ABB IRB 2600ID - Page 324

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IRB 2600 Standard, motor type A

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324 Product manual - IRB 2600

3HAC035504-001 Revision: AD

4 Repair

4.7.2 Refitting motors

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Table of Contents5
Overview of this Manual9
Product Documentation18
How to Read the Product Manual20
Safety21
Safety Information21
Limitation of Liability21
Requirements on Personnel22
Safety Signals and Symbols23
Safety Signals in the Manual23
Safety Symbols on Manipulator Labels25
Robot Stopping Functions31
Safety During Installation and Commissioning32
Safety During Operation35
Safety During Maintenance and Repair36
Emergency Release of the Robot Axes39
Brake Testing40
Safety During Troubleshooting41
Safety During Decommissioning42
Installation and Commissioning43
Introduction to Installation and Commissioning43
Unpacking44
Pre-Installation Procedure44
Technical Data45
Working Range and Type of Motion49
Risk of Tipping/Stability54
The Unit Is Sensitive to ESD56
On-Site Installation57
Lifting Robot with Roundslings57
Lifting and Turning a Suspended Mounted Robot60
Setting the System Parameters for a Suspended or Tilted Robot61
Manually Releasing the Brakes65
Orienting and Securing the Robot68
Fitting Equipment on Robot72
Loads Fitted to the Robot, Stopping Time and Braking Distances86
Restricting the Working Range87
Axes with Restricted Working Range87
Mechanically Restricting the Working Range of Axis 188
Installing Options91
Installation of Cooling Fan for Motors (Option)91
Installing an Expansion Container95
Installation of Foundry Plus Cable Guard (Option)100
Safety Lamp (Option for IRC5)101
Robot in Hot Environments102
Start of Robot in Hot Environments102
Robot in Cold Environments103
Start of Robot in Cold Environments103
Electrical Connections104
Robot Cabling and Connection Points104
Customer Connection on Robot108
Test Run after Installation, Maintenance, or Repair113
Maintenance115
Introduction115
Maintenance Schedule and Expected Component Life116
Specification of Maintenance Intervals116
Maintenance Schedule117
Expected Component Life120
Inspection Activities121
Inspecting Oil Level, Axis-1 Gearbox121
Inspecting the Oil Level, Axis 2 Gearbox126
Inspecting the Oil Level, Axis 3 Gearbox129
Inspecting the Oil Level, Axis 4 Gearbox131
Inspecting Oil Level, Gearbox Axes 5 - 6133
Inspecting the Cable Harness135
Inspecting Information Labels138
Inspecting the Mechanical Stop Pin, Axis 1140
Inspecting Additional Mechanical Stops143
Inspecting Dampers145
Inspecting the Pressure Relief Valve147
Inspecting Signal Lamp (Option)149
Replacement / Changing Activities151
Type of Lubrication in Gearboxes151
Changing the Oil, Axis 1 Gearbox on Floor Mounted Robots153
Changing the Oil, Axis-1 Gearbox on Suspended Robots161
Changing the Oil, Axis-2 Gearbox166
Changing the Oil, Axis-3 Gearbox170
Changing the Oil, Axis-4 Gearbox174
Changing Oil, Axes-5 and -6 Gearboxes178
Replacing SMB Battery183
Cleaning188
Cleaning the IRB 2600/IRB 2600 ID188
Repair191
Introduction191
General Procedures192
Performing a Leak-Down Test192
Mounting Instructions for Bearings193
Mounting Instructions for Sealings195
Cut the Paint or Surface on the Robot before Replacing Parts198
The Brake Release Buttons May be Jammed after Service Work199
Complete Robot200
Removing the Complete Cable Harness200
Refitting the Complete Cable Harness212
Replacing the Cable Harness in the Upper Arm - IRB 2600ID227
Replacing SMB Unit239
Replacing the Brake Release Board245
Upper Arm250
Replacing the Complete Upper Arm250
Replacing Complete Tubular Shaft Unit260
Replacing Wrist Unit267
Measuring the Play, Axis 5274
Measuring the Play, Axis 6276
Measuring the Play, Axis 5 (ID Upper Arm)278
Measuring the Play, Axis 6 (ID Upper Arm)281
Lower Arm284
Replacing the Lower Arm284
Frame and Base292
Replacing Stop Pin Axis292
Replacing the Base295
Motors307
Removing Motors307
Refitting Motors320
Replacing Motor Axis 5 - IRB 2600ID336
Replacing Motor Axis 6 and Wrist Unit - IRB 2600ID348
Adjusting the Play359
Gearboxes364
Replacing Gearbox Axis 1364
Replacing Gearbox Axis 2377
Replacing Gearbox Axis 3390
Calibration397
Introduction to Calibration397
Introduction and Calibration Terminology397
Calibration Methods398
When to Calibrate401
Synchronization Marks and Axis Movement Directions402
Synchronization Marks and Synchronization Position for Axes402
Calibration Movement Directions for All Axes405
Updating Revolution Counters406
Updating Revolution Counters on IRC5 Robots406
Updating Revolution Counters on Omnicore Robots410
Calibrating with Axis Calibration Method412
Description of Axis Calibration412
Calibration Tools for Axis Calibration415
Installation Locations for the Calibration Tools417
Axis Calibration - Running the Calibration Procedure421
Reference Calibration427
Calibrating with Calibration Pendulum Method429
Calibrating with Wrist Optimization Method430
Verifying the Calibration432
Checking the Synchronization Position433
Decommissioning435
Introduction to Decommissioning435
Environmental Information436
Scrapping of Robot438
Robot Description439
Robot Types439
Non-Compatible Versions of Axis-1 and Axis-2 Gearboxes440
Reference Information445
Introduction445
Applicable Standards446
Unit Conversion447
Screw Joints448
Weight Specifications451
Standard Tools452
Special Tools453
Lifting Accessories and Lifting Instructions455
Spare Part Lists457
Spare Part Lists and Illustrations457
Circuit Diagram459
Circuit Diagrams459

ABB IRB 2600ID - Page 324

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