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Contents

Chapter

Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.

Repair

Calibration procedures and general information about calibra-
tion.

Calibration

Environmental information about the robot and its components.

Decommissioning

Useful information when performing installation, maintenance
or repair work. Includes lists of necessary tools, additional
documents, safety standards etc.

Reference information

Complete spare part list of the robot components, shown in
exploded views.

Spare part / part list

Detailed illustrations of the robot with reference numbers to the
part list.

Exploded views

Reference to the circuit diagram for the robot.

Circuit diagram

References

Document ID

Document name

3HAC023932-001

Product specification - IRB 660

3HAC049102-001

Product manual, spare parts - IRB 660

3HAC031045-001

Safety manual for robot - Manipulator and IRC5 or OmniCore
controller

i

3HAC025691-001

Circuit diagram - IRB 660

3HAC021313-001

Product manual - 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 in gearboxes

3HAC050948-001

Technical reference manual - System parameters

3HAC030421-001

Application manual - CalibWare Field

i

This manual contains all safety instructions from the product manuals for the manipulators and the
controllers.

Revisions

Description

Revision

First edition

-

Detailed illustrations added in some procedures.

A

Art. no. on tools added.
Chapter "Replacement of tilthouse unit" has been changed, in order to
make it easier to follow the procedure.

Continues on next page

10

Product manual - IRB 660

3HAC025755-001 Revision: W

© Copyright 2006-2020 ABB. All rights reserved.

Overview of this manual

Continued

Summary of Contents for IRB 660

Page 1: ...ROBOTICS Product manual IRB 660 ...

Page 2: ...Trace back information Workspace 20C version a3 Checked in 2020 09 14 Skribenta version 5 3 075 ...

Page 3: ...Product manual IRB 660 180 3 15 IRB 660 250 3 15 IRC5 Document ID 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved Specifications subject to change without notice ...

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

Page 5: ... 2 3 1 Lifting robot with fork lift 55 2 3 2 Lifting robot with roundslings 58 2 3 3 Lifting robot with lifting slings 60 2 3 4 Manually releasing the brakes 62 2 3 5 Lifting the base plate 63 2 3 6 Securing the base plate 68 2 3 7 Orienting and securing the robot 71 2 3 8 Fitting equipment on robot 75 2 3 9 Signal lamp option 76 2 3 10 Loads fitted to the robot stopping time and braking distances...

Page 6: ...or bearings 145 4 2 3 Mounting instructions for sealings 148 4 2 4 Cut the paint or surface on the robot before replacing parts 149 4 2 5 The brake release buttons may be jammed after service work 150 4 3 Complete robot 150 4 3 1 Replacing cable harness lower end axes 1 3 158 4 3 2 Replacing the cable harness upper end incl axis 6 164 4 3 3 Replacing the base including axis 1 gearbox 172 4 4 Upper...

Page 7: ...unning the calibration procedure 327 5 4 5 Reference calibration 329 5 5 Calibrating with Calibration Pendulum method 330 5 6 Verifying the calibration 331 5 7 Checking the synchronization position 333 6 Decommissioning 333 6 1 Environmental information 335 6 2 Scrapping of robot 336 6 3 Decommissioning of balancing device 339 7 Reference information 339 7 1 Introduction 340 7 2 Applicable standar...

Page 8: ...This page is intentionally left blank ...

Page 9: ...pair maintenance work Product manual scope The manual covers covers all variants and designs of the IRB 660 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 installation or serv...

Page 10: ...5 or OmniCore controller i 3HAC025691 001 Circuit diagram IRB 660 3HAC021313 001 Product manual 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 A...

Page 11: ...bot is new Section Maintenance schedule in chapter Maintenance The inform ation about Service Information System SIS has been updated Section Maintenance schedule in chapter Maintenance Intervals for replacement of battery pack changed Section Expected lifetime in chapter Maintenance The lifetime of certain parts has been revised Section Cleaning of robot updated C This revision includes the follo...

Page 12: ...e 23 F This revision includes the following updates A new block about general illustrations added in section How to read the product manual on page 18 Added a KM10 socket to the list of required equipment and the in structions when replacing the lower rod see section Replacing the linkage lower rod on page 205 The tool is also added to the list of Special tools in the Reference chapter Added instr...

Page 13: ...tion about risks when scrapping a decommissioned robot see Scrapping of robot on page 335 Spare parts and exploded views are not included in this document but delivered as a separate document See Product manual spare parts IRB 660 Article number for lubrication tool changed see Lubricating balan cing device bearings and piston rod on page 136 J This revision includes the following updates The maxi...

Page 14: ... 2 The following updates are done in this revision Updated references R Published in release 19B The following updates are made in this revision New touch up color Graphite White available See Cut the paint or surface on the robot before replacing parts on page 148 Tightening torque for oil plug axis 6 changed to 20 Nm New adapter for axis 3 shaft replacement and updated article number for KM12 so...

Page 15: ...d tightening torques on the wrist oil plugs Removed lifting tool for axis 2 and axis 3 gearbox from the special tools list lifting method was changed in previous revision W Product manual IRB 660 15 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved Overview of this manual Continued ...

Page 16: ...sioning Reference information safety standards unit conversions screw joints lists of tools Spare parts list with corresponding figures or references to separate spare parts lists References to circuit diagrams Technical reference manuals The technical reference manuals describe reference information for robotics products for example lubrication the RAPID language and system parameters Application...

Page 17: ...ts The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters Product manual IRB 660 17 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved Product documentation Continued ...

Page 18: ...completed with a reference to the section where the equipment is listed with further information that is article number and dimensions The designation in the procedure for the component or attachment point corresponds to the designation in the referenced list The table below shows an example of a reference to a list of required equipment from a step in a procedure Note Illustration Action Art no i...

Page 19: ...ration of the robot when the safety devices are defective not in their intended location or in any other way not working When instructions for operation and maintenance are not followed Non authorized design modifications of the robot Repairs on the robot and its spare parts carried out by in experienced or non qualified personnel Foreign objects Force majeure Spare parts and equipment ABB supplie...

Page 20: ...ence of alcohol drugs or any other intoxicating substances are not allowed to install maintain service repair or use the robot The plant liable must make sure that the personnel is trained on the robot and on responding to emergency or abnormal situations Personal protective equipment Use personal protective equipment as stated in the product manual 20 Product manual IRB 660 3HAC025755 001 Revisio...

Page 21: ...ion which if not avoided will result in ser ious injury DANGER Signal word used to indicate a potentially hazardous situation which if not avoided could result in serious injury WARNING Signal word used to indicate a potentially hazardous situation related to electrical hazards which if not avoided could result in serious injury ELECTRICAL SHOCK Signal word used to indicate a potentially hazardous...

Page 22: ...ed to indicate where to find additional information or how to do an operation in an easier way TIP 22 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 1 Safety 1 2 1 Safety signals in the manual Continued ...

Page 23: ...ription 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 crushing impact fall from height etc Caution xx090000...

Page 24: ...o 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 24 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reser...

Page 25: ... over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page Product manual IRB 660 25 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 26: ...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 26 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 27: ...01242 Lifting of robot xx0900000822 Oil xx0900000823 Can be used in combination with prohibition if oil is not allowed Mechanical stop xx0900000824 Continues on next page Product manual IRB 660 27 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 28: ...at 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 28 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Cont...

Page 29: ...ergency stops are described in the product manual for the controller For more information see Product manual IRC5 Product manual IRC5 Panel Mounted Controller Product manual IRB 660 29 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 1 Safety 1 3 Robot stopping functions ...

Page 30: ...ot if dropped or released at maximum speed The maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot The maximum TCP speed and the maximum velocity of the robot axes are detailed in the section Robot motion in the product specification for the respective manipulator Consider exposure to hazards such as slipping tripping and falling Conside...

Page 31: ... When integrating the robot with external devices to a robot system The integrator of the robot system must ensure that emergency stop functions are interlocked in accordance with applicable standards The integrator of the robot system must ensure that safety functions are interlocked in accordance with applicable standards Other hazards WARNING Never stay beneath a robot arm Gravity and the relea...

Page 32: ... to drop Dump valves should be used in case of emergency Shot bolts should be used to prevent tools etc from falling due to gravity All pipes hoses and connections have to be inspected regularly for leaks and damage Damage must be repaired immediately Verify the safety functions Before the robot system is put into operation verify that the safety functions are working as intended and that any rema...

Page 33: ...e release of braking devices can create additional hazards A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment Product manual IRB 660 33 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 1 Safety 1 5 1 Unexpected movement of robot arm ...

Page 34: ...lubricants oil or grease When handling oil grease or other chemical substances the safety information of the respective manufacturer must be observed Note Take special care when handling hot lubricants Elimination 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 ...

Page 35: ...pecified amount de pends on drained volume For lifetime reasons always drain as much oil as possible from the gearbox The magnetic oil plugs will gather residual metal chips Contaminated oil in gearboxes Hazards related to batteries Under rated conditions the electrode materials and liquid electrolyte in the batteries are sealed and not exposed to the outside There is a hazard in case of abuse mec...

Page 36: ...erform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment Related information See also the safety information related to installation and operation 36 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 1 Safety 1 6 1 Maintenance and repair Continued ...

Page 37: ...ire using an overhead crane or similar equipment Increased injury Before releasing the brakes make sure that the weight of the manipulator does not result in additional hazards for example even more severe injuries on a trapped person DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unexpected ways Make sure no personnel is near or beneath the robot Pr...

Page 38: ...as described below 1 Run each axis to a position where the combined weight of the manipulator and any load is maximized maximum static load 2 Switch the motor to the MOTORS OFF 3 Inspect and verify that the axis maintains its position If the manipulator does not change position as the motors are switched off then the brake function is adequate 38 Product manual IRB 660 3HAC025755 001 Revision W Co...

Page 39: ...d engineers A risk assessment must be done to address both robot and robot system specific hazards WARNING Never stay beneath a robot arm Gravity and the release of braking devices can create additional hazards A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment Related information See also the safety informatio...

Page 40: ...rm Gravity and the release of braking devices can create additional hazards A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment 40 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 1 Safety 1 8 Decommissioning ...

Page 41: ...hat 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 660 is connected to power always make sure that the robot is connected to protective earth and...

Page 42: ...he robot as specified in Weight robot on page 42 5 If the robot is not installed directly it must be stored as described in Storage condi tions robot on page 44 6 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 44 7 Before taking the robot to its installation site make sure that the site conforms to Lo...

Page 43: ...e shows the various forces and torques working on the robot during different kinds of operation Note These forces and torques are extreme values that are rarely encountered during operation The values also never reach their maximum at the same time WARNING The robot installation is restricted to the mounting options given in following load table s Floor mounted Max load emergency stop Endurance lo...

Page 44: ...he pedestal where the robot is mounted The minimum resonance frequency should not be interpreted as the resonance frequency of the building floor etc For example if the equivalent mass of the floor is very high it will not affect robot movement even if the frequency is well below the stated frequency The robot should be mounted as rigid as possibly to the floor Disturbances from other machinery wi...

Page 45: ...e 87 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 Product manual IRB 660 45 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 2 Installation and commissioning 2 2 1 Pre installation procedure Continued ...

Page 46: ...cted working range of IRB 660 180 3 15 and IRB 660 250 3 15 xx0500002274 Mechanical stop H Max working range J Angle axis 3 de grees Angle axis 2 de grees Position z mm Position x mm 0 0 1833 1910 A 20 42 1966 972 B 28 42 870 895 C 120 50 207 866 D 120 85 505 1160 E 15 85 315 3139 F 20 50 1837 2809 G Continues on next page 46 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB...

Page 47: ... of motion Axis 180 to 180 Rotation motion 1 42 to 85 Arm motion 2 20 to 120 Arm motion 3 20 to 160 Arm motion 2 3 300 to 300 Turn motion 6 Product manual IRB 660 47 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range and type of motion Continued ...

Page 48: ...ng and transportation position This figure shows the robot in its shipping position and transportation position xx0500002275 WARNING The robot will be mechanically unstable if not properly secured to the foundation 48 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 2 Installation and commissioning 2 2 3 Risk of tipping stability ...

Page 49: ...st straps must be tested frequently to ensure that they are not damaged and are operating cor rectly Product manual IRC5 Product manual IRC5 Panel Mounted Controller Use a wrist strap The wrist strap button is located inside the control ler 1 The mat must be grounded through a current limit ing resistor Use an ESD protective floor mat 2 The mat should provide a controlled discharge of static volta...

Page 50: ...ints 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 51 3HAC023044 001 Fork lift set incl all required hardware Content is defined in section Standard tools on page 347 Standard toolkit Continues on next page 50 P...

Page 51: ...and 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 660 51 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 2 Installation and commissioning 2 3 1 Lifting robot with fork lift Continued ...

Page 52: ...g the brakes on page 60 xx0500002275 Position the robot as shown in the figure to the right 1 Attachment points are shown in figure Attachment points on robot on page50 Fit the two adapters to the robot and secure 2 Attachment screws 2 pcs M16 x 90 Tightening torque 270 Nm xx0500002278 Strap up axis 2 motor cable on the adapter 3 A Strap velcro Continues on next page 52 Product manual IRB 660 3HAC...

Page 53: ... tightened with different torque 5 Attachment points on the robot are shown in figure Attachment points on robot on page 50 xx0500002279 A Horizontal attachment screws 4 pcs M16 x 60 Tightening torque 60 Nm B Adapter xx0700000655 Make sure the securing screw is removed from the fork lift pocket It is only used for robot model IRB 6650S 6 A Securing screw Continues on next page Product manual IRB 6...

Page 54: ...ori zontal attachment screws 9 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 Attachment points on robot on page 50 Double check that pockets are properly se cured to the robot Insert fork lift forks into the pockets 10 CAUTION The IRB 660 robot weighs 1750 kg All lifting accessories used mu...

Page 55: ...tion Lifting with roundslings Note Action Position robot in a secure transport position 1 Attach roundslings to robot according to fig ure Attachment points on page 56 2 CAUTION The IRB 660 robot weighs 1750 kg All lifting accessories used must be sized accordingly 3 WARNING Personnel must not under any circum stances be present under the suspended load 4 Continues on next page Product manual IRB ...

Page 56: ...o the robot s frame xx0500002285 Chain sling with shortener A Roundsling robot B Roundsling upper arm Used to secure against rotation C Continues on next page 56 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 2 Installation and commissioning 2 3 2 Lifting robot with roundslings Continued ...

Page 57: ...e No sharp edges D Shackle E Product manual IRB 660 57 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 2 Installation and commissioning 2 3 2 Lifting robot with roundslings Continued ...

Page 58: ...ny other position may result in the robot tipping over causing severe damage or injury Illustration lifting slings The figure below shows how to lift the complete robot with lifting slings xx0500002460 Eye for lifting accessory A Swivelling lifting eyes 3 pcs B Chain C Lifting sling short Secures against rotation D Lifting slings long E Hook F Continues on next page 58 Product manual IRB 660 3HAC0...

Page 59: ...rklift pockets it is necessary to remove these in order to 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 59 Fit the lifting accessory to the robot as de scribed in the enclosed instruction 4 CAUTION The IRB 660 robot weighs 1750 kg All lifting accessories used must be sized ac cordingly 5 WARN...

Page 60: ...nit on page 60 The internal brake release unit is equipped with buttons for controlling the axes brakes The buttons are numbered according to the numbers of the axes Note Axes 4 and 5 do not exist 1 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 61 DANGER When releasing the holding br...

Page 61: ...e controller power must be supplied to connector R1 MP on the robot in order to enable the brake release 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 Product manual IRB 660 61 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 2 I...

Page 62: ...kg All lifting accessories used must be sized accordingly 1 Shown in figure Hole configur ation on page 62 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 62 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 AB...

Page 63: ...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 Product manual IRB 660 63 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 2 Installation...

Page 64: ...82 923 4x Ø16 5x Ø22 16x 861 2x 358 2x 18 0 905 813 475 137 45 0 0 37 2x 87 2x 293 2x 450 2x 630 2x 813 2x 947 2x 991 2x A xx1000001054 Four holes for alternative clamping 4x Ø18 Color RAL 9005 Thickness 80 100 µm A Continues on next page 64 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 2 Installation and commissioning 2 3 6 Securing the base plate Co...

Page 65: ...for 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 Product manual IRB 660 65 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 2 Installation and commissioning 2 3 6 Securing the base plate Continued ...

Page 66: ... Content is defined in section Standard tools on page 347 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 pa...

Page 67: ... orienting grooves and leveling bolts on page 65 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 68: ... 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 69: ...base 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 68 Fit the bolts and washers in the base attach ment holes 5 Shown in figure Illustration robot fitted to base plate on page 68 Note Lightly lubricate screws before as sembly Tighten bolts ...

Page 70: ...x0600002628 Cross section guide sleeve hole This illustration shows the cross section of the guide sleeve holes xx0600002629 70 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 2 Installation and commissioning 2 3 7 Orienting and securing the robot Continued ...

Page 71: ... of extra equipment on upper arm The illustration below shows the mounting holes available for fitting extra equipment on the upper arm For fitting of extra vacuum hose all holes shall be used 6 pcs These holes can only be used for extra vacuum hose The max weight of the vacuum hose and fastening device on the upper arm is calculated to 10 kg Max extra weight on the upper arm IRB 660 180 3 15 35 k...

Page 72: ...M10 2 pcs B Fitting holes M10 2 pcs C Illustration fitting of extra equipment on frame The illustration below shows the mounting holes available for fitting extra equipment on the frame xx0500002505 Continues on next page 72 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 2 Installation and commissioning 2 3 8 Fitting equipment on robot Continued ...

Page 73: ...holes available for fitting equipment on the turning disk xx0500002292 Mounting flange Continues on next page Product manual IRB 660 73 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 2 Installation and commissioning 2 3 8 Fitting equipment on robot Continued ...

Page 74: ...he turning disk see the figures above only use screws with quality 12 9 When fitting other equipment to mounting holes standard screws with quality 8 8 may be used 74 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 2 Installation and commissioning 2 3 8 Fitting equipment on robot Continued ...

Page 75: ...ion 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 660 75 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 2 Installation and commissioning 2 3 9 Signal lamp option ...

Page 76: ... 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 76 P...

Page 77: ...uration axis 1 is allowed to move 180º The working range may however be increased to 220º with option 561 1 Extended working range axis 1 Note that this option also requires installation of a position switch on axis 1 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...

Page 78: ...ops 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 Techn...

Page 79: ...The 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 ...

Page 80: ...Electronic Position Switches The system parameters that must be changed Upper joint bound 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 ...

Page 81: ...user Required equipment Note Art no Description Includes position switch and plate for customer connec tions 3HAC15715 1 Position switch axis 1 3HAC17252 1 Connector kit R1 SW1 An additional connection plate must be fitted to the ro bot base if not already in stalled 3HAC025778 001 Plate set for customer connec tions The plate differs from the connection plate for customer harness in regard to the...

Page 82: ...on switch is connected to different points on the robot system XT8 screw terminal in the controller cabinet when position switch cables are used R1 SW1 at the robot base Customer connection set is recommended Art no is specified in Required equipment on page 81 Further information about cables and connection points see section Robot cabling and connection points on page 88 Continues on next page 8...

Page 83: ... 1 to the robot Note Action 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 Product manual IRB 660 83 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 2 Installation and commissioning 2 4 4 I...

Page 84: ...onnect the connector R1 SW1 to the position switch of axis 1 D 6 Connect the connector R1 SW1 to the base of the robot B 7 A Cable pos switch axis 1 B Connection point R1 SW1 C Notch for cable D Position switch axis 1 Refit the rear cover to the robot base 8 Continues on next page 84 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 2 Installation and com...

Page 85: ...he parts of the position switch Note Action Use a sharp knife and rubber hammer or similair Cut the cam to a suitable length 1 Shown in the figure Illustration cutting the cam on page 86 Cut the edge of the cam edge to max 30 2 If the angle is larger this may damage the position switch Cut the part of the cam running in the profile to 90 3 Also see the figure Illustration cutting the cam on page 8...

Page 86: ...x 6 set screw A Adjustable cam B Profile C Illustration cutting the cam The illustration below shows how to cut the position switch cam xx0100000114 Remove the gray section A 86 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 2 Installation and commissioning 2 4 4 Installation of position switch axis 1 option Continued ...

Page 87: ...he speed can be regulated with the RAPID instruction VelSet Start the robot with its normal program but with reduced speed 1 Adjusting the speed and acceleration during warm up Depending on how cold the environment is and what program is being used the speed might need to be ramped up until reached maximum The table shows examples of how to adjust the speed Speed velocity AccSet Work cycles v100 1...

Page 88: ...ication See the product manual 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 sta...

Page 89: ...or 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 xx1600001007 Continues on next page Product manual IRB 660 89 3HAC025755 001 Revision W Copyright 2006 2020 ...

Page 90: ...t Connection point robot Art no Cable XS8 R1 SW 3HAC13175 1 Position switch cable axis 1 7 m XS8 R1 SW 3HAC13175 2 Position switch cable axis 1 15 m XS8 R1 SW 3HAC13175 3 Position switch cable axis 1 22 m XS8 R1 SW 3HAC13175 4 Position switch cable axis 1 30 m Cabling inside control cabinet Additional cabling must be connected inside the control cabinet when installing position switches Connection...

Page 91: ...fety information Observe all safety information before conducting any service work There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page 19 before performing any service work Note If the IRB 660 is connected to power always make sure that the IR...

Page 92: ...ing on how hard each part is run The SIS used in M2004 is further described in the Operating manual Service Information System Robots with the functionality Service Information System activated can show active counters in the device browser in RobotStudio or on the FlexPendant Overhaul Depending on application and operational environment a complete overhaul may be necessary in average around 40000...

Page 93: ...le below specifies the required maintenance activities and intervals Interval Equipment Maintenance activity Robot Cleaning Every 12 months Axis 1 gearbox oil level Inspection Every 12 months Axes 2 and 3 gearboxes oil level Inspection Every 12 months Axis 6 gearbox oil level Inspection Every 12 months Balancing device Inspection Every 12 monthsi Robot harness Inspection Every 12 months Informatio...

Page 94: ...ttery charge low is displayed when the battery needs to be replaced The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned on until the battery is to be replaced See the replacement instruction for more details iv The battery low alert 38213 Battery charge low is displayed when remaining backup capacity robot powered off is less than 2 months The typical ...

Page 95: ...applications major use of axis 1 movement iv The given life 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 softwa...

Page 96: ...il 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 122 Lubricating oil Content is defined in section Standard tools on page 347 Standard toolkit Continues on next page 96 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 3 Maint...

Page 97: ...ion 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 96 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 of oil and total amount is detailed in Type o...

Page 98: ...otational 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 98 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 3 Maintenance 3 3 2 Inspecting oil level gearbox axes 2 3 ...

Page 99: ...er 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 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 see Gearbox lubricants oil or grease on page34 1 Continues on next page Product manu...

Page 100: ...oil plug filling 4 Required oil level max 5 mm below oil plug hole Art no is specified in Required equipment on page 99 Add oil if required 5 Filling of oil is detailed further in section Changing oil gearbox axes 2 and 3 on page 126 Tightening torque 24 Nm Refit oil plug filling 6 100 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 3 Maintenance 3 3 2 ...

Page 101: ...tigear BM 100 3HAC0860 1 Lubricating oil Content is defined in section Standard tools on page 347 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 660 101 3HAC025755 001 Revision W Copyright 2006 2020 ABB All right...

Page 102: ...afeguarded space 2 Shown in figure Location of gear box on page 101 Open oil plug filling 3 Required oil level max 5 mm below the oil plug hole 4 Art no is specified in Required equipment on page 101 Add oil if required 5 Further information about how to fill the oil may be found in the section Changing oil gearbox axis 6 on page 130 Tightening torque 20 Nm Refit oil plug filling 6 102 Product man...

Page 103: ...cking liquid 3HAC5276 1 Auxiliary shaft upper 3HAC5275 1 Auxiliary shaft lower Content is defined in section Standard tools on page 347 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 660 103 3HAC025755 001 Revisi...

Page 104: ...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 103 Fit the auxiliary shafts on upper and lower axes of balancing device The shafts should be tightened to their bottom position 4 Continues on next page 104 Product manual IRB 660 3HAC025755 00...

Page 105: ...bearings support washers and sealing rings 9 Detailed in section Replacing the balancing device on page 236 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 106: ...pressure supply to the robot before entering the safeguarded space 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 4 106 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 3 Maintenance 3 3 4 Inspec...

Page 107: ...is shown below xx0500002497 Cable harness robot axes 1 6 A Connectors at base B Motor cables C Cable guide axis 2 D Metal clamps E Continues on next page Product manual IRB 660 107 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 3 Maintenance 3 3 5 Inspecting cable harness ...

Page 108: ...ors at the base 3 Shown in figure Location of cable har ness axes 1 6 on page 107 Check the motor cables 4 xx0600002691 If the robot is equipped with a fork lift device check that the velcro strap that holds the motor cable is properly attached to the adapter 5 Velcro strap Shown in figure Location of cable har ness axes 1 6 on page 107 Check the cable guide axis 2 Replace if damaged 6 Shown in fi...

Page 109: ... page 107 Check the metal clamp holding the motor cable on axis 6 9 Detailed in section Replace the cable harness if wear or damage is detected 10 Replacing cable harness lower end axes 1 3 on page 150 Replacing the cable harness upper end incl axis 6 on page 158 Product manual IRB 660 109 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 3 Maintenance 3 3 5 Inspecting cable ha...

Page 110: ... on motor cover 4 pcs A Warning label symbol of flash located on motor cover 4 pcs B Warning label concerning brake release D Warning label G Warning label J Warning label concerning extended working range option K Information labels at gearboxes and at robot base specifying which oil is used in gearboxes Continues on next page 110 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 20...

Page 111: ...ng labels Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 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 353 Replace any missing or damaged labels 3 Product manual IRB 660 111 3HAC025755 001 Revision W C...

Page 112: ...n the figure xx0600002695 Mechanical stop pin A Fixed stop B Required 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 safeguarded space 1 Continues on next page 112 Product ...

Page 113: ...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 660 113 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 3 Maintenance 3 3 7 Inspecting the axis 1 mechanical stop pin Continued ...

Page 114: ...mber Equipment etc Content is defined in section Standard tools on page 347 Standard toolkit Inspecting mechanical stops Use this procedure to inspect the additional mechanical stops 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 114 Product manual IRB 660 3HAC025755 00...

Page 115: ...tional mechanical stops Axis 1 120 Nm Article number is specified in Required equipment on page114 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 660 115 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 3 Maintenance 3 3 8 Inspecting the additional mechanical stops Continued ...

Page 116: ...0002501 Damper lower arm upper 2 pcs A Damper lower arm lower 1 pc B Damper axis 2 2 pcs C Damper axis 3 2 pcs Not visible in this view Continues on next page 116 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 3 Maintenance 3 3 9 Inspection dampers ...

Page 117: ...off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 1 Shown in figure Location of dampers on page 116 Check all dampers for damage cracks or existing impressions larger than 1 mm 2 Check attachment screws for deformation 3 Art no is specified in Required equipment on page 117 If any damage is detected the damper must be rep...

Page 118: ...ent 3HAC 024854 001 Position switch axis 1 Content is defined in section Standard tools on page 347 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 118 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rig...

Page 119: ...s have not caused any impressions on the cams Check that the cams are clean Wipe them if necessary Check that the set screws holding the cams in position are firmly attached 4 Check the protection sheets on axis 1 Check that the three sheets are in position and not damaged Deformation can result in rubbing against the cams Check that the area inside of the sheets is clean enough not to interfere w...

Page 120: ...f damage is detected See Spare part lists on page 353 Signal lamp kit Content is defined in section Stand ard tools on page 347 Standard toolkit Inspecting signal lamp Use this procedure to inspect the function of the signal lamp Note Action Inspect that signal lamp is lit when motors are put in operation MOTORS ON 1 Continues on next page 120 Product manual IRB 660 3HAC025755 001 Revision W Copyr...

Page 121: ...20 If the lamp is not lit trace the fault by inspecting whether the signal lamp is broken If so replace it inspecting cable connections measuring the voltage in the connectors of motor axis 6 24V inspecting the cabling Replace the cabling if a fault is detected 3 Product manual IRB 660 121 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 3 Maintenance 3 3 11 Inspecting the sig...

Page 122: ...n be found in Technical reference manual Lubrication in gearboxes available for registered users on myABB Business Portal www mypo rtal abb com Location of gearboxes The figure shows the location of the gearboxes xx0500002467 Gearbox axis 1 A Gearbox axis 2 B Gearbox axis 3 C Gearbox axis 6 D Equipment Note Equipment Includes pump with outlet pipe Oil dispenser Use the suggested dispenser or a sim...

Page 123: ... 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 122 See Type and amount of oil in gearboxes on page 122 Lubricating oil Capacity 8 000 ml Oil collecting vessel Continues on next page Product manual IRB 660 123 3HAC025755 001 Revision W Copyright 20...

Page 124: ...before entering the safeguarded space 1 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 34 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 hose Vessel capacity is specified in Re quired ...

Page 125: ...robot before entering the safeguarded space 1 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 34 2 Shown in figure Location of oil plugs on page 123 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 122 Refill the gearbox with clean lubricating oil The correct oil...

Page 126: ...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 126 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 3 Maintenance 3 4 3 Changing oil gearbox axes 2 and 3 ...

Page 127: ...es on page 122 See Type and amount of oil in gearboxes on page 122 Lubricating oil Capacity 6 000 ml Oil collecting vessel Content is defined in section Special tools on page 348 3HAC021745 001 Oil exchange equip ment Content is defined in section Standard tools on page 347 Standard toolkit Continues on next page Product manual IRB 660 127 3HAC025755 001 Revision W Copyright 2006 2020 ABB All righ...

Page 128: ... lecting vessel 4 Vessel capacity is specified in Re quired equipment on page 127 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 with oil When using oil change equipment follow the instructions enclosed with kit Note Action DANGER T...

Page 129: ...nt on page 127 Refill gearbox with lubricating oil The amount of oil to be filled depends on the amount that was previously drained 4 Shown in Location of oil plugs on page 126 Refit oil plug filling and ventilation hole plug 5 Tightening torque 24 Nm Product manual IRB 660 129 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 3 Maintenance 3 4 3 Changing oil gearbox axes 2 and...

Page 130: ... oil types 3HAC021745 001 Oil exchange equipment Vessel capacity 400 ml Oil collecting vessel Content is defined in section Standard tools on page 347 Standard toolkit Draining oil Use this procedure to drain oil from gearbox axis 6 When using oil change equipment follow the instructions enclosed with kit Note Action Put tilt house in a suitable position 1 Continues on next page 130 Product manual...

Page 131: ...tions enclosed with kit Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 1 Shown in figure Location of oil plugs on page 130 Remove the oil plug filling 2 Art no and the total amount are specified in Required equipment on page 130 Refill the gearbox with lubricating oil Amount of oil to be refille...

Page 132: ...f the robot is powered off 2 days week or 18 months if the robot is powered off 16 h day The lifetime can be extended for longer production breaks with a battery shutdown service routine See Operating manual IRC5 with FlexPendant for instructions WARNING See Hazards related to batteries on page 35 Location of SMB battery The SMB battery SMB serial measurement board is located on the left hand side...

Page 133: ...or 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 353 Battery unit Content is defined in section Standard tools...

Page 134: ... sensitive to ESD on page 49 3 Shown in figure Location of SMB battery on page 132 Remove the SMB battery cover 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 132 Pull out the battery and disconnect the battery cable 5 ...

Page 135: ...tteries are installed together with a battery holder to be properly secured inside the recess See figure 3 Shown in figure Location of SMB battery on page 132 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 132 Secure the SMB battery cover with its attachment screws 4 Detailed in ...

Page 136: ...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 Lock nut C Piston rod D Guide ring not visible in this view E Continues on next page 136 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 3 Maintenance 3 5 1 Lubricating balancing...

Page 137: ...ower supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 2 Be careful not to loose the sup port washer in the process Remove the locknut 3 Fit the lubricating tool It should be tightened to the bottom by hand only 4 Grease through nipple on the lubricating tool 5 Continue filling grease until clean grease exudes be hind the inner sealing ring 6 R...

Page 138: ...the greatest extent possible 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 2 Clean piston rod with isopropanol before applying new grease 3 Type of grease is specified in Required equipment on page137 Apply new grease 4 138 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All righ...

Page 139: ...ations see Inspection activities on page 96 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 Al...

Page 140: ...rime can be cleaned by rinsing with water water cleaner 1 The following list defines the prerequisites Maximum water pressure at the nozzle 700 kN m2 7 bar I Fan jet nozzle should be used min 45 spread Minimum distance from nozzle to encapsulation 0 4 meters Maximum flow 20 liters minI I Typical tap water pressure and flow Cables Movable cables need to be able to move freely Remove waste material ...

Page 141: ...d the revision of both the replaced unit and the replacement unit This is particularly important for safety equipment to maintain the safety integrity of the installation Safety information Make sure to read through the chapter Safety on page 19 before commencing any service work Note If the IRB 660 is connected to power always make sure that the IRB 660 is connected to protective earth and a resi...

Page 142: ...The 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 n...

Page 143: ... exposed to 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...

Page 144: ...tarted 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 144 Product manual IRB ...

Page 145: ...ction Check the sealing to ensure that The sealing is of the correct type There is no damage on the main lip 1 Inspect the shaft surface before mounting If scratches or damage are found the shaft must be replaced since it may result in future leakage Do not try to grind or polish the shaft surface to get rid of the defect 2 Article number is specified in Equipment on page 145 A B C xx2000000071 A ...

Page 146: ...ed because leakage could occur Clean the surfaces properly in accordance with the recommendations of ABB 2 Distribute the sealing compound evenly over the surface preferably with a brush 3 Tighten the screws evenly 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 dama...

Page 147: ...ontamination Lubricate the o ring with grease 4 Tighten the screws evenly while assembling 5 Check that the o ring is not squashed outside the o ring groove 6 Product manual IRB 660 147 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 2 3 Mounting instructions for sealings Continued ...

Page 148: ...int Standard Foundry Plus ABB Orange 3HAC037052 001 Touch up paint Standard Foundry Plus 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 2 148 Product manual IRB 660 3HAC025755 001 Revision W Copy...

Page 149: ...ge 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 ja...

Page 150: ...er end incl axis 6 on page 158 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 xx0600002608 Cable harness lower end A Cable harness upper end B Connector R1 MP C Connector R1 SMB D Attachment point for earth lug E Cover plate F Rear cover plate G Cable gland SMB H Cable guide axis 2 I Contin...

Page 151: ...al clamp B Connector at base C Cable guide axis 1 D Cable harness axes 1 6 E Cover plate F Rear cover plate G Attachment point for earth lug H Continues on next page Product manual IRB 660 151 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 3 1 Replacing cable harness lower end axes 1 3 Continued ...

Page 152: ...7 Standard toolkit These procedures include refer ences to the tools required Other tools and proced ures may be required See references to these proced ures in the step by step in structions below See Circuit diagrams on page 355 Circuit diagram Removing the cable harness lower end axes 1 3 Use this procedure to remove the cable harness lower end axes 1 3 Note Action This is done in order to faci...

Page 153: ...e 150 Disconnect the connectors R1 MP and R1 SMB 5 xx0600002698 A Cable guide ax 2 Unscrew the screws of the cable guide axis 2 inside the lower arm and loosen the cable guide 6 Shown in Location of cable harness lower end axes 1 3 on page 150 Unscrew the screws in the metal clamps hold ing the cable harness in the frame and lower arm 7 Unscrew the screws of the motor covers for axes 1 2 and 3 and...

Page 154: ... Disconnect connectors R2 SMB R1 SMB1 3 R1 SMB6 from the SMB unit 12 Disconnect X8 X9 and X10 from the brake re lease unit 13 Remove the SMB cover and put somewhere safe 14 xx1000001330 Unscrew the screws for the cable gland SMB from inside the SMB recess and lift the cable gland out Perform this removal with care in order not to damage any of the components inside the SMB recess 15 Continues on n...

Page 155: ... axes 1 3 Use this procedure to refit the cable harness lower end axes 1 3 Note Action xx1000001331 Push the cable harness and connectors down through the cable guide axis 1 in the center of the frame CAUTION Make sure the cables are not twisted with each other or with customer harness if any 1 Continues on next page Product manual IRB 660 155 3HAC025755 001 Revision W Copyright 2006 2020 ABB All ...

Page 156: ...0 xx1000001314 Reconnect the earth cable 4 Shown in Location of cable harness lower end axes 1 3 on page 150 Refit the rear cover plate to the robot base with its attachment screws 5 See sections Replacing motor axis 1 on page 251 Replacing motors axes 2 and 3 on page 258 Reconnect all connectors at motors axes 1 2 and 3 and refit the motor covers 6 Reconnect connectors R2 SMB R1 SMB1 3 R1 SMB6 of...

Page 157: ...3 on page 150 Refit the metal clamps holding the cable har ness in the frame and lower arm with its attach ment screws 11 xx1100000157 Refit the cable guide axis 2 12 See section Replacing the cable har ness upper end incl axis 6 on page 158 Continue refitting the cable harness in the upper arm 13 See section Updating revolution counters on page 311 Update the revolution counter 14 DANGER Make sur...

Page 158: ...e 150 Location of cable harness upper end The upper end of the cable harness is located as shown in the figure xx0600002608 Cable harness lower end A Cable harness upper end B Connector R1 MP C Connector R1 SMB D Attachment point for earth lug E Cover plate F Rear cover plate G Cable gland SMB H Cable guide axis 2 I Metal clamp frame J Metal clamp lower arm K Metal clamp upper arm L Continues on n...

Page 159: ...tools re quired Other tools and procedures may be required See references to these procedures in the step by step instructions below See chapter Circuit dia grams on page 355 Circuit diagram Removing cable harness upper end incl axis 6 Use this procedure to remove the cable harness upper arm incl axis 6 Note Action This is done in order to facilitate updating of the revolution counter Move the rob...

Page 160: ... 3 xx1000001106 Remove the axis 6 motor cover by removing its attachment screws in order to reach the connectors 4 A xx0600002694 Remove the cable gland cover at the cable exit by unscrewing its attachment screw on the inside Note Make sure the gasket is not damaged A Screw securing the cable gland Disconnect connectors at axis 6 motor 5 Continues on next page 160 Product manual IRB 660 3HAC025755...

Page 161: ...ove the nuts on the outside of the up per arm that secure the cable harness metal clamps inside the upper arm 2 2 pcs 8 Carefully pull out the cable harness from the upper and lower arm 9 Continues on next page Product manual IRB 660 161 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 3 2 Replacing the cable harness upper end incl axis 6 Continued ...

Page 162: ...the cable harness through the upper arm tube 2 xx1000001338 Refit the cable harness inside the upper arm by refitting the cable clamps with the nuts 2 2 pcs from the outside of the upper arm 3 xx1000001336 Refit the metal clamp at the tilthouse with its nuts 4 Continues on next page 162 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 3 2 Repl...

Page 163: ...Refit the cover motor axis 6 with its attach ment screws and washers Make sure the cabling is placed correctly when refitting the cover and does not get jammed Note Make sure the cover is tightly sealed 9 Detailed in section Updating revolution counters on page 311 Update the revolution counter 10 DANGER Make sure all safety requirements are met when performing the first test run 11 Product manual...

Page 164: ...luding gearbox axis 1 is shown in the figure It also shows the complete arm system as defined above xx0600002612 Parallel rod A Linkage B Complete upper arm incl tilthouse C Balancing device D Frame E Gearbox axis 1 F Base G Base attachment screws H Continues on next page 164 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 3 3 Replacing the b...

Page 165: ... re quired Other tools and procedures may be required See refer ences to these procedures in the step by step instructions below See chapter Circuit diagrams on page 355 Circuit diagram 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...

Page 166: ... 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 Removing the complete arm system Use this procedure to remove the complete arm system Note Action Decide which calibration routine to use and take actions accordingly prior to beginning...

Page 167: ...nter of the frame 7 See Replacing motor axis 1 on page251 Remove the axis 1 motor 8 CAUTION The robot arm system weighs 245 kg All lifting accessories used must be sized accordingly 9 Make sure the lift is done completely level Fit the lifting accessories and adjust it as described in the enclosed user instructions 10 This is detailed in section Lifting robot with lifting slings on page 58 Continu...

Page 168: ... out to be unbalanced despite earlier adjust ments The risk of damaging the interface is bigger if the load is lowered unbalanced 13 CAUTION Always move the robot at very low speed making sure it does not tip See Replacing the axis 1 gearbox on page 276 If needed continue to remove the axis 1 gearbox from the base 14 Refitting the complete arm system Use this procedure to refit the complete arm sy...

Page 169: ...hat the lifting accessory does not wear against sharp edges Lift the complete arm system and move it at very low speed to the mounting site making sure it does not tip Note The refitting must be made completely level Make sure the roundslings are adjusted prior to refitting the arm system 5 xx0600002632 The figure above shows the frame view from below A Attachment holes for the guide pins M12 Dime...

Page 170: ...ock washers are turned the correct way See figure 9 Parts A Serrated lock washer 24 pcs B Axis 1 gearbox C Attachment screws M12x110 qual ity 12 9 gleitmo 24 pcs Fit 22 of the 24 attachment screws before the arm system is completely lowered 10 This is done in order to be able to attach all screws into the threads correctly Replace the guide pins with the remaining attachment screws and secure the ...

Page 171: ...alibration is described in Operating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 19 Axis Calibration is described in Calibrat ing with Axis Calibration method on page 315 General calibration information is included in section Calibration on page 305 DANGER Make sure all safety requirements are met when performing the first test run 20 Product manual IRB 66...

Page 172: ...te Art no Equipment etc O rings are not included For spare part no see Spare part lists on page 353 Turning disk For robot v IRB 660 180 3 15 250 3 15 3HAB3772 65 1pc 21520431 20 6 pcs O ring Wrist type 1 Must be replaced when replacing the turning disk Shell Gadus S2 3HAC042536 001 Grease Used to lubricate the o rings Loctite 574 3HAC034903 001 Flange sealant Continues on next page 172 Product ma...

Page 173: ...off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Remove any equipment fitted to the turning disk 3 See section Changing oil gearbox axis 6 on page 130 Drain the axis 6 gearbox 4 Shown in the figure Location of turning disk on page 172 Remove the attachment screws that secure the turning disk 5 Remove the turning disk ...

Page 174: ...ure the turning disk with its attachment screws 3 Tightening torque 175 Nm Reused screws may be used providing they are lubricated as detailed in sec tion Screw joints on page343 before fit ting Detailed in the section Performing a leak down test on page 142 Perform a leak down test of the gearbox axis 6 4 See section Changing oil gearbox axis 6 on page 130 Refill the axis 6 gearbox with oil 5 Ref...

Page 175: ...e sure all safety requirements are met when performing the first test run 7 Product manual IRB 660 175 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 4 1 Replacing the turning disk Continued ...

Page 176: ...in the figure below xx0600002616 Tilthouse unit A Upper arm B Upper rod C Screw M6x10 D Washer 6 4x12x1 6 E Ballplug F Protection cap G Continues on next page 176 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 4 2 Replacement of tilthouse unit ...

Page 177: ...de of the robot B Cut away view of the assembly of the tilthouse unit The figure below shows a cut away view of how the tilthouse unit is fitted to the upper arm The letters in the figure are being referred to in the step by step procedures below xx0600002742 Continues on next page Product manual IRB 660 177 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 4 2 Repla...

Page 178: ... etc 3HAC023075 001 Press tool premounting bearing 3HAC023080 001 Press tool mounting axis 6 6369901 438 KM7 socket Width 3 mm Shims Shell Gadus S2 3HAC042536 001 Grease Dinitrol 490 Rust protection Loctite 243 Locking liquid Content is defined in section Standard tools on page 347 Standard toolkit These procedures include refer ences to the tools required Other tools and procedures may be require...

Page 179: ...ed when ordering the complete tool The article numbers are given only for identification Hydraulic cylinder 3HAC 11731 1 A Mounting washer 3HAC 023075 004 B Bushing 3HAC 023075 006 C Screw M6x25 2 pcs MC6S D Threaded washer 3HAC 5507 1 E Press washer 3HAC 023075 002 F Threaded bar M16 L 300 mm G Continues on next page Product manual IRB 660 179 3HAC025755 001 Revision W Copyright 2006 2020 ABB All...

Page 180: ...ool The article numbers are given only for identification Hydraulic cylinder 3HAC 11731 1 A Distance 3HAC 023062 001 B Press housing 3HAC 023080 004 C Support housing 3HAC 023080 003 D Screw M6x14 2pcs MC6S E Flange lock nut M16 F Threaded bar M16 L 435 mm G Nut M16 H Continues on next page 180 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 ...

Page 181: ...ion for Axis Calibration in Reference calibration routine on page 316 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 a...

Page 182: ...per rod on page 201 xx1000001065 Disassemble the upper link from the tilt house unit Note It is not needed to remove the upper link from the link 5 Part Upper link Detailed in section Replacing the cable harness upper end incl axis 6 on page 158 Disconnect motor cables from motor axis 6 Place the motor cables in a way that it will not be damaged 6 Continues on next page 182 Product manual IRB 660 ...

Page 183: ... a time by following the steps below 9 Put a hand with some paper over the VK cover in order to catch it xx1000001072 Use compressed air in the M6 hole for filling grease in order to remove the VK cover CAUTION Only a very low air pressure is needed 10 Parts M6 screw in hole for filling grease VK cover Continues on next page Product manual IRB 660 183 3HAC025755 001 Revision W Copyright 2006 2020 ...

Page 184: ...arm xx1000001073 Remove the small VK cover from the inside with the help of a punch 12 xx1000001074 Remove the lock nut 13 Continues on next page 184 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 4 2 Replacement of tilthouse unit Continued ...

Page 185: ...ply the hydraulic pump on the bar Secure the hydraulic pump with a nut Remove the shaft with the press tool mounting axis 6 Note A longer threaded bar M16 is needed when re moving the shaft than the one specified when fitting 14 xx1000001075 A Shaft Press out the shaft 15 xx1000001076 Remove the press tool mounting axis 6 and the shaft 16 Continues on next page Product manual IRB 660 185 3HAC02575...

Page 186: ...upper arm This work is best done on a workbench or similair Note Action Lift the tilthouse to a workbench or similair with a roundsling in an overhead crane 1 Art no is specified in Required equip ment on page 178 Apply some grease in the hole for the bearings J and K 2 Shown in the figure Cut away view of the assembly of the tilthouse unit on page 177 Shown in the figure Cut away view of the asse...

Page 187: ...on page 178 Apply some grease in the hole for the bearings J and K 1 Shown in the figure Cut away view of the assembly of the tilthouse unit on page 177 Shown in the figure Cut away view of the assembly of the tilthouse unit on page 177 Fit the outer race of the bearing J facing the outside of the tilthouse Use a plastic hammer or similiar 2 Shown in the figure Cut away view of the assembly of the...

Page 188: ...age 177 Shown in the figure Location of axes 2 and 3 sides of the robot on page177 Note Fit the axis 2 side first 4 Shown in the figure Cut away view of the assembly of the tilthouse unit on page 177 Push the axis 2 shaft M into its hole from the inside 5 Shown in the figure Cut away view of the assembly of the tilthouse unit on page 177 Thread the race of the bearing J facing the outside of the t...

Page 189: ...243 Apply locking liquid on the lock nut KM7 axis 2 side and fit it with the flat surface facing in side 13 Tightening torque 90 Nm Loctite 243 Apply locking liquid on the lock nut KM7 axis 3 side and fit it with the flat surface facing in side 14 Tightening torque 90 Nm xx0600002703 Apply locking liquid in the holes for the screws locking the shafts and fit screws and washers on both sides lockin...

Page 190: ...t the cover for filling grease 20 A Screw M6 grease filling hole Detailed in section Replacement of linkage upper rod on page 201 Refit the upper rod 21 Pendulum Calibration is described in Operating manual Calibration Pendu lum enclosed with the calibration tools Recalibrate the robot 22 Axis Calibration is described in Calib rating with Axis Calibration method on page 315 General calibration inf...

Page 191: ...ated as shown below xx0600002609 Upper arm A Motor axis 6 B Balancing device C Lower arm D Parallel rod E Linkage F Continues on next page Product manual IRB 660 191 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 4 3 Replacement of upper arm ...

Page 192: ...x0600002692 Shaft axis 2 A Shaft axis 3 B Set screw cup point M10 x 20 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 192 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 4 3 Replacement ...

Page 193: ...ginning 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 calibration routine on the Fle...

Page 194: ...led in section Remove the cable harness in the upper arm 6 CAUTION The complete upper arm with weighs 170 kg without any additional equipment fitted Use a suitable lifting accessory to avoid in jury to personnel 7 Raise the lifting equipment to take the weight of the upper arm 8 Detailed in section Replacing the balan cing device on page 236 Remove the balancing device 9 Detailed in section Replac...

Page 195: ...ed equipment on page 193 Shown in the figure View of the assembly of the upper arm components on page192 Note The adapter is not needed on this shaft 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 shaft 3 Remove the shaft axis 2 13 Put the shafts in a clean and safe place 14 Remove the upper arm 15 Continues on next page Product manual...

Page 196: ...fts Apply lubricant paste D on the threads and cones of the shafts Molycote 1000 Foundry Plus Apply rust preventive on the surfaces on the shaft according to illustration Note Apply rust preventive to the shafts on both sides of the robot xx1400001124 1 Art no is specified Required equipment on page 193 Prepare the bearings Fill the bearings G with bearing grease 2 Shown in the figure View of the ...

Page 197: ...ng is mounted askew there is a risk of play between the shaft and the upper arm Make sure the support rings are aligned correctly level inside the upper arm housing 3 xx1900001714 xx1900001205 Refitting upper arm The procedure below details how to refit the upper arm Note Action Secure the upper arm with roundslings in an overhead crane 1 CAUTION The complete upper arm with weighs 170 kg without a...

Page 198: ... shaft Tightening torque 800 Nm 3 Refit the sealing ring F on the shaft 4 Refit the bearing G on the shaft with the pressing tool upper arm 5 Fit an o ring H on the sealing ring I and fit it on the shaft Note The o ring shall be faced against the bearing 6 Fit the o ring L on the sealing as sembly J and refit the sealing as sembly on the shaft 7 Apply locking liquid Loctite 243 on the lock nut K a...

Page 199: ...in the figure View of the assembly of the upper arm components on page192 Apply locking liquid in the holes for the set screws C and fit the screws 7 Loctite 243 Tightening torque 35 Nm Wipe residual grease from the shafts 8 Detailed in section Replacing the parallel rod on page 216 Refit the parallel rod 9 Detailed in section Refit the cable harness upper end 10 Detailed in section Replacement of...

Page 200: ...e sure all safety requirements are met when performing the first test run 14 200 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 4 3 Replacement of upper arm Continued ...

Page 201: ...xx0600002592 Lower rod A Upper rod B Link C Required equipment Note Art no Spare part no Equipment White RAL 9003 3HAC023744 003 Upper rod Replace if damaged 3HAC3311 1 Needle bearing Shell Gadus S2 3HAC042536 001 Bearing grease Used to lubricate the bear ings Loctite 243 3HAB7116 1 Locking liquid Continues on next page Product manual IRB 660 201 3HAC025755 001 Revision W Copyright 2006 2020 ABB A...

Page 202: ... to re move the lock nut at the link Put the robot in a position where it is possible to reach all parts that shall be removed 1 xx1000001132 Let the tilthouse rest on a workbench on some pallets or similar This is done in order to prevent the tilthouse from falling downwards when the upper rod is removed 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to ...

Page 203: ...support washers and the sealing rings 6 Remove residual grease 7 Refitting upper rod The procedure below details how to refit the upper rod of the linkage Note Action Spare part no is specified in Required equipment on page 201 If needed replace the bearings in the rod Note The bearings are sensitive for pushes Make sure they are not damaged 1 Continues on next page Product manual IRB 660 203 3HAC...

Page 204: ...ts place on the shafts 6 xx1000001080 Lock nut 2 pcs Support washer 2 pcs Refit the support washers on the outside of the upper rod on the shaft ends 7 Apply locking liquid on the threads for the lock nuts 8 Tightening torque 120 Nm Refit the lock nuts on the link and tilthouse using locking liquid 9 DANGER Make sure all safety requirements are met when performing the first test run 10 204 Product...

Page 205: ... upper rod on page 201 Replacement of linkage link on page 209 Location of lower rod The lower rod is located as shown in the figure below xx0600002592 Lower rod A Upper rod B Link C Required equipment Note Art no Equipment For spare part no see Spare part lists on page 353 Lower rod Continues on next page Product manual IRB 660 205 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights rese...

Page 206: ...uc tions below Removal lower rod Use this procedure to remove the lower rod of the linkage 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 xx1000001252 If the upper rod is removed secure the link with a roundsling in a crane Use the hole in the middle of the link 2 This is done in order to pre...

Page 207: ...Note Action Spare part no is specified in Required equipment on page 205 If needed replace the bearings Note The bearings are sensitive for pushes Make sure they are not damaged 1 Specified in Required equipment on page 205 Lubricate the bearings properly with bearing grease 2 Refit the sealing spacer rings to the shaft ends on the link and frame 3 Replace if damaged Tip Putting some grease on the...

Page 208: ...wer rod on the link and frame shafts 8 Specified in Required equipment on page 205 Apply locking liquid on the threads of the lock nuts 9 Tightening torque 120 Nm Refit the lock nuts on the shaft ends Use a KM10 socket 10 DANGER Make sure all safety requirements are met when performing the first test run 11 208 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights res...

Page 209: ...f linkage upper rod on page 201 Replacing the linkage lower rod on page 205 Location of link The link is located as shown in the figure xx0600002592 Lower rod A Upper rod B Link C Cut away view of the assembly of the link The figure shows a cut view of how the link is fitted Continues on next page Product manual IRB 660 209 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Re...

Page 210: ...nce 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 the...

Page 211: ...ng in a crane Use the hole in the middle of the link This is done to prevent the link from moving when the upper rod and lower rod are re moved 3 Detailed in section Replacement of linkage upper rod on page 201 Remove the upper rod and lower rod 4 Detailed in section Replacing the linkage lower rod on page 205 Art no is specified in Required equipment on page 210 Fit the auxiliary shaft on the sha...

Page 212: ...ow air pressure into the hole for filling grease CAUTION Only a very low air pressure is needed 7 Put one hand with some paper on top of the VK cover in order to catch it when re leased Continues on next page 212 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 4 6 Replacement of linkage link Continued ...

Page 213: ...bend the link loose 11 Remove the link 12 Remove the support ring with the radial seal 13 Wipe off residual grease 14 If needed replace the bearings and radial seal 15 Preparations fitting outer races of the bearing and sealing in the link Use this procedure to fit the outer races of the bearings in the link Note Action Put the link on a workbench 1 Place the outer rings of the bearings in the lin...

Page 214: ...5 Lubricate and place the bearings and link on the shaft in the following order bearing link bearing 6 Art no is specified in Required equipment on page 210 Apply the pressing tool and secure the link 7 Loctite 243 Apply locking liquid on the lock nut 8 Secure the lock nut in these three steps 1 Tighten with a torque of 300 Nm 2 Unscrew the lock nut 3 Tighten the lock nut finally with a tightening...

Page 215: ...e upper rod to the link 14 Pendulum Calibration is described in Op erating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 15 Axis Calibration is described in Calibrating with Axis Calibration method on page315 General calibration information is included in section Calibration on page 305 DANGER Make sure all safety requirements are met when performing the fir...

Page 216: ...age 353 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 347 Standard toolkit Continues on next page 216 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 4 7...

Page 217: ...ll 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 xx0600002741 Remove the upper lock screw and washer that secure the parallel rod in position 4 A Lock screw M6x16 Continues...

Page 218: ... the parallel rod backwards from its upper connection point and let it rest against the frame and base 8 Secure the parallel rod with a roundsling in an overhead crane or similar 9 See figure above Remove the lower end of the parallel rod in the same way as the upper end 1 Remove the lower lock screw and washer 2 Remove the lower shaft A and cover washer B 3 Remove the thrust washer F 10 Remove th...

Page 219: ...st on the the frame and base 4 xx1400001126 Foundry Plus Apply rust preventive on the highlighted areas Note Rust preventive should be applied in both ends of the parallel rod 5 xx0700000065 Parts A Shaft B Cover washer C Parallel rod D Sealed spherical bearing E Bearing grease F Thrust washer Put the thrust washer F on the axis 2 side of the parallel rod C 6 See figure above Put the cover washer ...

Page 220: ...6x16 Refit the lock screw and plain washer 10 Lift the parallel rod up into position for fitting the upper end 11 Refit the upper end of the parallel rod in the same way as the lower end 12 Foundry Plus 13 Refit the protection plugs DANGER Make sure all safety requirements are met when performing the first test run 14 220 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All...

Page 221: ... Spare part lists on page 353 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 Product manual IRB 660 221 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 4 8 ...

Page 222: ...erence 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 223: ...36 Remove the balancing device 5 Also see Remove the parallel rod 6 Also see Remove the cable harness in the upper and lower arm 7 Secure the cable harness in a way that it is pro tected from oil spill and damage See Replacement of upper arm on page 191 Remove the complete upper arm 8 See Replacing motors axes 2 and 3 on page 258 Remove the axes 2 and 3 motors 9 Also see Remove the axes 2 and 3 ge...

Page 224: ... arm on both sides Note The axis 3 side has no M16 screws 14 xx1000001359 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 15 CAUTION The parallel arm system weighs 118 kg All lifting accessories used must be sized accord ingly 16 Continues on next page 224 Product manual IRB 660 3HAC02575...

Page 225: ...together with help of an iron bar or similar before remov ing them 18 CAUTION The robot lower arm weighs 65 kg All lifting accessories used must be sized accord ingly 19 xx1000001358 Remove the complete lower arm including the parallel arm 20 How to replace the parallel arm is detailed in section Replacement of parallel arm on page229 21 Continues on next page Product manual IRB 660 225 3HAC025755...

Page 226: ... 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 221 xx1000001368 Fit two guide sleeves for the axes 2 3 sealings to the lower arm and put the sealings on them See figure 4 Continues on next page 226 P...

Page 227: ...e 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 re...

Page 228: ... See Replacement of linkage upper rod on page 201 Refit the linkage 20 See Replacing the linkage lower rod on page 205 See Replacement of linkage link on page 209 Remove the lock screw 21 Pendulum Calibration is described in Operating manual Calibration Pen dulum enclosed with the calibration tools Recalibrate the robot 22 Axis Calibration is described in Calib rating with Axis Calibration method ...

Page 229: ...rt no see Spare part lists on page 353 Parallel arm VK cover VK cover Shell Gadus S2 3HAC042536 001 Bearing grease Mercasol 3110 Waxcoat 3HAC034903 001 Rust preventive 3HAC023092 001 Pressing tool lower arm 3HAC023098 001 Lifting accessory parallel arm Continues on next page Product manual IRB 660 229 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 4 9 Replacement ...

Page 230: ...e 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 calibration ro...

Page 231: ...age 221 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 Product manual IRB 660 231 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 4 9 Replacement of parallel arm Continued ...

Page 232: ...page 229 Disassemble the parallel arm from the lower arm by using the pressing tool lower arm 7 CAUTION The parallel arm system weighs 118 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 232 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair...

Page 233: ...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 229 xx1000001377 Refit a bearing on each shaft with pressing tool lower arm 4 Continues on next page Product manual IRB 660 233 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 4 9 Replacement of parallel arm Continued ...

Page 234: ...accessory parallel arm 9 Art no is specified in Required equipment on page 229 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 p...

Page 235: ...e complete lower arm 16 Pendulum Calibration is described 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 315 General calibration information is included in section Calibration on page 305 DANGER Make sure all safety requirements are met when performing the first...

Page 236: ... Hole to neutralize the spring force M12 B Hole on lifting ear C Hole for lock screw D Required equipment Note Art no Equipment etc For spare part num ber see Spare part lists on page 353 Balancing device Continues on next page 236 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the balancing device ...

Page 237: ...emoving balancing device Use this procedure to remove the balancing device Note Action The balancing device must be placed 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 236 xx...

Page 238: ...Screw in the screws until they have proper contact with the cylinder inside 5 The length of the cylinder is now locked and the balancing device is unloaded It should now be possible to easily rotate the balancing device xx1000001112 Attach a lifting accessories to the balancing device Use the hole in the lifting ear 6 Continues on next page 238 Product manual IRB 660 3HAC025755 001 Revision W Copy...

Page 239: ... Fit the short auxiliary shaft on the upper shaft and the longer on the lower shaft 8 Stretch the roundsling 9 xx1000001115 Apply a ball bearing puller behind the lower ear of the balancing device Note The ball bearing puller must be applied around the spacer ring See figure 10 CAUTION The balancing device weighs 70 kg All lifting accessories used must be sized ac cordingly 11 Continues on next pa...

Page 240: ...of the bearings 14 xx1000001116 Remove upper and lower spacer rings and support washers 2 2 pcs 15 Remove residual grease 16 Refitting balancing device use this procedure to refit the balancing device Note Action Check the bearings Replace if needed 1 Continues on next page 240 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the...

Page 241: ...upper and lower shafts Fit the short auxiliary shaft on the upper shaft and the longer on the lower shaft 4 CAUTION The balancing device weighs 70 kg All lifting accessories used must be sized ac cordingly 5 xx1000001112 Attach lifting accessory to the balancing device and lift it on to the auxiliary shafts 6 Continues on next page Product manual IRB 660 241 3HAC025755 001 Revision W Copyright 200...

Page 242: ...on Re quired equipment on page 236 Fit the lubricating tool The tool should be tightened to the bottom po sition by hand power only 9 Fill the bearings with grease through the nipple 10 Continue until grease excudes behind the inner 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 236 Apply lockin...

Page 243: ...arings 15 Remove the M12x50 screws from the balancing device to restore the springforce 16 xx1000001101 Remove the lock screw 17 DANGER Make sure all safety requirements are met when performing the first test run 18 Product manual IRB 660 243 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the balancing device Continued ...

Page 244: ... 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 353 SMB unit For spare part number see Spare part lists on page 353 Battery pack Content is defined in section Standard tools on page 347 Sta...

Page 245: ...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 244 Remove the nuts and washers from the guide pins that secure the board 6 Connectors R1 SMB1 3 R1 SM...

Page 246: ...own in the figure Location of SMB unit on page 244 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 Locatio...

Page 247: ...Required equipment Note Article number Equipment etc DSQC1050 3HAC065020 001 Brake release board Content is defined in section Standard tools on page 347 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page Product manual IRB 660 247 3HAC...

Page 248: ...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 4 Take a picture or make notes of how the robot cabling is positioned in regard to the brake release board 5 Remove the complete b...

Page 249: ...brake release board on page 247 Art no is specified in Required equip ment on page 247 Refit the complete brake release board includ ing brake release board and bracket to the SMB recess with the two attachment screws 4 Verify that the robot cabling is positioned cor rectly according to previously taken pic ture notes WARNING Screened cables must not get in contact with the brake release board aft...

Page 250: ...pter section Updating revolution counters on page 311 If the battery has been disconnected the revolu tion counter must be updated 10 DANGER Make sure all safety requirements are met when performing the first test run 11 250 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 5 3 Replacing the brake release board Continued ...

Page 251: ...d equipment Note Art no Equipment etc Includes motor pinion o ring The old o ring must be replaced when replacing the motor For spare part number see Spare part lists on page 353 Motor axis 1 Shell Gadus S2 3HAC042536 001 Grease For lubricating the o ring Used to reach the attachment screws for the motor 3HAC12342 1 Bits extension Continues on next page Product manual IRB 660 251 3HAC025755 001 Re...

Page 252: ...outine 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 Calib...

Page 253: ...le exit of the motor Note Make sure the gasket is undamaged Replace if damaged 4 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 Remove the attachment screws of the motor Use the bits extension 7 Continues on next page Product manual IRB 660 253 3HAC025755 001 Revision W Copyright 2006 2020 ...

Page 254: ...sized ac cordingly 9 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 Continues on next page 254 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved...

Page 255: ...accessories used must be sized ac cordingly 2 Connect to connector R2 MP1 pin 2 pin 5 In order to release the brake connect the 24 VDC power supply 3 Gently lower the motor into the gear making sure the pinion is properly mated to the gearbox of axis 1 Note Make sure the motor is turned the right way See figure Note Make sure the motor pinion does not get dam aged 4 Continues on next page Product ...

Page 256: ...ce gasket if damaged 8 Refit the motor cover with its attachment screws Note Make sure the cover is tightly sealed 9 Pendulum Calibration is described in Operating manual Calibration Pendu lum enclosed with the calibration tools Recalibrate the robot 10 Axis Calibration is described in Calib rating with Axis Calibration method on page 315 General calibration information is in cluded in section Cal...

Page 257: ...ke sure all safety requirements are met when performing the first test run 11 Product manual IRB 660 257 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 6 1 Replacing motor axis 1 Continued ...

Page 258: ...or pinion o ring the o ring must be re placed when the motor is re placed For spare part no see Spare part lists on page 353 chapter Motor axes 2 3 Shell Gadus S2 3HAC042536 001 Grease For lubricating the o ring M10x150 3HAC13120 2 Guide pins For guiding the motor Guide pins are to be used in pairs 3HAC15534 1 Lifting accessory motor axes 2 3 M16x90 Lock screw For securing the lower arm Used to re...

Page 259: ...ration 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 proced ure is co...

Page 260: ...apsing when the axis 2 motor is being removed CAUTION Tighten by hand Run axis 3 to the end position so that it rests against the mechanical stop Release the brake of axis 3 in order to set the weight of axis 3 against the mechanical stop 4 This is done in order to secure axis 3 from col lapsing when the axis 3 motor is being removed DANGER Turn off all electric power supply hydraulic pressure sup...

Page 261: ...Replace if damaged 8 Disconnect all connectors beneath 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 Continues on next page Product manual IRB 660 261 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 6 2 Replacing motors axes 2 and 3 Continued ...

Page 262: ... Art no is specified in Required equipment on page 258 xx1000001131 Fit two guide pins in two of the motors attach ment holes 12 Continues on next page 262 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 6 2 Replacing motors axes 2 and 3 Continued ...

Page 263: ...o the motor 14 CAUTION The motor weighs 32 kg All lifting accessories used must be sized ac cordingly 15 The figure shows IRB 760 but the principle is the same xx1000001105 Pull out the motor on the guide pins to get the pinion away from the gear Make sure the pinion does not get damaged 16 Remove the motor by gently lifting it straight out and place it on a secure surface 17 Continues on next pag...

Page 264: ...ng 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 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 258 Fit the lifting tool motor axes 2 3 to the motor 3 Continues on next page 264 Product manual IRB 660 3HAC025755 001 Revisi...

Page 265: ...inciple is the same xx1000001185 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 6 Remove the lifting tool and allow the motor to rest on the guide pins 7 Continues on next page Product manual IRB 660 265 ...

Page 266: ...01104 Secure the motor with its four attachment screws and plain washers Use the bits exten sion Reused screws can be used providing they are lubricated as detailed in section Screw joints on page 343 before fitting 10 Attachment screws M10 x 40 quality 12 9 Gleitmo Tightening torque 50 Nm Disconnect the brake release voltage 11 Connect in accordance with markings on connectors Reconnect all conne...

Page 267: ...ed 14 xx1000001101 Remove the lock screw from the hole for lock screw 15 See section Performing a leak down test on page 142 Perform a leak down test of the axis 2 or 3 gearbox 16 See section Changing oil gearbox axes 2 and 3 on page 126 Refill the gearbox with oil 17 Continues on next page Product manual IRB 660 267 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 ...

Page 268: ...ed in Calib rating with Axis Calibration method on page 315 General calibration information is in cluded in section Calibration on page 305 DANGER Make sure all safety requirements are met when performing the first test run 19 268 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 6 2 Replacing motors axes 2 and 3 Continued ...

Page 269: ...to reach attachment screws for motor 3HAC12342 1 Bits extension Loctite 243 3HAB7116 1 Locking liquid 24 VDC 1 5 A Power supply For releasing the brakes Shell Gadus S2 3HAC042536 001 Grease For lubricating the o ring Content is defined in section Standard tools on page 347 Standard toolkit These procedures include refer ences to the tools required Other tools and procedures may be required See ref...

Page 270: ...completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 316 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 Operati...

Page 271: ... screw A on the inside Note Make sure the gasket is not damaged 5 A B C D xx0500002466 A Signal lamp UL lamp B Cable straps outdoor C Cable D Connection point to the cable gland Disconnect all connectors beneath the cover Note The connection to the UL lamp must also be disconnected if the robot is equipped with one 6 Continues on next page Product manual IRB 660 271 3HAC025755 001 Revision W Copyr...

Page 272: ...tting two screws in the motor attach ment holes diagonal to each other 9 xx1000001108 Lift the motor carefully to get the pinion away from the gear Note Make sure the pinion does not get dam aged 10 Disconnect the brake release voltage 11 Remove the motor by gently lifting it straight up and place it on a secure surface 12 Continues on next page 272 Product manual IRB 660 3HAC025755 001 Revision W...

Page 273: ...e connect the 24 VDC power supply 2 Art no is specified in Required equipment on page 269 Fit the two guide pins in two of the motor attach ment holes 3 xx1000001108 Lift the motor carefully in place Make sure the motor pinion is properly mated to the gearbox axis 6 Note Make sure the motor is turned the correct way See figure 4 Remove the guide pins 5 Apply locking liquid Loctite 243 on the attac...

Page 274: ...nect the brake release voltage 8 See section Performing a leak down test on page 142 Perform a leak down test of the axis 6 gearbox 9 Connect in accordance with markings on connectors Reconnect all connectors in motor axis 6 10 Refit the connections to the UL lamp if the ro bot is equipped with one 11 xx1000001224 Check the gasket If damaged replace it 12 Continues on next page 274 Product manual ...

Page 275: ...on is described in Operating manual Calibration Pendu lum enclosed with the calibration tools Re calibrate the robot 15 Axis Calibration is described in Calib rating with Axis Calibration method on page 315 General calibration information is in cluded in section Calibration on page 305 DANGER Make sure all safety requirements are met when performing the first test run 16 Product manual IRB 660 275...

Page 276: ...if damaged 3HAB3772 54 O ring Replace if damaged 3HAB3772 55 O ring Replace if damaged 3HAC11581 4 Sealing ring Shell Gadus S2 3HAC042536 001 Grease For lubricating the o ring 3HAC15535 1 Support base and gear 1 3HAC15560 1 Lifting accessory base 3HAC15556 1 Lifting accessory chain 2 pcs M16x150 Guide pins Used for guiding the gearbox into place in the base Always use guide pins in pairs Continues...

Page 277: ...Pack 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 the axis or create new reference values These va...

Page 278: ... hydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 See Changing oil axis 1 gearbox on page 123 Drain the axis 1 gearbox 4 See Replacing the base including axis 1 gearbox on page 164 Remove the complete arm system 5 Unfasten the robot base from the foundation by removing the base attachment screws 6 Continues on next page 278 Product manual IRB 660 ...

Page 279: ...equip ment on page 276 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 660 279 3HAC025755 001 R...

Page 280: ... 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 280 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 gearbox Continue...

Page 281: ... 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 660 281 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 gearbox Continued ...

Page 282: ...t no is specified in Required equip ment on page 276 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 282 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights ...

Page 283: ... chain to the gearbox 4 Specified in Required equipment on page 276 Fit two guide pins in two of the attachment holes in the gearbox parallel to each other 5 CAUTION The gearbox weighs All lifting accessories used must be sized ac cordingly 6 Continues on next page Product manual IRB 660 283 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 g...

Page 284: ...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 284 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 gearbox Continued ...

Page 285: ...on Screw joints on page343 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 660 285 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 gea...

Page 286: ...on page 164 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 142 Perform a leak down test 16 See Changing oil axis 1 gearbox on page 123 Refill the gearbox with oil 17 Pendulum Calibration is described in Operating manual Calibration Pendu lum enclosed with the calibr...

Page 287: ...7 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 to lift the gearbox Use to keep the sealing in place 3HAC14628 1 2 Guide sleeves...

Page 288: ...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 289: ...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 Product manual IRB 660 289 3HAC025755 001 Revision W Co...

Page 290: ...to 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 290 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB...

Page 291: ...nd 3 on page 128 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 258 Remove the axis 2 or axis 3 motor depend ing on which gearbox is being removed 16 x...

Page 292: ...he 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 gearbo...

Page 293: ...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 Product manual IRB 660 293 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 7 2 Replacing the gearbox axes 2 3 Continued ...

Page 294: ... 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 287 Fit the lifting accessory to the gearbox and lift it with an overhead crane 4 Continues on next page 294 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All righ...

Page 295: ...t 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 Product manual IRB 660 295 3HAC025...

Page 296: ...er 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 Remov...

Page 297: ...screws 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 258 Refit the motors axes 2 3 17 See Performing a leak down test on page 142 Perform a leakdown test 18 Continues on next page Product manual IRB 660 297 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4...

Page 298: ...cs Tightening torque 300 Nm Axis 3 M12x60 quality 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 page315 General calibration information is included in section Calibration on page 305 DANGER Make...

Page 299: ... 6 For spare part no see Spare part lists on page 353 Turning disk Not included in gearbox 3HAA1001 172 Washers Replace only if damaged Must be replaced when reas sembling gearbox 3HAB3772 57 O ring type 2 164 7x3 53 Must be replaced when reas sembling gearbox 3HAB3772 64 O ring type 2 150 0x2 0 Must be replaced when reas sembling gearbox 3HAB3772 61 O ring type 2 12 pcs 13 1x1 6 Shell Gadus S2 3H...

Page 300: ...th refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 316 If no previous reference values exis...

Page 301: ...ing the turning disk on page 172 Remove the turning disk 5 Remove the gearbox by unscrewing the at tachment screws and washers that secure it 6 xx0200000220 If required apply two M8 screws in the holes shown in the figure and press out the gearbox 7 A M8 holes for pressing out the gearbox Continues on next page Product manual IRB 660 301 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights...

Page 302: ...6 Use this procedure to refit gearbox axis 6 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 302 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 7 3 Replacing gearbox axis 6 Continued ...

Page 303: ...age pinion or gears in the pro cess 8 pcs or 18 pcs depending on wrist ver sion M8 x 40 12 9 quality Gleitmo Tightening torque 30 Nm Secure the gearbox with its attachment screws and washers Reused screws may be used providing they are lubricated as detailed in section Screw joints on page 343 before fitting 6 See section Replacing the turning disk on page 172 Refit the turning disk 7 See section ...

Page 304: ...cribed in Calibrating with Axis Calibration method on page315 General calibration information is included in section Calibration on page 305 DANGER Make sure all safety requirements are met when performing the first test run 11 304 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 4 Repair 4 7 3 Replacing gearbox axis 6 Continued ...

Page 305: ...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 306: ...cription of calibration methods Calibration Pendulum method Calibration Pendulum is a standard calibration method for calibration of all ABB robots except IRB 6400R IRB 640 IRB 1400H and IRB 4400S Two different routines are available for the Calibration Pendulum method Calibration Pendulum II Reference calibration The calibration equipment for Calibration Pendulum is delivered as a complete toolki...

Page 307: ... the calibration tools are listed in the section Special tools on page 348 The calibration equipment for Calibration Pendulum is delivered as a complete toolkit including the Operating manual Calibration Pendulum which describes the method and the different routines further Product manual IRB 660 307 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 5 Calibration 5 1 2 Calibrat...

Page 308: ...ost If the revolution counter memory is lost the counters must be updated See Updating revolution counters on page 311 This will occur when The battery is discharged A resolver error occurs The signal between a resolver and measurement board is interrupted A robot axis is moved with the control system disconnected The revolution counters must also be updated after the robot and controller are conn...

Page 309: ...ation mark axis 3 D Synchronization plate and mark axis 6 E Synchronization marks at axes 2 and 3 The synchronization marks at axes 2 3 and 6 shown in the figure above consist of two single marks that should be positioned opposite to one another when the robot is standing in its synchronization position One of the marks is more narrow than the other and should be positioned within the limits of th...

Page 310: ...n the graphic below Calibration service routines will handle the calibration movements automatically and these might be different from the positive directions shown below Manual movement directions 4 axes Note The graphic shows an IRB 260 The positive direction is the same for all 4 axis robots xx0500001927 310 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights res...

Page 311: ...n resulting in an incorrect manipulator calibration Make sure the axes are positioned according to the correct calibration values not only according to the synchronization marks The correct values are found on a label located either on the lower arm underneath the flange plate on the base or on the frame At delivery the manipulator is in the correct position Do NOT rotate axis 4 or 6 at power up b...

Page 312: ... 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 312 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 5 Calibration 5 3 Updating revolution counters Continued ...

Page 313: ...s 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 Product manual IRB 660 313 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 5 Calibration 5 3 Updating revolution counters Continued ...

Page 314: ...he 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 C...

Page 315: ...able 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 inser...

Page 316: ...BB factory The reference value will be named according to tool name date etc Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values When reference calibration is performed the robot is restored to the status given by the reference values Update revolution counters Choose this routine to make a rough calibration of each manipulator axis by u...

Page 317: ...etween the axes Requirements for axis positioning during calibration Axis to calibrate Axis 6 Axis 5 Axis 4 Axis 3 Axis 2 Axis 1 Required position of axis Axis 1 0 0 Axis 2 0 0 Axis 3 Axis 6 Axis to be calibrated Unrestricted Axis is allowed to be jogged to other position than 0 degrees Axis must be put in position 0 degrees 0 Product manual IRB 660 317 3HAC025755 001 Revision W Copyright 2006 202...

Page 318: ...ngs 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 319: ...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 320: ...on pin the axis is equipped with two bushings instead for installation of two calibration tools when calibration is carried out This is shown in the figure xx1600000699 The fixed calibration pin for axis 1 is installed on a removable tower The tower will need to be removed if electronic position switches are fitted to the robot Keep the tower in a safe location for future recalibration needs and m...

Page 321: ...aling in the bushing Replace damaged parts with new Note Article number Spare part Contains replacement calibration pin covers and protective plugs for the bushing 3HAC056806 001 Protection cover and plug set Product manual IRB 660 321 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 5 Calibration 5 4 3 Installation locations for the calibration tools Continued ...

Page 322: ...ure 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 323: ...dant while conducting it Note Action DANGER While conducting the calibration the robot needs to be connected to power Make sure that the robot s working area is empty as the robot can make unpredictable movements 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 U...

Page 324: ...n the FlexPendant is given in Overview of the calibra tion procedure on the FlexPendant on page 322 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 325: ... and will force SafeMove to unsynchronize automatically However SafeMove may generate other warning messages anytime during the Axis Calibration routine When a warning message is displayed tap Acknowledge to confirm the unsynchronized state and continue Axis Calibration procedure CAUTION SafeMove must be synchronized after the calibration is completed After calibration Note Action xx1600002102 Che...

Page 326: ... 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 001 326 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 5 Calibration 5 4 4 Axis Calibration Running the calibration procedure Continued ...

Page 327: ...to save reference values for all axes that is to be replaced Make sure that the values are saved in RobotStudio or FTP program The files are located in Active system folder name HOME RefCalibFiles 7 Perform the repair 8 Make sure that the tooling and process equipment are the same as when creating the reference Use Reference calibration to update the system with new calibration offset value for th...

Page 328: ... ie 96 3 94 2 2 1 degrees 8 Manually jog axis 4 the calculated angle difference 2 1 NOTE The direction shall be the same direction as the direction used when axis 4 was manually jogged to coincide with the verification process In the example 2 1 degrees 9 Make a new manual fine calibration of axis 4 with axis in 2 1 degrees position 10 Check again against the verification position 11 Repeat the ma...

Page 329: ...ndulum Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools Product manual IRB 660 329 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 5 Calibration 5 5 Calibrating with Calibration Pendulum method ...

Page 330: ...ion program 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 309 Adjust the synchronization marks when the calibration is done if necessary 2 Write down the values on a new label and stick it on top of the calibration label 3 The label is located on the lower arm 330 Produc...

Page 331: ... page 309 and Updating revolution counters on page 311 Check that the synchronization marks for the axes align correctly If they do not update the revolu tion counters 6 Using the jogging window Use this procedure to jog the robot to the synchronization position of all axes Note Action On the ABB menu tap Jogging 1 Tap Motion mode to select group of axes to jog 2 Tap to select the axis to jog axis...

Page 332: ...This page is intentionally left blank ...

Page 333: ...bles motors Copper Base lower arm upper arm Cast iron nodular iron Gears screws base frame and so on Steel Brakes motors Neodymium Cables connectors drive belts and so on Plastic rubber Gearboxes Oil grease Covers synchronization brackets Aluminium Oil and grease Where possible arrange for oil and grease to be recycled Dispose of via an authorized person contractor in accordance with local regulat...

Page 334: ...to organisms Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination 334 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 6 Decommissioning 6 1 Environmental information Continued ...

Page 335: ...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 660 335 3HAC025755 001 Revision W Copyright 2006 2020 ABB All ri...

Page 336: ... 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 device is to be decommissioned Note Action ...

Page 337: ...pring coils are cut from a more safe distance 2 WARNING There is some grease and a plastic layer inside the balancing device When opening a hole in the device the cutting torch will cause the plastic and the grease to start to burn Wear protective clothing Make sure that the working area is well ventilated 3 DANGER The hole must be cut as specified in the figure Pieces can be ejected from the cyl ...

Page 338: ...evice so that the spatter will be directed away from personnel 6 Use a cutting torch with a long shaft Cut at least eight coils of the spring inside the housing 7 Double check the number of coils cut and make sure all the tension in the spring is removed 8 Cut more coils if there is still tension in the spring 338 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights ...

Page 339: ...apter includes general information complementing the more specific information in the different procedures in the manual Product manual IRB 660 339 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 7 Reference information 7 1 Introduction ...

Page 340: ...vices Coordinate systems and motion nomenclatures ISO 9787 2013 Manipulating industrial robots performance criteria and related test methods ISO 9283 1998 Classification of air cleanliness EN ISO 14644 1 2015i 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...

Page 341: ...pects Principles for design EN 574 1996 A1 2008 UL ANSI and other standards Description Standard Safety requirements for industrial robots and robot systems ANSI RIA 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 660 341 3HAC025755 001 Revision W Copyright 2006 2020 ABB All ri...

Page 342: ...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 342 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 7 Reference information 7 3 Unit conversion ...

Page 343: ...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 344: ...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 345: ...ening 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 660 345 3HAC025755 001 Rev...

Page 346: ...essory 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 arm weighs 25 kg All lifting accessories used must be sized accord ingly 346 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB Al...

Page 347: ...ion 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 75 800 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 bi...

Page 348: ...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 349: ...ifting tool motor ax 2 3 Fits motors axes 1 2 and 3 Removal tool motor M12x 3HAC17105 1 1 Rotation tool 3HAC12342 1 1 Bits extension 1 Standard toolkit content described in sec tion Standard tools on page 347 Lifting tools The following table specifies the lifting tools required during several of the service procedures The tools may be ordered separately and are also specified directly in concerne...

Page 350: ...AC023132 001 Pinion crank 3HAC072616 001 Press tool support ring 3HAC023092 001 Pressing lower arm balancing weight 3HAC023084 001 Pressing upper arm 3HAC5021 1 Pressing tie rod 3HAC023080 001 Pressing tilt house 3HAC023075 001 Pressing outer ring tilt house 3HAC5275 1 Auxiliary shaft long 3HAC5276 1 Auxiliary shaft short 3HAC5281 1 Support shaft bearing race 3HAC022436 001 Axis 1 pinion 3HAC5222 ...

Page 351: ...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 660 351 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 7 Reference information 7 8 Lifting accessories and lifting i...

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Page 353: ...iews 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 660 353 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 8 Spare part lists 8 1 Spare part lists and illustrations ...

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Page 355: ...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 356: ...B 6650S 3HAC025744 001 3HAC025744 001 Circuit diagram IRB 6660 3HAC029940 001 3HAC043446 005 Circuit diagram IRB 6700 IRB 6790 3HAC13347 1 Circuit diagram IRB 7600 3HAC025744 001 3HAC050778 003 Circuit diagram IRB 14000 3HAC056159 002 Circuit diagram IRB 910SC 356 Product manual IRB 660 3HAC025755 001 Revision W Copyright 2006 2020 ABB All rights reserved 9 Circuit diagrams 9 1 Circuit diagrams Co...

Page 357: ...on 330 when to calibrate 308 calibration manuals 307 calibration marks 309 Calibration Pendulum overview of method 329 calibration position jogging to 331 scales 309 calibration scales 309 carbon dioxide extinguisher 31 cast iron disposal 333 changing oil axis 1 123 axis 2 126 axis 3 126 axis 6 130 cleaning 139 climbing on robot 34 Cold environments 87 connecting the robot and controller cabling 8...

Page 358: ...ion amount in gearboxes 122 type of lubrication 122 M maintenance schedule 93 manually releasing brakes 60 mechanical stop axis 1 78 mechanical stop location 112 MoveAbsJ instruction 331 N national regulations 30 negative directions axes 310 neodymium disposal 333 nodular iron disposal 333 O oil 34 amount in gearboxes 122 disposal 333 type of oil 122 oil change axis 1 123 axis 2 126 axis 3 126 axi...

Page 359: ...340 ANSI 341 CAN 341 EN 341 EN IEC 340 EN ISO 340 start of robot in cold environments 87 steel disposal 333 storage conditions 44 symbols safety 21 synchronization position 311 sync marks 309 system integrator requirements 30 T temperatures operation 44 storage 44 testing brakes 38 tools Axis Calibration 348 Calibration Pendulum 348 for service 348 oil exchange equipment 349 torques on foundation ...

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Page 362: ...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 3HAC025755 001 Rev W en Copyright 2006 2020 ABB All rights reserved Specifications subject to change without notice ...

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