action Note
5 Check the o-ring or sealing. Replace if dam- See the figure in:
aged. • Location of wrist unit on
page 263
6 Prepare the refitting of the wrist by inserting the
attachment screws and washers in the upper
arm tube.
7
CAUTION
The robot wrist unit weighs 15 kg.

cordingly.
8 Carefully put the wrist unit in its place on the

upper arm.
CAUTION
Do not damage the gears.
CAUTION
Make sure that the o-ring stays in place on the

wrist unit.
9 Adjust the play of the wrist by following these

steps:
• Push the wrist as shown in the figure to
locate the smallest play in the same way
as for adjustment of motors for axes 4,
5 and 6. See Refitting motors on page 316.
xx1000000223
Parts:
• A: Gears on drive shaft unit,
axes 5-6
• B: Gears on the wrist
10 Secure the wrist unit with its attachment screws See the figure in
and washers. • Location of wrist unit on
page 263
11 Measure the play by moving axes 5 and 6 with How to measure the play is described
the measuring tool. in sections:
• Measuring the play, axis 5 on
page 270
• Measuring the play, axis 6 on
page 272
• Measuring the play, axis 5 (ID
upper arm) on page 274
• Measuring the play, axis 6 (ID
upper arm) on page 277

4 Repair
Continued
Action Note
page 188.
13 Refill oil in gearbox axes 5-6. How to fill oil in gearbox axes 5-6 is
• Changing oil, axes-5 and -6
gearboxes on page 173
14 Re-calibrate the robot. Pendulum Calibration is described in
Operating manual - Calibration Pendu-
lum, enclosed with the calibration
tools.
Axis Calibration is described in Calib-
rating with Axis Calibration method on
page 406.
General calibration information is in-
cluded in section Calibration on
page 393.
15
DANGER
Make sure all safety requirements are met when

performing the first test run.

4 Repair
4.4.4 Measuring the play, axis 5
General
This section is only valid for IRB 2600. For IRB 2600ID, see section Measuring the
play, axis 5 (ID upper arm) on page 274.
After reassembly due to repair work or any other reason, the play in axis 5 and 6
must be checked to ensure the repetition accuracy of the robot positioning. The
procedure for axis 5 is detailed below.
Required equipment

Standard toolkit - Content is defined in sec-
tion Standard tools on
page 447.
Other tools and procedures may be required. These procedures include
See references to these procedures in the references to the tools re-
step-by-step instructions below. quired.
Measurement, axis 5
The procedure below details how to measure the play of axis 5.
Action Information
1
DANGER
Turn off all:

working area.
2 Move the robot to calibration position and

turn the axis 4 90°.
3 Fit the measuring tool, play to the turning Article number is specified in Required
disc. equipment on page 270.

4 Repair
Continued
Action Information
4 Apply load F in one direction, as shown in
the figure to the right.
xx0300000186
Values for IRB 2600 -20/1.65, -12/1.65,

-12/1.85:
• A: Measuring tool, play
• B: 140 mm
• C: 85 mm
• F: 40N
5 Remove the load and set the dial indicator
to zero.
6 Apply load F in the opposite direction, as
shown in the figure to the right.
xx0300000187
Values for IRB 2600 - 20/1.65, -12/1.65,

-12/1.85:
• B: 140 mm
• C: 85 mm
• F: 40N
7 Remove the load and measure the play by The maximum play allowed at the given
reading the dial indicator. distance from the center of axis 5 is, for
robot version:
• IRB 2600 -20/1.65, -12/1.65, -
12/1.85: 0.12 mm

4 Repair
General
This section is only valid for IRB 2600. For IRB 2600ID, see section Measuring the
play, axis 6 (ID upper arm) on page 277.
must be checked to ensure the repetition accuracy of the robot positioning. The
procedure for axis 6 is detailed below.
Required equipment

page 447.
Measurement, axis 6
The procedure below details how to measure the play in axis 6.
Action Information
1
DANGER
Turn off all:

working area.
2 Fit the measuring tool, play to the turning Article number is specified in Required
disc. equipment on page 272.
3 Attach a weight (m) at a distance (B) from
the wrist flange, in order to avoid the ef-
fects of play on axis 5.
xx0300000188
Values for robot versions IRB 2600 -

20/1.65, -12/1.65, -12/1.85:
• B: 140 mm
• m: 10 kg

4 Repair
Continued
Action Information
4 Apply load F in one direction.
xx0300000189

20/1.65, -12/1.65, -12/1.85:
• B: 100 mm
• C: 150 mm
• F: 40N
5 Remove the load and set the dial indicat-
or to zero.
6 Apply load F in the opposite direction,
as shown in the figure to the right.
xx0300000190

20/1.65, -12/1.65, -12/1.85:
• B: 100 mm
• C: 150 mm
• F: 40N
7 Remove the load and measure the play The maximum play allowed at the given
by reading the dial indicator. distance (B) from the center of axis 6 is, for
robot version:
• Values for IRB 2600 -20/1.65, -
12/1.65, -12/1.85: 0.22 mm

4 Repair
4.4.6 Measuring the play, axis 5 (ID upper arm)
General
This section is only valid for IRB 2600ID. For measuring the play of IRB 2600, see
Measuring the play, axis 5 on page 270.
must be checked to ensure the repetition accuracy of the robot positioning.
Required equipment

page 447.
Turning disk adapter 3HAC027717-
020
Measuring tool 3HAB9238-1 For measuring play.
Measuring bracket 3HAC032976-
001
Dial indicator with a magnetic foot -
Measurement, axis 5
Use this procedure to measure the play of axis 5.
Action Information
1 Move the robot to calibration position. Turn
axis 4 to +90°.
2
DANGER
Turn off all:

working area.
3 Fit the turning disk adapter to the turning Art. no. is specified in Required equip-
disk. ment on page 274.
4 Fit the measuring tool to the turning disk Art. no. is specified in Required equip-
adapter. ment on page 274.

4 Repair
Continued
Action Information
5 Fit the measuring bracket to the wrist. Use Art. no. is specified in Required equip-
the holes that are pointed out in the figure. ment on page 274.
xx1100000688
6 Fit the magnetic foot of the dial indicator

on the measuring bracket.
7 Place the tip of the dial indicator on the
milled surface of the measuring tool shaft.
xx1100000689
Distance from the center line of axis 5.

IRB 2600ID - 15/1.85:
A 235 mm
IRB 2600ID - 8/2.00:
A 300 mm
8 Verify that axis 5 is put in calibration posi-
tion.
9 Apply load F=30N with a dynamometer at
the distance A from the turning disk.
F
A
xx1100000691
A 140 mm
to zero.

4 Repair
Continued
Action Information
11 Apply load F=30N in the opposite direction
(180°), at the distance A from the turning
disk. A
F
xx1100000693
A 140 mm
12 Remove the load and measure the play by The maximum play allowed is:
reading the dial indicator. • IRB 2600ID - 15/1.85: 0.25 mm
• IRB 2600ID - 8/2.00: 0.32 mm
13 Turn axis 5 to +90°.
14 Repeat step 9 to step 12.
15 Turn axis 5 to -90°.

4 Repair
General
This section is only valid for IRB 2600ID. For measuring the play of IRB 2600, see
Measuring the play, axis 6 on page 272.
must be checked to ensure the repetition accuracy of the robot positioning.
Required equipment

page 447.
Turning disk adapter 3HAC027717-
020
Measuring tool 3HAB9238-1 For measuring play.
Measuring bracket 3HAC032976-
001
Dial indicator with magnetic foot -
Measurement, axis 6
Use this procedure to measure the play of axis 6.
Action Information
1 Move the robot to calibration position. Turn
axis 4 to +90°.
2
DANGER
Turn off all:

working area.
3 Fit the turning disk adapter to the turning Art. no. is specified in Required equip-
disk. ment on page 277.
4 Fit the measuring tool to the turning disk Art. no. is specified in Required equip-
adapter. ment on page 277.

4 Repair
Continued
Action Information
5 Fit the measuring bracket to the wrist. Use Art. no. is specified in Required equip-
the holes that are pointed out in the figure. ment on page 277.
xx1100000688
6 Fit the magnetic foot of the dial indicator

on the measuring bracket.
7 Place the tip of the dial indicator on the
marking.
xx1100000690
Distance from the rotation center of axis

6:
A 100 mm
8 Verify that axis 6 is put in calibration posi-
tion.
9 Apply load F=40N upwards with a dynamo-
meter on the opposite side of the dial indic-
ator, at a distance B from the rotation cen-
ter of axis 6.
F
A
B
xx1100000692
A 100 mm (dial indicator)

B 140 mm
to zero.

4 Repair
Continued
Action Information
11 Apply load F=40N downwards at a distance
B from the rotation center of axis 6.
A
B
F
xx1100000694
A 100 mm (dial indicator)

B 140 mm
12 Remove the load and measure the play by The maximum play allowed is:
reading the dial indicator. • IRB 2600ID - 15/1.85: 0.20 mm
• IRB 2600ID - 8/2.00: 0.22 mm
13 Turn axis 6 to +180°.

4 Repair
4.5.1 Replacing the lower arm
4.5 Lower arm
Location of lower arm

The lower arm is located as shown in the figure.
B C D E
G
H J
xx0800000360
A Upper arm
B Gearbox axis 3
C Lower arm
D Washer (12 pcs)
E Attachment screws M8x40 quality Steel 12.9 Gleitmo (12 pcs)
F Frame
G Gearbox axis 2
H Washer (17 pcs)
J Attachment screws M8x40 quality Steel 12.9 Gleitmo (17 pcs)

4 Repair
Continued
xx1800000933
A Upper arm
B Gearbox axis 3
C Lower arm
D Washer (12 pcs)
E Attachment screws M8x40 quality Steel 12.9 Gleitmo (12 pcs)
F Frame
G Gearbox axis 2
H Washer (3 pcs)
J Attachment screws M10x40 12.9 Gleitmo 603+Geo500 (15 pcs)

4 Repair
Continued
Required equipment
Equipment Note
Lower arm For spare parts no. see Spare parts - Lower
arm and motors in Product manual, spare
parts - IRB 2600.
Lifting eye M8
on page 447.

Action Note
calibration:
Removing the lower arm

Use this procedure to remove the lower arm.
Action Note

4 Repair
Continued
Action Note
figure.
xx0800000336
3
DANGER
Turn off all:

working area.
4 Remove the cable package from all axes How to remove the cable package in
except in the base. frame, lower arm and armhouse is de-
scribed in sections:
on page 204
• Removing cable harness in lower
arm and armhouse on page 205
5 Secure the upper arm with a roundsling in
an overhead crane.
6 Remove the complete upper arm and put it How to remove the complete upper arm
on a loading pallet. is described in section:
• Removing the complete upper arm
on page 248
7
CAUTION
The robot lower arm weighs .

35 kg (IRB 2600-20/1.65, IRB 2600-12/1.65,
IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB
2600ID-8/2.0)
30 kg (IRB 2600-20/1.65 type C, IRB 2600-
12/1.65 type C)
accordingly!

4 Repair
Continued
Action Note
8 Fit a lifting lug in one of the upper holes in
the lower arm, for the attachment screws.
xx0800000379
Parts:
• A: Lifting lug
9 Remove the attachment screws and wash- Valid for IRB 2600-20/1.65, IRB 2600-
ers that secure the lower arm to the axis-2 12/1.65, IRB 2600-12/1.85, IRB 2600ID-
gearbox. 15/1.85, IRB 2600ID-8/2.0:
xx1800000935
Valid for IRB 2600-20/1.65 type C, IRB

2600-12/1.65 type C:
xx1800000934
10 Remove the lower arm.

4 Repair
Continued
Refitting the lower arm

Use this procedure to refit the lower arm.
Action Note
1
DANGER
Turn off all:

working area.
2
CAUTION
The robot lower arm weighs .

35 kg (IRB 2600-20/1.65, IRB 2600-12/1.65,
IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB
2600ID-8/2.0)
30 kg (IRB 2600-20/1.65 type C, IRB 2600-
12/1.65 type C)
accordingly!
3 Fit a lifting lug in one of the upper holes in

the lower arm, for the attachment screws.
xx0800000379
Parts:
• A: Lifting lug
4 Secure the lower arm with a roundsling in
an overhead crane and lift it to the robot.

4 Repair
Continued
Action Note
5 Refit the attachment screws and washers Valid for IRB 2600-20/1.65, IRB 2600-
to secure the lower arm to the axis-2 gear- 12/1.65, IRB 2600-12/1.85, IRB 2600ID-
box. 15/1.85, IRB 2600ID-8/2.0:
Attachment screws: M8x40 quality steel
Gleitmo 12.9 (17 pcs)
Washers: 3HAA1001-172 (17 pcs)
xx1800000935

2600-12/1.65 type C:
Attachment screws: M10x40 12.9 Gleitmo
603+Geo500 (15 pcs)
Washers: 3HAC043534-001 (3 pcs)
Tightening torque: 50 Nm ± 5 Nm and 90°
angle ± 10°.
xx1800000934
6 Secure the complete upper arm with round-

slings in an overhead crane and lift it to the
robot.
7 Refit the complete upper arm. How to refit the complete upper arm is
• Refitting the complete upper arm
on page 253
8 Refit the cable package. How to refit the cable package in frame,
lower arm and armhouse is described in
sections:
frame on page 211
page 220

4 Repair
Continued
Action Note
Axis Calibration is described in Calibrat-
ing with Axis Calibration method on
page 406.
10
DANGER


4 Repair
4.6.1 Replacing stop pin axis 1
4.6 Frame and base
Location of stop pin axis 1

The stop pin axis 1 is located as shown in the figure.
xx0800000045
A Attachment screws M6x16 quality 8.8-A2F (2 pcs)

B Bracket
C O-ring (2 pcs) - Not used if bracket (D) is installed.
D Bracket
E Stop pin
Required equipment
Equipment Note
Stop pin For spare parts number, see Spare parts -
Frame and base in Product manual, spare
parts - IRB 2600.
page 447.

4 Repair
Continued
Equipment Note
Removing the stop pin, axis 1

Use this procedure to remove the stop pin axis 1.
Action Note
1
DANGER
Turn off all:

working area.
2 Remove the attachment screws securing See the figure in

the bracket and stop pin. • Location of stop pin axis 1 on
page 288
3 Remove the bracket and stop pin. See the figure in
• Location of stop pin axis 1 on
page 288
Refitting the stop pin, axis 1

Use this procedure to refit the stop pin axis 1.
Action Note
1
DANGER
Turn off all:

working area.
2 Fit the two o-rings on the stop pin. See the figure in
Note page 288
The o-rings are not used when bracket (D)

is installed.

4 Repair
Continued
Action Note
3 Fit the stop pin on the bracket.
Note
The small spike on the bracket shall be

pointing downwards for correct fitting of the
stop pin.
A
B
xx0800000453
Parts:
• A: Bracket
• B: Stop pin
• C: Small spike
4 Secure the stop pin together with bracket 3HAB7116-1 (Loctite 243).
(D) on the frame with its attachment screws. Tightening torque: 10 Nm
Use Locking liquid
See the figure in
page 288
5
DANGER


4 Repair
4.6.2 Replacing the base
Location of base and complete arm system

The complete arm system is defined as:
• complete upper arm (includes: wrist unit, tubular shaft unit and armhouse)
• lower arm
• frame
• axis-1 gearbox
The location of the base and the complete arm system is shown in the figure.
xx0900000320
A Base
B Frame
C Lower arm
D Arm house (part of complete upper arm)
E Tubular shaft (part of complete upper arm)
F Wrist unit (part of complete upper arm)

4 Repair
Continued
Required equipment

Roundslings - Lengths: 2 m (1 pcs), 1.5 m (1
pcs)
Lifting capacity: 1,000 kg.
Support legs 3HAC15535-1 3 pcs
Guide pin, M8x150 3HAC15520-2 Valid for IRB 2600-20/1.65, IRB
2600-12/1.65, IRB 2600-12/1.85,
IRB 2600ID-15/1.85, IRB 2600ID-
8/2.0.
Always use guide pins in pairs.
Guide pin, M12x150 3HAC13056-2 Valid for IRB 2600-20/1.65 type
C, IRB 2600-12/1.65 type C.
Lifting eye - Valid for IRB 2600-20/1.65, IRB
2600-12/1.65, IRB 2600-12/1.85,
IRB 2600ID-15/1.85, IRB 2600ID-
8/2.0.
M8
3 pcs
Lifting eye - Valid for IRB 2600-20/1.65 type
C, IRB 2600-12/1.65 type C.
M12
3 pcs
Other tools and procedures may These procedures include refer-
be required. See references to ences to the tools required.
these procedures in the step-by-
step instructions below.
Gasket 3HAC065190-001 Included with spare part base. 3
pcs
Cleaning agent - Loctite 7063
For cleaning.
Flange sealant - Loctite 574
Only valid for IRB 2600-20/1.65, For sealing.
IRB 2600-12/1.65, IRB 2600-
12/1.85, IRB 2600ID-15/1.85, IRB
2600ID-8/2.0.

4 Repair
Continued

Action Note
calibration:
Removing the base

Use this procedure to remove the complete arm system from the base.
Action Note
2 Jog the robot to:
• Axis 1: 0°
• Axis 2: 0°
• Axis 3: -10°
• Axis 4: 0°
• Axis 5: 0°
• Axis 6: 0°
3
DANGER
Turn off all:

to the robot, before entering the safe-
guarded space.

4 Repair
Continued
Action Note
4 Drain the axis-1 gearbox. How to drain oil is detailed in section
• Changing the oil, axis 1 gearbox on
Note floor mounted robots on page 148
Elapsed time varies depending on the tem-
perature of the oil.
5 Remove the cable harness in the base, the How to remove the cable harness in base
frame and the lower arm of the robot. and frame is detailed in sections:
• Removing cable harness in base
on page 199
Tip
on page 204
Wrap up the cabling against the frame to
keep it undamaged during the remaining • Removing cable harness in lower
work. arm and armhouse on page 205
6 Secure the robot with roundslings in an Dimensions are specified in Required

overhead crane. equipment on page 292.
Stretch the roundslings so that the robot B
weight is secured when removing founda-
tion bolts in next step.
xx1800001211
A Roundsling 1.5 m
B Roundsling 2 m
7
CAUTION

kg.
accordingly!
8 Remove the bolts that secure the robot to

the foundation.

4 Repair
Continued
Action Note
9 Lift the robot and fit three support legs to
the robot base, using bolts, washers and
nuts.
DANGER
Working underneath the manipulator without

safely securing the support legs between
the robot base and the foundation will result
in serious or fatal injury.
Make sure the robot is stable and safely
secured to the foundation via the support
legs, before working underneath the robot.
Keep the lifting accessories stretched for xx1800000874
extra safety precautions.
10 Lower the robot and secure the support legs

to the foundation, using bolts and washers.
xx1800000875
11 Remove the cover plate at the bottom of the

base.
xx1800000879
12 Valid for IRB 2600-20/1.65, IRB 2600-

12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0:
Remove the expansion container, if avail-
able.
xx1800000881

4 Repair
Continued
Action Note
13 Remove the base attachment screws and Valid for IRB 2600-20/1.65, IRB 2600-
washers. 12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0:
xx1800000882

2600-12/1.65 type C:
xx1800000880
14 Fit two guide pins in opposite holes in the Valid for IRB 2600-20/1.65, IRB 2600-
axis-1 gearbox. 12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0:
Guide pin, M8x150: 3HAC15520-2
2600-12/1.65 type C:
xx1800000883
15
CAUTION
The arm system and axis-1 gearbox weighs

235 kg together.
All lifting accessories must be sized accord-
ingly.

4 Repair
Continued
Action Note
16 Lift away the robot arm system.
Remove the guide pins, if the arm system
is about to be laid down on the floor. See
Illustration of robot put down on its side on
page 363.
xx1800000884
17
CAUTION
The weight of the base is 49 kg

accordingly.
18 Fit three lifting eyes to the base and secure Valid for IRB 2600-20/1.65, IRB 2600-
with roundslings in an overhead crane or 12/1.65, IRB 2600-12/1.85, IRB 2600ID-
similar. 15/1.85, IRB 2600ID-8/2.0:
Lifting eye: M8
2600-12/1.65 type C:
Lifting eye: M12
xx1800000931
19 Remove the support legs attachments

screws and remove the base from the sup-
port legs.
xx1800000885

4 Repair
Continued
Refitting the base

Use this procedure to refit the complete arm system to the base.
Action Note
1
CAUTION
The weight of the base is 49 kg

accordingly.
2 Fit three lifting eyes to the base and secure Valid for IRB 2600-20/1.65, IRB 2600-
with roundslings in an overhead crane or 12/1.65, IRB 2600-12/1.85, IRB 2600ID-
similar. 15/1.85, IRB 2600ID-8/2.0:
Lifting eye: M8
2600-12/1.65 type C:
Lifting eye: M12
3 Fit the new base to the support legs and
secure with the attachment screws.
xx1800000885
4 Valid for IRB 2600-20/1.65, IRB 2600-

12/1.65, IRB 2600-12/1.85, IRB 2600ID- Tip
15/1.85, IRB 2600ID-8/2.0:
Remove residues of old Loctite and other Use Loctite 7063 (or similar) for cleaning.
contaminations from surfaces before apply-
ing new Loctite 574.

4 Repair
Continued
Action Note
5 Valid for IRB 2600-20/1.65, IRB 2600-
12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0:
Apply Loctite 574 around the screw holes
on the axis-1 gearbox as shown in the fig-
ure.
xx0800000353
Parts
A Loctite 574
B Screw hole in axis-1 gearbox
C Axis-1 gearbox
2600-12/1.65 type C:
Fit three new gaskets to the base. The gas-
kets are included with the gearbox spare
part.
xx1800000797
7
CAUTION
The arm system and axis-1 gearbox weighs

235 kg together.
All lifting accessories must be sized accord-
ingly.
8 Lift the arm system to the mounting site.

4 Repair
Continued
Action Note
axis-1 gearbox. 12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0:
2600-12/1.65 type C:
xx1800000932
10 Lower the arm system against the base and Valid for IRB 2600-20/1.65, IRB 2600-
secure with the attachment screws and 12/1.65, IRB 2600-12/1.85, IRB 2600ID-
washers. 15/1.85, IRB 2600ID-8/2.0:
Attachment screws: M8x40 quality Steel
12.9 Gleitmo and washers (24+24 pcs).
xx1800000882

2600-12/1.65 type C:
603 and washers (12+12 pcs).
xx1800000880

4 Repair
Continued
Action Note
11 Valid for IRB 2600-20/1.65, IRB 2600-
12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0:
Refit the expansion container, if available.
xx1800000881
12 Apply some grease to the o-ring and refit

the o-ring between the cover and base.
13 Refit the cover plate at the bottom of the Attachment screws: M6x16 quality 8.8-
base with its attachment screws. A2F (5 pcs)
xx1800000879
14 Remove the screws that secure the support

legs to the foundation.
DANGER
Stretch the roundslings to make sure that

the robot weight is secured.
xx1800000875
15 Lift the complete robot and remove the

support legs from the base.
xx1800000874

4 Repair
Continued
Action Note
16 Lower the robot and secure it to the found- See Orienting and securing the robot on
ation. page 66.
18
DANGER


4 Repair
4.7.1 Removing motors
4.7 Motors
Introduction
This procedure describes how to remove motors on all axes of the robot.
Note
For IRB 2600ID this section describes motors axes 1, 2, 3 and 4. Motors axes 5
and 6 are described in sections:
• Motor axis 5, section Replacing motor axis 5 - IRB 2600ID on page 332
• Motor axis 6, section Replacing motor axis 6 and wrist unit - IRB 2600ID on
page 344.
Location of axis-1 and axis-2 motors

The axis-1 and axis-2 motors are located as shown in the figure.
Motors:
(1) = Axis-1 motor
(2) = Axis-2 motor
xx0900000302
A Attachment screws M5x16, quality Steel 8-A2F (7 pcs)

B Motor cover
C Attachment screws, axis-1 motor (4 pcs) + washers. See Tightening torques and
attachment screws on page 323
C Attachment screws, axis-2 motor (4 pcs) + washers. See Tightening torques and
D Connection box
E Axis-1 motor
E Axis-2 motor

4 Repair
Continued
F O-ring
G Hole
H Cable gland cover
Location of axis-3, axis-4, axis-5 and axis-6 motors

The axis-3, axis-4, axis-5 and axis-6 motors are located as shown in the figures.
IRB 2600 Standard.
Motors: (3) = Axis-3 motor. (4) = Axis-4, axis-5 and axis-6 motors.
xx0900000303
A Markings inside armhouse, identifying the position of each motor

B Attachment screws, axis-3 motor (4 pcs) + washers. See Tightening torques and
B Attachment screws, axis-4, axis-5 and axis-6 motors (3x4 pcs) + washers.
Tightening torques and attachment screws on page 323
C Axis-3 motor
D Axis-4 motor
E Axis-5 motor
F Axis-6 motor
G O-ring (axis-4, axis-5 and axis-6)
H Armhouse

4 Repair
Continued
IRB 2600ID
xx1000000990

B Motor axis 3
C O-ring
D O-ring
E Motor axis 4
F Attachment screws (4 pcs)
Connectors, motors axes 3 - 6

The figures shows the connectors in the armhouse.
• IRB 2600 Standard: Axes 3-6
• IRB 2600ID: Axes 3-4

4 Repair
Continued
IRB 2600 Standard, motor type B
MP5 FB5 MP4 FB4
FB6
MP6
FB3
MP3
MP3-6 FB3-6
xx1400002568

4 Repair
Continued
IRB 2600 Standard, motor type A
xx0900000367

4 Repair
Continued
IRB 2600ID
R2.FB6
R2.FB5
R2.MP6
R2.FB4 R2.MP5
R2.MP4
R2.FB3
R2.MP3
xx1400002578
Required equipment
Equipment Note
Threaded bar 2 pcs. Dimension: M8.
Used for pressing out the axis-1 and axis-2
motors.
Extended reach hex bit socket head Required for:
• Axis-2 motor replacement: M6, length
minimum 260 mm.
minimum 160 mm.
on page 447.

4 Repair
Continued
Weights
The motors for the different axes weighs according to the table:
Motor Weight in kg
Axis-1 motor 13 kg
Axis-2 motor 13 kg
Axis-3 motor 8 kg
Axis-4 motor 6.5 kg
Axis-5 motor 6.5 kg
Axis-6 motor 6.5 kg
CAUTION
All lifting equipment must be sized accordingly!

Action Note
calibration:

4 Repair
Continued
Position of robot
Use this procedure to place the robot in the position recommended in order to
facilitate replacement of motors.
Action Information
Axis-1, axis-4, axis-5 and axis-6 motor (IRB
2600 Standard)
Axis-1 and axis-4 motors (IRB 2600ID)
• Move the robot to a position where the
wrist is pointing to the floor, as shown in
the figure. This will make it possible to
remove the motors without draining the
oil from the gearbox.
xx0800000388
Axis-2 motor
lower arm rests firmly on the damper of
axes 2 and 3. Release the brake of axis
2 to be sure that the lower arm rests in
the end position.
xx1100000548
Axis-3 motor
• Move axis-2 to 0° and axis-3 to maximal
+. Release the brake of axis-3 to be sure
that the upper arm is completely vertical
and rests against the damper of axis-2
and axis-3.
Draining gearbox
Use this procedure to drain gearboxes, if needed.
Note
Draining of gearbox is only needed when removing the axes 2 and 3 motors.
Action Note
1 Axis-1 motor: -
• Draining of gearbox is not needed.
2 Axis-2 motor: How to drain the gearbox is described
• The gearbox has to be drained before in section:
removing the motor. • Changing the oil, axis-2 gearbox
on page 161

4 Repair
Continued
Action Note
3 Axis-3 motor: How to drain the gearbox is described
• The gearbox has to be drained before in section:
removing the motor. • Changing the oil, axis-3 gearbox
on page 165
4 IRB 2600 - axes 4, 5, 6: -
• Draining of gearbox is not needed if ro-
bot is positioned as recommended.
IRB 2600ID - axis 4:
• Draining of gearbox is not needed if ro-
bot is positioned as recommended.
Removing motors
Use this procedure to remove the axis-1, axis-2, axis-3, axis-4, axis-5 and axis-6
motors.
Note
How to replace motors axes 5 and 6 on IRB 2600ID is described in sections:

• Replacing motor axis 6 and wrist unit - IRB 2600ID on page 344
Note
The procedure contains information how to remove motors on all axes of the
robot. Some steps are only applicable to a certain motor. Follow the steps
carefully in order not to miss vital information!
Action Note
take actions accordingly prior to beginning the
repair procedure.
2 Move the robot to the recommended position Also see
for the motor that shall be removed. • Position of robot on page 310
3
DANGER
Turn off all:

area.
4 Check if the gearbox needs to be drained. Also see

• Draining gearbox on page 310

4 Repair
Continued
Action Note
5 Only applicable to axis-3, axis-4, axis-5 and
axis-6 motors!
Remove the cover in the back of the arm house.
B
WARNING
The robot must never be run without the cover

in the armhouse fitted! It is a vital supporting
part of the robot.
A
xx0800000389
Parts:
• A: Cover
• B: Attachment screws (8 pcs) +
washers.
6 Only applicable to motors on axes 1 and 2 How to remove the fan is detailed in
with fan fitted! section:
Remove the fan before starting the removal! • Installation of cooling fan for
motors (option) on page 88
7 Only applicable to axis-1 and axis-2 motors! See the figure in:
Remove the motor cover. • Location of axis-1 and axis-2
motors on page 303
Remove the cable gland cover. • Location of axis-1 and axis-2
motors on page 303
Remove the connection box. • Location of axis-1 and axis-2
motors on page 303
Note
Only needed if the motor shall be replaced with

a new one.
10 Disconnect the motor cables.

Note
When removing motors 4,5 or 6 the

cables of motor axis 3 must be discon-
nected too. This must be done in order
to be able to remove the bracket on
top of motors axes 4, 5 and 6.

4 Repair
Continued
Action Note
11 Only applicable to motors axes 3, 4, 5 and 6 The figure shows IRB 2600 Standard.
on IRB 2600 Standard and axes 3 and 4 on
IRB 2600ID! G
Remove the bracket to reach the attachment A
screws of the motors.
F
E
B
C
D
xx0900000372
Parts:
• A: Attachment screws, M6x16
quality 8.8-A2F (2 pcs)
• B: Bracket
• C: Clamp
• D: Cable straps
• E: Connection bracket
• F: Connection bracket
• G: Hexagon nut, M5 quality
steel 8-A2F

4 Repair
Continued
Action Note
12 In order to release the brakes of the motor to Connectors and pins:
be removed, connect the 24 VDC power supply • Axis-1 motor: R2.MP1
to the motor connector. - + : pin 2
- -: pin 5
Tip • Axis-2 motor: R2.MP2
- + : pin 2
For axis-2 and axis-3 motors: release the mo- - -: pin 5
tor brake until the arm firmly rests on the
• Axis-3 motor: R2.MP3
damper for each axis respectively. See posi-
tions in Position of robot on page 310. - + : pin 2
- -: pin 5
- + : pin 4
- - : pin 6
- + : pin 4
- - : pin 6
IRB 2600:
- + : pin 4
- - : pin 6
IRB 2600ID:
- + : pin 7
- -: pin 8
CAUTION
The connections for the motor brakes

(24 VDC connection) are phase de-
pendent. If the connection on the pins
is switched, it can cause severe dam-
age to vital parts.
13
Note
Whenever parting/mating motor and gearbox,

the gears may be damaged if excessive force
is used!
14 Remove the attachment screws securing the See the figure in:
motor. • Location of axis-1 and axis-2
If needed use a 300 mm extension for bits 1/2" motors on page 303
(Motor axis 1).
15 If required, press the motor out of position by
fitting two threaded bars in the threaded holes Note
in the motor flange.
Always use removal tools in pairs diag-
onal to each other.
16 Remove the motor!

CAUTION
Lift the motor gently in order not to

damage pinion or gears.

4 Repair
Continued
Action Note
17 Only applicable to motor axis 1! See the figure in:
Cover the hole if replacement of motor axis 1 • Location of axis-1 and axis-2
is not immediate, in order to avoid contamina- motors on page 303
tion.
18 Only applicable to motors axes 4, 5 and 6! See the figure in:
Check that the o-ring also is removed. It might • Location of axis-1 and axis-2
stay in the armhouse when the motor is re- motors on page 303
moved.

4 Repair
4.7.2 Refitting motors
Introduction
This procedure describes how to refit motors on all axes of the robot.
WARNING
When a motor is replaced, make sure to use the correct type of new motor. Motors
of different types may not be compatible. See the Spare parts manual on myABB
business portal (www.myportal.abb.com).
Note
For IRB 2600ID this section describes motors axes 1, 2, 3 and 4. Motors axes 5
and 6 are described in sections:
• Motor axis 5, see section Replacing motor axis 5 - IRB 2600ID on page 332
• Motor axis 6, see section Replacing motor axis 6 and wrist unit - IRB 2600ID
on page 344.
Location of axis-1 and axis-2 motors

The axis-1 and axis-2 motors are located as shown in the figure.
Motors:
(1) = Axis-1 motor
(2) = Axis-2 motor
xx0900000302
A Attachment screws M5x16, quality Steel 8-A2F (7 pcs)

B Motor cover
C Axis-1 motor: Attachment screws(4 pcs) + washers. See Tightening torques
and attachment screws on page 323
C Axis-2 motor: Attachment screw (4 pcs) + washers. See Tightening torques and

4 Repair
Continued
D Connection box
E Axis-1 motor
E Axis-2 motor
F O-ring
G Hole
H Cable gland cover
Location of axis-3, axis-4, axis-5 and axis-6 motors

The axis-3, axis-4, axis-5 and axis-6 motors are located as shown in the figures.
IRB 2600 Standard.
Motors:
(3) = Axis-3 motor
(4) = Axis-4, axis-5 and axis-6 motors
xx0900000303
A Markings inside armhouse, identifying the position of each motor

B Attachment screws, axis-3 motor, (4 pcs) + washers. See Tightening torques
and attachment screws on page 323
B Attachment screws, axis-4, axis-5 and axis-6 motors, (3x4 pcs) + washers. See
Tightening torques and attachment screws on page 323
C Axis-3 motor
D Axis-4 motor
E Axis-5 motor
F Axis-6 motor
G O-ring (axis-4, axis-5 and axis-6)
H Armhouse

4 Repair
Continued
IRB 2600ID
xx1000000990

B Axis-3 motor
C O-ring
D O-ring
E Axis-4 motor
F Attachment screws (4 pcs)
Connectors, motors axes 3 - 6

The figures shows the connectors in the armhouse:
• IRB 2600 Standard: Axes 3-6
• IRB 2600ID: Axes 3-4.

4 Repair
Continued
IRB 2600 Standard, motor type B
MP5 FB5 MP4 FB4
FB6
MP6
FB3
MP3
MP3-6 FB3-6
xx1400002568
Note
On IRB 2600 standard, motor type B the connector FB6 shall be fitted in a 30°
angle.

4 Repair
Continued
IRB 2600 Standard, motor type A
xx0900000367

4 Repair
Continued
IRB 2600ID
R2.FB6
R2.FB5
R2.MP6
R2.FB4 R2.MP5
R2.MP4
R2.FB3
R2.MP3
xx1400002578
Required equipment
Equipment Note
Extended reach hex bit socket head Required for:
minimum 260 mm.
minimum 160 mm.
on page 447.
Lifting tool, axis-2 For art. no. see Reference information.
Lifting tool, axis-3 For art. no. see Reference information.
Motors For spare part no. see Spare part lists on
page 451.

4 Repair
Continued
Weights
The motors for the different axes weighs according to the table:
Motor Weight in kg
Axis-1 motor 13 kg
Axis-2 motor 13 kg
Axis-3 motor 8 kg
Axis-4 motor 6.5 kg
Axis-5 motor 6.5 kg
Axis-6 motor 6.5 kg
CAUTION
All lifting equipment must be sized accordingly!
Position of robot
Use this procedure to place the robot in the position recommended in order to
facilitate replacement of motors.
Action Information
Axis-1, axis-4, axis-5 and axis-6 motors (IRB
2600 Standard)
Axis-1 and axis-4 motors (IRB 2600ID)
wrist is pointing to the floor, as shown in
the figure. This will make it possible to
remove the motors without draining the
oil from the gearbox.
xx0800000388
Axis-2 motor
lower arm rests firmly on the axis-3
damper. Release the axis-2 brake to be
sure that the lower arm rests in the end
position.
xx1100000548
Axis-3 motor
• Move axis-2 to 0° and axis-3 to maximal
+. Release the axis-3 brake to be sure
that the upper arm is completely vertical
and rests against the damper.

4 Repair
Continued
Filling oil in gearbox

Use this procedure to fill oil in gearbox, if needed.
Note
Filling oil in the gearbox is only needed when refitting motors axes 2 and 3.
Action Note
1 Axis-1 motor: -
• Filling gearbox oil not needed.
2 Axis-2 motor: How to fill oil in gearbox is described
• Refill oil in gearbox after refitting. in section:
• Changing the oil, axis-2 gear-
box on page 161
3 Axis-3 motor: How to fill oil in gearbox is described
• Refill oil in gearbox after refitting. in section:
• Changing the oil, axis-3 gear-
box on page 165
4 IRB 2600 Standard - axes 4, 5, 6: -
• Filling oil not needed, provided it has not
been drained.
IRB 2600ID - axes 4:
• Filling oil not needed, provided it has not
been drained.
Tightening torques and attachment screws

The table shows the tightening torques for all motors.
Motor Attachment screw Quality Tightening torque
Motor, axis 1 M8x25 8.8-A2F 22 Nm
Motor, axis 6 M6x25 (Standard) 8.8-A2F 10 Nm (Standard)
M5x25 (IRB 2600ID) 6 Nm (IRB 2600ID)
Preparations before the refitting of motors

Use this procedure to make necessary preparations before refitting motors.
Action Note
1
DANGER
Turn off all:

area.

4 Repair
Continued
Action Note
2 Grind the paint on the surface carefully to get
a smoth surface.
3 Clean the surface from contamination such as
oil and dirt.
Remove any painting from the assembly sur-
faces, with a knife.
4 Make sure that the motor and the pinion are
not damaged or scratched.
5 Apply Loctite 574 on the o-ring.
6 Make sure the o-ring on the flange of the motor
is seated properly.
xx0900000082
Parts:
• A: Correct position of o-ring
• B: Incorrect position of o-ring !
Replace with a new o-ring if damaged!
7 In order to release the brakes, connect the 24 Connectors:
VDC power supply. • Motor axis 1: R2.MP1
• Motor axis 2: R2.MP2
Connect to pins:
Axes 1, 2 and 3:
• + : pin 2
• -: pin 5
Axes 4 and 5:
• + : pin 4
• - : pin 6
Axis 6 IRB 2600:
• + : pin 4
• - : pin 6
Axis 6 IRB 2600ID:
• + : pin 7
• -: pin 8
CAUTION
The connections for the motor brakes

(24 VDC connection) are phase de-
pendent. If the connection on the pins
is switched, it can cause severe dam-
age to vital parts.

4 Repair
Continued
Note
A fan is recommended to be used to avoid overheating of motor and gear in

applications with intensive motion (high average torque and/or short wait time)
of axes 1 and 2. IP54 is valid for cooling fan.
A fan is also recommended to be used if the environmental temperature is high.
How to install a fan is described in section Installation of cooling fan for motors
(option) on page 88.
Refitting motors
Use this procedure to refit motors axes 1, 2, 3, 4, 5 and 6.
Note
How to refit motors axes 5 and 6 on IRB 2600ID is described in sections:

• Replacing motor axis 6 and wrist unit - IRB 2600ID on page 344.
Note
The procedure contains information how to refit motors on all axes of the robot.
Some steps are only applicable to a certain motor. Follow the steps carefully in
order not to miss vital information!
Action Information
1 Also see
Note • Preparations before the refitting
of motors on page 323
Before starting the refitting of the motor, first
make the necessary preparations!
2
Note
Whenever parting/mating motor and gearbox,

the gears may be damaged if excessive force
is used!
3 Place the motor carefully in the gearbox.

4 Fit the motor, making sure the motor pinion is Make sure that:
properly mated to the gear in the gearbox. • the motor is turned the correct
way
• the pinion or gear of the motor
does not get damaged!

4 Repair
Continued
Action Information
5 IRB 2600 standard, motor type B
Applicable to motor axis 3!
Make sure that the wire exit holes of motor axis
3 is in the correct position. See illustration!
xx1400002570
Parts:
• A: Wire exit hole, motor axis 3
6 IRB 2600 standard, motor type A
Applicable to motor axis 3!
Make sure that the wire exit holes of motor axis
3 is in the correct position. See illustration!
xx0900000375
Parts:
• A: Wire exit hole, motor axis 3

4 Repair
Continued
Action Information
7 IRB 2600ID, motor type B
Make sure that the wire exit holes of motors D E
axes 3 and 4 are in the correct position. See il-
lustration!
xx1400002573
Parts:
A Wire exit hole, motor axis 3
B Motor axis 3
C Motor axis 4
D Power wire exit hole, motor axis
4
E Signal cable exit hole, motor
axis 4
8 IRB 2600ID, motor type A
Make sure that the wire exit holes of motors
axes 3 and 4 are in the correct position. See il-
lustration!
xx1000000992
Parts:
A Wire exit hole, motor axis 3
B Motor axis 3
C Motor axis 4
D Wire exit hole, motor axis 4

4 Repair
Continued
Action Information
9 IRB 2600 standard, motor type B B
Applicable to motors axes 4, 5 and 6!

Make sure that the orientation of the motor is
in the correct position! See illustration! A
A
A
B B
xx1400002571
Parts:
• A: Wire exits of motors axes 4,
5 and 6
10 IRB 2600 standard, motor type A
Applicable to motors axes 4, 5 and 6!
Make sure that the orientation of the motor is
in the correct position! See illustration!
xx0900000376
Parts:
• A: Wire exits of motors axes 4,
5 and 6
11 Only applicable to motors axes 4, 5 and 6! See Adjusting the play on page 355.
Adjust the play of the motor.
12 Secure the motor with its attachment screws Tightening torque and attachment
and washers. screws are specified in the table:
• Tightening torques and attach-
Note ment screws on page 323
Apply the correct tightening torque!
13 Disconnect the brake release voltage.

14 Only applicable to motors axes 1 and 2! See the figure in:
Refit the connection box (if it has been re- • Location of axis-1 and axis-2
moved). motors on page 316
Note
Make sure that the o-ring is in place!

4 Repair
Continued
Action Information
15 IRB 2600 Standard, motor type A G
Applicable to motors axes 3, 4, 5 and 6!
A
Refit the bracket in the armhouse on top of
motors axes 4, 5 and 6. F
E
B
C
D
xx0900000372
Parts:
A Attachment screws, M6x16
B Bracket
C Clamp
D Cable straps
E Connection bracket
F Connection bracket
G Hexagon nut, M5 quality steel
8-A2F
16 IRB 2600 Standard, motor type B
Note
Connection bracket for FB6 shall be fitted in a

30° angle. See figure!
xx1400002569

4 Repair
Continued
Action Information
17 IRB 2600ID IRB 2600ID
Refit the bracket in the armhouse with its attach- R2.FB6
ment screws. R2.FB5
R2.MP6
R2.FB4 R2.MP5
R2.MP4
R2.FB3
R2.MP3
xx1400002578
18 Reconnect the motor cables.

19 Applicable to motor axes 1 and 2! See the figure in:
Refit the cable gland and motor covers. • Location of axis-1 and axis-2
motors on page 316
Make sure that the o-ring is in place!
Note
Make sure that the cover is tightly

sealed!
20 Applicable to motors axis 2! How to fill oil in the gearbox is de-

Refill gearbox oil. scribed in sections:
on page 161
on page 165
21 Applicable to motors axes 3, 4, 5 and 6! If the gasket is damaged, it need to be
Make sure that the gasket on the cover on the replaced.
armhouse is intact.

4 Repair
Continued
Action Information
22 Applicable to motors axes 3, 4, 5 and 6! Make sure that the cover is tightly
Refit the cover in the back of the armhouse sealed.
with its attachment screws and washers.
WARNING
B
The cover on the armhouse must be fitted when
the robot is running. It is a vital part for the
stability of the robot.
A
xx0800000389
Parts:
• A: Cover
• B: Attachment screws M6x25,
Tightening torque:
• 14 Nm
23 Recalibrate the robot. Pendulum Calibration is described in
Operating manual - Calibration Pendu-
lum, enclosed with the calibration
tools.
Axis Calibration is described in Calib-
rating with Axis Calibration method on
page 406.
General calibration information is in-
cluded in section Calibration on
page 393.
24
DANGER


4 Repair
4.7.3 Replacing motor axis 5 - IRB 2600ID
Introduction
This procedure describes how to replace motor axis 5 on IRB 2600ID.
WARNING
When a motor is replaced, make sure to use the correct type of new motor. Motors
of different types may not be compatible. See the Spare parts manual delivered
as a separate document on myABB business portal (www.myportal.abb.com).
Location of motor axis 5

Motor axis 5 is located inside the upper arm tube as shown in the figure.
xx1000000877
A Motor axis 6
B Motor axis 5
Required equipment
Equipment Art. no. Note

Sikaflex 521FC 3HAC026759-001
below.

4 Repair
Continued

Action Note
calibration:
Removing motor axis 5

Use this procedure to remove motor axis 5.
Action Information
2 Rotate the upper arm in order to access the
two inner attachment screws securing the
cover and remove them.
xx1000000961
Parts:
• A: Inner attachment screws (2 pcs)
• B: Directions of rotation

4 Repair
Continued
Action Information
3 Move the upper arm to sync. position.
xx1000001007
4
DANGER
Turn off all:

working area.

upper arm and wrist.
6 Remove the wrist. How to remove the wrist see section:
This is done in order to be able to discon- • Replacing motor axis 6 and wrist
nect cables to motor axis 6. unit - IRB 2600ID on page 344
7
Note
Make a note of the position of axis 4 before

continueing the removal process.
It is important to refit the mechanical stop
and cable harness spiral, with axis 4 in the
same position as it was before the removal.
If axis 4 has been moved, it must be re-
turned to the position it was when the
mechanical stop was removed.
This is due to risk of damage to the cable
harness.

4 Repair
Continued
Action Information
8 Remove the mechanical stop.
Note
Don’t loose the o-ring and distance ring in

the removal process!
xx1000000879
Parts:
• A: Attachment screws (5 pcs)
• B: Mechanical stop
• C: O-ring
• D: Distance ring
• E: Bracket
• F: Cover
9 Remove the bracket. See figure above!
10 Remove the cover on the upper arm tube. See figure above!
11 Remove the two VK-covers, covering the
attachment screws securing the cable har-
ness to the arm tube.
xx1000000934
Parts:
• A: VK-covers (2 pcs)

4 Repair
Continued
Action Information
12 Remove the attachment screws (A) securing
the cover (B) on the armhouse.
xx1000001001
Parts:
B Cover
C Attachment screws (8 pcs) securing
arm tube
13 Remove the attachment screws (8 pcs) se-
curing the tube of the armhouse.
A
xx1000000936
Parts:
• A: Attachment screws (8 pcs)
14 Unscrew the attachment screws securing
the cable harness bracket to the upper arm
tube.
Note
The arm tube is not shown.
xx1000000939
Parts:
• A: Motor axis 5
• B: Cover
• C: Bracket (inside armhouse)
• D: Attachment screws (2 pcs)
• E: Bracket (upper arm tube)

4 Repair
Continued
Action Information
15 Pull carefully out the upper arm tube a little.
Not more than it is possible to reach the
connectors for motor axis 5.
CAUTION
Be careful not to damage the cable harness

in the process. The space is cramp.
16 IRB 2600ID, motor type B: R4.FB5

Disconnect connectors R4.MP5 and R4.FB5
to motor axis 5.
R4.MP5
xx1400002576
17 IRB 2600ID, motor type A

Disconnect the connectors to motor axis 5.
xx1000000998
Parts:
A Bracket
D Motor axis 5
18 Pull out the cable harness from motor axis
6 through the upper arm tube and secure
the cable harness with a roundsling or sim-
ilar to the armhouse.
19 Remove the upper arm tube.
20 Secure the upper arm tube with motor axis
5 pointing upwards.
This is done in order to avoid draining the
oil when motor axis 5 is removed.
xx1000000938

4 Repair
Continued
Action Information
21 Remove motor axis 5 by unscrewing its at-
tachment screws.
B
xx1000000937
Parts:
• A: Upper arm tube
• B: Motor axis 5
Refitting motor axis 5

Use this procedure to refit motor axis 5.
Action Information
1 Place motor axis 5 in the upper arm tube.
2 Tighten the attachment screws just enough
to still be able to move the motor.
B
xx1000000937
Parts:
• A: Upper arm tube
• B: Motor axis 5
3 Adjust the play by finding the smallest play.
4 Secure the motor with its attachment Tightening torque: 10 Nm.
screws.
5 Lift the upper arm tube to the robot.

4 Repair
Continued
Action Information
6 Push the cables to motor axis 6 into the
upper arm tube.
7 IRB 2600, motor type B R4.FB5
Connect connectors R4.MP5 and R4.FB5
to motor axis 5.
R4.MP5
xx1400002576
8 IRB 2600, motor type A

Connect the connectors to motor axis 5.
xx1000000998
Parts:
A Bracket
C Connectors to motor axis 5
D Motor axis 5
9 Apply flange sealing (Loctite 574) on the
surface where the cover shall be fitted. See
figure!
xx1000001006
Part:
A Flange sealing (Loctite 574)

4 Repair
Continued
Action Information
10 Secure the cover with its attachment Tightening torque: 10 Nm.
screws.
xx1000001001
Parts:
A Attachment screws (6 pcs) M6x20
quality 8.8-A2F
B Cover
C Attachment screws (8 pcs) M8x25
11 Secure the cable harness with its attach-
ment screws to the upper armtube.
xx1000000998
Parts:
A Bracket
D Motor axis 5
12 Check that the spiral of the cable harness See section
is fitted correctly. • Replacing the cable harness in the
upper arm - IRB 2600ID on page 223
13 Secure the upper arm tube with its attach- Tightening torque: 35 Nm.
ment screws.
A
xx1000000936
Parts:

4 Repair
Continued
Action Information
14 Apply flange sealing (Loctite 574) on the
surface shown in the figure.
Note
Do not apply flange sealing on the surfaces

where Sikaflex 521FC shall be applied!
See figure!
xx1000001003
Parts:
A Surface where Sikaflex 521FC shall
be applied
applied.
15 Refit the cover with two inner attachment
screws.
xx1000000879
Parts:
B Mechanical stop
C O-ring
D Distance ring
E Bracket
F Cover
16 Refit the bracket with the remaining attach- See figure above.
ment screws.

4 Repair
Continued
Action Information
17 Apply Sikaflex 521FC on the surfaces
xx1000001002
Parts:
A Sikaflex 521FC
B Cover
C Surface where to apply Sikaflex
521FC
18 Connect the cable to motor axis 6.
19 Refit the mechanical stop.
20 Fit new VK-covers.
xx1000000934
Parts:
A VK cover (2 pcs)
21 Refit the wrist. See section
• Replacing motor axis 6 and wrist
unit - IRB 2600ID on page 344

4 Repair
Continued
Action Information
22 Remove the oil plug, and refill the axis-5
gear with lubricating oil.
xx2000002311
Where to find type of oil and total amount

gearboxes on page 146.
23 Inspect the oil plug regarding thickness and Oil plug with sealing: 3HAC048968-001.
condition of the sealing.
Replace the complete oil plug if the sealing
thickness is less than 1.5 mm or if the seal-
ing is damaged.
CAUTION
Risk of damage to internal components of

the axis-5 gear. Tighten the oil plug with
correct torque and make sure the sealing
thickness is minimum 1.5 mm.
24 Refit the oil plug with sealing. Tightening torque: 3 Nm.

26
DANGER


4 Repair
4.7.4 Replacing motor axis 6 and wrist unit - IRB 2600ID
Introduction
This procedure describes how to replace the axis-6 motor on IRB 2600ID.
The replacement of the motor also contains the procedure for how to remove and
refit the wrist unit on IRB 2600ID
Location of motor axis 6

Motor axis 6 is located inside the upper arm tube, as shown in the figure.
xx1000000877
A Motor axis 6
B Motor axis 5
Required equipment

Motor, axis 6 For spare part number, see:
• Spare part lists on
page 451
Wrist unit, ID For spare part number, see:
• Spare part lists on
page 451
VK cover For spare part number, see: Always replace with a new
• Spare part lists on when removed.
page 451 One VK cover at the axis-5
flexible coupling.
One VK cover underneath the
arm tube.
Locking liquid - Loctite 574
below.

4 Repair
Continued

Action Note
calibration:
Removing axis-6 motor and wrist unit

Use this procedure to remove the axis-6 motor and the wrist unit.
Preparations before removing the wrist unit
Action Information
2 Move the upper arm to synchronization po-
sition.
3
DANGER
Turn off all:

working area.

upper arm.

4 Repair
Continued
Removing the wrist unit
Action Information
1 Remove the VK cover.
xx1600001486
2 Pull out the cabling from the upper arm

cavity through the VK cover hole and re-
lease the cable loop by straightening the
cables.
This is done in order not to damage the
cabling when the wrist is pulled out from
the arm tube with the axis-6 motor connect-
ors still connected.
xx1600001487
3 Remove the VK cover.
xx1000000873
4 Open the flexible coupling that secures the

axis-5 motor, on the side facing the wrist.
xx1000000874
Parts:
A Coupling
B Attachment screw

4 Repair
Continued
Action Information
5 Remove the attachment screws that secure
the wrist.
A
xx1000000875
Part:
6 Separate wrist and upper arm tube at the
marked division point (along the dotted line
in the figure).
Note
There is oil inside the wrist. The cover is

only secured with Loctite. If opened in the
wrong place oil will spill out.
xx1000000933
Parts:
A Wrist
B Cover (glued with Loctite to the
wrist)
C Division point
D Upper arm tube
7 Pull the wrist carefully out a little, in order
to be able to disconnect the motor cables
to the axis-6 motor.
Note
The wrist is fitted on cylindrical pins.

xx1000000876

4 Repair
Continued
Action Information
8 Fit two short screws in the holes for the at-
tachment screws in order to temporarily
secure that the cover is not opened.
xx1000000932
Parts:
A Short screws (2 pcs)
9 Disconnect the cables R4.MP6 and R4.FB6 R4.MP6
R4.FB6
xx1400002575
10 Put the wrist on a work bench.
Removing the axis-6 motor
Action Information
1
Note
Do not move the gears in the wrist when the

motor is removed! When refitting the motor
the gears in the wrist shall be in the same
position as they were before the removal.
2 Remove the cable protection by removing

the nuts securing it.
xx1000000931
Parts:
A Cable protection
B Nuts (2 pcs)
C Connector motor axis 6

4 Repair
Continued
Action Information
3 Open the flexible coupling securing motor
axis 6.
B
A C
xx1000000930
Parts:
A Attachment screw, coupling
B Flexible coupling
C Motor, axis 6
4 Remove the attachment screws that secure
the axis-6 motor and remove the motor.
Note
Do not remove the attachment screws se-

curing the motor bracket.
xx1000000929
Parts:
A Attachment screws, bracket
B Flexible coupling
C Attachment screws, motor (3 pcs)
D Cylindrical pins (2 pcs)
E Motor axis 6

4 Repair
Continued
Refitting axis-6 motor and wrist unit

Use this procedure to refit the axis-6 motor and the wrist unit.
Refitting the motor
Action Information
1 Place the motor axis into the axis-6 flexible
coupling.
xx1000000929
Parts:
A Attachment screws, bracket
B Flexible coupling
C Attachment screws, motor (3 pcs)
D Cylindrical pins (2 pcs)
E Motor axis 6
2 Secure the motor with its attachment Tightening torque: 6 Nm.
screws.
3 Secure the motor axis with the flexible Tightening torque: 15 Nm.
coupling with its attachment screw.
B
A C
xx1000000930
Parts:
A Attachment screw, coupling
B Flexible coupling
C Motor axis 6

4 Repair
Continued
Action Information
4 Fit the cable protection with its nuts.
xx1000000931
Parts:
A Cable protection
B Nuts (2 pcs)
C Connector motor axis 6
Refitting the wrist
Action Information
2 Place the wrist with the axis-6 motor fitted
a little into the upper arm tube.
3 Reconnect the cables R4.MP6 and R4.FB6 R4.MP6
R4.FB6
xx1400002575
4 Remove the short screws temporarily used

to secure from leakage from the wrist.
xx1000000932
Parts:
A Short screws (2 pcs)

4 Repair
Continued
Action Information
5 Apply locking liquid to the assembly surface Specified in Required equipment on
on the upper arm tube. page 344.
xx1200000063
6 Push the wrist and the axis-6 motor into its

position onto the cylindrical pins.
Tip A
Look through the hole for the VK cover
when fitting the axis into the flexible coup-
ling of motor axis 5.
xx1000000874
Parts:
A Flexible coupling axis 5
B Attachment screw
7 Secure the wrist with its attachment screws Tightening torque: 35 Nm.
and washers.
A
xx1000000875
Parts:

4 Repair
Continued
Action Information
8 Secure the axis-5 flexible coupling with its Tightening torque: 15 Nm.
attachment screw.
9 Fit a new VK cover. Article number is specified in Required
equipment on page 344.
xx1000000873
10 Pull out the cabling from the upper arm

cavity through the VK cover hole.
xx1600001487
11 Add a cable tie to the middle of the loop.

Then twist the cables into the shape of an
"8", fold the loop and insert the bundle into
the cavity in the upper arm tube, with direc-
tion against the arm house.
WARNING
If placing the cables into the cavity at the

opposite side, with direction against the
wrist, there is a risk of cable damage due
to rotating parts inside the arm tube.
xx1600001515
12 Fit a new VK cover. Article number is specified in Required

xx1600001486

4 Repair
Continued
Concluding procedure
Action Information
2
DANGER


4 Repair
4.7.5 Adjusting the play
Same instruction for all motors

This section describes how to adjust the play in the motors. The method is the
same for all motors. The illustrations show how to adjust the play in the axis-4
motor, but the same method can also be applied when adjusting the play of the
axis-5 and axis-6 motor.
Required equipment

Rotation tool 3HAB7887-1 M3 screw is included.
Used for feeling the play dur-
ing adjustment
Tool for adjusting play in mo- - See Drawing for adjustment
tors tool on page 355.
below.
Drawing for adjustment tool

Find or make a tool as described in the figure.
Drill holes in the middle so that they match the existing holes that are used to place
extra equipment at the wrist unit.
500
xx1200000066
Note
Do NOT drill holes in the robot!

4 Repair
Continued
Adjusting the play

Use this procedure to adjust the play of the motor. The figures show adjustment
of the axis-4 motor, but the method is also the same for the axis-5 and axis-6
motors.
Action Note
1
DANGER
Turn off all:

working area.
2 Before fitting the motor, look into the hole

to find the position of the gear. When ad-
justing to the correct play, the motor pinion
is pressed against the gear. How to do this
is detailed further on in this procedure.
xx1200000098
3
CAUTION
Whenever parting/mating motor and gear-

box, the gears may be damaged if excess-
ive force is used!
4 Place the motor carefully in the hole without

damaging the gear or pinion. Put the attach-
ment screws in the holes on the motor and
fit them a few revolutions. Do not tighten
the attachment screws yet!

4 Repair
Continued
Action Note
5 Fit the rotation tool on the motor axis with
the M3 attachment screw.
xx1200000099
Article number is specified in Required

6 Fit the tool for adjusting the play on the
axis in question.
xx1200000096
7 Release the brakes on the motor.

8 Push the motor, firmly in the direction of A B
the gear, as shown in figure.
Note
Do not use too much force!
xx1200000093
Parts:
• A: Motor pinion
• B: Gear

4 Repair
Continued
Action Note
9 Tighten attachment screws number 1 and 1
2 diagonally, alternatingly between the
screws, while at the same time pushing the
motor in the direction of the gear.
2
xx1200000094
10 Secure all four attachment screws.

For tightening torque, see Tightening
torques and attachment screws on page323.
11 Check the play by holding the rotation tool
fitted on the motor with one hand and
moving the tool fitted on the wrist back and
forth with the other.
xx1200000097
The figure shows how to do this on the ax-

is-4 motor.
12 If play is felt in the tool fitted on the motor
axis, unscrew the attachment screws of the
motor and repeat steps 7 to 10. Then check
the play again according to step 11.
If no play can be felt in the tool fitted on the
motor axis, it means that the play is adjus-
ted correctly.
13 When the play is adjusted correctly, rotate
the motor five revolutions and check the
play again.

4 Repair
Continued
Action Note
14 If no play is detected, continue to rotate the
motor and check the play in steps of five
revolutions until the motor has been rotated
20 revolutions.
(Rotate five revolutions - check play - rotate
five revolutions - check play - and so on)
15 If play is felt in the tool fitted on the motor
axis, unscrew the attachment screws of the
motor and repeat steps 7 to 10. Then check
the play again starting with step 11.
16 Perform a final check of the play by rotating
the motor back and forth with the tool fitted
(in the case of axis-4 motor) on the wrist,
to check that it is running smoothly. There
should be no unnormal noices.
xx1200000100
17 If motor and gear is not running smoothly

or if unnormal noice comes from the gears,
the play must be readjusted.

4 Repair
4.8.1 Replacing gearbox axis 1
4.8 Gearboxes

• 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

4 Repair
Continued
Location of gearbox
The gearbox is located as shown in the figure. The exploded view only shows the
principle of the assembly. The actual replacing is recommended to be done with
the robot resting on its side.
xx0800000400
Spinea gearbox
A Frame
B Radial sealing
C O-ring
D Gearbox axis 1
E Washer (21 pcs)
F Attachment screws M8x80 quality Steel 12.9 Gleitmo (21 pcs)

4 Repair
Continued
xx1800000800
Nabtesco gearbox
A Frame
B Radial sealing
C O-ring
D Gearbox axis 1
E Washer (14 pcs)
F Attachment screws M10x80 quality Steel 12.9 Gle 603+Geo500 (14 pcs)
Required equipment
Equipment Note
Gearbox See Spare part lists on page 451.
Guide pins Guide pin, M8x150: 3HAC15520-2
Used to guide the gearbox during removal/refitting.
Valid for IRB 2600-20/1.65 type C, IRB 3HAC15520-1
2600-12/1.65 type C: Always use guide pins in pairs.
Guide pin, M8x100 Additional pins to guide the gearbox during remov-
al/refitting.
Guide for reduction gear 3HAC068109-001
Used to guide axis-1 gear and frame during refit-
ting.
page 447.
ures in the step-by-step instructions
below.

4 Repair
Continued

Action Note
calibration:
Illustration of robot put down on its side

The robot is put down on its side for a safe removal of the axis-1 gearbox. Prepare
an area on the floor with cardboard, plastic foam or similar and prepare higher
support for the wrist.
Make sure the cabling brackets on the lower arm are unfastened and moved out
of the way so that the cabling is not getting squeezed.
xx1800000593

4 Repair
Continued
Removing gearbox axis 1

Use this procedure to remove the gearbox.
Action Note
2 Drain the oil from the gearbox. How to drain the oil from the gearbox is
• Changing the oil, axis 1 gearbox
on floor mounted robots on
page 148
3 Jog the robot to:
• Axis 1: 0°
• Axis 2: 0°
• Axis 3: -10°
• Axis 4: 0°
• Axis 5: 0°
• Axis 6: 0°
4
DANGER
Turn off all:

to the robot, before entering the safeguarded
space.
5 Remove the axis-1 motor. See Removing motors on page 303.

6 Remove the complete arm system from the See Removing the base on page 293.
base and lay down the robot on its side.
xx1800000593

4 Repair
Continued
Action Note
7 Fit a lifting lug in the uppermost hole for the
base attachment screws.
xx0800000440
A Roundsling
B Lifting lug
C Uppermost base attachment hole
D Axis-1 gearbox
8
CAUTION
The gearbox weighs .

27 kg (IRB 2600-20/1.65, IRB 2600-12/1.65,
IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB
2600ID-8/2.0)
24 kg (IRB 2600-20/1.65 type C, IRB 2600-
12/1.65 type C)
accordingly!
9 Secure the gearbox in an overhead crane or

similar.
10 Remove the attachment screws securing the See the figure in:
gearbox. • Location of gearbox on page 361
12/1.65 type C:
Fit two guide pins to the gearbox through
the holes in the frame.
xx1800000788

Always use guide pins in pairs!

4 Repair
Continued
Action Note
12 Remove two gearbox attachment screws
opposite to each other and fit two guide pins
into the holes.
xx1800000789

13 Remove the remaining attachment screws
and washers.
xx1800000790
14
Note

box, the gears may be damaged if excessive
force is used!
15
Note
There will be some excess oil running out

of the gearbox when it is removed. Use
some absorbent material to catch the oil.

4 Repair
Continued
Action Note
16 Slide the gearbox out onto the guide pins
and lift it away. Note
If necessary use removal tools to remove
the gearbox. Always use removal tools in pairs diagon-
al to each other.
xx1800000791
Refitting gearbox axis 1

Use these procedures to refit the gearbox.
Refitting the gearbox to the frame
Action Note
1
DANGER
Turn off all:

working area.
2 Check the radial sealing in the frame.

Replace if damaged.
xx1800000794

4 Repair
Continued
Action Note
3 Fit a lifting lug in the uppermost hole for the
base attachment screws.
xx0800000440
A Roundsling
B Lifting lug
C Uppermost base attachment hole
D Axis-1 gearbox
4
Note
Check, when fitting the lifting lug, that both

oil plugs will be placed in the correct posi-
tion after the gearbox is fitted as shown in
the figure. The oil plugs shall be placed in
the openings in the frame. A
(not valid for IRB 2600-20/1.65 type C, IRB
2600-12/1.65 type C)
B
xx0800000441
A Opening for oil plug in frame

B Oil plug
5 Apply grease on the o-ring. See the figure in:
• Location of gearbox on page 361
Replace o-ring if damaged.

4 Repair
Continued
Action Note
2600-12/1.65 type C:
Fit two guide pins to the gearbox.
xx1800000792

8 Fit two guide pins to the frame.
xx1800000793

9 Fit the guide for the gear on top of the pro- Guide for reduction gear: 3HAC068109-
tection tube. 001.
It protects the radial sealing from being
damaged during refitting.
xx1800000795
10
CAUTION
The gearbox weighs .

27 kg (IRB 2600-20/1.65, IRB 2600-12/1.65,
IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB
2600ID-8/2.0)
24 kg (IRB 2600-20/1.65 type C, IRB 2600-
12/1.65 type C)
accordingly!

4 Repair
Continued
Action Note
11 Lift the gearbox onto the guide pins and
slide it into position, using caution.
Check that the radial sealing in the frame
tube does not get damaged.
Valid for IRB 2600-20/1.65, IRB 2600-
12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0:
Double check that the oil plugs are in the
correct position.
xx1800000791
xx0800000441
A Opening for oil plug in frame

B Oil plug
12 Secure the gearbox with its attachment
screws and washers.
13 Remove the guide pins from the frame and
secure the remaining two screws.
xx1800000790
Valid for IRB 2600-20/1.65, IRB 2600-

12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0:
2600-12/1.65 type C:

4 Repair
Continued
Action Note
2600-12/1.65 type C:
Remove the two guide pins from the gear-
box.
xx1800000788
15 Remove the guide from the protection tube.
xx1800000796
Refitting the arm system to the base
Action Note
2600-12/1.65 type C:
1 Remove the three gaskets on the
base.
2 Wipe out the oil from the holes in the
base and wipe the sealing surfaces
dry.
3 Fit three new gaskets to the base.
The gaskets are included with the
gearbox spare part.
xx1800000797
2 Refit the complete arm system to the base. See Refitting the base on page 298.
3 Refit the axis-1 motor. See Refitting motors on page 316.
4 Refit the cable harness in the base, the Also see
frame and the lower arm. • Refitting the cable harness in the
base on page 214
frame on page 211
page 220
.

4 Repair
Continued
Action Note
5 Refill oil in the gearbox. See Changing the oil, axis 1 gearbox on
floor mounted robots on page 148.
7
DANGER


4 Repair

• 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
Location of gearbox axis 2

The gearbox is located as shown in the figure.
xx0900000380
A Attachment screws M8x80 quality steel 12.9 Gleitmo (17 pcs)

B Washers (17 pcs)
C Gearbox axis 2
D O-ring
E Frame

4 Repair
Continued
xx1800000940
A Attachment screws M10x40 12.9 Gleitmo 603+Geo500 (16 pcs)

B Washers (16 pcs)
C Gearbox axis 2
D O-ring
E Frame
Required equipment

Gearbox See Spare part
lists on page 451.
Rotation tool 3HAB7887-1
Lifting accessories - Roundslings.
Guide pin, M8x150 3HAC15520-2 Valid for IRB 2600-20/1.65, IRB
2600-12/1.65, IRB 2600-12/1.85,
IRB 2600ID-15/1.85, IRB 2600ID-
8/2.0.
Guide pin, M10x150 3HAC15521-2 Valid for IRB 2600-20/1.65 type C,
IRB 2600-12/1.65 type C.

4 Repair
Continued

Other tools and procedures may be These procedures include refer-
required. See references to these ences to the tools required.
procedures in the step-by-step in-
structions below.

Action Note
calibration:

WARNING
The procedure details how to replace the gearbox without removing the cable
harness, only by loosening it. This means that the upper and lower arm will be
separated from the frame but still be connected to the frame through the cabling.
Be careful not to damage the cables!
Action Note
1 Decide which calibration routine to
use, and take actions accordingly prior
to beginning the repair procedure.

4 Repair
Continued
Action Note
2 Move the robot to the position shown
in the figure.
Upper arm should rest on the axis-3
damper.
xx1200000068
3
DANGER
Turn off all:

working area.
4 Drain the gearbox. How to drain the gearbox is described in sec-

tion:
• Changing the oil, axis-2 gearbox on
page 161

4 Repair
Continued
Action Note
5 Loosen the cabling from the lower arm
by removing two cable brackets and a
cable strap.
B
C
xx1100000946
A Cable bracket
B Cable bracket
C Cable strap
6
CAUTION
The weight of the complete upper and

lower arm together is 100 kg
All lifting accessories used must be
sized accordingly.
7 Attach a roundsling around the upper

arm house.
8 Unload the weight of the lower and
upper arm package by stretching the
roundslings with the overhead crane.
Turn on the power temporarily and re-
lease the brakes of axis 2 to rest the
weight onto the roundslings.
9
DANGER
Turn off all:

working area.

4 Repair
Continued
Action Note
10 Remove the attachment screws and Valid for IRB 2600-20/1.65, IRB 2600-12/1.65,
washers that secure the lower arm to IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB
the axis-2 gearbox. 2600ID-8/2.0:
xx1800000935
Valid for IRB 2600-20/1.65 type C, IRB 2600-

12/1.65 type C:
xx1800000934
11 Remove the lower and upper arm

package from the frame.
WARNING
The cable harness is still installed on

the robot! Make sure not to damage
the cables or the cable brackets on the
robot.
12
CAUTION
The gearbox weighs

23 kg (IRB 2600-20/1.65, IRB 2600-
12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0)
14 kg (IRB 2600-20/1.65 type C, IRB
2600-12/1.65 type C)
All lifting accessories used must be
sized accordingly!

4 Repair
Continued
Action Note
13 Fit a lifting lug in the uppermost hole
for the attachment screws that secure A
the lower arm to the gearbox.
xx0800000445
Parts:
• A: Gearbox axis 2
• B: Lifting lug
• C: Holes for attachment screws that se-
cure the lower arm to the axis-2 gearbox
14 Secure the gearbox with a roundsling
in an overhead crane or similar.

4 Repair
Continued
Action Note
15 Remove the attachment screws and Valid for IRB 2600-20/1.65, IRB 2600-12/1.65,
washers that secure the gearbox to the IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB
frame. 2600ID-8/2.0:
CAUTION
Valid for IRB 2600-20/1.65, IRB 2600-

12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0:
Notice that there are six screws that
must not be removed! These six
screws keep the gearbox assembled.
Removing these screws would cause
the gearbox to fall apart!
Only remove the screws that secure
the gearbox to the frame, shown in the
figure!
xx1200000086

12/1.65 type C:
xx1800000939
16 Fit guide pins to help guiding the Valid for IRB 2600-20/1.65, IRB 2600-12/1.65,
gearbox out from the frame. IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB
2600ID-8/2.0:
12/1.65 type C:
17 If necessary, use removal tools to re-
move the gearbox. Note
Always use removal tools in pairs diagonal to

each other.

4 Repair
Continued
Action Note
18 Remove the gearbox.
CAUTION
Use caution in order not to damage

gearbox or pinion!
Refitting gearbox axis 2

Use this procedure to refit the gearbox.
Action Note
1
DANGER
Turn off all:

working area.
2
CAUTION
The gearbox weighs

23 kg (IRB 2600-20/1.65, IRB 2600-12/1.65,
IRB 2600-12/1.85, IRB 2600ID-15/1.85, IRB
2600ID-8/2.0)
14 kg (IRB 2600-20/1.65 type C, IRB 2600-
12/1.65 type C)
accordingly!
3 Fit a lifting lug in the uppermost hole for

A
the attachment screws securing the lower
arm to the gearbox.
xx0800000445
Parts:
• A: Gearbox axis 2
• B: Lifting lug
• C: Holes for attachment screws
securing the lower arm to gearbox
axis 2.

4 Repair
Continued
Action Note
5 Apply some grease on the o-ring before fit- Valid for IRB 2600-20/1.65 type C, IRB
ting. 2600-12/1.65 type C:
Valid for IRB 2600-20/1.65 type C, IRB O-ring: 3HAB3772-106.
2600-12/1.65 type C: See the figure in:
Replace if damaged. • Location of gearbox axis 2 on
page 373
frame. 12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0:
2600-12/1.65 type C:
7 Secure the gearbox with a roundsling in an
overhead crane or similar.
9 Lift the gearbox onto the guide pins and Article number is specified in Required
slide it into position while rotating the motor equipment on page 374.
pinion to find the mating position. Use a ro-
tation tool.

4 Repair
Continued
Action Note
10 Secure the gearbox with its attachment Valid for IRB 2600-20/1.65, IRB 2600-
screws and washers. 12/1.65, IRB 2600-12/1.85, IRB 2600ID-
15/1.85, IRB 2600ID-8/2.0:
12.9 Gleitmo (17 pcs)
xx1200000086

2600-12/1.65 type C:
Attachment screws M10x40 12.9 Gleitmo
603+Geo500 (16 pcs)
xx1800000939

page 188.
12 Fit the guide pins to the gearbox.
13
CAUTION
The weight of the complete upper and lower

arm together is 100 kg
accordingly.

4 Repair
Continued
Action Note
14 Lift the upper and lower arms into mounting
position and guide them in place with the
guide pins.
It might be necessary to rotate the motor
pinion with the rotating tool to find the mat-
ing position.
15 Refit the attachment screws and washers Valid for IRB 2600-20/1.65, IRB 2600-
to secure the lower arm to the axis-2 gear- 12/1.65, IRB 2600-12/1.85, IRB 2600ID-
box. 15/1.85, IRB 2600ID-8/2.0:
Gleitmo 12.9 (17 pcs)
Washers: 3HAA1001-172 (17 pcs)
xx1800000935

2600-12/1.65 type C:
603+Geo500 (15 pcs)
Washers: 3HAC043534-001 (3 pcs)
Tightening torque: 50 Nm ± 5 Nm and 90°
angle ± 10°.
xx1800000934

4 Repair
Continued
Action Note
16 Refit the cable brackets and cable strap to
the lower arm.
B
C
xx1100000946
A Cable bracket
B Cable bracket
C Cable strap
17 Refill the gearbox with lubrication oil. How to fill the gearbox with oil is de-
scribed in section:
on page 161
19
DANGER


4 Repair
Location of gearbox axis 3

The gearbox is located as shown in the figure.
The figure shows the standard version of IRB 2600. Assembly is the same for IRB
2600ID.
D
xx0900000381
A Upper arm
B O-ring
C Gearbox, axis 3
D Attachment screws M6x40 quality Steel 12.9 Gleitmo (16 pcs)
Required equipment

Gearbox See Spare part lists on page 451.
Guide pins 2 pcs, dimension: M6. 2 pcs, dimen-
sion: M8.
Used to guide the gearbox and the
upper arm during removal/refitting.
Rotation tool 3HAB7887-1

4 Repair
Continued

Other tools and procedures may be These procedures include refer-
required. See references to these ences to the tools required.
procedures in the step-by-step in-
structions below.

Action Note
calibration:

WARNING
The procedure details how to replace the gearbox without removing the cable
harness. This means that the upper and lower arm will be separated but still be
connected to eachother through the cabling. Be careful not to damage the cables!
Action Note
2 Drain the gearbox. How to drain the gearbox is described in
section:
on page 165

4 Repair
Continued
Action Note
figure.
xx0800000336
4
DANGER
Turn off all:

working area.
5 Unscrew the attachment screws securing

the cable harness to the lower arm by the
the two cable brackets and a cable strap.
B
C
xx1100000946
A Cable bracket
B Cable bracket
C Cable strap
6 Loosen the cabling from the lower arm by
unhooking the two cable brackets.
CAUTION
The cable harness is still mounted in other

parts of the robot. Make sure not to damage
the cable harness or any cable brackets in
the continued removal.
arm. the upper arm on page 251
8 Connect the 24 VDC power supply to the
axis-3 motor and release the brakes.

4 Repair
Continued
Action Note
9 Releasing the brakes of the axis-3 motor
unloads the weight of the upper arm by
stretching the roundslings.
10 Remove the attachment screws that secure See the figure in:
the upper arm to the lower arm. • Location of the complete upper arm
on page 246
Note
Do not remove the attachment screws se-

curing the gearbox axis 3 to the armhouse!
11
CAUTION
The robot upper arm weighs 65 kg.

accordingly!
12 Remove the upper arm from the lower arm

and leave it hanging in the air. WARNING
CAUTION The cable harness is still installed on the

robot! Make sure not to damage the cable
When the upper arm no longer is attached harness or the cable brackets on the ro-
to the robot, the armhouse has a tendency bot.
to drop down a little. In order to prevent this
is to rise the front end of the upper arm a
little before removing the attachment screws
securing the upper arm.
13
CAUTION
The gearbox weighs 6 kg.

accordingly!
14 Remove two attachment screws diagonally Always use guide pins in pairs!
located and insert guide pins.
15 Remove the remaining attachment screws See the figure in:
that secures the gearbox. • Location of gearbox axis 3 on
page 386
16
Note
There will be some surplus oil in the gear-

box. Place some absorbant cloth or similar
under the gearbox.
17 Slide the gearbox carefully out onto the

guide pins and lift it away. Note
If necessary, use a pair of screws to push
out the gearbox. Always use removal tools in pairs diagon-
al to each other.
CAUTION
Remaining oil will drain out from the gear-

box cavity when the gearbox is lifted out.

4 Repair
Continued
Refitting the gearbox axis 3

Use this procedure to refit the gearbox.
Action Note
1
DANGER
Turn off all:

working area.
2
CAUTION
The gearbox weighs 6 kg.

accordingly!

Remove any painting or other contamination
from the assembly surfaces, with a knife.
4 Apply some grease on the o-ring before fit- See the figure in:
ting it to the gearbox. • Location of gearbox axis 3 on
page 386
5 Fit two guide pins in two opposite screw Always use guide pins in pairs!
holes in the upper arm.
6 Remove the arm house cover.
7 Attach the rotation tool on the axis-3 motor.
9 Lift the gearbox onto the guide pins.
10
Note

box, the gears may be damaged if excessive
force is used!
11 Slide the gearbox into position while rotating Article number for the rotation tool is
the motor pinion to find the mating position. specified in Required equipment on
Use a rotation tool. page 386.
Tip
Two persons are required for this step since

the upper arm is hanging freely in the air.
One person needs to hold the upper arm
still while the other fits the gearbox into the
upper arm.
12 Rotate the motor pinion and slide the gear-

box into position.

4 Repair
Continued
Action Note
13 Secure the gearbox with its attachment See the figure in:
screws. • Location of gearbox axis 3 on
page 386
14 Remove the guide pins and replace them
with the remaining attachment screws.
page 188.
16 Fit guide pins in the upper arm. Specified in Required equipment on
page 386.
17 Move the upper arm to its mounting posi-
tion.
(With the brakes of the axis 3 motor still re-
leased.)
18 Refit the upper arm to the lower arm with See the figure in:
its attachment screws. • Location of the complete upper arm
on page 246
Tightening torque:
• 35 Nm
19 Remove the guide pins and replace with the
remaining attachment screws.
20 Remove the 24 VDC power supply.
21 Refit the upper armhouse cover with its at- Tightening torque: 14 Nm.
tachment screws and washers. Make sure that the cover is tightly sealed.
WARNING
The cover on the armhouse must be fitted B

when the robot is running. It is a vital part
for the stability of the robot.
A
xx0800000389
Parts:
• A: Cover
• B: Attachment screws M6x25,

4 Repair
Continued
Action Note
22 Refit the two cable brackets and a cable
strap to the lower arm.
B
C
xx1100000946
A Cable bracket
B Cable bracket
C Cable strap
23 Refill the gearbox with lubrication oil. How to fill the gearbox with oil is de-
scribed in section:
on page 165
25
DANGER


5 Calibration
5.1.1 Introduction and calibration terminology
5 Calibration
5.1 Introduction to calibration
5.1.1 Introduction and calibration terminology
Calibration information
This chapter includes general information about the recommended calibration
methods and also the detailed procedures for updating the revolution counters,
checking the calibration position etc.
Detailed instructions of how to perform Axis Calibration are given on the
FlexPendant during the calibration procedure. To prepare calibration with Axis
Calibration method, see Calibrating with Axis Calibration method on page 406.
Detailed instructions of how to perform Pendulum Calibration are given in the
documentation enclosed with the calibration tools.
Calibration terminology
Term Definition
Calibration method A collective term for several methods that might be
available for calibrating the ABB robot. Each method
contains calibration routines.
Synchronization position Known position of the complete robot where the
angle of each axis can be checked against visual
synchronization marks.
Calibration position Known position of the complete robot that is used
for calibration of the robot.
Standard calibration A generic term for all calibration methods that aim
to move the robot to calibration position.
Fine calibration A calibration routine that generates a new zero posi-
tion of the robot.
Reference calibration A calibration routine that in the first step generates
a reference to current zero position of the robot. The
same calibration routine can later on be used to re-
calibrate the robot back to the same position as when
the reference was stored.
This routine is more flexible compared to fine calib-
ration and is used when tools and process equipment
are installed.
Requires that a reference is created before being
used for recalibrating the robot.
Requires that the robot is dressed with the same
tools and process equipment during calibration as
during creation of the reference values.
Update revolution counter A calibration routine to make a rough calibration of
each manipulator axis.
Synchronization mark Visual marks on the robot axes. When marks are
aligned, the robot is in synchronization position.

5 Calibration
5.1.2 Calibration methods
Overview
This section specifies the different types of calibration and the calibration methods
that are supplied by ABB.
Types of calibration
Type of calibration Description Calibration method

Standard calibration The calibrated robot is positioned at calibration Axis Calibration or Cal-
position. ibration Pendulum i
Standard calibration data is found on the SMB
(serial measurement board) or EIB in the robot.
For robots with RobotWare 5.04 or older, the
calibration data is delivered in a file, calib.cfg,
supplied with the robot at delivery. The file
identifies the correct resolver/motor position
corresponding to the robot home position.
Absolute accuracy Based on standard calibration, and besides CalibWare
calibration (option- positioning the robot at synchronization posi-
al) tion, the Absolute accuracy calibration also
compensates for:
• Mechanical tolerances in the robot
structure
• Deflection due to load
Absolute accuracy calibration focuses on pos-
itioning accuracy in the Cartesian coordinate
system for the robot.
Absolute accuracy calibration data is found
on the SMB (serial measurement board) in the
robot.
For robots with RobotWare 5.05 or older, the
absolute accuracy calibration data is delivered
in a file, absacc.cfg, supplied with the robot at
delivery. The file replaces the calib.cfg file and
identifies motor positions as well as absolute
accuracy compensation parameters.
A robot calibrated with Absolute accuracy has
a sticker next to the identification plate of the
robot.
To regain 100% Absolute accuracy perform-
ance, the robot must be recalibrated for abso-
lute accuracy after repair or maintenance that
affects the mechanical structure.
xx0400001197

5 Calibration
Continued
Type of calibration Description Calibration method

Optimization Optimization of TCP reorientation perform- Wrist Optimization
ance. The purpose is to improve reorientation
accuracy for continuous processes like weld-
ing and gluing.
Wrist optimization will update standard calib-
ration data for axes 4, 5 and 6.
i The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory. Always use
the same calibration method as used at the factory.
Information about valid calibration method is found on the calibration label or in the calibration
menu on the FlexPendant.
If no data is found related to standard calibration, Calibration Pendulum is used as default.
Brief description of calibration methods

Calibration Pendulum method
Calibration Pendulum is a standard calibration method for calibration of all ABB
robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S).
Two different routines are available for the Calibration Pendulum method:
• Calibration Pendulum II
• Reference calibration
The calibration equipment for Calibration Pendulum is delivered as a complete
toolkit, including the Operating manual - Calibration Pendulum, which describes
the method and the different routines further.
Axis Calibration method

Axis Calibration is a standard calibration method for calibration of IRB 2600/IRB
2600 ID and is the most accurate method for the standard calibration. It is the
recommended method in order to achieve proper performance.
The following routines are available for the Axis Calibration method:
• Fine calibration
• Update revolution counters
• Reference calibration
The calibration equipment for Axis Calibration is delivered as a toolkit.
An introduction to the calibration method is given in this manual, see Calibrating
The actual instructions of how to perform the calibration procedure and what to
do at each step is given on the FlexPendant. You will be guided through the
calibration procedure, step by step.
Wrist Optimization method

Wrist Optimization is a method for improving reorientation accuracy for continuous
processes like welding and gluing and is a complement to the standard calibration
method.
The following routines are available for the Wrist Optimization method:
• Wrist Optimization

5 Calibration
Continued
CalibWare - Absolute Accuracy calibration

The CalibWare tool guides through the calibration process and calculates new
compensation parameters. This is further detailed in the Application
manual - CalibWare Field.
If a service operation is done to a robot with the option Absolute Accuracy, a new
absolute accuracy calibration is required in order to establish full performance.
For most cases after replacements that do not include taking apart the robot
structure, standard calibration is sufficient.
References
Article numbers for the calibration tools are listed in the section Special tools on
page 448.
The calibration equipment for Calibration Pendulum is delivered as a complete
toolkit, including the Operating manual - Calibration Pendulum, which describes
the method and the different routines further.

5 Calibration
5.1.3 When to calibrate
5.1.3 When to calibrate
When to calibrate
The system must be calibrated if any of the following situations occur.
The resolver values are changed

If resolver values are changed, the robot must be re-calibrated using the calibration
methods supplied by ABB. Calibrate the robot carefully with standard calibration,
according to information in this manual.
If the robot has absolute accuracy calibration, it is also recommended, but not
always necessary to calibrate for new absolute accuracy.
The resolver values will change when parts affecting the calibration position are
replaced on the robot, for example motors or parts of the transmission.
The revolution counter memory is lost

If the revolution counter memory is lost, the counters must be updated. See
Updating revolution counters on page 402. This will occur when:
• The battery is discharged
• A resolver error occurs
• The signal between a resolver and measurement board is interrupted
• A robot axis is moved with the control system disconnected
The revolution counters must also be updated after the robot and controller are
connected at the first installation.
The robot is rebuilt

If the robot is rebuilt, for example, after a crash or when the reach ability of a robot
is changed, it needs to be re-calibrated for new resolver values.
If the robot has absolute accuracy calibration, it needs to be calibrated for new
absolute accuracy.
Robot is not floor mounted

The original calibration data delivered with the robot is generated when the robot
is floor mounted. If the robot is not floor mounted, then the robot accuracy could
be affected. The robot needs to be calibrated after it is mounted.

5 Calibration
5.2.1 Synchronization marks and synchronization position for axes
5.2 Synchronization marks and axis movement directions
Introduction
This section shows the position of the synchronization marks and the
synchronization position for each axis.
Synchronization marks, IRB 2600 and 2600ID

IRB 2600-20/1.65, -12/1.65, -12/1.85
IRB 2600 Type C-20/1.65, -12/1.65
xx0800000312
A Synchronization mark, axis 1

B Synchronization mark, axis 2
C Synchronization mark, axis 3

5 Calibration
Continued
IRB 2600 -20/1.65, -12/1.65, -12/1.85
xx0800000320
D Synchronization mark, axis 4

E Synchronization mark, axis 5
IRB 2600ID -15/1.85, -8/2.00
A B
xx1000000445
A Synchronization mark, axis 4

B Synchronization mark, axis 5
C Synchronization mark, axis 6

5 Calibration
Continued
IRB 2600 -20/1.65, -12/1.65, -12/1.85
xx0800000321
F Synchronization mark, axis 6

5 Calibration
5.2.2 Calibration movement directions for all axes
5.2.2 Calibration movement directions for all axes
Overview
When calibrating, the axis must consistently be run towards the calibration position
in the same direction in order to avoid position errors caused by backlash in gears
and so on. Positive directions are shown in the graphic below.
Calibration service routines will handle the calibration movements automatically
and these might be different from the positive directions shown below.
Manual movement directions, 6 axes

Note! The graphic shows an IRB 7600. The positive direction is the same for all
6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in the
opposite direction!
xx0200000089

5 Calibration
5.3 Updating revolution counters
Introduction
This section describes how to do a rough calibration of each manipulator axis by
updating the revolution counter for each axis, using the FlexPendant.
Coupled axes
When updating the revolution counters for a coupled axis, also the axis it is coupled
to needs to be at its synchronization position for the update to be correct; i.e. axis
4 needs to be in synchronization position when updating axis 5 and 6.
With reversed coupled joints, the relationship is the opposite, i.e. axis 4 needs to
be in synchronization position to update axis 3.
Coupled axes
IRB 910 SC
IRB 1600ID
IRB 1660ID
IRB 2600ID
IRB 4450S
IRB 1410
IRB 1520
IRB 1600
IRB 2400
IRB 2600
IRB 4400
IRB 4600
IRB 140
Axis 4, 5, 6 x x x x x x x
Axis 5, 6 x x x x x
Axis 4, 3 x
Step 1 - Manually running the manipulator to the synchronization position

Use this procedure to manually run the manipulator to the synchronization position.
Action Note
1 Select axis-by-axis motion mode.
2 Jog the manipulator to align the synchron- See Synchronization marks and synchron-
ization marks. ization position for axes on page 398.
3 When all axes are positioned, update the Step 2 - Updating the revolution counter
revolution counter. with the FlexPendant on page 403.
Correct calibration position of axis 4 and 6

When jogging the manipulator to synchronization position, it is extremely important
to make sure that axes 4 and 6 of the following mentioned manipulators are
positioned correctly. The axes can be calibrated at the wrong turn, resulting in an
incorrect manipulator calibration.
Make sure the axes are positioned according to the correct calibration values, not
only according to the synchronization marks. The correct values are found on a
label, located either on the lower arm, underneath the flange plate on the base or
on the frame.
At delivery the manipulator is in the correct position. Do NOT rotate axis 4 or 6 at
power up before the revolution counters are updated.

5 Calibration
Continued
If one of the following mentioned axes are rotated one or more turns from its
calibration position before updating the revolution counter, the correct calibration
position will be lost due to non-integer gear ratio. This affects the following
manipulators:
Manipulator variant Axis 4 Axis 6
IRB 2600 No No
If the synchronization marks seem to be wrong (even if the motor calibration data
is correct), try to rotate the axis one turn, update the revolution counter and check
the synchronization marks again (try both directions, if needed).
Step 2 - Updating the revolution counter with the FlexPendant

Use this procedure to update the revolution counter with the FlexPendant (IRC5).
Action
1 On the ABB menu, tap Calibration.
xx1500000942

5 Calibration
Continued
Action
2 All mechanical units connected to the system are shown with their calibration status.
Tap the mechanical unit in question.
xx1500000943
3 This step is valid for RobotWare 6.02 and later.

Calibration method used at factory for each axis is shown, as well as calibration
method used during last field calibration.
Tap Manual Method (Advanced).
xx1500000944

5 Calibration
Continued
Action
4 A screen is displayed, tap Rev. Counters.
en0400000771
5 Tap Update Revolution Counters....

A dialog box is displayed, warning that updating the revolution counters may change
programmed robot positions:
• Tap Yes to update the revolution counters.
• Tap No to cancel updating the revolution counters.
Tapping Yes displays the axis selection window.
6 Select the axis to have its revolution counter updated by:
• Ticking in the box to the left
• Tapping Select all to update all axes.
Then tap Update.
7 A dialog box is displayed, warning that the updating operation cannot be undone:
• Tap Update to proceed with updating the revolution counters.
• Tap Cancel to cancel updating the revolution counters.
Tapping Update updates the selected revolution counters and removes the tick from
the list of axes.
8
CAUTION
If a revolution counter is incorrectly updated, it will cause incorrect manipulator posi-

tioning, which in turn may cause damage or injury!
Check the synchronization position very carefully after each update. See Checking
the synchronization position on page 428.

5 Calibration
5.4.1 Description of Axis Calibration
5.4 Calibrating with Axis Calibration method
Instructions for Axis Calibration procedure given on the FlexPendant

This manual contains a brief description of the method, additional information to
the information given on the FlexPendant, article number for the tools and images
of where to fit the calibration tools on the robot.
Overview of the Axis Calibration procedure

The Axis Calibration procedure applies to all axes, and is performed on one axis
at the time. The robot axes are both manually and automatically moved into position,
as instructed on the FlexPendant.
A fixed calibration pin/bushing is installed on each robot axis at delivery.
The Axis Calibration procedure described roughly:
1 A removable calibration tool is inserted by the operator into a calibration
bushing on the axis chosen for calibration, according to instructions on the
FlexPendant.
WARNING
Calibrating the robot with Axis Calibration requires special calibration tools
from ABB. Using other pins in the calibration bushings may cause severe
damage to the robot and/or personnel.
WARNING
The calibration tool must be fully inserted into the calibration bushing, until
the steel spring ring snaps into place.
2 During the calibration procedure, RobotWare moves the robot axis chosen
for calibration so that the calibration tools get into contact. RobotWare records
values of the axis position and repeats the coming-in-contact procedure
several times to get an exact value of the axis position.
WARNING
Risk of pinching! The contact force for large robots can be up to 150 kg.
Keep a safe distance to the robot.
3 The axis position is stored in RobotWare with an active choice from the
operator.

5 Calibration
Continued
Routines in the calibration procedure

The following routines are available in the Axis Calibration procedure, given at the
beginning of the procedure on the FlexPendant.
Fine calibration routine

Choose this routine to calibrate the robot when there are no tools, process cabling
or equipment fitted to the robot.
Reference calibration routine

Choose this routine to create reference values and to calibrate the robot when the
robot is dressed with tools, process cabling or other equipment.
Also choose this routine if the robot is wall mounted or suspended.
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.
If calibrating the robot with reference calibration there must be reference values
created before repair is made to the robot, if values are not already available.
Creating new values requires possibility to move the robot. The reference values
contain positions of all axes, torque of axes and technical data about the tool
installed. A benefit with reference calibration is that the current state of the robot
is stored and not the state when the robot left the ABB factory. The reference value
will be named according to tool name, date etc.
Follow the instructions given in the reference calibration routine on the FlexPendant
to create reference values.
When reference calibration is performed, the robot is restored to the status given
by the reference values.
Update revolution counters

Choose this routine to make a rough calibration of each manipulator axis by
updating the revolution counter for each axis, using the FlexPendant.
Validation
In the mentioned routines, it is also possible to validate the calibration data.
System containing SafeMove/EPS

SafeMove/EPS
SafeMove will lose its synchronization to the controller if a new calibration is done.
New calibration values have to be downloaded to SafeMove, and a new
SafeMove/EPS calibration has to be done. Make sure that the user rights admit to
change the safety settings and to synchronize SafeMove/EPS.

5 Calibration
Continued
Position of robot axes

The robot axes should be positioned close to 0 degrees before commencing the
calibration program. The axis chosen for calibration is then automatically run by
the calibration program to its exact calibration position during the calibration
procedure.
It is possible to position some of the other axes in positions different from 0 degrees.
Information about which axes are allowed to be jogged is given on the FlexPendant.
These axes are marked with Unrestricted in the FlexPendant window. Also the
following table shows the dependencies between the axes.
Requirements for axis positioning during calibration
Axis to calibrate
Required Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6
position of
axis
Axis 1 - * * * * *
Axis 2 0 - 0 * * *
Axis 3 0 0 - * * *
Axis 4 * * * - 0 i / * ii 0 i / * ii
Axis 5 * * * * - 0
Axis 6 * * * * * -
i Valid for IRB 2600.
ii Valid for IRB 2600ID.
- Axis to be calibrated
* Unrestricted. Axis is allowed to be jogged to other position than 0 degrees.
0 Axis must be put in position 0 degrees.
How to calibrate a suspended or wall mounted robot

The IRB 2600/IRB 2600 ID is fine calibrated floor standing in factory, prior to
shipping.
To calibrate a suspended or wall mounted robot, reference calibration must be
used. Reference values for a suspended or a wall mounted robot must be created
with the robot mounted at its working position, not standing on a floor.
To calibrate a suspended or wall mounted robot with the fine calibration routine,
the robot must first be taken down and mounted standing on the floor.

5 Calibration
5.4.2 Calibration tools for Axis Calibration
Calibration tool set

The calibration tools used for Axis Calibration are designed to meet requirements
for calibration performance, durability and safety in case of accidental damage.
The calibration tool will eventually break from fatigue after longer period of use
and then needs to be replaced. There is no risk for bad calibrations as long as the
calibration tool is in one piece.
WARNING
Calibrating the robot with Axis Calibration requires special calibration tools from
ABB. Using other pins in the calibration bushings may cause severe damage to
the robot and/or personnel.

Calibration tool box, 3HAC074119-001 Delivered as a set of calibration tools.
Axis Calibration Required if Axis Calibration is the valid calib-
ration method for the robot.
Contains a removal tool for removing special
protection plugs on the turning disc.
Examining the calibration tool

Check prior to usage
Before using the calibration tool, make sure that the tube insert, the plastic
protection and the steel spring ring are present.
WARNING
If any part is missing or damaged, the tool must be replaced immediately.
xx1500001914
A Tube insert
B Plastic protection
C Steel spring ring

5 Calibration
Continued
Periodic check of the calibration tool

If including the calibration tool in a local periodic check system, the following
measures should be checked.
• Outer diameter within Ø12g4 mm, Ø8g4 mm or Ø6g5 mm (depending on
calibration tool size).
• Straightness within 0.005 mm.
xx1500000951
A Outer diameter

5 Calibration
5.4.3 Installation locations for the calibration tools
Location of fixed calibration items

This section shows how the robot is equipped with items for installation of
calibration tools for Axis Calibration (fixed calibration pins and/or bushings).
Installed calibration tools are not shown.
A fixed calibration pin and a bushing for the movable calibration tool are located
on each axis as follows.
If there is not enough space on an axis to install a fixed calibration pin, the axis is
equipped with two bushings instead, for installation of two calibration tools when
calibration is carried out. This is shown in the figure.
xx1800000963
xx1800000964

5 Calibration
Continued
IRB 2600, IRB 2600ID
xx1600000521

5 Calibration
Continued
IRB 2600
xx1600000522

5 Calibration
Continued
IRB 2600ID
xx1600000523
Spare parts
When calibration is not being performed, a protective cover and an o-ring should
always be installed on the fixed calibration pin as well as a protective plug, included
a sealing, in the bushing. Replace damaged parts with new.
Spare part Article number Note
Protection cover and plug set 3HAC059487-001 Contains replacement calibration
pin covers and protective plugs
for the bushing.
Protective plug on turning disc 3HAC057676-001 Replace if damaged or missing.
(IRB 2600ID)
3HAC057511-001
(IRB 2600)

5 Calibration
5.4.4 Axis Calibration - Running the calibration procedure
Required tools
The calibration tools used for Axis Calibration are designed to meet requirements
for calibration performance, durability and safety in case of accidental damage.
WARNING
Calibrating the robot with Axis Calibration requires special calibration tools from
ABB. Using other pins in the calibration holes may cause severe damage to the
robot and/or personnel.

Calibration tool box, Axis 3HAC074119-001 Delivered as a set of calibration tools.
Calibration Required if Axis Calibration is the valid
calibration method for the robot.
Contains a removal tool for removing
special protection plugs on the turning
disc.
Required consumables
Consumable Article number Note
Clean cloth -
Spare parts
Spare part Article number Note

Protection cover and plug set 3HAC059487-001 Contains replacement calibration
pin covers and protective plugs
for the bushing.
Protective plug on turning disc 3HAC057676-001 Replace if damaged or missing.
(IRB 2600ID)
3HAC057511-001
(IRB 2600)
Overview of the calibration procedure on the FlexPendant

Use the following list to learn about the calibration procedure before running the
RobotWare program on the FlexPendant. It gives you a brief overview of the
calibration procedure sequence.
After the calibration method has been called for on the FlexPendant, the following
sequence will be run.
1 Choose calibration routine. The routines are described in Routines in the
calibration procedure on page 407.
2 Choose which axis/axes to calibrate.
3 The robot moves to synchronization position.

5 Calibration
Continued
4 Validate the synchronization marks.

5 The robot moves to preparation position.
6 Remove the protective cover from the fixed pin and the protection plug from
the bushing, if any, and install the calibration tool.
Use the removal tool included in the calibration tool box to remove the special
protection plug(s) on the turning disc.
IRB 2600
xx1700000407 xx1700000408
IRB 2600ID
xx1700000410 xx1700000411
When calibrating axis 6, push in the calibration tool into the turning disc until
the snap ring engages, no further.
7 The robot performs a measurement sequence by rotating the axis back and
forth.
8 Remove the calibration tool and reinstall the protective cover on the fixed
pin and the protection plug in the bushing, if any.
Refit the protection plug(s) to the turning disc, push until the steel spring ring
snaps into place.
9 The robot moves to verify that the calibration tool is removed.
10 Choose whether to save the calibration data or not.
Calibration of the robot is not finished until the calibration data is saved, as last
step of the calibration procedure.
5 Calibration
Continued
Preparation prior to calibration

The calibration procedure is described in the FlexPendant while conducting it.
Action Note
1
DANGER
While conducting the calibration, the robot needs

to be connected to power.
Make sure that the robot's working area is empty,
as the robot can make unpredictable movements.
2 Wipe the calibration tool clean. Use a clean cloth.
Note
The calibration method is exact. Dust, dirt or color

flakes will affect the calibration value.
3 Check if the standard calibration data for axes 4, If the data is optimized, the calibra-
5 or 6 are updated with wrist optimization. tion routine Wrist Optimization
This is shown in the Calibration Method Overview must be re-run after standard calib-
window on the FlexPendant. ration.
See Calibrating with Wrist Optimiza-
tion method on page 425.
xx2000000509
Starting the calibration procedure

Use this procedure to start the Axis Calibration routine on the FlexPendant.
Action Note
1 On the ABB menu, tap Calibration.
xx1500000942

5 Calibration
Continued
Action Note
2 All mechanical units connected to the system are
shown with their calibration status.
Tap the mechanical unit in question.
xx1500000943
3 Calibration method used at factory for each axis The FlexPendant will give all inform-
is shown, as well as calibration method used for ation needed to proceed with Axis
the robot during last field calibration. Calibration.
Tap Run Calibration Method. The software will
automatically call for the procedure for the valid
calibration method.
xx1500000944
4 Follow the instructions given on the FlexPendant. A brief overview of the sequence
that will be run on the FlexPendant
is given in Overview of the calibra-
tion procedure on the FlexPendant
on page 415.
Restarting an interrupted calibration procedure

If the Axis Calibration procedure is interrupted before the calibration is finished,
the RobotWare program needs to be started again. Use this procedure to take
required action.
Situation Action
The three-position enabling device on the Press and hold the three-position enabling
FlexPendant has been released during robot device and press Play.
movement.

5 Calibration
Continued
Situation Action
The RobotWare program is terminated with Remove the calibration tool, if it is installed,
PP to Main. and restart the calibration procedure from
the beginning. See Starting the calibration
procedure on page 417.
If the calibration tool is in contact the robot
axis needs to be jogged in order to release
the calibration tool. Jogging the axis in wrong
direction will cause the calibration tool to
break. Directions of axis movement is shown
in Calibration movement directions for all
axes on page 401
Axis Calibration with SafeMove option

To be able to run Axis Calibration, SafeMove needs to be unsynchronized. The
Axis Calibration routine recognizes if the robot is equipped with SafeMove and will
force SafeMove to unsynchronize automatically.
However, SafeMove may generate other warning messages anytime during the
Axis Calibration routine. When a warning message is displayed, tap Acknowledge
to confirm the unsynchronized state and continue Axis Calibration procedure.
CAUTION
SafeMove must be synchronized after the calibration is completed.
After calibration
Action Note
1 Check the o-ring on the fixed calibration pin.
Replace if damaged or missing.
2 Reinstall the protective cover on the fixed calibra-
tion pin on each axis, directly after the axis has
been calibrated.
Replace the cover with new spare part, if missing
or damaged.
xx1600002102
Protection cover and plug set:

3HAC059487-001.

5 Calibration
Continued
Action Note
3 Reinstall the protective plug and sealing in the
bushing on each axis, directly after the axis has
been calibrated. Ensure that the sealing is not
damaged.
Replace the plug and the sealing with new spare
part, if missing or damaged.
xx1500000952
Protection cover and plug set:

3HAC059487-001.
4 Refit the special protection plug to the turning IRB 2600
disc using the tool included in the calibration tool
box.
xx1700000408
IRB 2600ID
xx1700000411

5 Calibration
Continued
Action Note
5 Remove the tool from the protection plug. IRB 2600
xx1700000901
IRB 2600ID
xx1700000902
6 If the standard calibration data for axes 4, 5 or 6 See Calibrating with Wrist Optimiz-
should be updated with wrist optimization, run the ation method on page 425.
calibration routine Wrist Optimization.

5 Calibration
5.4.5 Reference calibration
Brief introduction to Reference Calibration

Reference calibration is a faster method compared to Fine calibration, as it refers
to a previously made calibration.
1 Create a backup of the current robot system.
2 Check that the active calibration offset values corresponds to the values on
the silver label (on the lower arm or the base).
3 Jog the manipulator so that all axes are in zero position (ex use MoveAbsJ
instruction). Check that all axis scales are aligned with calibration marks.
4 If the scales differ from calibration marks it might depend on wrong turns of
the revolution counters. Make a marker line on the corresponding axis to be
able to validate the result of the calibration. If more than one motor revolutions
are wrong, the calibration will fail.
5 Use a verification position. This is especially recommended if all axes were
not aligned with the synchronization marks (step 3). Reuse an existing
position that is suitable and accurate so it can be used to validate the repair.
Use a position where a deviation in axis calibration gives a big deviation in
positioning. Note! Check the position after each repair in one axis.
6 Use Reference calibration to save reference values for all axes that is to be
replaced. Make sure that the values are saved in RobotStudio or FTP program.
The files are located in "Active system folder name/HOME/RefCalibFiles".
7 Perform the repair.
8 Make sure that the tooling and process equipment are the same as when
creating the reference. Use Reference calibration to update the system with
new calibration offset value for the repaired axis.
9 Check the position against the verification position (step 5).
10 Proceed with the repair of the next axis, if necessary, and repeat (step 8-9)
for every axis.
11 (For system containing SafeMove or EPS) Download new calibration values
to SafeMove. Use Visual SafeMove in RobotStudio.
12 (For system containing SafeMove or EPS) Synchronize SafeMove to activate
SafeMove.
13 Perform test run.
14 Update the label for resolver values with new calibration values.
Manual tuning of calibration offset

Manual tuning of calibration offset is normally not needed, but can be useful in
some situations. The requirement to do manual tuning is that there is a known
accurate position, that worked accurately before the repair (step 5, see Brief
introduction to Reference Calibration on page 422).
Example "Adjust axis 4":
1 Create a backup.

5 Calibration
Continued
2 Run the manipulator to the verification position. (The manipulator position

is now deviating from the verification position.)
3 Read and note current axis 4 value in degrees (example: 96.3 degrees).
4 Manually jog, only axis 4, so that the manipulator is correctly positioned to
the verification position.
5 Read and note current axis 4 value in degrees (example: 94.2 degrees).
6 Move the manipulator to its calibration position.
7 Calculate the angle difference (ie 96.3-94.2=2.1 degrees).
8 Manually jog axis 4 the calculated angle difference (-2.1). NOTE! The direction
+/- shall be the same direction as the direction used when axis 4 was manually
jogged to coincide with the verification process. In the example -2.1 degrees.
9 Make a new manual fine calibration of axis 4 with axis in -2.1 degrees position.
10 Check again against the verification position.
11 Repeat the manual tuning if needed.
12 Create a new reference if the intention is to use the reference in the future.

5 Calibration
5.5 Calibrating with Calibration Pendulum method
5.5 Calibrating with Calibration Pendulum method
Where to find information for Calibration Pendulum

Detailed instructions of how to perform Pendulum Calibration are given in the
documentation enclosed with the calibration tools.

5 Calibration
5.6 Calibrating with Wrist Optimization method
When to run Wrist Optimization

Wrist Optimization routine is run to improve TCP reorientation performance.
Calibrating the robot with standard calibration method overwrites the optimized
positions of axes 4, 5, 6. Re-run the Wrist Optimization routine after standard
calibration to re-achieve the optimized positions of the wrist axes.
Overview of the calibration procedure on the FlexPendant

Use the following list to learn about the calibration procedure before running the
RobotWare program on the FlexPendant. It gives you a brief overview of the
calibration procedure sequence.
After the calibration method has been called for on the FlexPendant, the following
sequence will be run.
1 Choose calibration routine Wrist Optimization.
2 Modify targets for 4-point tool frame definition, in Wrist Optimization routine.
Tip
Select positions with large reorientations around the TCP. For best results,
make sure that axis 4 and 5 have large movements.
a Jog the robot to an appropriate position,
A, for the first approach point.
Use small increments to accurately posi-
tion the tool tip as close to the reference
point as possible.
b Tap Modify Position to define the point.
c Repeat for each approach point to be
defined, positions B, C, and D.
Jog away from the fixed world point to
achieve the best result. Just changing the
tool orientation will not give as good a
result.
en0400000906
3 Improved calibration data to the wrist axes is identified and presented.

4 Optimized positions for the wrist axes are presented.

5 Calibration
Continued
5 The robot moves to the optimized positions for the wrist axes and
automatically overwrites previous calibration data.
WARNING
Robot moves automatically when pressing Calibrate.
6 Wrist optimization is finished.

7 Redefine / verify TCP for all tools.

5 Calibration
5.7 Verifying the calibration
5.7 Verifying the calibration
Introduction
Always verify the results after calibrating any robot axis to verify that all calibration
positions are correct.
Verifying the calibration

Use this procedure to verify the calibration result.
Action Note
1 Run the calibration home position program twice. See Checking the synchron-
Do not change the position of the robot axes after running ization position on page 428.
the program!
2 Adjust the synchronization marks when the calibration is This is detailed in section
done, if necessary. Synchronization marks and
synchronization position for
axes on page 398.
3 Write down the values on a new label and stick it on top
of the calibration label.
The label is located on the lower arm.

5 Calibration
5.8 Checking the synchronization position
5.8 Checking the synchronization position
Introduction
Check the synchronization position of the robot before beginning any programming
of the robot system. This may be done:
• Using a MoveAbsJ instruction with argument zero on all axes.
• Using the Jogging window on the FlexPendant.
Using a MoveAbsJ instruction

Use this procedure to create a program that runs all the robot axes to their
synchronization position.
Action Note
1 On ABB menu tap Program editor.
2 Create a new program.
3 Use MoveAbsJ in the Motion&Proc menu.
4 Create the following program:
MoveAbsJ [[0,0,0,0,0,0],
[9E9,9E9,9E9,9E9,9E9,9E9]]
\NoEOffs, v1000, fine, tool0
5 Run the program in manual mode.

6 Check that the synchronization marks for the axes See Synchronization marks and
align correctly. If they do not, update the revolu- synchronization position for axes on
tion counters. page 398 and Updating revolution
counters on page 402.
Using the jogging window

Use this procedure to jog the robot to the synchronization position of all axes.
Action Note
1 On the ABB menu, tap Jogging.
2 Tap Motion mode to select group of axes
to jog.
3 Tap to select the axis to jog, axis 1, 2, or
3.
4 Manually run the robots axes to a position
where the axis position value read on the
FlexPendant, is equal to zero.
5 Check that the synchronization marks for See Synchronization marks and synchron-
the axes align correctly. If they do not, up- ization position for axes on page 398 and
date the revolution counters. Updating revolution counters on page 402.

6 Decommissioning
6.1 Introduction
6 Decommissioning
6.1 Introduction
Introduction
This section contains information to consider when taking a product, robot or
controller, out of operation.
It deals with how to handle potentially dangerous components and potentially
hazardous materials.
General
All used grease/oils and dead batteries must be disposed of in accordance with
the current legislation of the country in which the robot and the control unit are
installed.
If the robot or the control unit is partially or completely disposed of, the various
parts must be grouped together according to their nature (which is all iron together
and all plastic together), and disposed of accordingly. These parts must also be
disposed of in accordance with the current legislation of the country in which the
robot and control unit are installed.

6 Decommissioning
6.2 Environmental information
Symbol
The following symbol indicates that the product must not be disposed of as common
garbage. Handle each product according to local regulations for the respective
content (see table below).
xx1800000058
Hazardous material
The table specifies some of the materials in the product and their respective use
throughout the product.
Dispose components properly according to local regulations to prevent health or
environmental hazards.
Material Example application
Aluminium Covers, synchronization brackets
Batteries, Lithium Serial measurement board
Cast iron/nodular iron Base, lower arm, upper arm
Copper Cables, motors
Neodymium Brakes, motors
Nickel Turning disc (foundry)
Oil, grease Gearboxes
Plastic/rubber Cables, connectors, drive belts, and so on.
Steel Gears, screws, base, frame, and so on.
Oil and grease

Where possible, arrange for oil and grease to be recycled. Dispose of via an
authorized person/contractor in accordance with local regulations. Do not dispose
of oil and grease near lakes, ponds, ditches, down drains, or onto soil. Incineration
must be carried out under controlled conditions in accordance with local regulations.

6 Decommissioning
Continued
Also note that:

• Spills can form a film on water surfaces causing damage to organisms.
Oxygen transfer could also be impaired.
• Spillage can penetrate the soil causing ground water contamination.

6 Decommissioning
6.3 Scrapping of robot
6.3 Scrapping of robot
Important when scrapping the robot
DANGER
When a robot is disassembled while being scrapped, it is very important to

remember the following before disassembling starts, in order to prevent injuries:
• Always remove all batteries. If a battery is exposed to heat, for example
from a blow torch, it will explode.
• Always remove all oil/grease in gearboxes. If exposed to heat, for example
from a blow torch, the oil/grease will catch fire.
• When motors are removed from the robot, the robot will collapse if it is not
properly supported before the motor is removed.

7 Robot description
7.1 Robot types
7 Robot description
7.1 Robot types
Robot types
There are different variants of the IRB 2600, Type A and Type B, and they may
have different motor types; i.e. a Type A robot may use Type B motors. The
following table explains the differences.
There is also a Type C of IRB 2600, but it only affects two variants of the robot,
see the table and see Non-compatible versions of axis-1 and axis-2 gearboxes on
page 434.
IRB 2600 (standard IRB 2600ID

variants)
Initial version motor type A motor type A
IRB 2600 Type A Axis 2 changes Axis 1-5 change to motor type B
gearbox Axis 6 keeps motor type A
IRB 2600 Type B Axis 1-6 change to
motor type B
IRB 2600 Type C - only IRB 2600- Axis 1 and 2
20/1.65 type C, IRB 2600-12/1.65 changes gearbox
type C. and motor pinion
Axis 3, 4, 5 and 6
has motor type B

7 Robot description
7.2 Non-compatible versions of axis-1 and axis-2 gearboxes
Gearboxes from different suppliers are not compatible

There are two different versions of the axis-1 and axis-2 gearboxes for robot variants
IRB 2600-20/1.65 and IRB 2600-12/1.65.
• Version 1 for IRB 2600-20/1.65, IRB 2600-12/1.65, IRB 2600-12/1.85, IRB
2600ID-15/1.85, IRB 2600ID-8/2.0 (supplier Spinea, gearbox option 1564-1).
• Version 2 for IRB 2600-20/1.65 type C, IRB 2600-12/1.65 type C (supplier
Nabtesco, gearbox option 1564-2).
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.

7 Robot description
Continued
Designation label on lower arm

At delivery there is a designation label fitted to the lower arm of the Type C variant
of the robot, informing that the robot is a Type C variant.
xx1800002211

7 Robot description
Continued
Identifying the gearbox version visually

The mechanical structure of the robot differs depending on which axis-1 and axis-2
gearbox the robot is equipped with. Some of the differences are visible, as shown
in the table.
Identification of gearbox - mechanical Identification of gearbox - mechanical
structure structure
IRB 2600-20/1.65, IRB 2600-12/1.65, IRB IRB 2600-20/1.65 type C, IRB 2600-12/1.65
2600-12/1.85, IRB 2600ID-15/1.85, IRB type C
2600ID-8/2.0
xx1800001133
xx1800000551
xx1800001134
xx1800000554
A The fixed calibration pin for Axis Calibra- The fixed calibration pin for Axis Calibra-
tion is located straight below the motor tion is located on a casted arm on the
flange. motor flange.
The bushing for the calibration tool is The bushing for the calibration tool is loc-
centered on the base. ated to the right on the base.
B The oil plug for drainage is located on the The oil plug for drainage is located in front
left side of the gearbox and visible through of the gearbox (when robot is standing in
an opening in the frame (when robot is synchronization position).
standing in synchronization position).
C The cable cover shape is triangular. The cable cover shape is rectangular.
D Hole pattern for 17 screws that fasten the Hole pattern for 16 screws that fasten the
lower arm to the gearbox. lower arm to the gearbox.

7 Robot description
Continued
Identifying the gearbox version by article number

Only robot variants IRB 2600-20/1.65 and IRB 2600-12/1.65 are affected by different
gearbox suppliers.
Use the table to identify which gearbox versions are installed on the robot, by
article number. The article numbers specified are found in WebConfig.
Contact ABB Service for further assistance regarding which gearbox versions are
installed on the robot, if needed.
Robot variant Article number, axis-1 gear- Article number, axis-2 gear-
box box
IRB 2600-20/1.65 3HAC028837-001 3HAC039109-001
IRB 2600 Type C-20/1.65 3HAC043130-001 3HAC043134-001
IRB 2600 - 12/1.65 3HAC028837-001 3HAC039109-001
IRB 2600 Type C-12/1.65 3HAC043130-001 3HAC043134-001
Identifying the gearbox version on the FlexPendant

The robot type is found on the System Info view on the FlexPendant.
Expand System properties, Drive modules and Robot1, and then tap Options.
xx1900002213

8 Reference information
8.1 Introduction
8.1 Introduction
General
This chapter includes general information, complementing the more specific
information in the different procedures in the manual.

8.2 Applicable standards
Note
The listed standards are valid at the time of the release of this document. Phased
out or replaced standards are removed from the list when needed.
General
The product is designed in accordance with ISO 10218-1:2011, Robots for industrial
environments - Safety requirements -Part 1 Robots, and applicable parts in the
normative references, as referred to from ISO 10218-1:2011. In case of deviations
from ISO 10218-1:2011, these are listed in the declaration of incorporation which
is part of the product delivery.
Normative standards as referred to from ISO 10218-1
Standard Description
ISO 9283:1998 Manipulating industrial robots - Performance criteria and related
test methods
ISO 10218-2 Robots and robotic devices - Safety requirements for industrial
robots - Part 2: Robot systems and integration
ISO 12100 Safety of machinery - General principles for design - Risk as-
sessment and risk reduction
ISO 13849-1:2006 Safety of machinery - Safety related parts of control systems
- Part 1: General principles for design
ISO 13850 Safety of machinery - Emergency stop - Principles for design
IEC 60204-1:2005 Safety of machinery - Electrical equipment of machines - Part
1: General requirements
IEC 62061:2005 Safety of machinery - Functional safety of safety-related elec-
trical, electronic and programmable electronic control systems
Region specific standards and regulations
ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems
ANSI/UL 1740 Safety standard for robots and robotic equipment
CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require-
ments
Other standards used in design
ISO 9787:2013 Robots and robotic devices -- Coordinate systems and motion
nomenclatures
IEC 61000-6-2 Electromagnetic compatibility (EMC) – Part 6-2: Generic
standards – Immunity standard for industrial environments
IEC 61000-6-4 Electromagnetic compatibility (EMC) – Part 6-4: Generic
(option 129-1) standards – Emission standard for industrial environments

Continued
ISO 13732-1:2006 Ergonomics of the thermal environment - Part 1
IEC 60974-1:2012 i Arc welding equipment - Part 1: Welding power sources
IEC 60974-10:2014 i Arc welding equipment - Part 10: EMC requirements
ISO 14644-1:2015 ii Classification of air cleanliness
IEC 60529:1989 + A2:2013 Degrees of protection provided by enclosures (IP code)
i Only valid for arc welding robots. Replaces IEC 61000-6-4 for arc welding robots.
ii Only robots with protection Clean Room.

8.3 Unit conversion
8.3 Unit conversion
Converter table
Use the following table to convert units used in this manual.
Quantity Units
Length 1m 3.28 ft. 39.37 in
Weight 1 kg 2.21 lb.
Weight 1g 0.035 ounces
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.225 lbf
Moment 1 Nm 0.738 lbf-ft
Volume 1L 0.264 US gal

8.4 Screw joints
8.4 Screw joints
General
This section describes how to tighten the various types of screw joints on ABB
robots.
The instructions and torque values are valid for screw joints comprised of metallic
materials and do not apply to soft or brittle materials.
UNBRAKO screws
UNBRAKO is a special type of screw recommended by ABB for certain screw joints.
It features special surface treatment (Gleitmo as described below) and is extremely
resistant to fatigue.
Whenever used, this is specified in the instructions, and in such cases, no other
type of replacement screw is allowed. Using other types of screws will void any
warranty and may potentially cause serious damage or injury.
Gleitmo treated screws

Gleitmo is a special surface treatment to reduce the friction when tightening the
screw joint. Screws treated with Gleitmo may be reused 3-4 times before the coating
disappears. After this the screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber
type should be used.
Screws lubricated in other ways

Screws lubricated with Molycote 1000 should only be used when specified in the
repair, maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1 Apply lubricant to the screw thread.
2 Apply lubricant between the plain washer and screw head.
3 Screw dimensions of M8 or larger must be tightened with a torque wrench.
Screw dimensions of M6 or smaller may be tightened without a torque wrench
if this is done by trained and qualified personnel.
Lubricant Article number
Molycote 1000 (molybdenum disulphide grease) 3HAC042472-001
Tightening torque
Before tightening any screw, note the following:
• Determine whether a standard tightening torque or special torque is to be
applied. The standard torques are specified in the following tables. Any
special torques are specified in the repair, maintenance or installation
procedure descriptions. Any special torque specified overrides the standard
torque!
• Use the correct tightening torque for each type of screw joint.
• Only use correctly calibrated torque keys.

8.4 Screw joints
Continued
• Always tighten the joint by hand, and never use pneumatic tools.
• Use the correct tightening technique, that is do not jerk. Tighten the screw
in a slow, flowing motion.
• Maximum allowed total deviation from the specified value is 10%!
Oil-lubricated screws with slotted or cross-recess head screws

The following table specifies the recommended standard tightening torque for
oil-lubricated screws with slotted or cross-recess head screws.
Note
A special torque specified in the repair, maintenance or installation procedure

overrides the standard torque.
Oil-lubricated screws with allen head screws

oil-lubricated screws with allen head screws.
Note

Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm)
Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric-
ated ated
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340
M20 400 560 670
M24 680 960 1150
Lubricated screws (Molycote, Gleitmo or equivalent) with allen head screws

screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head
screws.
Note

Dimension Tightening torque (Nm) Tightening torque (Nm)

Class 10.9, lubricated i Class 12.9, lubricated i
M8 28 35

8.4 Screw joints
Continued
Dimension Tightening torque (Nm) Tightening torque (Nm)

Class 10.9, lubricated i Class 12.9, lubricated i
M10 55 70
M12 96 120
M16 235 280
M20 460 550
M24 790 950
i Lubricated with Molycote 1000, Gleitmo 603 or equivalent
Water and air connectors

water and air connectors when one or both connectors are made of brass.
Note

Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm -

Nominal Min. Max.
1/8 12 8 15
1/4 15 10 20
3/8 20 15 25
1/2 40 30 50
3/4 70 55 90

8.5 Weight specifications
8.5 Weight specifications
Definition
In installation, repair, and maintenance procedures, weights of the components
handled are sometimes specified. All components exceeding 22 kg (50 lbs) are
highlighted in this way.
To avoid injury, ABB recommends the use of a lifting accessory when handling
components with a weight exceeding 22 kg. A wide range of lifting accessories
and devices are available for each manipulator model.
Example
Following is an example of a weight specification in a procedure:
Action Note
CAUTION
The arm weighs 25 kg.

All lifting accessories used must be sized accord-
ingly.

8.6 Standard tools
8.6 Standard tools
General
All service (repairs, maintenance, and installation) procedures contains lists of
tools required to perform the specified activity.
All special tools required are listed directly in the procedures while all the tools
that are considered standard are gathered in the standard toolkit and defined in
the following table.
This way, the tools required are the sum of the standard toolkit and any tools listed
in the instruction.
Contents, standard toolkit
Qty Tool
1 Ring-open-end spanner 8-19 mm
1 Socket head cap 2.5-17 mm
1 Torx socket no: 20-60
1 Small screwdriver
1 Plastic mallet
1 Ratchet head for torque wrench 1/2"
1 Socket head cap no: 5, socket 1/2" bit L 20 mm
1 Small cutting plier
1 T-handle with ball head

8.7 Special tools
8.7 Special tools
General
All service instructions contain lists of tools required to perform the specified
activity. The required tools are a sum of standard tools, defined in the section
Standard tools on page 447, and of special tools, listed directly in the instructions
and also gathered in this section.
Measuring tools, play

The tools listed for measuring the play are used after service work on axes 5 and
6.
Description Robot variant Art. no.
Measuring tool, play IRB 2600 - 20/1.65, -12/1.65, 12/1.85 3HAB6337-1
Measuring tool, play IRB 2600ID 3HAB9238-1
Turning disk adapter IRB 2600ID 3HAC027717-020
Measuring bracket IRB 2600ID 3HAC032976-001
Rotation tool IRB 2600, IRB 2600ID 3HAB7887-1
(Used on motor axis. M3
screw is included.)
Tool for adjusting play in IRB 2600, IRB 2600ID See Drawing for ad-
motors justment tool on
page 355.
Calibration equipment, Levelmeter (alternative method)

The following table specifies the calibration equipment required when calibrating
the robot with the alternative method, Levelmeter Calibration.
Description Art. no. Note
Angle bracket 68080011-LP
Calibration bracket 3HAC13908-9
Calibration tool ax1 3HAC13908-4
Measuring pin 3HAC13908-5
Sensor fixture 68080011-GM
Sensor plate 3HAC0392-1
Sync. adapter 3HAC13908-1
Calibration equipment, Calibration Pendulum

The following table specifies the calibration equipment needed when calibrating
the robot with the Calibration Pendulum method.
The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory.
Always use the same calibration method as used at the factory.
Information about valid calibration method is found on the calibration label or in
the calibration menu on the FlexPendant.

8.7 Special tools
Continued
If no data is found related to standard calibration, Calibration Pendulum is used

as default.
Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes operating
manual.
Calibration equipment, Axis Calibration

The following table specifies the calibration equipment needed when calibrating
the robot with the Axis Calibration method.
The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory.
Always use the same calibration method as used at the factory.
Information about valid calibration method is found on the calibration label or in
the calibration menu on the FlexPendant.
If no data is found related to standard calibration, Calibration Pendulum is used
as default.
Calibration tool box, Axis Cal- 3HAC074119- Delivered as a set of calibration tools.
ibration 001 Required if Axis Calibration is the valid
calibration method for the robot.
Contains a removal tool for removing
special protection plugs on the turning
disc.
Turning tool for suspended mounting

The following table specifies the lifting tool required when fitting the robot in a
suspended position.
Turning tool (includes lifting instruction) 3HAC034766-001
Turning tool (includes lifting instruction 3HAC048502-001
3HAC051688-001)
Special tools
This table specifies the special tools required during several of the service
procedures. The tools are specified directly in concerned instructions.
Description Qty Article no.
Guide for reduction gear 1 3HAC068109-001
Used to guide axis-1 gear and frame
during refitting.

8.8 Lifting accessories and lifting instructions
8.8 Lifting accessories and lifting instructions
General
Many repair and maintenance activities require different pieces of lifting accessories,
which are specified in each procedure.
The use of each piece of lifting accessories is not detailed in the activity procedure,
but in the instruction delivered with each piece of lifting accessories.
The instructions delivered with the lifting accessories should be stored for later
reference.

9 Spare part lists
9.1 Spare part lists and illustrations
9 Spare part lists

9.1 Spare part lists and illustrations
Location
Spare parts and exploded views are not included in the manual but delivered as
a separate document for registered users on myABB Business Portal,
www.abb.com/myABB.
Tip
All documents can be found via myABB Business Portal, www.abb.com/myABB.

10 Circuit diagram
10.1 Circuit diagrams
10 Circuit diagram
Overview
The circuit diagrams are not included in this manual, but are available for registered
users on myABB Business Portal, www.abb.com/myABB.
See the article numbers in the tables below.
Controllers
Product Article numbers for circuit diagrams

Circuit diagram - IRC5 3HAC024480-011
Circuit diagram - IRC5 Compact 3HAC049406-003
Circuit diagram - IRC5 Panel Mounted Con- 3HAC026871-020
troller
Circuit diagram - Euromap 67, design 14 3HAC024120-005
Circuit diagram - Spot welding cabinet 3HAC057185-001
Robots

Circuit diagram - IRB 140 type C 3HAC6816-3
Circuit diagram - IRB 1600/1660 3HAC021351-003
Circuit diagram - IRB 4400/4450S 3HAC9821-1
Circuit diagram - IRB 6620 / IRB 6620LX 3HAC025090-001
Circuit diagram - IRB 6650S 3HAC13347-1
3HAC025744-001

10 Circuit diagram
Continued

3HAC029940-001
Circuit diagram - IRB 6700 / IRB 6790 3HAC043446-005
3HAC025744-001
Circuit diagram - IRB 910SC 3HAC056159-002

Index
Index D
direction of axes, 401
A E
Absolute Accuracy, calibration, 396 environmental information, 430
allergenic material, 32 ESD
aluminum damage elimination, 54
disposal, 430 sensitive equipment, 54
ambient humidity expansion container
operation, 47 installing, 92
storage, 47 expected life, 116
ambient temperature
operation, 47 F
storage, 47 fire extinguishing, 33
assembly instructions, 43 FlexPendant
assessment of hazards and risks, 32 jogging to calibration position, 428
Axis Calibration, 406 MoveAbsJ instruction, 428
calibration tool updating revolution counters, 403
article number, 409, 415 foundation
examining, 409 requirements, 46
installation position, 411
overview of method, 406 G
procedure on FlexPendant, 415, 425 gearboxes
protective cover and protection plug, 411, 415 location of, 146
Gravity Alpha, 60
B Gravity Beta, 59
batteries grease, 36
disposal, 430 disposal, 430
battery pack
replacing, interval, 114 H
brakes hanging
testing function, 40 installed hanging, 32
hazard levels, 23
C hazardous material, 430
cabinet lock, 33 height
cabling, robot, 101 installed at a height, 32
cabling between robot and controller, 101 hot surfaces, 36
calibrating HRA, 32
robot, 406 humidity
roughly, 402 operation, 47
calibrating robot, 406, 424–425 storage, 47
calibration
Absolute Accuracy type, 394 I
rough, 402 instructions for assembly, 43
standard type, 394 integrator responsibility, 32
verification, 427 intervals for maintenance, 113
when to calibrate, 397
calibration, Absolute Accuracy, 396 L
calibration manuals, 396 labels
calibration marks, 398 robot, 25
Calibration Pendulum leak-down test, 188
overview of method, 424 lifting
calibration position accessory, 58
jogging to, 428 lifting accessory, 446
scales, 398 limitation of liability, 21
calibration scales, 398 Lithium
CalibWare, 394 disposal, 430
carbon dioxide extinguisher, 33 loads on foundation, 45
cast iron lock and tag, 33
disposal, 430 lubricants, 36
cleaning, 183 lubrication
climbing on robot, 36 amount in gearboxes, 146
Cold environments, 100 type of lubrication, 146
connecting the robot and controller, cabling, 101
copper M
disposal, 430 magnesium
disposal, 430

Index
maintenance schedule, 113 ESD, 54

MoveAbsJ instruction, 428 fire extinguishing, 33
release robot axes, 39
N signal lamp, 98
national regulations, 32 signals, 23
negative directions, axes, 401 signals in manual, 23
neodymium symbols, 23
disposal, 430 symbols on robot, 25
nodular iron safety devices, 33
disposal, 430 safety hazard
hydraulic system, 34
O pneumatic system, 34
oil, 36 safety signals
amount in gearboxes, 146 in manual, 23
disposal, 430 safety standards, 440
type of oil, 146 scales on robot, 398
oil change schedule for maintenance, 113
axis 1, floor mounted robots, 148 screw joints, 443
axis 1, suspended robots, 156 signal lamp, 98
axis 2, 161 signals
axis 3, 165 safety, 23
axis 4, 169 special tools, 448
axis 5, 173 speed
axis 6, 173 adjusting, 100
operating conditions, 47 stability, 53
options standards, 440
expansion container, 92 ANSI, 440
original spare parts, 21 CAN, 440
EN IEC, 440
P EN ISO, 440
pedestal start of robot in cold environments, 100
installed on pedestal, 32 steel
personnel disposal, 430
requirements, 22 storage conditions, 47
plastic suspended mounting, 59
disposal, 430 symbols
positive directions, axes, 401 safety, 23
PPE, 22 synchronization position, 402
product standards, 440 sync marks, 398
protection classes, 47 system integrator requirements, 32
protection type, 47 system parameter
protective equipment, 22 Gravity Alpha, 60
protective wear, 22 Gravity Beta, 59
R T
regional regulations, 32 temperatures
release brakes, 39 operation, 47
replacements, report, 187 storage, 47
report replacements, 187 testing
requirements on foundation, 46 brakes, 40
responsibility and validity, 21 tilted mounting, 59
revolution counters tools
storing on FlexPendant, 403 Axis Calibration, 449
updating, 402 calibration equipment, Levelmeter, 448
risk of burns, 36 Calibration Pendulum, 448
risk of tipping, 53 for service, 448
robot torques on foundation, 45
labels, 25 troubleshooting
protection class, 47 oil spills, 183
protection types, 47 safety, 41
symbols, 25 turning
rubber accessory, 58
disposal, 430
U
S updating revolution counters, 402
safety users
brake testing, 40 requirements, 22

Index
V robot, 56, 68, 259–260, 265, 268, 283, 285, 294, 365,
validity and responsibility, 21 369, 378, 381, 389–390
velocity upper and lower arm, 377, 383
adjusting, 100 upper arm, complete, 249, 253
verifying calibration, 427 Wrist Optimization
overview of method, 425
W
wall mounting, 59 Z
weight, 44 zero position
base, 297–298 checking, 428

ABB AB
Robotics & Discrete Automation
S-721 68 VÄSTERÅS, Sweden
Telephone +46 (0) 21 344 400
ABB AS
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000
ABB Engineering (Shanghai) Ltd.

No. 4528 Kangxin Highway
PuDong District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666
ABB Inc.
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000
abb.com/robotics
3HAC035504-001, Rev AB, en


3HAC035504 PM IRB 2600-En

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© Copyright 2009-2021 ABB. All rights reserved.

© Copyright 2009-2021 ABB. All rights reserved.

2 Installation and commissioning 43

Product manual - IRB 2600 5

3.2 Maintenance schedule and expected component life ............................................... 112

6 Product manual - IRB 2600

4.7.3 Replacing motor axis 5 - IRB 2600ID ........................................................... 332

7 Robot description 433

8 Reference information 439

9 Spare part lists 451

10 Circuit diagram 453

Product manual - IRB 2600 7

Overview of this manual

Who should read this manual?

Product manual scope

Continues on next page

Product manual - IRC5 3HAC021313-001

Continues on next page

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Product manual - IRB 2600 17

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

Technical reference manuals

Continues on next page

Product manual - IRB 2600 19

How to read the product manual

References to required equipment

20 Product manual - IRB 2600

1.1.1 Limitation of liability

Spare parts and equipment

Product manual - IRB 2600 21

1.1.2 Requirements on personnel

Personal protective equipment

22 Product manual - IRB 2600

1.2 Safety signals and symbols

1.2.1 Safety signals in the manual

Introduction to safety signals

WARNING Signal word used to indicate a potentially hazardous

ELECTRICAL Signal word used to indicate a potentially hazardous

CAUTION Signal word used to indicate a potentially hazardous

ELECTROSTATIC Signal word used to indicate a potentially hazardous

NOTE Signal word used to indicate important facts and

Continues on next page

Symbol Designation Significance

24 Product manual - IRB 2600

1.2.2 Safety symbols on manipulator labels

Symbols on safety labels

Continues on next page

Before disassembly, see product manual

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Chain sling with shortener

Continues on next page

Shut off with handle

30 Product manual - IRB 2600

1.3 Robot stopping functions