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1 Safety

1.1 General safety information

1.1.1 Limitation of liability

Limitation of liability

Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial robot will not cause injury or damage even if
all safety instructions are complied with.

The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment that can influence the safety of
the entire system.

In particular, liability cannot be accepted if injury/damage has been caused for any
of the following reasons:

•

Use of the robot in other ways than intended.

•

Incorrect operation or maintenance.

•

Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.

•

When instructions for operation and maintenance are not followed.

•

Non-authorized design modifications made in or around the robot.

•

Repairs carried out by in-experienced or non-qualified personnel.

•

Foreign objects.

•

Force majeure.

Nation/region specific regulations

To protect personnel, the complete system must be designed and installed in
accordance with the safety requirements set forth in the standards and regulations
of the country where the robot is installed.

To be observed by the supplier of the complete system

The integrator is responsible that the safety devices necessary to protect people
working with the robot system are designed and installed correctly.

When integrating the robot with external devices and machines:

•

The supplier of the complete system must ensure that all circuits used in the
safety function are interlocked in accordance with the applicable standards
for that function.

•

The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance
with the applicable standards for the emergency stop function.

Continues on next page

Product manual - IRB 6660

19

3HAC028197-001 Revision: S

© Copyright 2007-2018 ABB. All rights reserved.

1 Safety

1.1.1 Limitation of liability

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Summary of Contents for IRB 6660

Page 1: ...ROBOTICS Product manual IRB 6660 ...

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

Page 3: ...Product manual IRB 6660 100 3 3 IRB 6660 130 3 1 IRB 6660 205 1 9 IRC5 Document ID 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved Specifications subject to change without notice ...

Page 4: ... persons or property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission Keep for future reference Additional copies of this manual may be obtained from ABB Original instructions ...

Page 5: ...ual 42 1 4 2 Safety symbols on product labels 49 2 Installation and commissioning 49 2 1 Introduction 50 2 2 Unpacking 50 2 2 1 Pre installation procedure 54 2 2 2 Working range and type of motion 58 2 2 3 Risk of tipping stability 60 2 3 On site installation 60 2 3 1 Lifting robot with fork lift 66 2 3 2 Lifting robot with roundslings 69 2 3 3 Lifting robot with lifting slings 73 2 3 4 Manually r...

Page 6: ...ox 162 3 4 7 Replacing the SMB battery 166 3 5 Lubrication activities 166 3 5 1 Lubricating balancing device bearings and piston rod 169 3 6 Cleaning activities 169 3 6 1 Cleaning the IRB 6660 173 4 Repair 173 4 1 Introduction 174 4 2 General procedures 174 4 2 1 Performing a leak down test 175 4 2 2 Mounting instructions for bearings 177 4 2 3 Mounting instructions for seals 179 4 2 4 Cut the pai...

Page 7: ...2 5 4 1 Description of Axis Calibration 354 5 4 2 Calibration tools for Axis Calibration 356 5 4 3 Installation locations for the calibration tools 357 5 4 4 Axis Calibration Running the calibration procedure 363 5 5 Calibrating with Calibration Pendulum method 364 5 6 Verifying the calibration 365 5 7 Checking the synchronization position 367 6 Decommissioning 367 6 1 Introduction 368 6 2 Environ...

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Page 9: ...nstallation repair maintenance work Product manual scope The manual covers covers all variants and designs of the IRB 6660 Some variants and designs may have been removed from the business offer and are no longer available for purchase Organization of chapters The manual is organized in the following chapters Contents Chapter Safety information that must be read through before performing any insta...

Page 10: ... IRC5 IRC5 with main computer DSQC 639 3HAC047136 001 Product manual IRC5 IRC5 with main computer DSQC1000 3HAC050941 001 Operating manual IRC5 with FlexPendant 3HAC16578 1 Operating manual Calibration Pendulum 3HAC050944 001 Operating manual Service Information System 3HAC051016 001 Application manual Additional axes and stand alone controller 3HAC042927 001 Technical reference manual Lubrication...

Page 11: ...gearbox oil The text in the introductions to chapters Installation Maintenance and Repair has been updated concerning the robot being connected to earth when power connected Section Expected component life in chapter Maintenance The lifetime of certain parts has been updated Section Foundry Plus Cable guard added to chapter Installation This revision includes the following additions and or changes...

Page 12: ...ded to the foundation recommendation for the base plate and class designation for foundation is changed to european standard C25 C30 previously Swedish standard K25 K30 see Securing the base plate on page 76 Corrections and improvements are made in the instruction for how to replace the axis 2 and axis 3 gearbox see Replacing the gearbox axes 2 3 on page 324 All data about type of lubrication in g...

Page 13: ...ctions due to updates in terminology Information about grounding point added See Robot cabling and connection points on page 104 Published in release R17 2 The following updates are made in this revision P Caution about removing metal residues added in sections about SMB boards Information about minimum resonance frequency added Bending radius of static floor cables added Updated list of applicabl...

Page 14: ...so added de tailed images to installation procedure for the fan Published in release R18 2 The following updates are made in this revision R Removed doubled information Published in release R18 2 The following updates are made in this revision S Updated references 14 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved Overview of this manual Continued ...

Page 15: ...ioning Reference information safety standards unit conversions screw joints lists of tools Spare parts list with corresponding figures or references to separate spare parts lists References to circuit diagrams Technical reference manuals The technical reference manuals describe reference information for robotics products for example lubrication the RAPID language and system parameters Application ...

Page 16: ...s The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters 16 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved Product documentation Continued ...

Page 17: ...ompleted with a reference to the section where the equipment is listed with further information that is article number and dimensions The designation in the procedure for the component or attachment point corresponds to the designation in the referenced list The table below shows an example of a reference to a list of required equipment from a step in a procedure Note Illustration Action Art no is...

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Page 19: ...arried out by in experienced or non qualified personnel Foreign objects Force majeure Nation region specific regulations To protect personnel the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed To be observed by the supplier of the complete system The integrator is respo...

Page 20: ...orking in the work cell see the section Robot motion in the Product specification Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot Safe handling Users shall not be exposed to hazards including slipping tripping and falling hazards It must be possible to safely turn off tools such as milling cutters etc Make sure that...

Page 21: ...view The protective stops and emergency stops are described in the product manual for the controller Product manual IRB 6660 21 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 1 Safety 1 1 2 Protective stop and emergency stop ...

Page 22: ...uishing Note Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the manipulator or controller 22 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 1 Safety 1 2 1 Fire extinguishing ...

Page 23: ... may require using an overhead crane or similar equipment Increased injury Before releasing the brakes make sure that the weight of the robot does not increase the pressure on the trapped person further increasing any injury DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unexpected ways Make sure no personnel is near or beneath the robot Product manu...

Page 24: ... arrest burn injuries or other severe injuries To avoid these personal injuries switch off the main power on the controller before proceeding work Note Switch off all main power switches in a MultiMove system 24 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 1 Safety 1 2 3 Make sure that the main power has been switched off ...

Page 25: ...afety lock Make sure that no one else can turn on the power to the controller and robot while you are working with the system A good method is to remove the power cable to the controller If the robot is installed at a height hanging or other than standing directly on the floor there may be additional risks than those for a robot standing directly on the floor Energy stored in the robot for the pur...

Page 26: ...odifications to the robot Connection of external safety devices Apart from the built in safety functions the robot is also supplied with an interface for the connection of external safety devices An external safety function can interact with other machines and peripheral equipment via this interface This means that control signals can act on safety signals received from the peripheral equipment as...

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

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

Page 29: ...in USA or Canada Pay attention to the rotating axes of the robot Keep away from axes to not get entangled with hair or clothing Also be aware of any danger that may be caused by rotating tools or other devices mounted on the robot or inside the cell Keep clear of moving parts so that limbs hands or fingers do not get trapped or crushed by the robot To prevent anyone else from taking control of the...

Page 30: ...manipulator switches to the MOTORS OFF state To ensure safe use of the teach pendant the following must be implemented The enabling device must never be rendered inoperational in any way During programming and testing the enabling device must be released as soon as there is no need for the robot to move Anyone entering the working space of the robot must always hold the teach pendant This is to pr...

Page 31: ...risks IRC5 controller A danger of high voltage is associated with for example the following parts Be aware of stored electrical energy DC link Ultracapacitor bank unit in the controller Units such as I O modules can be supplied with power from an external source The main supply main switch The transformers The power unit The control power supply 230 VAC The rectifier unit 262 400 480 VAC and 400 7...

Page 32: ...e live even if the robot system is in the OFF position Power supply cables which are in motion during the working process may be damaged 32 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 1 Safety 1 3 6 Risks associated with live electric parts Continued ...

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

Page 34: ... your hand at some distance to feel if heat is radiating from the potentially hot component before actually touching it Wait until the potentially hot component has cooled if it is to be removed or handled in any other way Do not put anything on hot metal surfaces e g paper or plastic 34 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 1 Safety 1 3 8 Ho...

Page 35: ...re must be released in the complete pneumatic or hydraulic systems before starting to repair them Work on hydraulic equipment may only be performed by persons with special knowledge and experience of hydraulics All pipes hoses and connections have to be inspected regularly for leaks and damage Damage must be repaired immediately Splashed oil may cause injury or fire Safe design Gravity may cause a...

Page 36: ...as described below 1 Run each robot axis to a position where the combined weight of the robot arm and any load is maximized maximum static load 2 Switch the motor to the MOTORS OFF 3 Inspect and verify that the axis maintains its position If the robot does not change position as the motors are switched off then the brake function is adequate 36 Product manual IRB 6660 3HAC028197 001 Revision S Cop...

Page 37: ...losion fire may follow depending upon the circumstances Note Appropriate disposal regulations must be observed Safe handling Use safety glasses when handling the batteries In the event of leakage wear rubber gloves and chemical apron In the event of fire use self contained breathing apparatus Do not short circuit recharge puncture incinerate crush immerse force discharge or expose to temperatures ...

Page 38: ...ion Action Description Warning Make sure that protective gear like goggles and gloves are al ways worn during this activity Changing and draining gearbox oil or grease may require hand ling hot lubricant heated up to 90 C Hot oil or grease Make sure that protective gear like goggles and gloves are al ways worn When working with gearbox lub ricant there is a risk of an allergic reaction Allergic re...

Page 39: ... time to heat up the oil Warm oil drains quicker than cold oil Heat up the oil After filling verify that the level is correct The specified amount of oil or grease is based on the total volume of the gearbox When changing the lubricant the amount refilled may differ from the specified amount depending on how much has previously been drained from the gearbox Specified amount de pends on drained vol...

Page 40: ...e instructions are not followed that can lead to serious injury pos sibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc WARNING Warns for electrical hazards which could result in severe personal injury or deat...

Page 41: ...d conditions NOTE Describes where to find additional information or how to do an operation in an easier way TIP Product manual IRB 6660 41 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 1 Safety 1 4 1 Safety signals in the manual Continued ...

Page 42: ...lish German and French Symbols on safety labels Description Symbol Warning xx0900000812 Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of c...

Page 43: ... Do not disassemble xx0900000815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the robot arm can fall down Continues on next page Product manual IRB 6660 43 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights re...

Page 44: ...ip over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page 44 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 45: ...1 1 06 xx1300001087 Moving robot 1 2 3 4 5 6 xx0900000819 The robot can move unexpectedly xx1000001141 1 2 3 4 xx1500002616 Continues on next page Product manual IRB 6660 45 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 46: ...0001242 Lifting of robot xx0900000822 Oil xx0900000823 Can be used in combination with prohibition if oil is not allowed Mechanical stop xx0900000824 Continues on next page 46 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 47: ...hat this part is pressurized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller Do not step xx1400002648 Warns that stepping on these parts can cause damage to the parts Product manual IRB 6660 47 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Contin...

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Page 49: ...portant that all safety information is observed There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page19 before performing any installation work Note If the IRB 6660 is connected to power always make sure that the robot is connected to protective...

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

Page 51: ...ne Txy Bending torque in the Z plane Tz 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 Co...

Page 52: ...The value is recommended for optimal perform ance 22 Hz Note It may affect the manipulator life time to have a lower resonance frequency than recommended Minimum resonance frequency Due to foundation stiffness consider robot mass including equipment i For information about compensating for founda tion flexibility see Application manual Control ler software IRC5 section Motion Process Mode i The mi...

Page 53: ... ambient temperature 50 Ci Maximum ambient temperature 95 at constant temperature Maximum ambient humidity i In a high speed presstending application max ambient temperature is 40 C Protection classes robot The table shows the available protection types of the robot with the corresponding protection class Protection class Protection type IP 67 Manipulator protection type Standard IP 67 Manipulator...

Page 54: ...D E G A F 2958 851 xx1200000979 Mechanical stop A Max working range B Max working range C Positions at wrist center Axis 3 angle de grees Axis 2 angle de grees Z position mm X position mm Position num ber see figure above 0 0 2374 5 2055 5 A 20 42 2629 997 B 28 42 1189 1125 C 120 50 23 645 D 120 85 734 940 E 15 85 742 3343 F 20 50 2501 2834 G Continues on next page 54 Product manual IRB 6660 3HAC0...

Page 55: ...t wrist center Axis 3 angle de grees Axis 2 angle de grees Z position mm X position mm Position num ber see figure above 0 0 2374 5 1805 5 A 20 42 2544 763 B 28 42 1306 904 C 120 50 194 770 D 120 85 518 1065 E 15 85 807 3102 F 20 50 2415 2596 G Continues on next page Product manual IRB 6660 55 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 2 Installation and commissioning 2 ...

Page 56: ...ure above 0 0 1794 5 1193 A 20 42 1903 2 575 B 28 42 1162 7 751 5 C 120 50 351 1 632 2 D 120 85 37 9 793 3 E 15 85 914 8 1932 4 F 20 50 1833 1579 6 G 20 0 2083 2 1043 4 H 107 4 85 60 4 997 3 K Continues on next page 56 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range and type of motion Continued ...

Page 57: ...20 Bend motion 5 300 to 300 Turn motion 6 Turning radius A B xx1200000980 Radius B Radius A axis 3 motor Robot variant 3343 mm 710 mm IRB 6660 100 3 3 3102 mm 710 mm IRB 6660 130 3 1 1932 mm 710 mm IRB 6660 205 1 9 Product manual IRB 6660 57 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range and type of motion Continued ...

Page 58: ...n is the most stable position Do not change the robot position before securing it to the foundation Shipping and transportation position This figure shows the robot in its shipping position and transportation position 2 8 42 xx0700000001 IRB 6660 130 3 1 IRB 6660 100 3 3 A IRB 6660 205 1 9 B Continues on next page 58 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rig...

Page 59: ...o be mechanically unstable if not secured to the foundation Product manual IRB 6660 59 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 2 Installation and commissioning 2 2 3 Risk of tipping stability Continued ...

Page 60: ...nts on adapter and horizontal attachment screws A Attachment points horizontal attachment screws B Attachment points vertical attachment screws C Required equipment Note Art no Equipment etc See figure Fork lift set 3HAC023044 001 on page 61 3HAC023044 001 Fork lift set incl all required hardware Content is defined in section Standard tools on page 381 Standard toolkit Continues on next page 60 Pr...

Page 61: ...nd one short A Adapter 2 pcs B Horizontal attachment screws 4 pcs fork lift pocket C Attachment screw for adapter 1 pc adapter D Vertical attachment screws 2 pcs E Continues on next page Product manual IRB 6660 61 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 2 Installation and commissioning 2 3 1 Lifting robot with fork lift Continued ...

Page 62: ...y releasing the brakes on page 73 xx0700000517 A IRB 6660 100 3 3 IRB 6660 130 3 1 B IRB 6660 205 1 9 Position the robot as shown in the figure to the right 2 Attachment points are shown in figure Attachment points on robot on page60 Fit the two adapters to the robot and secure 3 Attachment screws 2 pcs M16 x 90 Tightening torque 270 Nm Continues on next page 62 Product manual IRB 6660 3HAC028197 ...

Page 63: ... and washers Note The screws which are attached horizontally and vertically are identical However they are tightened with different torque 6 Attachment points on the robot are shown in figure Attachment points on robot on page 60 xx0500002279 A Horizontal attachment screws 4 pcs M16 x 60 Tightening torque 60 Nm B Adapter Continues on next page Product manual IRB 6660 63 3HAC028197 001 Revision S C...

Page 64: ...re shown in figure Attachment points on robot on page 60 CAUTION The fork lift pocket weighs 22 kg 9 4 pcs M16x60 Secure the shorter fork lift pocket on the other side of the robot with the four remaining hori zontal attachment screws 10 Tightening torque 60 Nm Always use original screws or replace ments of equivalent quality M16 qual ity 12 9 Attachment points on robot are shown in figure Attachm...

Page 65: ... be sized ac cordingly 12 Carefully lift the robot and move it to its install ation site 13 WARNING Personnel must not under any circumstances be present under the suspended load 14 Refit the cooling fan to the motor if any 15 Product manual IRB 6660 65 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 2 Installation and commissioning 2 3 1 Lifting robot with fork lift Continue...

Page 66: ...figure Attachment points on page 66 When attaching the roundsling A on the up per arm put it in a U shape through the hole in the wrist 4 Note If the robot is equipped with fork lift pockets an extra weight of 90 kg must be added to the robot weight CAUTION The IRB 6660 robot weighs 1950 kg All lifting accessories used must be sized accordingly 5 WARNING Personnel must not under any circum stances...

Page 67: ...130 3 1 IRB 6660 100 3 3 xx0700000002 Roundsling 2 m A Roundsling 2 m B Roundsling 2 m C Continues on next page Product manual IRB 6660 67 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 2 Installation and commissioning 2 3 2 Lifting robot with roundslings Continued ...

Page 68: ...6 Roundsling 2 m A Roundsling 2 m B Roundsling 2 m C 68 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 2 Installation and commissioning 2 3 2 Lifting robot with roundslings Continued ...

Page 69: ...ipment Note Move the robot to the recommended position shown in the figure and in the instruction Attempting to lift a robot in any other position may result in the robot tipping over causing severe damage or injury Continues on next page Product manual IRB 6660 69 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 2 Installation and commissioning 2 3 3 Lifting robot with liftin...

Page 70: ... Load hook A Swivelling lifting eyes 4 pcs B Shortening hook C Chain D Lifting eye M12 E Eye for lifting accessory F Lifting slings 4 pcs I Hook L Continues on next page 70 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 2 Installation and commissioning 2 3 3 Lifting robot with lifting slings Continued ...

Page 71: ...k C Chain D Lifting eye M12 E Eye for lifting accessory F Lifting slings 4 pcs J Hook L Continues on next page Product manual IRB 6660 71 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 2 Installation and commissioning 2 3 3 Lifting robot with lifting slings Continued ...

Page 72: ...o reach the lower holes in the frame These are used to attach the hooks of the lifting slings 3 Article number is specified in Required equipment on page 72 Fit the lifting accessory to the robot as de scribed in the enclosed instruction 4 Note If the robot is equipped with fork lift pockets an extra weight of 90 kg must be added to the robot weight CAUTION The IRB 6660 robot weighs 1950 kg All li...

Page 73: ... brakes The buttons are numbered according to the numbers of the axes If the robot is not connected to the controller power must be supplied to the connector R1 MP according to the section Supplying power to connector R1 MP on page 74 1 DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unexpec ted ways Make sure no personnel is near or beneath the ro bo...

Page 74: ...se buttons Note Action DANGER Incorrect connections such as supplying power to the wrong pin may cause all brakes to be released simultaneously 1 xx0600002937 Supply 0V on pin 12 and 24V on pin 11 2 74 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 2 Installation and commissioning 2 3 4 Manually releasing the brakes Continued ...

Page 75: ...g All lifting accessories used must be sized accordingly 1 Shown in figure Hole configur ation on page 75 Fit lifting eyes in specified holes 2 Fit lifting slings to the eyes and to the lifting accessory CAUTION Lift and move the base plate very slowly If the base plate starts to swing it is a risk for injuries or damage 3 Product manual IRB 6660 75 3HAC028197 001 Revision S Copyright 2007 2018 AB...

Page 76: ...3x45º 0 3 Ø 45P7 A A Ø1 5 4x 6 3 4 8 2 1 6 3x45º B B 2 1 3 3x R1 3 x 4 3x 90º C C 4 5 K 7 0 5 0 47 0 25 c 2x R22 5 1 6 D 2 c 5 2 5 º Common Zone E F G H xx1000001053 Common tolerance zone accuracy all over the base plate from one contact surface to the other E F G H Continues on next page 76 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 2 Installatio...

Page 77: ...for alternative clamping 4x Ø18 A Continues on next page Product manual IRB 6660 77 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 2 Installation and commissioning 2 3 6 Securing the base plate Continued ...

Page 78: ...or leveling bolts in the base plate A A A B B B B xx1500000312 Orienting grooves 3 pcs A Levelling bolts attachment holes 4 pcs B Continues on next page 78 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 2 Installation and commissioning 2 3 6 Securing the base plate Continued ...

Page 79: ...Content is defined in section Standard tools on page 381 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Base plate This section details how to secure the base plate to the foundation Note Action Make sure the foundation is levelled 1 Continues on next pag...

Page 80: ... orienting grooves and leveling bolts on page 78 Fit the base plate and use the levelling bolts to level the base plate 6 If required fit strips of sheet metal underneath the base plate to fill any gaps 7 Secure the base plate to the foundation with screws and sleeves 8 Maximum allowed deviation all over the base plate from one contact surface to the other 0 3 mm Recheck the four contact surfaces ...

Page 81: ... the base plate B Levelling screws C Base plate attachment screws D Attachment screws The table below specifies the type of securing screws and washers to be used for securing the robot to the base plate foundation M24 x 140 Suitable screws lightly lubricated Quality 8 8 Quality Thickness 4 mm Suitable washer Outer diameter 44 mm Inner diameter 25 mm 725 Nm Tightening torque Continues on next page...

Page 82: ...ase plate 3 Make sure the robot base is correctly fitted onto the guide sleeves Guide the robot gently using two M24 screws while lowering it into its mounting position 4 Specified in Attachment screws on page 81 Fit the bolts and washers in the base attach ment holes 5 Shown in figure Illustration robot fitted to base plate on page 81 Note Lightly lubricate screws before as sembly Tighten bolts i...

Page 83: ...x0300000046 Cross section guide sleeve hole This illustration shows the cross section of the guide sleeve holes xx0100000109 Product manual IRB 6660 83 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 2 Installation and commissioning 2 3 7 Orienting and securing the robot Continued ...

Page 84: ...nd or its parts Note No extra equipment may be fitted on the lower arm of the robot Illustration fitting of extra equipment on upper arm The illustrations below shows the mounting holes available for fitting extra equipment on the upper arm xx0700000015 D C B A Robot variant Number 128 mm 490 mm 190 mm 1747 5 mm IRB 6660 100 3 3 1 128 mm 490 mm 190 mm 1497 5 mm IRB 6660 130 3 1 128 mm 490 mm 190 m...

Page 85: ...14 xx0700000674 Continues on next page Product manual IRB 6660 85 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 2 Installation and commissioning 2 3 8 Fitting equipment on robot Continued ...

Page 86: ...elow Illustrations show robot variant IRB 6660 130 3 1 but all shown measurements are the same on all variants xx0700000013 xx0700000012 Continues on next page 86 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 2 Installation and commissioning 2 3 8 Fitting equipment on robot Continued ...

Page 87: ...quality When fitting tools on the turning disk see the figures above only use screws with quality 12 9 Standard screws with quality 8 8 may be used when fitting other equipment to the mounting holes on the upper arm house or frame Product manual IRB 6660 87 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 2 Installation and commissioning 2 3 8 Fitting equipment on robot Contin...

Page 88: ... D Required equipment Note Art no Equipment 3HAC030124 001 Chip protection Loctite 243 Locking liquid For locking screws Content is defined in section Standard tools on page381 Standard toolkit These procedures include references to the tools re quired Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page 88 Prod...

Page 89: ...rm 2 Art no is detailed in Required equipment on page 88 Fit the bracket on the chip protection with its attachment screws two screws on each side of the lower arm 3 Lock screws with locking liquid As shown in the figure Location of chip protection on page 88 Let the protection hang down in front of the lower arm and base of the robot 4 Product manual IRB 6660 89 3HAC028197 001 Revision S Copyrigh...

Page 90: ...is 1 and or axis 2 as shown in the figure below The figure shows IRB 7600 but the principle fitting is the same xx1800000170 xx1800000169 Cooling fan axis 1 A Cooling fan axis 2 B Continues on next page 90 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 2 Installation and commissioning 2 3 10 Installation of cooling fan for motors option ...

Page 91: ... robot base if not already in stalled The plate is shown in the figure Plate for customer connections at base on page 92 3HAC025778 001 Plate for customer connec tions Specified in section Fan cables option on page 106 Additional cabling to the controller The set includes fan axes 1 2 cable harness plate customer attachment screws and nuts 3HAC023999 001 Material set fan axes 1 and 2 3HAC025488 00...

Page 92: ...tools required Other tools and procedures may be required See refer ences to these procedures in the step by step instruc tions below Plate for customer connections at base xx0500002301 Plate for customer connections A Attachment screws 3 pcs M6x16 quality 8 8 A2F B Continues on next page 92 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 2 Installatio...

Page 93: ... groove pointing inwards as shown in the figure Cooling fan on page 91 2 Temporarily lift the motor cabling out of the way of the current motor to make room for the fanbox 3 Fit the parts of the fanbox to the motor and reassemble with the nine attachment screws 4 Lift the box axis 1 so that it does not rest directly on the robot and secure the box with the three tightening screws using locking liq...

Page 94: ...ooling fan of axis 1 or 2 Note Action This is detailed in section Syn chronization marks and synchron ization position for axes on page 345 Move the robot to its calibration position 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 Continues on next page 94 Product manual IRB 66...

Page 95: ... not be strapped to the motor cable along the part of the cable that is twisted when the robot is in operation Connect the connector R3 FAN2 to the fan of axis 1 8 Connect the connector R1 SW2 3 to the base of the robot Make sure that the cabling run through the frame and base is not twisted and runs freely from the robot cabling 9 Refit the rear cover plate to the robot base 10 Cable is specified...

Page 96: ...e Sys tem Builder of RobotStudio Read more about modifying the system in Operating manual RobotStudio Modify the settings in RobotWare to include the cooling fans 1 96 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 2 Installation and commissioning 2 3 10 Installation of cooling fan for motors option Continued ...

Page 97: ...0 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 myportal abb com and delivered with the Cable guard article number 3HAC035933 001 Product manual IRB 6660 97 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 2 Installation and commissioning 2 3 11 Installation of Foundry Plus...

Page 98: ... 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 98 P...

Page 99: ...on delivered with the signal lamp Function The lamp is active in MOTORS ON mode Further information Further information about the MOTORS ON MOTORS OFF mode may be found in the product manual for the controller Product manual IRB 6660 99 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 2 Installation and commissioning 2 3 13 Signal lamp option ...

Page 100: ...dware mechanical stop and software Axis 2 software Axis 3 software As standard configuration axis 1 is allowed to move 180º 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 100 Product manual IRB 6660 3HAC...

Page 101: ...ps available for axis 1 xx0300000049 Additional mechanical stop A Stop pin B Required equipment Note Article number Equipment etc Includes attachment screws and an assembly drawing 3HAC11076 1 Mechanical stop for axis 1 7 5 Includes attachment screws and an assembly drawing 3HAC11076 2 Mechanical stop for axis 1 15 Standard toolkit Article number is specified in section References on page10 Techni...

Page 102: ...he system parameters that must be changed Upper joint bound and Lower joint bound are described in Technical reference manual System parameters Adjust the software working range limitations system parameter configuration to corres pond to the mechanical limitations 3 WARNING If the mechanical stop pin is deformed after a hard collision it must be replaced Deformed movable stops and or additional s...

Page 103: ...d and Lower joint bound are described in Technical reference manual System parameters Redefine the software working range limit ations in the system parameters topic Motion The Arm parameters Upper Joint Boundand Lower Joint Bound must be changed to 3 84 respectively 3 84 The values are in radians that is 3 84 radians 220 degrees 2 Product manual IRB 6660 103 3HAC028197 001 Revision S Copyright 20...

Page 104: ...ual for the controller see document number in References on page 10 Handles power supply to and control of the external axes motors as well as feedback from the servo system External axes cables option See the Application manual Additional axes and stand alone controller M2004 see document number in Refer ences on page 10 Robot cables These cables are included in the standard delivery They are com...

Page 105: ...r static floor cables A B xx1600002016 Diameter A Diameter x10 B Grounding and bonding point on manipulator There is a grounding bonding point on the manipulator base The grounding bonding point is used for potential equalizing between control cabinet manipulator and any peripheral devices xx1600001000 Continues on next page Product manual IRB 6660 105 3HAC028197 001 Revision S Copyright 2007 2018...

Page 106: ...ered without cables If equipping the robot with cooling fans use the cabling specified below The cables for cooling fans listed below are used together with a distributing cable also specified below Connection point Art no Cable Distributing cable R1 FAN SW2 3 3HAC022723 001 Harness cooling 7 m Inside cabinet A43 X10 and A43 X11 Distributing cable R1 FAN SW2 3 3HAC022723 004 Harness cooling 15 m I...

Page 107: ...regulated with the RAPID instruction VelSet Start the robot with its normal program but with reduced speed 1 Adjusting the speed and acceleration during warm up Depending on how cold the environment is and what program is being used the speed might need to be ramped up until reached maximum The table shows examples of how to adjust the speed Speed velocity AccSet Work cycles v100 100 mm s 20 20 3 ...

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Page 109: ...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 19 before performing any service work Note If t...

Page 110: ...alue is given for a typical work cycle but the value will differ depending on how hard each part is run The SIS used in M2004 is further described in the Operating manual Service Information System Overhaul Depending on application and operational environment a complete overhaul may be necessary in average around 40000 hours ABB Connected Services and its Assessment tools can help you to identify ...

Page 111: ... page 169 Robot Cleaning Every 12 months Oil level in axis 1 gearbox Inspection Every 12 months Oil level in axis 2 gearbox Inspection Every 12 months Oil level in axis 3 gearbox Inspection Every 12 months Oil level in axis 4 gearbox Inspection Every 12 months Oil level in axis 5 gearbox Inspection Every 12 months Oil level in axis 6 gearbox Inspection Every 6 months Balancing device Inspection Ev...

Page 112: ...he 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 d...

Page 113: ...e for the balancing device is based on a test cycle of 4 000 000 cycles that starts from the initial position and goes to maximum extension and back Deviations from this cycle will result in differences in expected life v Depending on application the lifetime can vary The Service Information System SIS that is integrated in the robot software can be used as guidance when planning gearbox service f...

Page 114: ...l plug filling C Motor axis 1 D Drain hose Behind cover E Required equipment Note Art no Equipment Note Do not mix with other oils See Type and amount of oil in gearboxes on page 144 Lubricating oil Content is defined in section Standard tools on page 381 Standard toolkit Continues on next page 114 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 3 Main...

Page 115: ... the robot working area 2 This is a precaution to reduce the temperature dependency of the measurement Make sure that the oil temperature is 25 C 10 C 3 Shown in figure Location of gear box on page 114 Open the oil plug inspection 4 A B C xx1400002785 A Oil plug hole B Required oil level C Gearbox oil Measure the oil level Required oil level max 10 mm below the oil plug hole 5 Where to find type o...

Page 116: ...tational center underneath the motor attachment xx0500002482 Gearbox axis 2 A Oil plug draining B Oil plug filling C Ventilation hole gearbox axis 2 D Continues on next page 116 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 3 Maintenance 3 3 2 Inspecting oil level gearbox axes 2 3 ...

Page 117: ...ocedures may be required See references to these procedures in the step by step instructions below Inspecting oil level gearbox 2 3 Use this procedure to inspect the oil level in gearbox axes 2 3 Note Action WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety inform ation in the section Safety risks during work with gearbox lubricants oil or grease o...

Page 118: ...level at the oil plug filling 4 Required oil level max 5 mm below oil plug hole Art no is specified in Required equipment on page 117 Add oil if required 5 Filling of oil is detailed further in section Changing oil gearbox axes 2 and 3 on page 149 Tightening torque 24 Nm Refit oil plug filling 6 118 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 3 Mai...

Page 119: ...unt of oil in gearboxes on page 144 Lubricating oil Content is defined in section Stand ard tools on page 381 Standard toolkit These procedures include refer ences to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page Product manual IRB 6660 119 3HAC028197 001 Revision S Copyright 2007 2018 ...

Page 120: ...obot working area 3 This is a precaution to reduce the tem perature dependency of the measure ment Make sure that the oil temperature is 25 C 10 C 4 Shown in the figure Location of gear box on page 119 Open the oil plug filling and inspection 5 A B C xx1400002785 A Oil plug hole B Required oil level C Gearbox oil Measure the oil level Required oil level 0 10 mm 6 Where to find type of oil and tota...

Page 121: ...res include refer ences to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Inspecting the oil level in axis 5 gearbox Use this procedure to inspect the oil level in the axis 5 gearbox Note Action WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety inform ation in ...

Page 122: ...on of gearbox on page 121 Open the oil plug filling and inspection 6 xx0500002222 Measure the oil level Required oil level to the upper edge of the filling and inspection oil plug hole a 30 mm 7 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 144 Adjust the oil level if required 8 Further information about how to fill the oil may be found in th...

Page 123: ... Cooling element IRB 6660 100 3 3 and IRB 6660 130 3 1 E Required equipment Note Art no Equipment See Type and amount of oil in gearboxes on page 144 Lubricating oil Content is defined in section Standard tools on page 381 Standard toolkit These procedures include refer ences to the tools required Other tools and procedures may be required See references to these procedures in the step by step ins...

Page 124: ...perature dependency of the measurement Make sure that the oil temperature is 25 C 10 C 4 xx1300002447 Remove the oil plug filling and inspection 5 Slowly turn axis 4 until the axis 4 angle reads 72 5 to 77 5 6 A B C xx1400002786 A Oil plug hole B Required oil level C Gearbox oil Inspect the oil level in the hole for the oil plug filling and inspection The oil should reach all the way up to the ext...

Page 125: ... in the section Filling oil axis 6 on page 160 Tightening torque 24 Nm Refit the oil plug 9 WARNING Do not mix oil types If wrong oil is refilled the gearbox must be rinsed as detailed in Technical reference manual Lubrication in gearboxes 10 Product manual IRB 6660 125 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 3 Maintenance 3 3 5 Inspecting the oil level in axis 6 gear...

Page 126: ...Guide ring not visible in this figure C Required equipment Note Art no Equipment 3HAB3537 1 Grease Loctite 243 Locking liquid 3HAC5276 1 Auxiliary shaft upper 3HAC5275 1 Auxiliary shaft lower Content is defined in section Standard tools on page 381 Standard toolkit Continues on next page 126 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 3 Maintenance...

Page 127: ...e entering the robot working area 2 xx0500002496 Remove locknuts KM10 sealing rings and support washers 3 A Ear adjustable needle bearing located inside B Support washer C Lock nut KM10 with sealing ring D Piston rod E Guide ring not visible in this view F Inner ring Art no is specified in Required equipment on page 126 Fit the auxiliary shafts on upper and lower axes of balancing device The shaft...

Page 128: ...earings support washers and sealing rings 9 Detailed in section Replacing the balancing device on page 266 If any of the parts looks abnormal re place 10 Lubricate the shafts if needed 11 Make sure that the inner support washers and sealing rings get in the correct position Push the cylinder back in 12 Remove the auxiliary shafts 13 Note Don t forget to remove the screw If the screw isn t removed ...

Page 129: ...e robot air pressure supply to the robot Before entering the robot working area 2 xx0600002689 Check the guide ring for wear Replace if necessary 3 A Guide ring B Circlip Note If there is a risk of metallic contact between the piston rod and the end cover the guide ring must be replaced 4 Product manual IRB 6660 129 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 3 Maintenanc...

Page 130: ... as shown in the figures below xx0700000022 Cable guide axis 2 A Metal clamp 4 pcs B Connectors at base C Cable guide D Cable harness E Continues on next page 130 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 3 Maintenance 3 3 7 Inspection cable harness ...

Page 131: ...xis 1 A Cable gland SMB unit B Cable guide axis 2 C Continues on next page Product manual IRB 6660 131 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 3 Maintenance 3 3 7 Inspection cable harness Continued ...

Page 132: ...e harness Content is defined in section Standard tools on page381 Standard toolkit These procedures include references to the tools re quired Other tools and procedures may be re quired See references to these proced ures in the step by step instructions be low See chapter Circuit diagram on page 389 Circuit diagram Continues on next page 132 Product manual IRB 6660 3HAC028197 001 Revision S Copyr...

Page 133: ...n page 130 Check the metal clamps at the rear of the upper arm and in the upper arm tube 4 Check that the velcro straps and the mounting plate are properly attached to the frame 5 Check the cabling leading into the lower arm Make sure it is attached by the straps and not damaged 6 Detailed in sections Replacement of cable harness lower end axes 1 3 on page181 and Replacement of cable harness upper...

Page 134: ...temperature 2 pcs A Warning label symbol of flash located on motor cover 2 pcs B Instruction label C Instruction label concerning lifting the robot E Warning label concerning risk of tipping F Information labels at gearboxes and at robot base specifying which oil is used in gearboxes Continues on next page 134 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights res...

Page 135: ...ed tools and equipment Visual inspection no tools are required Inspecting labels Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Inspect the labels located as shown in the figures 2 Article numbers for the labels and plate set is specified in Spare part lists on page 387 Replace any missing or...

Page 136: ...equired equipment Visual inspection no tools are required Inspecting mechanical stop pin Use this procedure to inspect the axis 1 mechanical stop pin Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Continues on next page 136 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018...

Page 137: ...te The expected life of gearboxes can be reduced after collision with the mechanical stop Make sure the mechanical stop pin can move in both directions 3 Product manual IRB 6660 137 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 3 Maintenance 3 3 9 Inspecting the axis 1 mechanical stop pin Continued ...

Page 138: ... pin B Required equipment Note Article number Equipment etc Limits the robot working range by 7 5 3HAC11076 1 Mechanical stop axis 1 Limits the robot working range by 15 3HAC11076 2 Mechanical stop axis 1 Content is defined in section Standard tools on page 381 Standard toolkit Continues on next page 138 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved ...

Page 139: ...e sure no additional stops are damaged 2 Make sure the stops are properly attached 3 Correct tightening torque additional mechanical stops Axis 1 120 Nm Article number is specified in Required equipment on page138 If any damage is detected the mechanical stops must be replaced Correct attachment screws Axis 1 M16 x 35 quality 12 9 4 Product manual IRB 6660 139 3HAC028197 001 Revision S Copyright 2...

Page 140: ... Not visible in this view C Damper 1 pcs D Damper axis 4 1 pcs inside armhouse E Damper axis 5 2 pcs F Required equipment A damper must be replaced if damaged Note Spare part art no Equipment 3HAC12991 1 Damper axis 2 3HAC022338 001 Damper 3HAC022339 001 Damper Content is defined in section Standard tools on page 381 3HAC15571 1 Standard toolkit Continues on next page 140 Product manual IRB 6660 3...

Page 141: ...on page 140 Check all dampers for damage and for cracks or existing impressions larger than 1 mm To inspect the damper axis 4 remove the two covers on top of the upper arm 2 Check attachment screws for deformation 3 Art no is specified in Required equipment on page 140 If any damage is detected the damper must be re placed with a new one 4 Product manual IRB 6660 141 3HAC028197 001 Revision S Copy...

Page 142: ...amage 3HAC028196 001 Signal lamp Content is defined in section Stand ard tools on page 381 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Inspecting signal lamp Use this procedure to inspect the function of the signal lamp Note Action Check that signal la...

Page 143: ...ment on page 142 If the lamp is not lit trace the fault by Checking whether the signal lamp is broken If so replace it Checking cable connections Measuring the voltage in connectors motor axis 3 24V Checking the cabling Replace cabling if a fault is detected 3 Product manual IRB 6660 143 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 3 Maintenance 3 3 12 Inspecting signal la...

Page 144: ...siness Portal www mypo rtal abb com Before starting any inspection maintenance or changing activities of lubrication always contact the local ABB Service organization for more information For ABB personnel Always check ABB Library for the latest revision of the manual Technical reference manual Lubrication in gearboxes in order to always get the latest information of updates about lubrication in g...

Page 145: ...with outlet pipe Oil dispenser Use the suggested dispenser or a similar one Orion OriCan article number 22590 pneumatic Nipple for quick connect fitting with o ring Product manual IRB 6660 145 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 3 Maintenance 3 4 1 Type of lubrication in gearboxes Continued ...

Page 146: ... A Gearbox axis 1 B Oil plug filling C Motor axis 1 D Drain hose E Required equipment Note Amount Art no Equipment etc Note Do not mix with other oils See Type and amount of oil in gear boxes on page 144 See Type and amount of oil in gearboxes on page 144 Lubricating oil Capacity 8 000 ml Oil collecting vessel Continues on next page 146 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2...

Page 147: ... Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section Safety risks during work with gearbox lubricants oil or grease on page 38 2 Remove rear cover on the base by unscrewing its attachment screws 3 xx0200000237 Pull out the draining hose from the rear of the base 4 The hose is located beneath the base seen from below A Oil draining ...

Page 148: ... area 1 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section Safety risks during work with gearbox lubricants oil or grease on page 38 2 Shown in figure Location of oil plugs on page 146 Open the oil plug filling 3 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 144 Refil...

Page 149: ...or attachment The figure shows the position of gearbox axis 2 xx0500002482 Gearbox axis 2 A Oil plug draining B Oil plug filling C Ventilation hole plug gearbox axis 2 D Continues on next page Product manual IRB 6660 149 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 3 Maintenance 3 4 3 Changing oil gearbox axes 2 and 3 ...

Page 150: ...s on page 144 See Type and amount of oil in gearboxes on page 144 Lubricating oil Capacity 6 000 ml Oil collecting vessel Content is defined in section Special tools on page 382 3HAC021745 001 Oil exchange equip ment Content is defined in section Standard tools on page 381 Standard toolkit Continues on next page 150 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All righ...

Page 151: ...on page 149 Remove the oil plug draining and drain gear box using a hose with a nipple and an oil col lecting vessel 4 Vessel capacity is specified in Re quired equipment on page 150 Draining is time consuming Elapsed time varies depending on the temperature of the oil Tightening torque 24 Nm Refit the oil plug draining 5 Filling axes 2 and 3 Use this procedure to fill gearboxes of axes 2 and 3 wi...

Page 152: ...g torque 24 Nm Note Don t mix Kyodo Yushi TMO 150 with other oil types 4 Art no and total amount are specified in Required equipment on page 150 Refill gearbox with lubricating oil The amount of oil to be filled depends on the amount that was previously drained 5 Shown in Location of oil plugs on page 149 Refit oil plug filling and ventilation hole plug 6 Tightening torque 24 Nm 152 Product manual...

Page 153: ...of oil in gear boxes on page 144 See Type and amount of oil in gearboxes on page 144 Lubricating oil Content is defined in section Special tools on page 382 3HAC021745 001 Oil exchange equipment Capacity 9 000 ml Oil collecting vessel Content is defined in section Standard tools on page 381 Standard toolkit Continues on next page Product manual IRB 6660 153 3HAC028197 001 Revision S Copyright 2007...

Page 154: ... the oil from the gearbox into a vessel by opening the oil plug draining 5 Vessel capacity is specified in Re quired equipment on page 153 This is detailed in section Synchroniz ation marks and synchronization pos ition for axes on page 345 Run the upper arm back to its calibration posi tion horizontal position 6 Tightening torque 24 Nm Refit the oil plug draining 7 Filling oil The procedure below...

Page 155: ...53 Refill the gearbox with clean lubricating oil The correct oil level is detailed in section In specting the oil level in axis 4 gearbox on page 119 3 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 144 Tightening torque 24 Nm Refit the oil plug filling 4 Product manual IRB 6660 155 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights ...

Page 156: ...3HAC021745 001 Oil exchange equipment Capacity 7 000 ml Oil collecting vessel Content is defined in sec tion Standard tools on page 381 Standard toolkit Draining oil axis 5 The procedure below details how to change the oil in gearbox axis 5 When using the oil exchange equipment follow the instructions enclosed with the kit Art no for the kit is specified in Required equipment on page 156 Note Acti...

Page 157: ...l axis 5 The procedure below details how to change the oil in gearbox axis 5 When using the oil exchange equipment follow the instructions enclosed with the kit Art no for the kit is specified in Required equipment on page 156 Note Action Run axis 4 to a position where the oil plug filling is facing upwards 1 WARNING Handling gearbox oil involves several safety risks Before proceeding please read ...

Page 158: ...ing the oil level in axis 5 gearbox on page 121 4 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 144 Tightening torque 24 Nm Refit the oil plug filling 5 158 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 3 Maintenance 3 4 5 Changing oil axis 5 gearbox Continued ...

Page 159: ...Cooling elements IRB 6660 100 3 3 IRB 6660 130 3 1 E Required equipment Note Amount Art no Equipment etc Note Do not mix with other oils See Type and amount of oil in gearboxes on page 144 See Type and amount of oil in gearboxes on page 144 Lubricating oil Content is defined in section Special tools on page 382 3HAC021745 001 Oil exchange equip ment Vessel capacity Oil collecting vessel 500 ml Con...

Page 160: ... lubricants oil or grease on page 38 3 Vessel capacity is specified in Re quired equipment on page 159 Drain the oil from the gearbox into a vessel by removing the oil plug 4 The amount of oil to be refilled de pends on the amount previously drained Measure the amount of oil drained Tightening torque 24 Nm Refit the oil plug draining 5 Filling oil axis 6 The procedure below details how to fill oil...

Page 161: ...d total amount is detailed in Type and amount of oil in gearboxes on page 144 Refill the gearbox with clean lubricating oil The correct oil level is detailed in section Inspect ing the oil level in axis 6 gearbox on page 123 4 Tightening torque 24 Nm Refit the oil plug 5 Detailed in the section Inspecting the oil level in axis 6 gearbox on page 123 Inspect the oil level Product manual IRB 6660 161...

Page 162: ...week or 18 months if the robot is powered off 16 h day The lifetime can be extended for longer production breaks with a battery shutdown service routine See Operating manual IRC5 with FlexPendant for instructions WARNING See instructions for batteries Safety risks during handling of batteries on page37 Location of SMB battery The SMB battery SMB serial measurement board is located on the left hand...

Page 163: ...r the battery It is important that the SMB unit uses the correct battery Make sure to order the correct spare parts Do not exchange battery contacts Note Spare part no Equipment etc Battery includes protection circuits Only re place with a specified spare part or an ABB approved equivalent For spare part no see Spare part lists on page 387 Battery unit Content is defined in section Standard tools ...

Page 164: ...ver by unscrewing the attachment screws CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures 4 Shown in figure Location of SMB battery on page 162 Pull out the battery and disconnect the battery cable 5 Shown in figure Location of SMB battery on page 162 Remove the SMB battery Battery includes protection circu...

Page 165: ... page 162 A B D C xx1300000307 A Battery pack RMU B Battery holder C Battery cable D Strap Strap the battery cable to the holder Shown in figure Location of SMB battery on page 162 Secure the SMB battery cover with its attachment screws 4 Detailed in chapter Calibration section Updating revolution coun ters on page 348 Update the revolution counters 5 DANGER Make sure all safety requirements are m...

Page 166: ...the balancing device Location of bearing and piston rod This figure shows the location of bearings and piston rod Note Balancing device must be fitted on robot when lubricating bearings xx0500002489 Ear bearing located inside A Support washer B Continues on next page 166 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 3 Maintenance 3 5 1 Lubricating ba...

Page 167: ...ngs Note Action Move axis 2 to calibration position 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 Be careful not to loose the sup port washer in the process Remove locknut 3 Fit the lubricating tool It should be tightened to the bottom by hand only 4 Grease through nipple on ...

Page 168: ... device is in horizontal position and the piston rod extended as much as possible 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 Clean piston rod with isopropanol before applying new grease 3 Type of grease is specified in Required equipment on page167 Apply new grease 4 168 P...

Page 169: ... activities on page 114 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 ...

Page 170: ...r cleaner 1 The following list defines the prerequisites Maximum water pressure at the nozzle 700 kN m2 7 bar I Fan jet nozzle should be used min 45 spread Minimum distance from nozzle to encapsulation 0 4 meters Maximum flow 20 liters minI I Typical tap water pressure and flow Instructions for steam or high pressure water cleaning ABB robots with protection types Foundry Plus Wash or Foundry Prim...

Page 171: ...ooling fans Inspect the air supply inlet of the the motor cooling fans Clean to remove any contamination that could hinder the air supply Product manual IRB 6660 171 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 3 Maintenance 3 6 1 Cleaning the IRB 6660 Continued ...

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Page 173: ...perform a specific repair activity are listed in the respective procedures The details of equipment are also available in different lists in the chapter Reference information on page 373 Safety information There are general safety information and specific safety information The specific safety information describes the danger and safety risks while performing specific steps in a procedure Make sur...

Page 174: ...he pressure must under no circumstance be higher than 0 25 bar 20 25 kPa Also during the time when the pressure is raised 3 0 2 0 25 bar 20 25 kPa Disconnect the compressed air supply 4 If the compressed air is signific antly colder or warmer than the gearbox to be tested a slight pressure increase or decrease may occur This is quite normal Wait for approximately 8 10 minutes and make sure that no...

Page 175: ...o any stresses during the assembly work 3 Assembly of tapered bearings Follow the preceding instructions for the assembly of the bearings when mounting a tapered bearing on the robot In addition to those instructions the following procedure must be carried out to enable the roller elements to adjust to the correct position against the race flange Note Action Tension the bearing gradually until the...

Page 176: ...arted During operation the bearing should be filled to 70 80 of the available volume Ensure that grease is handled and stored properly to avoid contamination Grease the different types of bearings as following description Grooved ball bearings must be filled with grease from both sides Tapered roller bearings and axial needle bearings must be greased in the split condition 176 Product manual IRB 6...

Page 177: ... correct type provided with cutting edge There is no damage to the sealing edge feel with a fingernail 1 Inspect the sealing surface before mounting If scratches or damage are found the seal must be replaced since it may result in future leakage 2 Article number is specified in Equipment on page177 Lubricate the seal with grease just before fitting Not too early there is a risk of dirt and foreign...

Page 178: ...nly when fastening the flange joint 4 O rings The following procedure describes how to fit o rings Note Action Ensure that the correct o ring size is used 1 Defective o rings including damaged or deformed o rings may not be used Check the o ring for surface defects burrs shape accuracy or deformation 2 Defective o rings may not be used Check the o ring grooves 3 The grooves must be geometrically c...

Page 179: ...52 001 Touch up paint Standard Foundry Plus ABB Orange Removing Description Action xx0900000121 Cut the paint with a knife in the joint between the part that will be removed and the struc ture to avoid that the paint cracks 1 Carefully grind the paint edge that is left on the structure to a smooth surface 2 Product manual IRB 6660 179 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights re...

Page 180: ...e to the robot Elimination To eliminate the danger after service work has been performed inside the SMB recess follow the procedure below Action Make sure the power is turned off 1 Remove the push button guard if necessary 2 Verify that the push buttons of the brake release unit are working by pressing them down one by one 3 Make sure none of the buttons are jammed in the tube If a button gets jam...

Page 181: ...ection Replacement of cable harness upper end on page 196 Location of cable harness lower end axes 1 3 The cable harness lower end axes 1 3 is located throughout the base frame and lower arm as shown in the figure below xx0700000070 Cable guide axis 2 A Metal clamp B Connector at base C Cable guide axis 1 D Cable harness axes 1 6 E Cover plate F Rear cover plate G Continues on next page Product ma...

Page 182: ...age 387 Cable harness axes 1 6 Motor axes 1 5 3HAC3537 1 Gasket Content is defined in sec tion Standard tools on page 381 Standard toolkit These procedures include references to the tools re quired Other tools and pro cedures may be re quired See refer ences to these pro cedures in the step by step instructions below See chapter Circuit dia gram on page 389 3HAC025744 001 Circuit diagram Continues...

Page 183: ... of cable harness lower end axes 1 3 on page 181 Disconnect the earth cable 4 Shown in Location of cable harness lower end axes 1 3 on page 181 Disconnect connectors R1 MP and R1 SMB 5 xx0600002698 A Cable guide ax 2 Remove the cable guide axis 2 6 Shown in Location of cable harness lower end axes 1 3 on page 181 Unscrew the screws in the metal clamps holding the cable harness in the frame and low...

Page 184: ...B SMB battery pack C Battery cable Disconnect connectors R2 SMB R1 SMB1 3 R1 SMB4 6 from the SMB unit 11 Disconnect X8 X9 and X10 from the brake re lease unit xx0600002701 Remove the cable gland SMB by removing its four attachment screws from inside the SMB recess Perform this removal with care in order not to damage any of the components inside the SMB recess 12 A Cable gland SMB B Attachment scr...

Page 185: ...mp frame C Cable guide axis 1 Detailed in Replacement of cable har ness upper end on page 196 Continue removal of the cable harness in the upper arm 14 Continues on next page Product manual IRB 6660 185 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 3 1 Replacement of cable harness lower end axes 1 3 Continued ...

Page 186: ... B Metal clamp frame C Cable guide axis 1 xx0600002701 Pull out the cables and connectors to the SMB unit through the frame and refit the cable gland with its four attachment screws from inside the SMB recess Perform this refitting with care in order not to damage any of the components inside the SMB recess 2 A Cable gland SMB B Attachment screws 4 pcs Continues on next page 186 Product manual IRB...

Page 187: ...e sure the cabling is placed correctly when refitting the cover and does not get jammed Reconnect connectors R2 SMB R1 SMB1 3 R1 SMB4 6 to the SMB unit 8 Reconnect X8 X9 and X10 to the brake release unit Reconnect R1 G if it has been disconnected Secure the SMB cover with its attachment screws 9 If cabling is used for 7th axis option refit the connector R2 FB7 to the SMB cover and tighten with 6 N...

Page 188: ...of cable harness upper end on page196 Continue refitting of the cable harness in the upper arm 14 Detailed in section Updating revolution counters on page 348 Update the revolution counter 15 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 28 16 188 Product manual IRB 666...

Page 189: ...n in the figure below xx0700000657 Metal clamp inside lower arm A Process cable package cables B Process cable package hose C Cable guide D Metal clamp E Connectors at base F Customer plate G Rear cover plate H Earth J Continues on next page Product manual IRB 6660 189 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 3 2 Replacement of process cable package 1 3 MH ...

Page 190: ...e package 1 3 MH Note Action Move the robot to the calibration position 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 CAUTION The cable package is sensitive to mechanic al damage They must be handled with care especially the connectors in order to avoid damaging them 3 Shown in the figure Location of process cable package axes 1 3 MH on page189 Remov...

Page 191: ...ROC1 xx0700000645 Disconnect the cable connectors from the customer plate 6 Parts A Connector R1 CP CS B Connector R1 SP R3 FP7 Continues on next page Product manual IRB 6660 191 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 3 2 Replacement of process cable package 1 3 MH Continued ...

Page 192: ...nuts Order of removal 1 Hose 2 Cables Pull the lower end of the process cable package out through the centrum hole in gearbox axis 1 8 xx0700000649 Remove the prev torque nuts securing the process cable package on the inside of the lower arm 9 Parts A Position for prev torque nuts B Process cable package Continues on next page 192 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 20...

Page 193: ...the lower arm 11 Refitting The procedure below details how to refit the process cable package 1 3 MH Note Action Make sure that the cables are not twisted with each other Note Perform this carefully in order not to damage the cable harness of the robot Push the process cable package gently down through the lower arm 1 Continues on next page Product manual IRB 6660 193 3HAC028197 001 Revision S Cop...

Page 194: ...able package on the inside of the lower arm 3 Parts A Position for prev torque nuts B Process cable package Order of refitting 1 Cables 2 Hose Push the process cable package gently down through the cable guide in the centrum hole in gearbox axis 1 4 Continues on next page 194 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 3 2 Replacement of...

Page 195: ...mer plate 6 Parts A Connector R1 CP CS B Connector R1 SP R3 FP7 Shown in the figure Location of process cable package axes 1 3 MH on page189 Refit the rear cover plate 7 Update the revolution counter 8 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page28 9 Product manual IRB...

Page 196: ...4 to 6 runs throughout the upper arm and wrist unit as shown in the figure below xx0700000071 Cable harness axes 1 6 A Cable bracket upper arm tube B Cable bracket wrist unit C Cable starps outdoor D Attachment screws cable attachment armhouse M10x16 quality 8 8 2 pcs E Attachment screw cable attachment rear M6x25 quality 12 9 Gleitmo F Required equipment Note Equipment etc See Spare part lists on...

Page 197: ...d tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating ...

Page 198: ...ng the robot working area 3 Detailed in the section Replacement of cable harness lower end axes 1 3 on page 181 Before starting the removal of the axes 4 6 cable harness first remove the cable har ness of axes 1 3 4 xx0700000140 Remove the cover wrist unit in order to reach the cable harness at axes 5 and 6 Note Foundry Plus Make sure not to lose the washers placed in the holes of the foundry gask...

Page 199: ...ation of cable harness on page 196 Disconnect all connectors at motor axis 6 R2 MP6 and R2 FB6 9 Loosen the cable bracket in the upper arm tube by undoing its two attachment screws on top of the tube 10 xx0700000072 Disconnect the two connectors R2 FB5 and R2 MP5 inside the tube 11 Parts A Motor axis 5 with connectors R4 FB5 and R4 MP5 B Connectors R2 FB5 and R2 MP5 C Upper arm tube Remove eventua...

Page 200: ...y refitting the cable harness lower end axes 1 3 1 Arrange the cable harness as shown in the figure Location of cable harness on page 196 Insert the cable harness gently from the rear into the upper arm 2 xx0700000041 Refit the cable gland securing the cables to the armhouse Make sure not to twist the harness 3 Connect the two connectors inside the up per arm tube R2 MP5 and R2 FB5 and secure the ...

Page 201: ... are visibly located at the rear of the cable hold er The third screw M4x10 is located at the bottom of the cable holder securing the carrier 8 A Cable holder B Attachment screws M6x16 quality 8 8 2 pcs C Attachment screws M4x10 quality 8 A2F securing the carrier Shown in the figure Location of cable harness on page 196 Reconnect the motor cables axis 6 R2 MP6 and R2 FB6 9 Refit cover motor axis 6...

Page 202: ...in the gasket holes 14 Foundry Plus 15 Fit the wrist cover Foundry Plus Make sure the gasket stays undamaged after fitting Replace if damaged xx1400002581 Foundry Plus Make sure the gasket on the adapter ring is undamaged Replace if damaged 16 Continues on next page 202 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 3 3 Replacement of cable...

Page 203: ... manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 20 Axis Calibration is described in Calibrat ing with Axis Calibration method on page 352 General calibration information is included in section Calibration on page 341 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may...

Page 204: ...R4 FB5 and R4 MP5 A Connectors R3 FB5 and R3 MP5 B IRB 6660 205 1 9 xx0700000632 Cable cover A Motor axis 5 with connectors R4 FB5 and R4 MP5 B Connectors R3 FB5 and R3 MP5 C Required equipment Note Spare part no Equipment See Spare part lists on page 387 Cable harness axis 5 Continues on next page 204 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 ...

Page 205: ...cover of motor axis 5 3 Disconnect all connectors at motor axis 5 4 Remove the cable gland cover at the cable exit by unscrewing its two attachment screws 5 Remove the cable axis 5 6 Refitting cabling axis 5 motor The procedure below details how to refit the cabling to the motor of axis 5 Note Action DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot air ...

Page 206: ...formation is in cluded in section Calibration on page 341 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 28 7 206 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 3 4 Replacement of cabling axis 5 motor Continued ...

Page 207: ...d its position may be found in Spare part lists on page 387 IRB 6660 100 3 3 IRB 6660 130 3 1 xx0700000073 Upper arm A Lower arm B Motor axis 1 C Frame D Base E Gearbox axis 1 F Attachment screws base M12x70 quality 12 9 Gleitmo 24 pcs G Calibration plate axis 1 H Continues on next page Product manual IRB 6660 207 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 3 5...

Page 208: ...e the complete arm system when lifting it 3HAC022637 001 Guide pins M12 x 130 Always use the guide pins in pairs In order to make the refitting easier it is recommended to use two guide pins of different lengths Notice that longer guide pins than 140 mm will not be possible to remove from the frame be cause lack of space after refitting Continues on next page 208 Product manual IRB 6660 3HAC028197...

Page 209: ... create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibrat...

Page 210: ...tering the robot work ing area 4 Detailed in section Changing oil axis 1 gearbox on page 146 Drain the oil from gearbox axis 1 5 Disconnect the cabling in the rear of the robot base and re move the cable support plate in side the base 6 How to replace the cabling is detailed in Replacement of cable harness lower end axes 1 3 on page 181 Pull the disconnected cabling up through the center of the ax...

Page 211: ...escribed in the enclosed instruction to the lifting accessory Follow the instructions before lifting IRB 6660 130 3 1 IRB 6660 100 3 3 xx0700000004 IRB 6660 205 1 9 xx0700000427 A Load hook B Swiveling lifting eyes 4 pcs C Shortening hook D Chain E Lifting eye M12 F Eye of lifting accessory I Lifting slings 4 pcs L Hook Continues on next page Product manual IRB 6660 211 3HAC028197 001 Revision S C...

Page 212: ...4 attachment screws 11 Parts A Serrated lock washer B Gearbox axis 1 C Attachment screws M12x80 Art no is specified in section Required equipment on page 208 Fit two guide pins in two oppos ite screw holes 12 CAUTION The complete arm system weighs 1330 1520 kg All lifting equipment used must be sized accordingly 13 Continues on next page 212 Product manual IRB 6660 3HAC028197 001 Revision S Copyri...

Page 213: ...ed despite earlier adjust ments The risk of damaging the interfaces is bigger if the load is lowered unbalanced 14 Refitting arm system The procedure describes how to lift and refit the complete arm system Note Action 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 1 Continues on n...

Page 214: ...ting access ory Follow the instructions before lifting IRB 6660 130 3 1 IRB 6660 100 3 3 xx0700000004 IRB 6660 205 3 1 xx0700000427 A Load hook B Swiveling lifting eyes 4 pcs C Shortening hook D Chain E Lifting eye M12 F Eye of lifting accessory I Lifting slings L Hook Continues on next page 214 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair ...

Page 215: ...Attachment holes for the guide pins M12 Lubricate the outer surface of the gearbox for easier mating of the gearbox and arm system 7 This is a complex task to be performed with utmost care in order to avoid injury or damage Look through the empty mounting hole of motor 1 to assist in aligning the assembly during refitting of the arm system 8 Lower the arm system with guidance from the guide pins p...

Page 216: ...s 1 gearbox 13 Detailed in section Replacement of cable harness lower end axes 1 3 on page181 Refit the cabling in the base 14 Detailed in section Changing oil axis 1 gearbox on page 146 Refill the gearbox with lubricating oil 15 Pendulum Calibration is described in Op erating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 16 Axis Calibration is described in ...

Page 217: ... 3 3 IRB 6660 130 3 1 F Required equipment Note Art no Equipment etc For spare part no see Spare part lists on page 387 Turning disk Must be replaced when replacing the turning disk 3HAB3772 64 1 pc 3HAB3772 61 12 pcs O ring Wrist type 2 Used to lubricate the o rings 3HAB3537 1 Grease Loctite 574 3HAC034903 001 Flange sealant Content is defined in section Standard tools on page 381 Standard toolki...

Page 218: ...area 2 Remove any equipment fitted to the turning disk 3 See section Changing oil axis 6 gear box on page 159 Drain the axis 6 gearbox 4 xx1400000994 Remove the attachment screws that secure the turning disk 5 Shown in the figure Location of turning disk on page 217 Remove the turning disk 6 Foundry Plus 7 Remove old flange sealant residues and other con tamination from the contact surfaces Contin...

Page 219: ... ring of the turning disk with grease and fit it to the turning disk Also fit the 12 o rings when refitting the attach ment screws 1 xx1400000995 Foundry Plus Apply Loctite 574 flange sealant on the contact surface 2 Continues on next page Product manual IRB 6660 219 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 4 1 Replacing the turning disk Continued ...

Page 220: ...m a leak down test of the gearbox axis 6 4 See section Changing oil axis 6 gearbox on page 159 Refill the axis 6 gearbox with oil 5 Refit any equipment removed during disas sembly to the turning disk 6 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 28 7 220 Product manua...

Page 221: ...IRB 6660 130 3 1 xx0700000069 Wrist unit A Turning disk B Cover wrist unit C Cover upper arm tube D Connectors upper arm tube with cable bracket R3 FB5 R3 MP5 E Cable bracket F Attachment point for lifting tool wrist unit G Attachment screws and washers wrist unit H Upper arm tube I Continues on next page Product manual IRB 6660 221 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights rese...

Page 222: ...in pairs 3HAC13056 3 Guide pins M12 x 200 3HAC13605 1 Lifting accessory wrist unit Content is defined in section Standard tools on page 381 Standard toolkit These procedures include refer ences to the tools required Other tools and procedures may be required See refer ences to these procedures in the step by step instructions below See chapter Circuit diagram on page 389 Circuit diagram Continues ...

Page 223: ... new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 353 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is ...

Page 224: ...of cable bracket 2 pcs C Attachment screw bottom of cable bracket Pick out the cabling from motor axis 6 and place it safely on the tube 9 Art no is specified in Required equipment on page 222 Fit the lifting accessory to the wrist unit 10 CAUTION The complete wrist unit weighs 130 kg All lift ing equipment used must be sized accordingly 11 Slightly raise the wrist unit to unload the screw joint f...

Page 225: ... safely run into the arm tube and does not get jammed 5 Shown in the figure Location of wrist unit on page 221 Reconnect the motor axis 5 by connecting the two connectors inside the upper arm tube R3 FB5 R3 MP5 and secure the cable bracket with the two attachment screws to the tube 6 Shown in the figure Location of wrist unit on page 221 Secure the wrist unit with 10 of the 12 attach ment screws a...

Page 226: ...e axis 6 motor and refit the motor cover 13 Shown in the figure Location of wrist unit on page 221 Refit the cover upper arm tube 14 Shown in the figure Location of wrist unit on page 221 Refit the cover wrist unit 15 Tightening torque 14 Nm 10 Screw 3HAB3409 25 with Loctite Washer 3HAC062379 001 Pendulum Calibration is described in Operating manual Calibration Pendu lum enclosed with the calibrat...

Page 227: ... below IRB 6660 100 3 3 IRB 6660 130 3 1 xx0700000059 Upper arm A Motor axis 4 B Balancing device C Lower arm D Parallel rod E Continues on next page Product manual IRB 6660 227 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 4 3 Replacement of upper arm ...

Page 228: ...0636 Upper arm A Upper arm B Lower arm C Parallel rod D Continues on next page 228 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 4 3 Replacement of upper arm Continued ...

Page 229: ...30 3 1 xx0700000058 Shaft axis 2 A Shaft axis 3 B Set screw cup point M10 x 20 quality 45H A3F C Lubricant paste Molycote 1000 D Sealing ring V ring E Sealing ring F Taper roller bearing G O ring H Sealing ring I Sealing assembly J Lock nut KM12 K O ring Di 54 2 mm t 5 7 mm L Continues on next page Product manual IRB 6660 229 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 ...

Page 230: ...ote 1000 D Sealing ring V ring E Sealing ring F Taper roller bearing G O ring H Sealing ring I Sealing assembly including support ring J Lock nut KM12 K O ring Di 54 2 mm t 5 7 mm L Continues on next page 230 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 4 3 Replacement of upper arm Continued ...

Page 231: ... Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proce...

Page 232: ... to a horizontal position Rotate axis 4 so that the attachment hole for lifting eye is facing upwards 3 IRB 6660 205 1 9 42 xx0700000518 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 4 Secure the upper arm with lifting slings in an overhead crane 5 Continues on next page 232 Product manual IRB 6660 3HAC02...

Page 233: ...he set screw C holding the shaft 13 Shown in the figure View of the assembly of the upper arm components on page229 Remove the shaft axis 3 B 14 Perform the removal with care Threads can otherwise be damaged Shown in the figure View of the assembly of the upper arm components on page229 Then remove the shaft axis 2 A in the same order 1 Remove the lock nut K 2 Remove the set screw C holding the sh...

Page 234: ...preventive on the surfaces on the shaft according to illustration Note Apply rust preventive to the shafts on both sides of the robot 5 Refitting upper arm The procedure below details how to refit the upper arm Note Action Secure the upper arm with lifting slings in an overhead crane 1 CAUTION The complete upper arm weighs 380 kg without any additional equipment fitted Use a suitable lifting acces...

Page 235: ...d in Required equipment on page 231 Secure the shaft Tightening torque 400 Nm 6 Shown in the figure View of the assembly of the upper arm components on page229 Refit the sealing ring F on the shaft 7 Shown in the figure View of the assembly of the upper arm components on page229 Refit the bearing G on the shaft with the pressing tool upper arm 8 Shown in the figure View of the assembly of the uppe...

Page 236: ...ng torque of 300 Nm 2 Unscrew the lock nut 3 Fit the lock nut once again This time with a tightening torque of 90 Nm Shown in the figure View of the assembly of the upper arm components on page229 Apply locking liquid in the holes for the set screws C and fit the screws 14 Loctite 243 Tightening torque 35 Nm Wipe residual grease from the shafts 15 Detailed in section Replacing the parallel rod on ...

Page 237: ...forming the first test run These are further detailed in the section First test run may cause injury or damage on page28 20 Product manual IRB 6660 237 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 4 3 Replacement of upper arm Continued ...

Page 238: ...r spare part no see Spare part lists on page 387 Parallel rod 3HAC5021 1 Mounting Demounting tool Loctite 243 3HAB7116 1 Locking liquid Mercasol 3110 Waxcoat 3HAC034903 001 Rust preventive F21 28x22 4x12x9 3HAC4836 2 Protection plug Content is defined in section Standard tools on page 381 Standard toolkit Continues on next page 238 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2...

Page 239: ...h ends of the parallel rod Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 CAUTION Secure the upper arm with a roundsling in an overhead crane or similar in order to avoid accidents 2 Foundry Plus 3 Remove the protection plugs Continues on next page Product manual IRB 6660 239 3HAC028197 001 R...

Page 240: ...38 xx0700000065 Parts A Shaft B Cover washer C Parallel rod D Sealed spherical bearing E Bearing grease F Thrust washer Remove the upper shaft A and cover washer B using the fitting removing tool 5 See figure above Remove the thrust washer F 6 Continues on next page 240 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 4 4 Replacing the parall...

Page 241: ... above Replace the bearings D if necessary 12 Refitting parallel rod Use this procedure to refit the parallel rod The procedure is the same in both ends of the parallel rod Note Action Start by refitting the lower end 1 Verify that the bearings are in correct posi tion in the parallel rod 2 CAUTION The parallel rod weighs 45 kg All lifting accessories used must be sized accordingly 3 Lift the para...

Page 242: ...ied in Required equip ment on page 238 Refit the shaft A by pressing it through the parallel bar with the fitting removing tool 8 See figure above Loctite 243 Apply locking liquid in the hole of the lock screw 9 xx0700000066 Parts A Lock screw M6x16 upper B Lock screw M6x16 lower Refit the lock screw and plain washer 10 Continues on next page 242 Product manual IRB 6660 3HAC028197 001 Revision S C...

Page 243: ...Plus 13 Refit the protection plugs DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page28 14 Product manual IRB 6660 243 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 4 4 Replacing the parallel rod Continued ...

Page 244: ...Spare part lists on page 387 Lower arm Always change the sealing Sealing axes 2 3 Used to keep the axes 2 3 sealing in place during refitting of lower arm 3HAC14446 1 Guide sleeves 3HAC023132 001 Crank M16x90 Lock screw 3HAC8446 1 Lifting tool lower arm com plete Continues on next page 244 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 4 5 ...

Page 245: ...rence values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine ...

Page 246: ...cted from oil spill and damage See Replacement of upper arm on page 227 Remove the complete upper arm 7 See Replacing motors axes 2 and 3 on page 281 Remove the axes 2 and 3 motors 8 See Replacing the gearbox axes 2 3 on page 324 Remove the axes 2 and 3 gearboxes 9 CAUTION The robot lower arm weighs 160 kg IRB 6660 100 3 3 IRB 6660 130 3 1 110 kg IRB 6660 205 1 9 All lifting accessories used must ...

Page 247: ...parallel arm to the lower arm before lifting the lower arm system If not secured the parallel arm can fall down and cause a serious accident 14 CAUTION The parallel arm system weighs 92 kg All lifting accessories used must be sized accord ingly 15 Continues on next page Product manual IRB 6660 247 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 4 5 Replacing the co...

Page 248: ... and parallel arm together with help of an iron bar or similar before remov ing them 17 CAUTION The robot lower arm weighs 160 kg IRB 6660 100 3 3 IRB 6660 130 3 1 110 kg IRB 6660 205 1 9 All lifting accessories used must be sized accord ingly 18 xx1000001358 Remove the complete lower arm including the parallel arm 19 Continues on next page 248 Product manual IRB 6660 3HAC028197 001 Revision S Cop...

Page 249: ...Specified in Required equipment on page 244 Fit a lifting tool lower arm complete to the lower arm system and lift it up DANGER Secure the parallel arm to the lower arm before lifting the lower arm system If not secured the parallel arm can fall down and cause a serious accident 3 Art no is specified in Required equipment on page 244 xx1000001368 Fit two guide sleeves for the axes 2 3 sealings to ...

Page 250: ... on the axis 2 side 8 Tightening torque M12 120 Nm Push the parallel arm against the axis 3 side with the help of an iron bar or similar 9 Tightening torque M12 120 Nm Refit all screws and washers that are possible to fit on the axis 3 side Note The axis 3 side has no M16 screws 10 Remove the guide sleeves and secure two screws more 11 Change the position of the lower arm in order to reach the rem...

Page 251: ...applicable to robot variant IRB 6660 205 1 9 Refit the balancing device 19 Remove the lock screw 20 Pendulum Calibration is described in Operating manual Calibration Pen dulum enclosed with the calibration tools Recalibrate the robot 21 Axis Calibration is described in Calib rating with Axis Calibration method on page 352 General calibration information is in cluded in section Calibration on page ...

Page 252: ...ipment Note Art no Equipment etc For spare part no see Spare part lists on page 387 Parallel arm D 120 mm T 12 mm 3HAA2166 23 VK cover D 35 mm T 8 mm 3HAA2166 18 VK cover 3HAB3537 1 Bearing grease Mercasol 3110 Waxcoat 3HAC034903 001 Rust preventive 3HAC023092 001 Pressing tool lower arm Continues on next page 252 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights...

Page 253: ...e FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Re...

Page 254: ...ge 244 Remove the complete lower arm 3 xx1000001024 Put the complete lower arm on a workbench as shown in the figure Tip Removal of the parallel arm is best performed on a workbench 4 xx1000001371 Remove the two VK covers 5 Continues on next page 254 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 4 6 Replacement of parallel arm Continued ...

Page 255: ...page 252 Disassemble the parallel arm from the lower arm by using the pressing tool lower arm 7 CAUTION The parallel arm system weighs 92 kg All lifting accessories used must be sized accord ingly 8 xx1000001018 Remove the parallel arm 9 If needed change the bearings 10 Continues on next page Product manual IRB 6660 255 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair...

Page 256: ...me grease on the shafts on the parallel arm 2 xx1000001376 Refit a spacing sleeve on each shaft 3 Art no is specified in Required equipment on page 252 xx1000001377 Refit a bearing on each shaft with pressing tool lower arm 4 Continues on next page 256 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 4 6 Replacement of parallel arm Continued ...

Page 257: ...ccessory parallel arm 9 Art no is specified in Required equipment on page 252 Lift the parallel arm onto the workbench where the lower arm is placed 10 Adjust the lower arm in a way that both holes are parallel 11 Use a level xx1000001380 Apply some grease in the holes in the lower arm thick blue arrows Note Do not put grease on the surfaces for the VK covers thin red arrow 12 Continues on next pa...

Page 258: ...escribed in Operating manual Calibration Pendulum enclosed with the cal ibration tools Recalibrate the robot 17 Axis Calibration is described in Calibrating with Axis Calibration method on page 352 General calibration information is included in section Calibration on page 341 DANGER Make sure all safety requirements are met when performing the first test run These are further de tailed in the sect...

Page 259: ...es 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 Note Article number Equipment etc For spare part number see Spare part lists on page 387 SMB unit For spare part number see Spare part lists on page 387 Battery pack Continues on n...

Page 260: ...by unscrewing its attachment screws CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures 4 Use caution and remove the connectors X8 X9 and X10 from the brake release board if need of more space 5 Shown in the figure Location of SMB unit on page 259 Remove the nuts and washers from the guide pins that secure th...

Page 261: ... 259 Fit the SMB unit onto the guide pins 5 Secure the SMB unit to the pins with the nuts and washers 6 X9 X8 X10 xx1700000978 If disconnected reconnect the 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 are snapped down properly 7 Shown in the figure Location of SMB unit on page 259 Secure the SMB cover...

Page 262: ...equired equipment Note Article number Equipment etc DSQC1050 3HAC065020 001 Brake release board Content is defined in section Standard tools on page 381 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page 262 Product manual IRB 6660 3HAC...

Page 263: ...a correct refitting of the brake release board Shown in the figure Location of brake release board on page 262 Open the SMB cover by unscrewing the attach ment screws Let the battery stay connected to avoid the need of synchronization of the robot CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures 5 Take a p...

Page 264: ...ximum tightening torque 5 Nm Fasten the brake release board on the bracket with the attachment screws Make sure the board is positioned as straight as possible on the bracket The push buttons can otherwise get jammed when the SMB cover is refitted 3 Shown in the figure Location of brake release board on page 262 Art no is specified in Required equip ment on page 262 Refit the complete brake releas...

Page 265: ...e push buttons 1 to 6 one at a time to make sure that the buttons are moving freely and do not stay in a locked position 10 Detailed in the Calibration chapter section Updating revolution counters on page 348 If the battery has been disconnected the revolu tion counter must be updated 11 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed ...

Page 266: ...Piston rod B Guide ring not visible in this figure C Required equipment Note Art no Equipment etc For spare part num ber see Spare part lists on page 387 Balancing device For fitting the inner rings of the bearings 3HAC5281 1 Auxiliary shaft 3HAC5275 1 Auxiliary shaft long Continues on next page 266 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Rep...

Page 267: ...in a 90 angle from the floor in order the be lifted in the most secure way Move the robot to a position close enough to its calibration position to allow the lock screw to be inserted into the hole for the lock screw 1 See the figure in Location balancing device on page 266 xx1000001101 Lock the lower arm by inserting the lock screw into the hole CAUTION Tighten by hand 2 DANGER Turn off all elect...

Page 268: ... in the lifting ear 6 xx1000001113 Remove the upper and lower lock nuts and support washers 2 2 pcs Note Make sure that the shaft between the upper and lower arm does not rotate when unscrewing the lock nuts The lock nut is locked with Loctite 243 7 Art no is specified in Required equip ment on page 266 Fit the auxiliary shafts on the upper and lower pivot shaft Fit the short auxiliary shaft on th...

Page 269: ...0 kg All lifting accessories used must be sized ac cordingly 11 xx1000001114 With the help of the ball bearing puller carefully remove the balancing device from its upper and lower attachments 12 Remove the balancing device and put it in a safe place 13 Remove the inner rings of the bearings 14 Continues on next page Product manual IRB 6660 269 3HAC028197 001 Revision S Copyright 2007 2018 ABB All...

Page 270: ...washers in both ends 2 Refit the inner ring of the bearings on the upper and lower pivot shaft with the auxialiary shaft 3 Art no is specified in section Required equipment on page 266 Fit the auxiliary shafts on the upper and lower shafts Fit the short auxiliary shaft on the upper shaft and the longer on the lower shaft 4 Continues on next page 270 Product manual IRB 6660 3HAC028197 001 Revision ...

Page 271: ...gth between the upper and lower bearings by means of the M12 screws used to neutralize the spring force This length should preferably be 0 5 mm too short than 0 1 mm too long If the distance is too long the bearings may be damaged when erecting the balancing device 7 Continues on next page Product manual IRB 6660 271 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 ...

Page 272: ...er sealing Remove the lubricating tool and wipe off pro truding grease 11 Remove the auxiliary shafts 12 Specified in section Required equip ment on page 266 Apply locking liquid on the threads of the lock nuts 13 Tightening torque 120 Nm xx1000001113 Refit the lock nuts and support washers 14 Check play min 0 1 mm between support washers and bearing seat at both bearings 15 Continues on next page...

Page 273: ...ANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 28 18 Product manual IRB 6660 273 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 5 3 Replacing the balancing device Continued ...

Page 274: ...quired equipment Note Art no Equipment etc Includes motor pinion o ring Old o ring must be re placed when replacing the motor See spare part number in Spare part lists on page 387 Motor axis 1 Replace if damaged 21522012 430 O ring Used to lubricate the o ring 3HAB3537 1 Grease Option Foundry Plus 12340011 116 Loctite 574 Flange sealant Continues on next page 274 Product manual IRB 6660 3HAC028197...

Page 275: ...ine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibrat...

Page 276: ...land cover at the motor cable exit Note Make sure the gasket is undamaged Replace if damaged 4 Part Position of Cable gland cover Disconnect all connectors beneath the motor cover 5 Connect to connector R2 MP1 pin 2 pin 5 In order to release the brake connect the 24 VDC power supply 6 Continues on next page 276 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights re...

Page 277: ...9 xx1000001021 Remove the motor by carefully lifting it straight up to get the pinion away from gear CAUTION Be careful not to damage the pinion in the pro cess 10 Disconnect the brake release voltage 11 Check the pinion If there is any damage the pinion must be replaced 12 Foundry Plus 13 Remove old Loctite 574 flange sealant residues and other contamination from the contact sur faces on both mot...

Page 278: ...replaced when re placing the motor CAUTION The motor weighs 29 kg All lifting equipment used must be sized accordingly 2 Connect to connector R2 MP1 pin 2 pin 5 In order to release the brake connect the 24 VDC power supply 3 xx1400000986 Foundry Plus Apply Loctite 574 flange sealant on the contact surface 4 Continues on next page 278 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007...

Page 279: ...or axis 1 on page 274 Tightening torque 50 Nm Disconnect the brake release voltage 7 Reconnect all connectors beneath the motor cover 8 xx1000001094 Refit the cable gland cover at the cable exit with its attachment screws Note Make sure the cover is tightly sealed Replace gasket if damaged 9 Part Position of Cable gland cover xx1000001092 Refit the motor cover with its attachment screws Note Make ...

Page 280: ...od on page 352 General calibration information is in cluded in section Calibration on page 341 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 28 12 280 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 6 1 Replacing ...

Page 281: ...or pinion o ring the o ring must be re placed when the motor is re placed See spare part number in Spare part lists on page 387 Motor axes 2 3 Replace if damaged 21522012 430 O ring motor For lubricating the o ring 3HAB3537 1 Grease Option Foundry Plus 12340011 116 Loctite 574 Flange sealant M10x150 3HAC13120 2 Guide pins For guiding the motor Guide pins are to be used in pairs 3HAC14586 1 Lifting...

Page 282: ... the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the rob...

Page 283: ...removed DANGER Turn off all electric power hydraulic and pneu matic pressure supplies to the robot 4 Secure the upper arm with roundslings in an overhead crane 5 This is done in order to secure axis 3 from col lapsing when gearbox axis 3 is being removed See section Draining axes 2 and 3 on page 151 Drain the oil from gearbox 6 xx1000001102 Remove the motor cover 7 Continues on next page Product m...

Page 284: ...h the motor cover 9 Connect to connector R2 MP2 pin 2 pin 5 In order to release the brake connect the 24 VDC power supply 10 xx1000001104 Unscrew attachment screws and washers of the motor 11 Continues on next page 284 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 6 2 Replacing motors axes 2 and 3 Continued ...

Page 285: ... in the remaining attachment holes of the motor diagonal to each other 13 Art no is specified in Required equipment on page 281 Remove the two screws and fit the lifting tool motor axes 2 3 to the motor 14 CAUTION The motor weighs 32 kg All lifting equipment used must be sized accordingly 15 Continues on next page Product manual IRB 6660 285 3HAC028197 001 Revision S Copyright 2007 2018 ABB All ri...

Page 286: ...brake release voltage 18 Check the pinion If there is any damage the motor pinion must be replaced 19 xx1400000988 Foundry Plus Remove old Loctite 574 flange sealant residues and other contamination from the contact sur faces on both motor and gearbox 20 Continues on next page 286 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 6 2 Replacing...

Page 287: ...connector R2 MP1 pin 2 pin 5 In order to release the brake connect the 24 VDC power supply 2 Art no is specified in Required equipment on page 281 Fit the lifting tool motor axes 2 3 to the motor 3 xx1400000987 Foundry Plus Apply Loctite 574 flange sealant on the contact surface 4 Continues on next page Product manual IRB 6660 287 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserv...

Page 288: ...185 Lift the motor and guide it on to the guide pins as close to the correct position as possible without pushing the motor pinion into the gear Note Make sure the motor is turned the right way that is connections for the cables facing down wards 7 Remove the lifting tool and allow the motor to rest on the guide pins 8 Continues on next page 288 Product manual IRB 6660 3HAC028197 001 Revision S Co...

Page 289: ...or with its attachment screws and plain washers 11 M10 x 40 4 pcs Tightening torque 50 Nm Reused screws may be used provid ing they are lubricated as detailed in section Screw joints on page 377 be fore fitting Disconnect the brake release voltage 12 Connect in accordance with markings on connectors Reconnect all connectors beneath the motor cover 13 Refit the cable gland cover at the cable exit w...

Page 290: ...l the gearbox with oil 18 Pendulum Calibration is described in Operating manual Calibration Pendu lum enclosed with the calibration tools Recalibrate the robot 19 Axis Calibration is described in Calib rating with Axis Calibration method on page 352 General calibration information is in cluded in section Calibration on page 341 Continues on next page 290 Product manual IRB 6660 3HAC028197 001 Revi...

Page 291: ...ming the first test run These are further detailed in the section First test run may cause injury or damage on page 28 20 Product manual IRB 6660 291 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 6 2 Replacing motors axes 2 and 3 Continued ...

Page 292: ...ate the o ring 3HAB3537 1 Grease Option Foundry Plus 12340011 116 Loctite 574 Flange sealant Always use the removal tools in pairs 3HAC14972 1 Removal tool motor M10x For guiding the motor 3HAC15520 1 Guide pins M8 x 100 For guiding the motor 3HAC15520 2 Guide pins M8 x 150 Used to rotate the motor pinion when mating it to the gear when brakes are released with 24 VDC power supply 3HAC17105 1 Rota...

Page 293: ...ools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new...

Page 294: ...motor cover 6 Connect to connector R2 MP4 pin 2 pin 5 In order to release the brake connect the 24 VDC power supply 7 Shown in the figure Location of motor on page 292 Unscrew the motors four attachment screws and plain washers 8 Fit the two guide pins in two of the motor attachment screw holes 9 Art no is specified in Required equipment on page 292 If required press the motor out of position by f...

Page 295: ...n 2 pin 5 In order to release the brakes connect the 24 VDC power supply 3 xx1400000990 Foundry Plus Apply Loctite 574 flange sealant on the contact surface 4 Art no is specified in Required equip ment on page 292 Fit the two guide pins in two of the motor attachment holes 5 Shown in the figure Location of motor on page 292 Make sure the motor pinion does not get damaged Fit the motor with guidanc...

Page 296: ...p of the motor with its four attachment screws 12 Shown in the figure Location of motor on page 292 Refit the cable gland cover at the cable exit with its two attachment screws 13 Detailed in the section Performing a leak down test on page 174 Perform a leak down test if the gearbox has been drained 14 Refill the gearbox with oil if drained 15 Pendulum Calibration is described in Op erating manual...

Page 297: ...uipment etc For spare part number see Spare part lists on page 387 Motor Used to obtain the correct distance between motor flange and outer sur face of motor pinion 3HAC7941 28 Set of shim motor Must be replaced when reassembling motor 21522012 430 O ring For lubricating the o ring 3HAB3537 1 Grease Option Foundry Plus 12340011 116 Loctite 574 Flange sealant For cleaning motor pinion and motor pin...

Page 298: ...ls can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to...

Page 299: ...he wrist unit safely on a workbench in a fixture or similar 5 Remove the cover on top of the motor by unscrew ing its four attachment screws 6 Remove the cable gland cover at the cable exit by unscrewing its two attachment screws 7 Disconnect all connectors beneath the motor cover and remove the cable of the axis 5 motor 8 Connect to either In order to release the brake connect the 24 VDC power su...

Page 300: ...lant residues and other contamination from the contact sur faces on both motor and gearbox 15 Refitting motor axis 5 The procedure below details how to refit motor axis 5 Note Action 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 1 Art no is specified in Required equip ment on pag...

Page 301: ...age 8 Refit the cable of the axis 5 motor and recon nect all connectors beneath the motor cover 9 Refit the cable gland cover at the cable exit with its two attachment screws 10 Make sure the cover is tightly sealed Refit the cover on top of the motor with its four attachment screws 11 Detailed in the section Performing a leak down test on page 174 Perform a leak down test 12 Refit the wrist unit ...

Page 302: ... tools Re calibrate the robot 17 Axis Calibration is described in Calib rating with Axis Calibration method on page 352 General calibration information is in cluded in section Calibration on page 341 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 28 18 302 Product manual...

Page 303: ...e Art no Spare part no Equipment etc Includes motor pinion o ring See spare part number in Spare part lists on page 387 Motor axis 6 Must be replaced when reas sembling motor 21522012 430 O ring Must be replaced when repla cing motor 3HAC048560 001 Gasket Must be replaced when opening cover 3HAC033489 001 Gasket cover Always use the removal tools in pairs 3HAC14972 1 Removal tool motor M10x For gu...

Page 304: ...n might be required prior to beginning the repair work of the robot see the table Note Action 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 1 Follow the instructions given in the refer ence...

Page 305: ...rocedure 1 Move the robot to a position where the motor in axis 6 is pointed straight up This position enables the motor to be replaced without draining the gear oil which in turn saves time 2 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 3 Remove the rear motor cover by unscrewi...

Page 306: ...e special repair routines to maintain the tightness level in addition to the procedure below described in Replacement of the motor axis 6 Foundry Plus on page 308 Note Action Art no is specified in Required equipment on page 303 Make sure the o ring on the circumference of the motor is seated properly Lightly lubricate the o ring with grease 1 Connect to connector R3 MP6 pin 2 pin 5 In order to re...

Page 307: ...alibration Pen dulum enclosed with the calibration tools Re calibrate the robot 11 Axis Calibration is described in Calib rating with Axis Calibration method on page 352 General calibration information is in cluded in section Calibration on page 341 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause...

Page 308: ...sure supply to the robot Before entering the robot working area 1 xx1500002524 Remove the rear motor cover by unscrewing the five attachment screws 2 A Motor unit B Connection box C Attachment screw 5 pcs D Rear motor cover E Gasket Continue to remove the motor unit according to step 6 and forwards in Removal motor on page 305 3 Note Keep the old rear motor cover with the air nipple 4 Continues on...

Page 309: ...ket and mount it on the motor 6 A Attachment screw 4pcs Mercasol 3106 B Motor unit C O ring D Sikaflex in screw recesses E Tilt house F Washer G Rear motor cover H Sealing J Loctite 574 Apply Mercasol 3106 on the motor end cover 7 Continues on next page Product manual IRB 6660 309 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 6 5 Replacement of motor axis 6 Conti...

Page 310: ...e 8 Apply grease on the o ring on the motor 9 Continue to refit the new motor according to section Refitting motor on page 306 10 310 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 6 5 Replacement of motor axis 6 Continued ...

Page 311: ...lity 12 9 UNBRAKO 18 pcs E Required equipment Note Art no Equipment etc Includes gearbox all o rings and seal ing rings For spare part no see Spare part lists on page 387 Gearbox Replace if damaged 3HAB3772 54 O ring Replace if damaged 3HAB3772 55 O ring Replace if damaged 3HAC11581 4 Sealing ring For lubricating the o rings 3HAB3537 1 Grease Continues on next page Product manual IRB 6660 311 3HAC...

Page 312: ...hese procedures include references to the tools re quired Other tools and pro cedures may be re quired See refer ences to these pro cedures in the step by step instructions below 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 ...

Page 313: ...353 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removal gearbox axis 1 Use this procedure ...

Page 314: ...he robot before entering the robot working area 3 See Changing oil axis 1 gearbox on page 146 Drain the axis 1 gearbox 4 Detailed in section Removal arm system on page 209 Remove the complete arm system 5 Unfasten the robot base from the foundation by removing the base attachment screws 6 Continues on next page 314 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All right...

Page 315: ...ed equip ment on page 311 Lift the robot base including the axis 1 gearbox to allow the base and gear 1 sup port be fitted on each sides of the base 9 xx1000000364 A Support base 4 pcs Secure the support to the base and to the foundation Make sure the base remains in a stable position before performing any work under neath the base 10 Continues on next page Product manual IRB 6660 315 3HAC028197 0...

Page 316: ... Bottom plate B Rear connector plate C Attachment screw D Groove xx0200000227 A view from below A Oil drain hose B Attachment screws gearbox axis 1 18 pcs C Washers 3 pcs Unscrew the attachment screws and re move the washers 12 Continues on next page 316 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 gearbox Continu...

Page 317: ...gly 14 Lift the gearbox away with the already mounted lifting tools 15 xx1400000786 Turn the gearbox and remove the protec tion pipe by unscrewing two attachment screws Note Move the protective pipe over to the new gearbox 16 Continues on next page Product manual IRB 6660 317 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 gearbox Continued...

Page 318: ...t no is specified in Required equip ment on page 311 xx0200000055 A Guide pin C O ring 3HAB 3772 54 D O ring 3HAB 3772 55 E Sealing ring 3HAC 11581 4 Make sure the two o rings on the circumfer ence of the gearbox are seated properly in their respective groove Lubricate them with grease 2 Continues on next page 318 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights...

Page 319: ...in to the gearbox 4 Specified in Required equipment on page 311 Fit two guide pins in two of the attachment holes in the gearbox parallel to each other 5 CAUTION The gearbox weighs 200 kg All lifting accessories used must be sized ac cordingly 6 Continues on next page Product manual IRB 6660 319 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis...

Page 320: ...ith the base 7 xx1000001391 Always use guide pins in pairs Lift gearbox axis 1 onto the guide pins and lower it carefully to its mounting position 8 Continues on next page 320 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 gearbox Continued ...

Page 321: ...n Screw joints on page377 before fit ting xx0200000227 A view from below A Oil drain hose B Attachment screws gearbox axis 1 18 pcs C Washers 3 pcs xx1000001393 Refit the cable guide in the center of gearbox 1 with its attachment screws 10 Continues on next page Product manual IRB 6660 321 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 gea...

Page 322: ...n section Refitting arm sys tem on page 213 Refit the complete arm system CAUTION This is a complex task to be performed with utmost care in order to avoid injury or dam age 15 See section Performing a leak down test on page 174 Perform a leak down test 16 See Changing oil axis 1 gearbox on page 146 Refill the gearbox with oil 17 Pendulum Calibration is described in Operating manual Calibration Pe...

Page 323: ...ming the first test run These are further detailed in the section First test run may cause injury or damage on page 28 19 Product manual IRB 6660 323 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 gearbox Continued ...

Page 324: ... 3 Always replace 3HAC022379 001 Sealing axes 2 3 Replace if damaged 3HAB3772 127 O ring Use to lock the lower arm Lock screw M16x55 2 pcs Use to unload the balancing device Screw M12x50 2 pcs must have full thread Use to press the gearbox free from the frame Screw M12x100 Use guide pins in pairs Guide pins M12 Roundsling and a rotating lifting point Lifting accessory Lifting capacity 100 kg Used ...

Page 325: ...in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about refer...

Page 326: ...r axes to 0 Axis 2 xx1100000623 When removing axis 2 gearbox Remove all screws in the lower screw area on the inside of the lower arm 7 pcs M12 2 pcs M16 See figure When removing axis 3 gearbox Remove all screws in the upper front screw area and three screws in the upper back area 3 Axis 3 xx1100000624 Run axis 2 to 0 4 Continues on next page 326 Product manual IRB 6660 3HAC028197 001 Revision S C...

Page 327: ...o rest the weight of the axis against the lock screw 8 Release the brakes of axis 3 to rest the weight of the axis by the roundslings and overhead crane 9 xx1000001111 Remove the two plastic screws in the upper end of the balancing device Note Keep the plastic screws They will be refit ted later 10 Continues on next page Product manual IRB 6660 327 3HAC028197 001 Revision S Copyright 2007 2018 ABB...

Page 328: ...nd 3 on page 151 Note Time consuming activity Drain the gearbox 13 Remove the motor cables of axis 2 or axis 3 motor depending on which gearbox is being removed Protect the cables from getting damaged and from oil spill 14 Remove one gearbox at a time 15 Detailed in section Replacing motors axes 2 and 3 on page 281 Remove the axis 2 or axis 3 motor depend ing on which gearbox is being removed 16 x...

Page 329: ...e gearbox weighs 69 kg All lifting accessories used must be sized accordingly 22 If required apply two screws M12x100 to the holes in the gearbox in order to press it free The screws need to have a full thread 23 CAUTION When the gearbox comes free from the frame and comes off the guide pins it will tilt and there is a risk of damage to the gearbox surfaces Be aware of this and re move the gearbox...

Page 330: ...guide pins 25 xx1200000630 Remove the sealing from the lower arm and clean it Note The sealing can hang onto the gearbox sticking to the oil 26 Continues on next page 330 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4 7 2 Replacing the gearbox axes 2 3 Continued ...

Page 331: ...the frame 2 Use two of the attachment holes for the screws that hold the gearbox CAUTION The gearbox weighs 69 kg All lifting equipment used must be sized accordingly 3 Specified in Required equipment on page 324 Fit the lifting accessory to the gearbox and lift it with an overhead crane 4 Continues on next page Product manual IRB 6660 331 3HAC028197 001 Revision S Copyright 2007 2018 ABB All righ...

Page 332: ... one guide sleeve in the middle screw hole in the upper back area and one guide sleeve in the middle screw hole in the the lower area Axis 3 xx1100000622 xx1400000993 Foundry Plus Apply bearing grease on the highlighted areas on both sides of the sealing Note Do not apply grease closer than 20 mm from the edge of the holes in the sealing 6 Continues on next page 332 Product manual IRB 6660 3HAC028...

Page 333: ...r arm with the attachment screws and washers in two of the screw areas the third is not reach able at this point Do not remove the guide sleeves yet 10 M12x60 quality 12 9 Gleitmo 6 6 pcs Tightening torque 120 Nm M16x90 quality 12 9 Gleitmo 2 2 pcs Tightening torque 300 Nm Axis 3 M12x60 quality 12 9 Gleitmo Tightening torque 120 Nm M12x60 quality 12 9 Gleitmo 1 1 pc Tightening torque 120 Nm Remove...

Page 334: ...crews and washers Note Fit the cover so that the arrow on the cover points upwards 16 Tightening torque 24 Nm xx1000001408 See Replacing motors axes 2 and 3 on page 281 Refit the motors axes 2 3 17 See Performing a leak down test on page 174 Perform a leakdown test 18 Continues on next page 334 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 4 Repair 4...

Page 335: ...y 12 9 Gleitmo Tightening torque 120 Nm Pendulum Calibration is described in Op erating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 23 Axis Calibration is described in Calibrating with Axis Calibration method on page352 General calibration information is included in section Calibration on page 341 DANGER Make sure all safety requirements are met when perfo...

Page 336: ...Cooling elements G Required equipment Note Article number Equipment etc Includes o ring For spare part number see Spare part lists on page 387 Gearbox Not included in gearbox 3HAA1001 172 Washers Replace when damaged 164 7x3 53 3HAB3772 57 O ring Must be replaced when reas sembling gearbox 150 0x2 0 3HAB3772 64 O ring Must be replaced when reas sembling gearbox 12 pcs 13 1x1 6 3HAB3772 61 O ring M...

Page 337: ...ence 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 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for th...

Page 338: ...ox axis 6 3 Detailed in the section Removing turning disk on page 218 Remove the turning disc 4 Shown in the figure Location of gearbox on page 336 Remove the gearbox by unscrewing its attach ment screws 5 xx0200000220 If required apply M8 screws to the holes shown in the figure beside to press the gearbox out 6 A M8 holes for pressing out the gearbox xx1400001123 Foundry Plus Remove old Loctite 5...

Page 339: ... 1 Article number is specified in Required equipment on page 336 xx0200000221 Make sure the o ring is fitted to the rear of the gearbox Lubricate the o ring with grease 2 A O ring gearbox axis 6 Detailed in the section Manually releasing the brakes on page 73 Release the holding brake of motor axis 6 3 xx1400001122 Foundry Plus Apply Loctite 574 flange sealant on the contact surface 4 Continues on...

Page 340: ...e turning disc 7 Detailed in the section Performing a leak down test on page 174 Perform a leak down test 8 Detailed in the section Changing oil axis 6 gearbox on page 159 Refill the gearbox with oil 9 Pendulum Calibration is described in Oper ating manual Calibration Pendulum en closed with the calibration tools Re calibrate the robot 10 Axis Calibration is described in Calibrating with Axis Cali...

Page 341: ...at is used for calibration of the robot Calibration position A generic term for all calibration methods that aim to move the robot to calibration position Standard calibration A calibration routine that generates a new zero posi tion of the robot Fine calibration A calibration routine that in the first step generates a reference to current zero position of the robot The same calibration routine ca...

Page 342: ...rdinate system for the robot Absolute accuracy calibration option al Absolute accuracy calibration data is found on the SMB serial measurement board in the robot For robots with RobotWare 5 05 or older the absolute accuracy calibration data is delivered in a file absacc cfg supplied with the robot at delivery The file replaces the calib cfg file and identifies motor positions as well as absolute a...

Page 343: ...of how to perform the calibration procedure and what to do at each step is given on the FlexPendant You will be guided through the calibration procedure step by step CalibWare Absolute Accuracy calibration To achieve a good positioning in the Cartesian coordinate system Absolute Accuracy calibration is used as a TCP calibration The CalibWare tool guides through the calibration process and calculat...

Page 344: ...unter memory is lost If the revolution counter memory is lost the counters must be updated See Updating revolution counters on page 348 This will occur when The battery is discharged A resolver error occurs The signal between a resolver and measurement board is interrupted A robot axis is moved with the control system disconnected The revolution counters must also be updated after the robot and co...

Page 345: ...ch axis Synchronization marks IRB 6660 The figure shows robot variant IRB 6660 130 3 1 but the position of the marks are the same on all IRB 6660 robot variants xx0700000148 Synchronization plate axis 1 A Synchronization tab on robot B Continues on next page Product manual IRB 6660 345 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks a...

Page 346: ...ization mark axis 4 E Synchronization mark axis 5 F Synchronization mark axis 6 G 346 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchronization position for axes Continued ...

Page 347: ...nes will handle the calibration movements automatically and these might be different from the positive directions shown below Manual movement directions 6 axes Note The graphic shows an IRB 7600 The positive direction is the same for all 6 axis robots except the positive direction of axis 3 for IRB 6400R which is in the opposite direction xx0200000089 Product manual IRB 6660 347 3HAC028197 001 Rev...

Page 348: ...sulting 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 befor...

Page 349: ...ABB menu tap Calibration xx1500000942 1 All mechanical units connected to the system are shown with their calibration status 2 Tap the mechanical unit in question xx1500000943 Continues on next page Product manual IRB 6660 349 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 5 Calibration 5 3 Updating revolution counters Continued ...

Page 350: ... calibration method used during last field calibration Tap Manual Method Advanced xx1500000944 A screen is displayed tap Rev Counters en0400000771 4 Continues on next page 350 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 5 Calibration 5 3 Updating revolution counters Continued ...

Page 351: ...e updating operation cannot be undone Tap Update to proceed with updating the revolution counters Tap Cancel to cancel updating the revolution counters Tapping Update updates the selected revolution counters and removes the tick from the list of axes 7 CAUTION If a revolution counter is incorrectly updated it will cause incorrect manipulator posi tioning which in turn may cause damage or injury Ch...

Page 352: ...vable calibration tool is inserted by the operator into a calibration bushing on the axis chosen for calibration according to instructions on the FlexPendant WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB Using other pins in the calibration bushings may cause severe damage to the robot and or personnel WARNING The calibration tool must be fully inse...

Page 353: ... the FlexPendant to create reference values When reference calibration is performed the robot is restored to the status given by the reference values Note When calibrating the robot with the reference calibration routine the robot must be dressed with the same tools process cabling and any other equipment as when the reference values were created Update revolution counters Choose this routine to m...

Page 354: ...gs may cause severe damage to the robot and or personnel Note Article number Equipment etc Delivered as a set of calibration tools Required if Axis Calibration is the valid calib ration method for the robot 3HAC055412 001 Calibration tool box Axis Calibration Examining the calibration tool Check prior to usage Before using the calibration tool make sure that the tube insert the plastic protection ...

Page 355: ...solution Note Action It is possible to use any RFID solution with the correct dimensions ABB has verifed function on some suppliers fulfilling the requirements of NFC compatible devices 13 56 Mhz according to ISO 14443 or ISO 15693 Note The maximum dimensions on the RFID chip must not exceed Ø7 9 mm x 8 0 mm Ø5 9 mm x 8 0 mm or Ø3 9 mm x 8 0 mm depending on calibra tion tool size 1 There is a cavi...

Page 356: ...hes are fitted to the robot Keep the tower in a safe location for future recalibration needs and mark it with robot serial number to ensure that the correct one is refitted 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 w...

Page 357: ...re on the FlexPendant The actual instructions of how to perform the calibration procedure and what to do at each step is given on the FlexPendant You will be guided through the calibration procedure step by step 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 ...

Page 358: ...ant while conducting it Note Action DANGER While conducting the calibration the robot needs to be connected to power Make sure that the robots working area is empty as the robot can make unpredictable movements 1 Use a clean cloth Wipe the calibration tool clean Note The calibration method is exact Dust dirt or color flakes will affect the calibration value 2 Starting the calibration procedure Use...

Page 359: ...n the FlexPendant is given in Overview of the calibra tion procedure on the FlexPendant on page 357 Follow the instructions given on the FlexPendant 4 Restarting an interrupted calibration procedure If the Axis Calibration procedure is interrupted before the calibration is finished the RobotWare program needs to be started again Use this procedure to take required action Action Situation Press and...

Page 360: ...alibration SafeMove needs to be unsynchronized The Axis Calibration routine recognizes if the robot is equipped with SafeMove and will force SafeMove to unsynchronize automatically However SafeMove may generate other warning messages anytime during the Axis Calibration routine Safety controller not synchronized SafeMove message Note Action SafeMove generates the message Safety control ler not sync...

Page 361: ... Unsynchronized time limit expired SafeMove message anytime during Axis Calibration routine Note Action SafeMove generates the message Unsynchron ized time limit expired anytime xx1500002482 1 Press OK to continue Axis Calibration procedure 2 Restart Axis Calibration procedure by pressing Play 3 Continues on next page Product manual IRB 6660 361 3HAC028197 001 Revision S Copyright 2007 2018 ABB Al...

Page 362: ...ection cover and plug set 3HAC056806 001 xx1500000952 Reinstall the protective plug and sealing in the bushing on each axis directly after the axis has been calibrated Ensure that the sealing is not damaged Replace the plug and the sealing with new spare part if missing or damaged 3 Protection cover and plug set 3HAC056806 001 362 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 20...

Page 363: ...ndulum Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools Product manual IRB 6660 363 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 5 Calibration 5 5 Calibrating with Calibration Pendulum method ...

Page 364: ...ram twice Do not change the position of the robot axes after running the program 1 This is detailed in section Synchronization marks and synchronization position for axes on page 345 Adjust the synchronization marks when the calibration is done if necessary 2 Write down the values on a new label and stick it on top of the calibration label 3 xx Remove any calibration equipment from the robot 4 364...

Page 365: ... page 345 and Updating revolution counters on page 348 Check that the synchronization marks for the axes align correctly If they do not update the revolu tion counters 6 Using the jogging window Use this procedure to jog the robot to the synchronization position of all axes Note Action On the ABB menu tap Jogging 1 Tap Motion mode to select group of axes to jog 2 Tap to select the axis to jog axis...

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Page 367: ... the country in which the robot and the control unit are installed If the robot or the control unit is partially or completely disposed of the various parts must be grouped together according to their nature which is all iron together and all plastic together and disposed of accordingly These parts must also be disposed of in accordance with the current legislation of the country in which the robo...

Page 368: ...me and so on Steel Brakes motors Neodymium Cables connectors drive belts and so on Plastic rubber Gearboxes Oil grease Covers synchronization brackets Aluminium 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 ...

Page 369: ...attery is exposed to heat for example from a blow torch it will explode Always remove all oil grease in gearboxes If exposed to heat for example from a blow torch the oil grease will catch fire When motors are removed from the robot the robot will collapse if it is not properly supported before the motor is removed Product manual IRB 6660 369 3HAC028197 001 Revision S Copyright 2007 2018 ABB All r...

Page 370: ...ed See references to these procedures in the step by step in structions below DANGER Do not under any circumstances deal with the balancing device in any other way than that detailed in the product documentation For example attempting to open the balancing device is potentially lethal Action on field decommissioning The procedure below details the actions to perform on field when the balancing dev...

Page 371: ...r will be directed away from personnel 1 Clamp the device at the working location Place the device at ground level so that the hole and spring coils are cut from a more safe distance 2 DANGER The hole must be cut as specified in the figure Pieces can be ejected from the cyl inder at high speed if the hole is cut larger than specified 3 Use a cutting torch with a long shaft Cut a hole in the housin...

Page 372: ...irected away from personnel 5 Use a cutting torch with a long shaft Cut the coils of the springs inside the housing as specified below Outer spring cut at least five coils Middle spring cut at least four coils Inner spring cut at least four coils 6 Double check the number of coils cut and make sure all the tension in the springs are removed 7 372 Product manual IRB 6660 3HAC028197 001 Revision S C...

Page 373: ...pter includes general information complementing the more specific information in the different procedures in the manual Product manual IRB 6660 373 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 7 Reference information 7 1 Introduction ...

Page 374: ...015i Ergonomics of the thermal environment Part 1 EN ISO 13732 1 2008 EMC Generic emission EN 61000 6 4 2007 A1 2011 IEC 61000 6 4 2006 A1 2010 option 129 1 EMC Generic immunity EN 61000 6 2 2005 IEC 61000 6 2 2005 Arc welding equipment Part 1 Welding power sources EN IEC 60974 1 2012ii Arc welding equipment Part 10 EMC requirements EN IEC 60974 10 2014ii Safety of machinery Electrical equipment o...

Page 375: ...R15 06 Safety standard for robots and robotic equipment ANSI UL 1740 Industrial robots and robot Systems General safety require ments CAN CSA Z 434 14 Product manual IRB 6660 375 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 7 Reference information 7 2 Applicable standards Continued ...

Page 376: ...39 37 in 3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume 376 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 7 Reference information 7 3 Unit conversion ...

Page 377: ...ld 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 ...

Page 378: ...pair maintenance or installation procedure overrides the standard torque Tightening torque Nm Class 12 9 oil lubric ated Tightening torque Nm Class 10 9 oil lubric ated Tightening torque Nm Class 8 8 oil lubricated Dimension 6 M5 10 M6 40 34 24 M8 80 67 47 M10 140 115 82 M12 340 290 200 M16 670 560 400 M20 1150 960 680 M24 Lubricated screws Molycote Gleitmo or equivalent with allen head screws The...

Page 379: ...ning torque for water and air connectors when one or both connectors are made of brass Note A special torque specified in the repair maintenance or installation procedure overrides the standard torque Tightening torque Nm Max Tightening torque Nm Min Tightening torque Nm Nominal Dimension 15 8 12 1 8 20 10 15 1 4 25 15 20 3 8 50 30 40 1 2 90 55 70 3 4 Product manual IRB 6660 379 3HAC028197 001 Rev...

Page 380: ...sory when handling components with a weight exceeding 22 kg A wide range of lifting accessories and devices are available for each manipulator model Example Following is an example of a weight specification in a procedure Note Action CAUTION The robot weighs 1950 kg All lifting accessories used must be sized accord ingly 380 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB...

Page 381: ...on Contents standard toolkit Rem Tool Qty Ring open end spanner 8 19 mm 1 Socket head cap 5 17 mm 1 Torx socket no 20 60 1 Box spanner set 1 Torque wrench 10 100 Nm 1 Torque wrench 75 400 Nm 1 Ratchet head for torque wrench 1 2 1 Hexagon headed screw M10x100 2 Hex bit socket head cap no 14 socket 40 mm L 100 mm 1 To be shortened to 12 mm Hex bit socket head cap no 14 socket 40 mm L 20 mm 1 Hex bit...

Page 382: ...lum is used as default Note Art no Description Complete kit that also includes operating manual 3HAC15716 1 Calibration Pendulum toolkit 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 ...

Page 383: ... 2 Guide pins M10 x 100 3HAC15521 2 2 Guide pins M10 x 150 3HAC14459 1 1 Lifting tool motor ax 1 3HAC15534 1 1 Lifting tool motor ax 2 3 3HAC14972 1 2 Removal tool motor M10x Fits motors axes 6 Fits motors axes 1 2 and 3 Removal tool motor M12x 3HAC17105 1 1 Rotation tool 1 Standard toolkit content described in sec tion Standard tools on page 381 Lifting tools The following table specifies the lif...

Page 384: ...he special tools required during several of the service procedures The tools may be ordered separately and are also specified directly in concerned instructions Article no Qty Description Standard KM8 socket Standard KM10 socket 3HAC023132 001 Pinion crank 3HAC023092 001 Pressing lower arm balancing weight 3HAC023084 001 Pressing upper arm 3HAC5021 1 Pressing tie rod 3HAC5275 1 Auxiliary shaft lon...

Page 385: ...ting accessories is not detailed in the activity procedure but in the instruction delivered with each piece of lifting accessories This implies that the instructions delivered with the lifting accessories should be stored for later reference Product manual IRB 6660 385 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 7 Reference information 7 8 Lifting accessories and lifting ...

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Page 387: ...ews are not included in the manual but delivered as a separate document for registered users on myABB Business Portal www mypo rtal abb com Product manual IRB 6660 387 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 8 Spare part lists 8 1 Spare part lists and illustrations ...

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Page 389: ...B 140 type C 3HAC025611 001 Circuit diagram IRB 260 3HAC028647 009 Circuit diagram IRB 360 3HAC036446 005 Circuit diagram IRB 460 3HAC025691 001 Circuit diagram IRB 660 3HAC025691 001 Circuit diagram IRB 760 3HAC046307 003 Circuit diagram IRB 1200 3HAC2800 3 Circuit diagram IRB 1410 3HAC021351 003 Circuit diagram IRB 1600 1660 3HAC039498 007 Circuit diagram IRB 1520 3HAC6670 3 Circuit diagram IRB ...

Page 390: ...B 6650S 3HAC025744 001 3HAC025744 001 Circuit diagram IRB 6660 3HAC029940 001 3HAC043446 005 Circuit diagram IRB 6700 3HAC13347 1 Circuit diagram IRB 7600 3HAC025744 001 3HAC050778 003 Circuit diagram Product ProductName 3HAC056159 002 Circuit diagram IRB 910SC 390 Product manual IRB 6660 3HAC028197 001 Revision S Copyright 2007 2018 ABB All rights reserved 9 Circuit diagram 9 1 Circuit diagrams C...

Page 391: ... standard type 342 verification 364 when to calibrate 344 calibration Absolute Accuracy 343 calibration manuals 343 calibration marks 345 calibration position jogging to 365 scales 345 calibration scales 345 CalibWare 342 carbon dioxide extinguisher 22 cast iron disposal 368 changing oil axis 1 146 axis 2 149 axis 3 149 cleaning 169 climbing on robot 25 Cold environments 107 complete arm system re...

Page 392: ...ton rod 166 lubrication amount in gearboxes 144 type of lubrication 144 M maintenance schedule 111 manually releasing brakes 73 mechanical stop axis 1 101 mechanical stop location 136 motion of axes 57 motor axis 4 replacement 292 motor axis 5 replacement 297 motor axis 6 replacement 303 MoveAbsJ instruction 365 N nation specific regulations 19 negative directions axes 347 neodymium disposal 368 N...

Page 393: ...fety 40 SMB replacing 259 SMB battery extension of lifetime 162 259 replacing 162 259 special tools 382 speed adjusting 107 stability 58 standards 374 ANSI 375 CAN 375 EN 374 EN IEC 374 EN ISO 374 start of robot in cold environments 107 steel disposal 368 storage conditions 53 symbols safety 40 synchronization position 348 sync marks 345 system integrator requirements 19 T temperatures operation 5...

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Page 396: ...Telephone 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics and Motion No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics and Motion 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC028197 001 Rev S en Copyright 2007 2018 ABB All rights reserved Specifications subject to change without notice ...

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