ABB IRB 6660 - 130/3.1 Product Manual Download Page 170

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4 Repair

4.3.4. Replacement of cabling, axis 5 motor

3HAC028197-001 Revision: A

168

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200

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Removal, cabling axis 5 motor

The procedure below details how to remove the cabling from the axis 5 motor.

Refitting, cabling axis 5 motor

The procedure below details how to refit the cabling to the motor of axis 5.

Action

Note

DANGER!

Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!

2. Remove the complete wrist unit.

Detailed in section:

•

Removal, wrist unit on page
184

3. Remove the cover of motor, axis 5.

4. Disconnect all connectors at motor, axis 5.

5. Remove the cable gland cover at the cable

exit by unscrewing its two attachment screws.

6. Remove the cable, axis 5.

Action

Note

DANGER!

Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!

2. Reconnect all connectors at motor, axis 5.

3. Refit the cable gland cover at the cable exit

with its two attachment screws.

4. Refit the cover of motor, axis 5.

5. Refit the complete wrist unit.

Detailed in section:

•

Refitting, wrist unit on page
185

6. Recalibrate the robot.

This is done if a new wrist has been
fitted.

Calibration is detailed in a separate
calibration manual, enclosed with the
calibration tools.

General calibration information is
included in section

Calibration infor-

mation

Continued

Continues on next page

Summary of Contents for IRB 6660 - 130/3.1

Page 1: ...Product manual Articulated robot IRB 6660 130 3 1 IRB 6660 205 1 9 M2004 ...

Page 2: ......

Page 4: ...sons 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 and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravent...

Page 5: ...ety and information labels 29 1 3 Safety related instructions 30 1 3 1 Safety signals general 30 1 3 2 DANGER Moving robots are potentially lethal 32 1 3 3 DANGER First test run may cause injury or damage 33 1 3 4 WARNING The brake release buttons may be jammed after service work 34 1 3 5 WARNING The unit is sensitive to ESD 35 1 3 6 WARNING Safety risks during work with gearbox oil 36 2 Installat...

Page 6: ...lacement changing activities 116 3 4 1 Type of oil in gearboxes 116 3 4 2 Oil change gearbox axis 1 120 3 4 3 Oil change gearbox axes 2 3 123 3 4 4 Oil change gearbox axis 4 126 3 4 5 Oil change gearbox axis 5 128 3 4 6 Oil change gearbox axis 6 130 3 4 7 Replacement of SMB battery 133 3 5 Lubrication activities 136 3 5 1 Lubrication of bearing balancing device 136 3 6 Cleaning activities 139 3 6 ...

Page 7: ...5 4 Calibration movement directions for all axes 264 5 5 Updating revolution counters 265 5 6 Checking the calibration position 267 6 Decommissioning 269 6 1 Introduction 269 6 2 Environmental information 270 6 3 Decommissioning of balancing device 271 7 Reference information 273 7 1 Introduction 273 7 2 Applicable Safety Standards 274 7 3 Unit conversion 275 7 4 Screw joints 276 7 5 Weight specif...

Page 9: ...ge of mechanical and electrical installation repair maintenance work Organization of chapters The manual is organized in the following chapters Chapter Contents Safety Safety information that must be read through before performing any installation or service work on the robot Contains general safety aspects as well as more specific information on how to avoid personal injuries and damage to the pr...

Page 10: ...expendant 3HAC16590 1 Operating manual Calibration pendulum 3HAC16578 1 Operating manual Service Information System 3HAC025709 001 Application manual Additional axes and stand alone controller 3HAC021395 001 Technical reference manual System parameter 3HAC17076 1 Application manual Electronic Position Switches 3HAC027709 001 Revision Description First edition A This revision includes the following...

Page 11: ...ures including spare parts Additional procedures if any calibration decommissioning Reference information article numbers for documentation referred to in Product manual procedures lists of tools safety standards Part list Foldouts or exploded views Circuit diagrams Technical reference manuals The following manuals describe the robot software in general and contain relevant reference information R...

Page 12: ... having first hand operational contact with the robot that is production cell operators programmers and trouble shooters The group of manuals includes Emergency safety information General safety information Getting started IRC5 and RobotStudio IRC5 with FlexPendant RobotStudio Introduction to RAPID Trouble shooting IRC5 for the controller and robot Continued ...

Page 13: ...nclude references to equipment spare parts tools etc required for the different actions in the procedure The equipment is marked with italic text in the procedures and completed with a reference to the section where the equipment is listed with further information that is article number dimensions The denomination in the procedure for the component or attachment point corresponds to the denominati...

Page 15: ...s important to attend to before performing any service work on the robot These are applicable for all service work and are found in section General safety information specific safety information pointed out in the procedure at the moment of the danger How to avoid and eliminate the danger is either detailed directly in the procedure or further detailed in separate instructions found in section Saf...

Page 16: ...tion and handling of the industrial robot described in the applicable documents for example Operating Manual IRC5 with FlexPendant M2004 Product Manual Connection of external safety devices Apart from the built in safety functions the robot is also supplied with an interface for the connection of external safety devices Via this interface an external safety function can interact with other machine...

Page 17: ...t be crossed before admittance must be set up in front of the robot s working space Light beams or sensitive mats are suitable devices Turntables or the like should be used to keep the operator out of the robot s working space The axes are affected by the force of gravity when the brakes are released In addition to the risk of being hit by moving robot parts you run the risk of being crushed by th...

Page 18: ...lt in burns too Removed parts may result in collapse of robot WARNING Take any necessary measures to ensure that the robot does not collapse as parts are removed e g secure the lower arm with fixtures if removing motor axis 2 Safety risk Description Cable packs are sensitive to mechanical damage CAUTION The cable packs are sensitive to mechanical damage They must be handled with care especially th...

Page 19: ...safely turn off tools such as milling cutters etc Make sure that guards remain closed until the cutters stop rotating It should be possible to release parts by manual operation valves Safe design Grippers end effectors must be designed so that they retain workpieces in the event of a power failure or a disturbance of the controller CAUTION Ensure that a gripper is prevented from dropping a workpie...

Page 20: ... to pneumatic and hydraulic systems Residual energy Residual energy may be present in these systems After shutdown particular care must be taken The pressure in pneumatic and hydraulic systems must be released before starting to repair them Safe design Gravity may cause any parts or objects held by these systems to drop Dump valves should be used in case of emergency Shot bolts should be used to p...

Page 21: ...rried out professionally and in accordance with the applicable safety regulations Care must be taken at all times Qualified personnel Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts Extraordinary risks If the working process is interrupted extra care must be taken d...

Page 22: ...re of stored electrical energy DC link Ultracapacitor bank unit in the controller Units such as I O modules can be supplied with power from an external source The mains supply mains switch The transformers The power unit The control power supply 230 VAC The rectifier unit 400 480 VAC and 700 VDC Note Capacitors The drive unit 700 VDC The drive system power supply 230 VAC The service outlets 115 23...

Page 23: ...mension the fence or enclosure to enable it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed Determine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot is working in the work cell see Product Specification Description Robot Motion Also consider the maximum possible impact caused by ...

Page 24: ...e extinguishing 3HAC028197 001 Revision A 22 Copyright 2007 2008 ABB All rights reserved 1 2 3 2 Fire extinguishing NOTE Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the robot system robot or controller ...

Page 25: ...eased manually by pushing the brake release buttons on the robot How to release the brakes is detailed in section Manually releasing the brakes on page 56 The robot arm may be moved manually on smaller robot models but larger models may require using an overhead crane or similar Increased injury Before releasing the brakes make sure that the weight of the arms does not increase the pressure on the...

Page 26: ...m its function How to test The function of the holding brake of each axis motor may be checked as detailed below 1 Run each robot axis to a position where the combined weight of the robot arm and any load is maximized max static load 2 Switch the motor to the MOTORS OFF position with the Operating mode selector on the controller 3 Check that the axis maintains its position If the robot does not ch...

Page 27: ...7 001 Revision A Copyright 2007 2008 ABB All rights reserved 1 2 3 5 Risk of disabling function Reduced speed 250 mm s NOTE Do not change Transm gear ratio or other kinematic system parameters from the FlexPendant or a PC This will affect the safety function Reduced speed 250 mm s ...

Page 28: ...released or pushed all the way in the robot is taken to the MOTORS OFF state To ensure safe use of the FlexPendant the following must be implemented The enabling device must never be rendered inoperative in any way During programming and testing the enabling device must be released as soon as there is no need for the robot to move The programmer must always bring the FlexPendant with him her when ...

Page 29: ...ntrol panel The robot s speed is limited to max 250 mm s when the operating mode selector is in position manual mode with reduced speed This should be the normal position when entering the working space The position manual mode with full speed 100 may only be used by trained personnel who are aware of the risks that this entails Pay attention to the rotating axes of the robot Keep a distance to th...

Page 30: ...reserved 1 2 3 8 Signal lamp optional Description A signal lamp with an yellow fixed light can be mounted on the robot as a safety device 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 controller documentation ...

Page 31: ... on page 106 Translation possibilities The labels fitted to the product contain space for adding a fourth language underneath the three standard languages English German and French Add a local language to the label by Using a transparent sticker over the standard label with text added in a fourth language Drawings detailing the design text figure dimensions of the standard labels can be ordered fr...

Page 32: ...h for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc warning WARNING Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high volt...

Page 33: ...lectrostatic discharge ESD symbol indicates electrostatic hazards which could result in severe damage to the product Note NOTE Note symbols alert you to important facts and conditions Tip TIP Tip symbols direct you to specific instructions where to find additional information or how to perform a certain operation in an easier way Symbol Designation Signification Continued ...

Page 34: ...ment located within the working range of the robot Elimination Action Note 1 Before attempting to run the robot make sure all emergency stop equipment is correctly installed and connected Emergency stop equipment such as gates tread mats light curtains etc 2 If possible use the hold to run function whenever possible The hold to run function is used in manual mode not in automatic mode How to use t...

Page 35: ... to take into consideration before the first test run Elimination Follow the procedure below when performing the first test run after a service activity repair installation or maintenance Action 1 Remove all service tools and foreign objects from the robot and its working area 2 Install all safety equipment properly 3 Make sure all personnel are standing at a safe distance from the robot that is o...

Page 36: ...se the power is turned on while a brake release button is jammed in depressed position the affected motor brake is released This may cause serious personal injuries and damage to the robot Elimination To eliminate the danger after service work has been performed inside the SMB recess follow the procedure below Action 1 Make sure the power is turned off 2 Remove the push button guard if necessary 3...

Page 37: ...ot grounded may potentially transfer high static charges This discharge may destroy sensitive electronics Elimination Location of wrist strap button The wrist strap button is located in the right corner as shown in the illustration below xx0500002171 Action Note 1 Use a wrist strap Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly 2 Use an ESD p...

Page 38: ...the opening Do not overfill the gearbox when filling Do not overfill Overfilling of gearbox oil can lead to internal over pressure inside the gearbox which in turn may damage seals and gaskets completely press out seals and gaskets prevent the robot from moving freely Make sure not to overfill the gearbox when filling with oil After filling check the correct oil level Do not mix types of oil Mixin...

Page 39: ...erved 2 Installation and commissioning 2 1 Introduction General This chapter contains information for installing the robot to the working site More detailed technical data such as load diagram permitted extra loads equipment and location of extra loads equipment may be found in the Product Specification for the robot ...

Page 40: ... installation personnel conforming to all national and local codes are allowed to perform the installation 2 Visually inspect the robot to make sure it is not damaged 3 Make sure the lifting device used is suitable to handle the weight of the robot as specified in Weight robot on page 38 4 If the robot is not installed directly it must be stored as described in Storage conditions robot on page 39 ...

Page 41: ... 3 1 18 0 7 7 kN IRB 6660 205 1 9 Torque xy 25 6 kNm IRB 6660 130 3 1 19 6 kNm IRB 6660 205 1 9 37 2 kNm IRB 6660 130 3 1 32 4 kNm IRB 6660 205 1 9 Torque z 10 3 kNm IRB 6660 130 3 1 7 1 kNm IRB 6660 205 1 9 19 3 kNm IRB 6660 130 3 1 14 7 kNm IRB 6660 205 1 9 Force Endurance load operation Max load emergency stop Requirement Value Note Min levelity 0 5 mm Max tilt 5 The limit for the maximum load ...

Page 42: ...opyright 2007 2008 ABB All rights reserved 2 2 2 Working range and type of motion Working range The following figures show the working ranges of the robot models The extreme positions of the robot arm are specified at the wrist center dimensions in mm IRB 6660 130 3 1 xx0700000011 Continues on next page ...

Page 43: ...007 2008 ABB All rights reserved IRB 6660 205 1 9 xx0700000563 Type of motion Axis Type of motion Range of movement Note 1 Rotation motion 180º to 180º 2 Arm motion 85 to 42 3 Arm motion 120 to 20 2 3 Arm motion 20 to 160 4 Wrist motion 300º to 300º 5 Bend motion 120º to 120º 6 Turn motion 300º to 300º Continued ...

Page 44: ...e robot is not stable in the whole working area Moving the arms will displace the center of gravity which may cause the robot to tip over Do not change the robot position before securing it to the foundation Stabililty The figure below shows the robot in its shipping position which also is its most stable position xx0700000001 WARNING The robot is likely to be mechanically unstable while not secur...

Page 45: ...uipment to the robot Attachment points The attachment points for the fork lift equipment are shown in the figure below xx0500002276 Required equipment A Attachment points on adapter and horizontal attachment screws B Attachment points horizontal attachment screws C Attachment points vertical attachment screws Equipment etc Art no Note Fork lift set incl all required hardware 3HAC023044 001 See the...

Page 46: ...th fork lift The section below details how to secure the fork lift set to the robot in order to lift and move the robot using the fork lift ONLY A Fork lift pocket 2 pcs one long one short B Adapter 1 1 pcs C Horizontal attachment screws 4 pcs fork lift pocket D Attachment screws for adapter 1 pc adapter E Vertical attachment screws 2 pcs Action Note 1 If a cooling fan for the axis 1 motor is used...

Page 47: ... the right Release the brakes if required as detailed in section Manually releasing the brakes on page 56 xx0700000517 A IRB 6660 130 3 1 B IRB 6660 205 1 9 3 Fit the two adapters to the robot and secure Attachment points on the robot are shown in the figure Attachment points on page 43 Attachment screws 2 pcs M16 x 90 Tightening torque 60 Nm Action Note Continued Continues on next page ...

Page 48: ... adapter and frame with four of the horizontal attachment screws and washers NOTE The vertically and the horizontally attached screws are identical but tightened with different torques Make sure the original screws are always used or replacements of equivalent quality M16 quality 12 9 Attachment points on the robot are shown in the figure Attachment points on page 43 xx0500002279 A Horizontal atta...

Page 49: ...s xx0500002284 A Vertical attachment screws 2 pcs M16x60 Tightening torque 270 Nm Make sure the original screws are always used or replacements of equivalent quality M16 quality 12 9 Attachment points on the robot are shown in the figure Attachment points on page 43 9 CAUTION The fork lift pocket weighs 22 kg 10 Secure the shorter fork lift pocket on the other side of the robot with the four remai...

Page 50: ...pockets 12 CAUTION The robot models weigh IRB6660 130 3 1 1910 kg IRB6660 205 1 9 1730 kg All lifting equipment used must be sized accordingly NOTE The weight 90 kg of the fork lift pockets must be added to the robot weight 13 Carefully lift the robot and move it to its instal lation site 14 WARNING Personnel must not under any circumstances be present under the suspended load 15 Refit the cooling...

Page 51: ...th roundslings General The robot may be lifted with roundslings according to the illustration below The illustration is identical with the label attached to the robot s lower arm Attachment points The figure below shows how to attach the roundslings to the robot xx0700000002 IRB 6660 130 3 1 A Roundsling 2 m B Roundsling 2 m C Roundsling 2 m Continues on next page ...

Page 52: ...197 001 Revision A 50 Copyright 2007 2008 ABB All rights reserved xx0700000426 Sling specification IRB 6660 205 1 9 A Roundsling 2 m B Roundsling 2 m C Roundsling 2 m Sling type Qty Lifting capacity Length Note Roundsling robot 3 pcs 3 000 kg 2 m Continued Continues on next page ...

Page 53: ...der 2 NOTE Make sure that the roundslings do not lie against sensitive parts for example harness and customer equipment 3 When attaching the roundsling A on the upper arm put it in a U shape through the hole in the wrist Shown in the figure Attachment points on page 49 4 CAUTION The robot models weigh IRB6660 130 3 1 1910 kg IRB6660 205 1 9 1730 kg All lifting equipment used must be sized accord i...

Page 54: ...cluded with the equipment NOTE Move the robot to the recommended position shown in the figure below and in the instruction Attempting to lift a robot in any other position may result in the robot tipping over causing severe damage or injury Illustration lifting slings The figure below shows how to lift the complete robot with lifting slings xx0700000004 IRB 6660 130 3 1 A Load hook B Swivelling li...

Page 55: ...rights reserved xx0700000427 Required equipment IRB 6660 205 1 9 A Load hook B Swivelling lifting eyes 4 pcs C Shortening hook D Chain E Lifting eye M12 F Lifting device s eye J Lifting slings 4 pcs L Hook Equipment Art no Note Lifting device robot 3HAC15607 1 Includes user instructions 3HAC15971 2 Continued Continues on next page ...

Page 56: ...ot using lifting slings when these are attached directly onto the robot frame Action Note 1 Run the overhead crane to a position above the robot 2 Make sure the robot is positioned as shown in the figure on the right If it is not position it that way Release the brakes if required as detailed in section Manually releasing the brakes on page 56 xx0700000137 IRB 6660 130 3 1 xx0700000518 IRB 6660 20...

Page 57: ...52 4 Fit the lifting device robot to the robot as described in the enclosed instruction Art no is specified in Required equipment on page 53 5 CAUTION The robot models weigh IRB6660 130 3 1 1910 kg IRB6660 205 1 9 1730 kg All lifting equipment used must be sized accordingly 6 WARNING Personnel must not under any circum stances be present under the suspended load 7 Raise the overhead crane to lift ...

Page 58: ... located on the frame beside motor axis 1 The internal brake release unit is equipped with six buttons for controlling the axes brakes The buttons are numbered according to the numbers of the axes If the robot is not connected to the controller power must be supplied to the connector R1 MP according to section Supplying power to connector R1 MP on page 57 The buttons are shown in the figure Locati...

Page 59: ...r R1 MP If the robot is not connected to the controller power must be supplied to connector R1 MP in the robot base in order to enable the brake release buttons on the robot Action Note 1 DANGER Incorrect connections such as supplying power to the wrong pin may cause all brakes to be released simultaneously 2 Supply 0V on pin 12 and 24V on pin 11 xx0300000565 Continued ...

Page 60: ...fting base plate Equipment Art no Note Lifting eye M16 3HAC14457 4 3 pcs Lifting slings 3 pcs Length approx 2 m A Attachment holes for lifting eyes x3 Action Note 1 CAUTION The base plate weighs 353 kg All lifting equipment used must be sized accordingly 2 Fit the lifting eyes in the three lifting holes Shown in the figure Hole con figuration on page 58 3 Fit the lifting slings to the eyes and to ...

Page 61: ...ecuring the base plate 59 3HAC028197 001 Revision A Copyright 2007 2008 ABB All rights reserved 2 3 6 Securing the base plate General This section details how to secure the base plate Base plate dimensions xx0100000105 Continues on next page ...

Page 62: ...on and commissioning 2 3 6 Securing the base plate 3HAC028197 001 Revision A 60 Copyright 2007 2008 ABB All rights reserved xx0400000715 A Four holes for alternative clamping 4x Ø18 Continued Continues on next page ...

Page 63: ...s attachment holes 4 pcs Equipment Art no Note Base plate 3HAC12937 7 Includes guide sleeves 3HAC12937 3 levelling screws 9ADA120 79 attachment screws and washers for securing the robot to the base plate A drawing of the base plate itself may be ordered from ABB Robotics Standard toolkit The content is defined in section Standard toolkit on page 280 Other tools and procedures may be required See r...

Page 64: ...tion to the robot work location using the three grooves in the base plate Shown in the figure Base plate grooves and holes on page 61 4 Lift the base plate to its mounting position Detailed in section Lifting the base plate on page 58 5 Use the base plate as a template and drill 16 attachment holes as required by the selected bolt dimension If possible observe the recommenda tions specified in sec...

Page 65: ...bot fitted to base plate The illustration below shows the robot base fitted to the base plate xx0100000107 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 A Robot attachment bolts and washers 12 pcs M24 x 140 B Orienting grooves in the robot base and in the base plate C Levelling screws D Base plate ...

Page 66: ...the vicinity of its installation location 3 Fit two guide sleeves to the guide sleeve holes in the base plate NOTE One of the guide sleeve holes is elongated 4 Guide the robot gently using two M24 screws while lowering it into its mounting position Make sure the robot base is correctly fitted onto the guide sleeves 5 Fit the bolts and washers in the base attachment holes Specified inAttachment scr...

Page 67: ...sion A Copyright 2007 2008 ABB All rights reserved Hole configuration base The illustration below shows the hole configuration used when securing the robot xx0300000046 Cross section guide sleeve hole The illustration below shows the cross section of the guide sleeve holes xx0100000109 Continued ...

Page 68: ... by any additional cabling equipment etc fitted by the robot user Make sure the required mounting holes are accessible when planning the robot cell NOTE No extra equipment may be fitted on the lower arm of the robot Illustration fitting of extra equipment on upper arm The illustrations below shows the mounting holes available for fitting extra equipment on the upper arm xx0700000015 Robot variant ...

Page 69: ...2 Installation and commissioning 2 3 8 Fitting equipment on robot 67 3HAC028197 001 Revision A Copyright 2007 2008 ABB All rights reserved xx0700000014 xx0700000674 Continued Continues on next page ...

Page 70: ...rved Illustration fitting of extra equipment on frame The illustrations below shows the mounting holes available for fitting extra equipment on the frame Illustrations shows robot variant IRB 6660 130 3 1 but all shown measurements are the same on the variant IRB 6660 205 1 9 xx0700000013 xx0700000012 Continued Continues on next page ...

Page 71: ...tration below shows the mounting holes available for fitting equipment on the turning disk xx0200000197 Fastener quality When fitting tools on the turning disk see the figures above only use screws with quality 12 9 When fitting other equipmenton upper arm house or frame standard screws with quality 8 8 may be used Turning disk for robot versions IRB 6660 130 3 1 and 205 1 9 Continued ...

Page 72: ...m as shown in the figure below xx0700000630 Required equipment A Bracket B Attachment screws M6x16 quality 8 8 A2F 2 pcs per side C Attachment screws M6x16 quality 8 8 A2F 4 pcs D Protection Equipment Art no Note Chip protection 3HAC030124 001 Locking liquid Loctite 243 For locking screws Standard toolkit The content is defined in section Standard toolkit on page 280 Other tools and procedures may...

Page 73: ...ctric power hydraulic and pneumatic pressure supplies to the robot 2 Place the chip protection around the lower arm As shown in the figure Location of Chip protection on page 70 3 Fit the bracket on the chip protection with its attachment screws two screws on each side of the lower arm Lock screws with locking liquid Art no is detailed in Required equipment on page 70 4 Let the protection hang dow...

Page 74: ... Installation of cooling fan for motors axis 1 or 2 option General A cooling fan can be installed on motor axis 1 or 2 Location of cooling fans The fan can be installed on motor axis 1 or 2 as shown in the figure below The figure shows IRB 6600 but the principle fitting is the same xx0700000671 A Cooling fan axis 2 B Cooling fan axis 1 C Rear cover plate Continues on next page ...

Page 75: ...g fan 3HAC15374 1 Cabling cooling fan axes 1 or 2 3HAC023599 001 Choose this cabling if equipping the robot with cooling fans on axis 1 or 2 not on axis 3 Plate for customer connections 3HAC025778 001 An additional connection plate must be fitted to the robot base if not already installed The plate is shown in the figure Plate for customer connections at base on page 74 Additional cabling to the c...

Page 76: ...ightening screws Standard toolkit The content is defined in section Standard toolkit on page 280 Circuit diagram 3HAC025744 001 See chapter Circuit diagram Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Equipment Art no Note A Plate for customer connections B Attachment s...

Page 77: ...ng inwards as shown in the figure Cooling fan on page 73 Shown in the figure Cooling fan on page 73 3 Temporarily lift the motor cabling out of the way of the current motor to make room for the fanbox 4 Fit the parts of the fanbox to the motor and reassemble with the nine attachment screws 5 Lift the box axis 1 so that it does not rest directly on the robot and secure the box with the three tighte...

Page 78: ...me at motor axis 1 or 2 Strap the fan cable to the cable of the motor axis 1 or 2 close to the motor NOTE The fan cable must not be strapped to the motor cable along the part of the cable that is twisted when the robot is in operation 8 Connect the connector R3 FAN2 to the fan of axis 1 9 Connect the connector R1 SW2 3 to the base of the robot Make sure that the cabling run through the frame and b...

Page 79: ...ents and overloading motors gears and structure CAUTION Incorrect defined loads may result in operational stops or major damage on the robot References Load diagrams permitted extra loads equipment and their positions are specified in the Product Specification The loads must also be defined in the software as detailed in Operating manual IRC5 with FlexPendant Stop time and braking distances Robot ...

Page 80: ... risk that it may collide with other objects its working space should be limited The working range of the following axis may be restricted Axis 1 hardware mechanical stop and software Axis 2 software Axis 3 software As standard configuration axis 1 is allowed to move 180º This section describes how to install hardware that restricts the working range Notice that adjustments must also be made in th...

Page 81: ...s axis 1 The illustration below shows the mounting position of the stop pin and one of the additional mechanical stops available for axis 1 xx0300000049 Required equipment A Additional mechanical stop B Stop pin Equipment etc Art no Note Mechanical stop for axis 1 7 5 3HAC11076 1 Includes attachment screws and an assembly drawing Mechanical stop for axis 1 15 3HAC11076 2 Includes attachment screws...

Page 82: ...l stop to the frame according to the figure Mechanical stops axis 1 on page 79 Tightening torque 120 Nm 3 NOTE To utilize the option 561 1 Extended working range axis 1 the software working range limitations must be re defined The motion configuration parameter arm rob1_1 Upper Joint Bound and arm rob1_1 Lower Joint Bound must be changed to 3 84 resp 3 84 The values are in radians that is 220 deg ...

Page 83: ...s on page 81 Fan cables option Handles supply to and feedback from any cooling fan on the robot Specified in the table Fan cables robot base to control cabinet option on page 82 Customer cables option Handles communication with equipment fitted on the robot by the customer including databus communication low voltage signals and high voltage power supply protective ground See the product manual for...

Page 84: ...g fans runs all the way from the robot base to the inside of the cabinet If equipping the robot with cooling fans use the cabling specified below The cables for cooling fans listed below are used together with a distributing cable also specified below Robot cable power 22 m 3HAC11818 3 Robot cable power 30 m 3HAC11818 4 Cable Art no Cable Art no Robot cable signal shielded 7 m 3HAC7998 1 Robot cab...

Page 85: ...ncluding intervals and refers to procedures for the activities Each procedure contains all information required to perform the activity that is required tools and materials The procedures are gathered in different sections and divided according to the maintenance activity Safety information Before any service work is commenced it is extremely important that all safety information is observed There...

Page 86: ... working conditions of the robot Calendar time specified in months regardless of whether the robot system is run or not Operating time specified in operating hours More frequent running of the robot means more frequent maintenance activities SIS specified by the robot s SIS Service Information System A typical value is given for a typical work cycle but the value will differ depending on how hard ...

Page 87: ... 1 on page 89 Inspection Axis 2 gear oil level 12 mths Inspection oil level gearbox axes 2 3 on page 91 Inspection Axis 3 gear oil level 12 mths Inspection oil level gearbox axes 2 3 on page 91 Inspection Axis 4 gear oil level 12 mths Inspection oil level gearbox axis 4 on page 93 Inspection Axis 5 gear oil level 12 mths Inspection oil level gearbox axis 5 on page 95 Inspection Axis 6 gear oil lev...

Page 88: ...gearbox As specified by the SIS or typically 96 mths 8 Replacement of gearbox axis 1 on page 243 Replacement Axis 2 gearbox As specified by the SIS or typically 96 mths Replacement of gearbox axes 2 3 on page 251 Replacement Axis 3 gearbox As specified by the SIS or typically 96 mths Replacement of gearbox axes 2 3 on page 251 Replacement Axis 4 gearbox 5 96 mths 2 Replacement of upper arm on page...

Page 89: ... bearing after refitting the balancing device shaft 5 It is recommended to replace the complete upper arm house instead of only replacing the gearbox 6 It is recommended to replace the complete wrist unit instead of only replacing the gearbox 7 If the robot is run in presstending applications 120 hours week typically 24 mths 8 If the robot is run in presstending applications typically 36 mths 9 24...

Page 90: ...e is based on a test cycle that starts from the initial position and goes to maximum extension and back Deviations from this cycle will result in differences in expected life 3 The robot is dimensioned for a life of 8 years 350 000 cycles per year in a normal application Depending on the actual application the life of individual gearboxes may vary greatly from this specification The Service Inform...

Page 91: ... xx0500002479 Required equipment A Oil plug inspection B Gearbox axis 1 C Oil plug filling D Motor axis 1 E Drain hose Behind cover Equipment Art no Note Lubricating oil 3HAC032140 001 Kyodo Yushi TMO 150 Note Do not mix with other oil types Standard toolkit The content is defined in section Standard toolkit on page 280 Other tools and procedures may be required See references to these procedures ...

Page 92: ...y information in section WARNING Safety risks during work with gearbox oil on page 36 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 3 Open the oil plug inspection Shown in the figure Location of gearbox on page 89 4 Required oil level max 10 mm below the oil plug hole 5 Add oil if required Art no is specified in Required equipment on page 89 Further in...

Page 93: ...es 2 3 The gearboxes axes 2 3 are located in the lower arm rotational center underneath the motor attachment The figures below shows the position of gearbox axes 2 and 3 xx0500002482 xx0500002483 A Gearbox axis 2 B Oil plug draining C Oil plug filling D Ventilation hole gearbox axis 2 A Gearbox axis 3 B Oil plug draining C Oil plug filling D Ventilation hole gearbox axis 3 Continues on next page ...

Page 94: ...ions below These procedures include references to the tools required Action Note 1 WARNING Handling gearbox oil involves several safety risks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 36 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 3 Open the oil plug filling Shown in L...

Page 95: ...arm as shown in the figure below xx0700000018 Required equipment A Oil plug filling B Oil plug draining Equipment etc Art no Note Lubricating oil 11712016 604 Mobilgear 600 XP320 Standard toolkit The content is defined in section Standard toolkit on page 280 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include...

Page 96: ...g work with gearbox oil on page 36 2 Move the robot to the calibration position Shown in section Calibration scales and correct axis position on page 262 3 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 4 Open the oil plug filling Shown in the figure Location of gearbox on page 93 5 Required oil level max 10 mm below the oil plug hole 6 Add oil if require...

Page 97: ...ug draining Equipment etc Art no Note Lubricating oil 11712016 604 Mobilgear 600 XP320 Standard toolkit The content is defined in section Standard toolkit on page 280 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Action Note 1 WARNING Handling gearbox oil involves severa...

Page 98: ...4 Open the oil plug filling Shown in the figure Location of gearbox on page 95 5 Measure the oil level Required oil level to the upper edge of the oil plug hole a 30mm xx0500002222 6 Add oil if required Art no is specified in Required equipment on page 95 Further information about how to fill the oil may be found in section Filling oil axis 5 on page 129 7 Refit the oil plug Tightening torque 24 N...

Page 99: ...5 1 9 has no cooling elements xx0700000161 Required equipment A Strap securing cooling elements B Gearbox axis 6 C Oil plug draining D Oil plug filling E Cooling element IRB6660 130 3 1 Equipment Art no Note Lubricating oil 3HAC032140 001 Kyodo Yushi TMO 150 Note Do not mix with other oil types Standard toolkit The content is defined in section Standard toolkit on page 280 Other tools and procedur...

Page 100: ...e the safety information in section WARNING Safety risks during work with gearbox oil on page 36 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 3 Make sure the oil plug filling is facing upwards and open it Shown in the figure Location of gearbox on page 97 4 Add oil if required Art no is specified in Required equipment on page 97 Further information ab...

Page 101: ...ls how to inspect the bearings and piston rod of the balancing device Location of balancing device The figure below shows the location of the balancing device xx0700000019 Required equipment A Balancing device B Piston rod C Guide ring not visible in this figure Equipment Spare part no Art no Note Balancing device 3HAC024779 001 Grease 3HAB3537 1 Locking liquid Loctite 243 Auxiliary shaft upper 3H...

Page 102: ...procedures in the step by step instruc tions below These procedures include references to the tools required Equipment Spare part no Art no Note Action Note 1 Move the axis 2 to calibration position 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 3 Remove the locknuts KM 8 sealing rings and the outer support washers xx0500002496 A Ear adjustable needle b...

Page 103: ...rings clean and check that there are no pressure marks or other similar deformations NOTE It is quite normal for the bearing races to have a darker color than the surrounding material 9 Inspect the bearings support washers and sealing rings Shown in the figure above in this procedure Inspection bearings on page 100 10 If any of the parts looks abnormal replace Detailed in section Replacement of ba...

Page 104: ... on the guide ring Action Note 1 Move axis 2 to a position where the balancing device is in a horizontal position 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 3 Check the guide ring for wear Replace if necessary xx0600002689 A Guide ring B Circlip 4 NOTE If there is a risk of metallic contact between the piston rod and the end cover the guide ring mus...

Page 105: ...spection cable harness Location of cable harness The robot cable harness axes 1 6 is located as shown in the figures below xx0700000022 xx0700000631 A Cable guide axis 2 B Metal clamp 4 pcs C Connectors at base D Cable guide E Cable harness A Cable guide axis 1 B Cable gland SMB unit C Cable guide axis 2 Continues on next page ...

Page 106: ...6x25 quality steel 12 9 Gleitmo Equipment etc Art no Note Cable harness IRB6660 130 3 1 3HAC026733 001 Cable harness IRB6660 205 1 9 3HAC028715 001 Standard toolkit The content is defined in section Standard toolkit on page 280 Other tools and procedures may be required See references to these procedures in the step by step instruc tions below These procedures include references to the tools requi...

Page 107: ...e connectors at the base Shown in the figure Location of cable harness on page 103 4 Check the metal clamps at the rear of the upper arm and in the upper arm tube Shown in the figure Location of cable harness on page 103 5 Check that the velcro straps and the mounting plate are properly attached to the frame 6 Check the cabling leading into the lower arm Make sure it is attached by the straps and ...

Page 108: ...g label High temperature 29454489 16 2 pcs B Warning sign symbol of flash located on motor cover 3HAC1589 1 2 pcs C Instruction label Safety instructions 3HAC4591 1 E Instruction label Lifting the robot 3HAC027252 001 F Warning label Robot can tip forward 3HAC9191 1 Information labels about what oil is filled on gearboxes and at the robot base A Warning label High temperature 29454489 16 2 pcs B W...

Page 109: ...sk 3HAC4517 1 Equipment Art no Note Labels and plate set 3HAC027176 001 Includes all labels specified in the two previous figures The labels are in english Label set oil labels 3HAC021505 003 Includes only the oil labels at the gearboxes and at the robot base Are fitted to the robot if the gearboxes include Kyodo Yushi TMO 150 Action Note 1 DANGER Turn off all electric power hydraulic and pneumati...

Page 110: ... procedure below details how to inspect the mechanical stop axis 1 A Mechanical stop pin Equipment etc Art no Note Mechanical stop ax 1 3HAC12812 2 To be replaced when damaged Standard toolkit The content is defined in section Standard toolkit on page 280 Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Inspect the mechanical stop axis 1 Sho...

Page 111: ... A Copyright 2007 2008 ABB All rights reserved 4 If the stop pin is bent or damaged it must be replaced NOTE The expected life of gearboxes can be reduced as a result of collissions with the mechanical stop Art no is specified in Required equipment on page 108 Action Note Continued ...

Page 112: ...additional mechanical stops on axes 1 A Mechanical stop axis 1 Equipment etc Art no Note Mechanical stop axis 1 3HAC11076 1 Limits the robot working range by 7 5 Mechanical stop axis 1 3HAC11076 2 Limits the robot working range by 15 Standard toolkit The content is defined in section Standard toolkit on page 280 Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supp...

Page 113: ...7 001 Revision A Copyright 2007 2008 ABB All rights reserved 4 If any damage is detected the mechanical stops must be replaced Correct attachment screws lubricated with Molycote 1000 Axis 1 M16 x 35 Art no is specified in Required equipment on page 110 Action Note Continued ...

Page 114: ...nd the position of the dampers are the same on IRB 6660 205 1 9 xx0700000024 Required equipment A damper must be replaced if damaged A Damper 2 pcs B Damper axis 2 2 pcs C Damper axis 3 2 pcs Not visible in this view D Damper 1 pcs E Damper axis 4 1 pcs inside armhouse F Damper axis 5 2 pcs Equipment Spare part art no Note Damper axis 2 3HAC12991 1 Damper 3HAC022338 001 Damper 3HAC022339 001 Stand...

Page 115: ...ower hydraulic and pneumatic pressure supplies to the robot 2 Check all dampers for damage and for cracks or existing impressions larger than 1 mm To inspect the damper axis 4 remove the two covers on top of the upper arm Shown in the figure Location of dampers on page 112 3 Check attachment screws for deformation 4 If any damage is detected the damper must be replaced with a new one Art no is spe...

Page 116: ...dure below details how to inspect the function of the signal lamp A Signal lamp B Metal clamp C Cable strap outdoor Equipment etc Art no Note Signal lamp 3HAC028196 001 To be replaced in case of detected damage Standard toolkit The content is defined in section Standard toolkit on page 280 Other tools and procedures may be required See references to these procedures in the step by step instruction...

Page 117: ...d 3 If the lamp is not lit trace the fault by Checking whether the signal lamp is broken If so replace it Checking the cable connections Measuring the voltage in connectors motor axis 3 24V Checking the cabling Replace cabling if a fault is detected Art no is specified in Required equipment on page 114 Action Note Continued ...

Page 118: ...es on the robot The figure show robot variant IRB 6660 130 3 1 The position of gearboxes are the same on variant IRB 6660 205 1 9 xx0700000026 Type of oil historically used The six gearboxes of the robot have historically been filled with different types of oils Today only the types of oil specified in the table is recommended A Gearbox axis 1 B Gearbox axis 2 C Gearbox axis 3 D Gearbox axis 4 E G...

Page 119: ...oil is used in gearboxes Labels next to oil plugs Labels located next to oil plugs of each gearbox show which type of oil it contains All gearboxes must have the correct label clearly visible xx0800000230 xx0800000234 Gearbox Type of oil Art no Amount Axis 1 Kyodo Yushi TMO 150 3HAC032140 001 8 000 ml Axis 2 Kyodo Yushi TMO 150 3HAC032140 001 5 000 ml Axis 3 Kyodo Yushi TMO 150 3HAC032140 001 5 00...

Page 120: ...ox See Type of oil currently used If the oil used is other than the one in the list of currently used types of oil it is recommended to replace the oil As Kyodo Yushi TMO 150 as well as Shell Tivela S 150 is not compatible with mineral oil contamination with other types of oil in the gearboxes is not accepted Equipment used in handling of Kyodo Yushi as well as Shell Tivela S 150 must be carefully...

Page 121: ... procedure to rinse the contaminated gearbox if the oil types Kyodo Yushi TMO 150 and Optimol Optigear RMO 150 are mixed Flush the gearbox properly three times with the correct type of oil Use a service program when flushing Refill the gearbox with the correct type of oil Kyodo Yushi TMO 150 mixed with Mobilgear 600 XP320 Use this procedure to rinse the contaminated gearbox if the gearbox shall co...

Page 122: ...le in the rear of the robot base not shown in the figure xx0500002479 Required equipment A Oil plug inspection B Gearbox axis 1 C Oil plug filling D Motor axis 1 E Drain hose Equipment etc Art no Amount Note Lubricating oil 3HAC032140 001 8 000 ml Kyodo Yushi TMO 150 Note Do not mix with other oil types Oil collecting vessel Capacity 8 000 ml Oil exchange equipment 3HAC021745 001 The content is de...

Page 123: ...s during work with gearbox oil on page 36 3 Remove the rear cover on the base by unscrewing its attachment screws 4 Pull the oil draining hose out of the rear of the base xx0200000237 The hose is located beneath the base as shown in the figure with a view from below A Oil draining hose 5 Place an oil vessel close to the hose end Vessel capacity is specified in Required equipment on page 120 6 Remo...

Page 124: ...mation in section WARNING Safety risks during work with gearbox oil on page 36 3 Open the oil plug filling Shown in the figure Location of oil plugs on page 120 4 Refill the gearbox with lubricating oil The amount of oil to be refilled depends on the amount previously being drained The correct oil level is detailed in section Inspection oil level gearbox axis 1 on page 89 Art no and the total amou...

Page 125: ...arboxes axes 2 3 are located in the lower arm rotational center underneath the motor attachment The figures below shows the position of gearbox axis 2 and 3 xx0500002482 xx0500002483 A Gearbox axis 2 B Oil plug draining C Oil plug filling D Ventilation hole gearbox axis 2 A Gearbox axis 3 B Oil plug draining C Oil plug filling D Ventilation hole gearbox axis 3 Continues on next page ...

Page 126: ...te 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 WARNING Handling gearbox oil involves several safety risks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 36 3 Remove the plug of the vent hole Shown in Location of oil plugs on page 123 4 Remove the oil plug draining and dra...

Page 127: ...bserve the safety information in section WARNING Safety risks during work with gearbox oil on page 36 3 Refit the oil plug draining Shown in Location of oil plugs on page 123 Tightening torque 24 Nm 4 NOTE Don t mix Kyodo Yushi TMO 150 with other oil types 5 Refill the gearbox with lubricating oil The amount of oil to be filled depends on the amount previously being drained Art no and total amount...

Page 128: ... When using the oil exchange equipment follow the instructions enclosed with the kit Art no for the kit is specified in Required equipment on page 126 A Oil plug filling B Oil plug draining Equipment etc Art no Amount Note Lubricating oil 11712016 604 8 100 ml Mobilgear 600 XP320 Oil exchange equipment 3HAC021745 001 The content is defined in section Special tools on page 281 Oil collecting vessel...

Page 129: ...ox on page 126 Vessel capacity is specified in Required equipment on page 126 5 Run the upper arm back to its calibration position horizontal position Shown in section Calibration scales and correct axis position on page 262 6 Refit the oil plug draining Tightening torque 24 Nm Action Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 WAR...

Page 130: ...closed with the kit Art no for the kit is specified in Required equipment on page 128 A Oil plug filling B Oil plug draining Equipment etc Art no Amount Note Lubricating oil 11712016 604 6 700 ml Mobilgear 600 XP320 Oil exchange equipment 3HAC021745 001 The content is defined in section Special tools on page 281 Oil collecting vessel Capacity 7 000 ml Standard toolkit The content is defined in sec...

Page 131: ...8 Vessel capacity is specified in Required equipment on page 128 5 Refit the oil plug draining Tightening torque 24 Nm Action Note Action Note 1 Run axis 4 to a position where the oil plug filling is facing upwards 2 WARNING Handling gearbox oil involves several safety risks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page...

Page 132: ...here are no cooling elements on motor axis 6 on robot variant IRB 6660 205 1 9 xx0700000161 Required equipment A Strap B Gearbox axis 6 C Oil plug draining D Oil plug filling E Cooling elements IRB6660 130 3 1 Equipment etc Art no Amount Note Lubricating oil 3HAC032140 001 450 ml Kyodo Yushi TMO 150 Note Don t mix with other oil types Oil exchange equipment 3HAC021745 001 The content is defined in...

Page 133: ...upwards Shown in the figure Location of gearbox on page 130 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 3 WARNING Handling gearbox oil involves several safety risks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 36 4 Drain the oil from the gearbox into a vessel by removing ...

Page 134: ...box with lubricating oil The amount of oil to be refilled depends on the amount previously being drained The correct oil level is detailed in section Inspection oil level gearbox axis 6 on page 97 Art no and the total amount are specified in Required equipment on page 130 5 Refit the oil plug Tightening torque 24 Nm Action Note Continued ...

Page 135: ...e below details how to remove the SMB battery A SMB battery cover B SMB battery pack C Battery cable Equipment etc Spare part no Note Battery pack 3HAC16831 1 Battery includes protection circuits Replace it only with given spare part no or an ABB approved eqvivalent Standard toolkit The content is defined in section Standard toolkit on page 280 Circuit Diagram 3HAC025744 001 See chapter Circuit di...

Page 136: ...e Location of SMB battery on page 133 6 Remove the SMB battery Battery includes protection circuits Replace it only with the specified spare part or with an ABB approved equivalent Shown in the figure Location of SMB battery on page 133 Action Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 esd WARNING The unit is sensitive to ESD befo...

Page 137: ...d 5 Update the revolution counter Detailed in chapter Calibration section Updating revolution counters on page 265 6 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 33 Action Note Continued ...

Page 138: ...licable to the robot variant IRB 6660 205 1 9 Overview The procedure below details how to lubricate the bearings and piston rod of the balancing device Location of bearing and piston rod The figure below shows the location of the bearings and piston rod Note The balancing device must be fitted on the robot when lubricating the bearings xx0500002489 A Ear adjustable needle bearing located inside B ...

Page 139: ...ls and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Action Note 1 Move axis 2 to the calibration position 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 3 Remove the locknut Be careful not to loose the support washer in the process 4 Fit the...

Page 140: ...ghtening torque on the locknuts 120 Nm 10 Check the play between support washer and bearingseat at both bearings Minimum play 0 1 mm Action Note Action Note 1 Move axis 2 to a position where the balancing device is in the horizontal position and the piston rod extended as much as possible 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 3 The piston rod m...

Page 141: ...truction specifies how to clean the robot Periodicity The periodicity of cleaning the robot varies a great deal depending on the actual environment and function of the robot Clean a contamined robot as required Special points Special points to be observed are shown in the figure below xx0700000032 A Spiral cable to motor 6 B Inside of upper arm tube C Rear of upper arm tube D Inside of lower arm E...

Page 142: ...an 0 4 m Never remove any covers or other protective devices before cleaning the robot Never use any cleaning agents for example compressed air or solvents other than those specified above Never spray with a high pressure cleaner onto the sealing cup at the bottom of the motor 6 spiral cable item A in the figure Special points Although the robot is watertight avoid spraying connectors and similar ...

Page 143: ...dures are gathered in sections divided according to the component location on the robot Required equipment All equipment required to perform a specific repair activity is listed together with the current procedure The equipment is also gathered in different lists in the chapter Reference information Safety information Before any service work is commenced it is extremely important that all safety i...

Page 144: ...hich are included in the leakdown tester kit Art no is specified in Required equipment on page 142 3 Apply compressed air and raise the pressure with the knob until the correct value is shown on the manometer Recommended value 0 2 0 25 bar 20 25 kPa 4 Disconnect the compressed air supply 5 Wait for approx 8 10 minutes No pressure loss must be detected If the compressed air is signifi cantly colder...

Page 145: ... 1 Used to grease the bearings if not specified otherwise Action Note 1 To avoid contamination let a new bearing remain in its wrapping until it is time for fitting 2 Ensure that all parts included in the bearing fitting are free from burrs grinding waste and other contamination Cast components must be free from foundry sand 3 Bearing rings inner rings and roller elements must under no cir cumstan...

Page 146: ...g fitting the bearing may be totally filled with grease when mounted as excessive grease will be pressed out from the bearing when the robot is started During operation the bearing should be filled to 70 80 of the available volume Ensure that grease is handled and stored properly to avoid contamination Grease the different types of bearings as detailed below Grooved ball bearings must be filled wi...

Page 147: ...to lubricate the seals Action Note 1 Check the seal to ensure that the seal is of the correct type provided with cutting edge there is no damage to the sealing edge feel with a fingernail 2 Inspect the sealing surface before mounting If scratches or damage are found the seal must be replaced as it may result in future leakage 3 Lubricate the seal with grease just before fitting Not too early as th...

Page 148: ...ver the surface preferably with a brush 4 Tighten the screws evenly when fastening the flange joint Action Action Note 1 Ensure that the correct o ring size is used 2 Check the o ring for surface defects burrs shape accuracy etc Defective o rings may not be used 3 Check the o ring grooves The grooves must be geometrically correct and free from pores and contamination Defective o rings may not be u...

Page 149: ... The procedure below details replacement of lower end of the cable harness The procedure for replacing the upper end is detailed in section Replacement of cable harness upper end on page 162 Location of cable harness lower end axes 1 3 The cable harness lower end axes 1 3 is located throughout the base frame and lower arm as shown in the figure below xx0700000070 A Cable guide axis 2 B Metal clamp...

Page 150: ...he motor E Motor cover Equipment etc Spare part no Art no Note Cable harness 1 6 3HAC026733 001 Robot variant IRB 6660 130 3 1 Cable harness 1 6 3HAC028715 001 Robot variant IRB 6660 205 1 9 Gasket 3HAC3537 1 Motor axes 1 5 Standard toolkit The content is defined in section Standard toolkit on page 280 Other tools and procedures may be required See references to these procedures in the step by ste...

Page 151: ...cable Shown in Location of cable harness lower end axes 1 3 on page 147 5 Disconnect connectors R1 MP and R1 SMB Shown in Location of cable harness lower end axes 1 3 on page 147 6 Remove the cable guide axis 2 xx0600002698 A Cable guide ax 2 7 Unscrew the screws in the metal clamps holding the cable harness in the frame and lower arm Shown in Location of cable harness lower end axes 1 3 on page 1...

Page 152: ...tely the connector R1 G must be disconnected This causes a necessary updating of the revolution counter xx0600002700 A SMB battery cover B SMB battery pack C Battery cable 11 Disconnect connectors R2 SMB R1 SMB1 3 R1 SMB4 6 from the SMB unit Disconnect X8 X9 and X10 from the brake release unit 12 Remove the cable gland SMB by removing its four attachment screws from inside the SMB recess Perform t...

Page 153: ...erved 13 Gently pull the cable harness out of base through the cable guide axis 1 and the frame xx0700000154 A Cable gland SMB B Metal clamp frame C Cable guide axis 1 14 Continue removal of the cable harness in the upper arm Detailed in Replacement of cable harness upper end on page 162 Action Note Continued Continues on next page ...

Page 154: ...s 1 in the center of the frame Make sure the cables are not twisted with each other or with eventual customer harness xx0700000154 A Cable gland SMB B Metal clamp frame C Cable guide axis 1 2 Pull out the cables and connectors to the SMB unit through the frame and refit the cable gland with its four attachment screws from inside the SMB recess Perform this refitting with care in order not to damag...

Page 155: ...r end axes 1 3 on page 147 6 Reconnect all connectors at motor 1 2 and 3 7 Refit the motor cover axis 1 2 3 Make sure the cabling is placed correctly when refitting the cover and does not get jammed 8 Reconnect connectors R2 SMB R1 SMB1 3 R1 SMB4 6 to the SMB unit Reconnect X8 X9 and X10 to the brake release unit Reconnect R1 G if it has been disconnected 9 Secure the SMB cover with its attachment...

Page 156: ...harness lower end axes 1 3 on page 147 xx0700000037 14 Continue refitting of the cable harness in the upper arm Detailed in section Replacement of cable harness upper end on page 162 15 Update the revolution counter Detailed in section Updating revolution counters on page 265 16 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in sectio...

Page 157: ...package 1 3 MH is located throughout the base frame and lower arm as shown in the figure below xx0700000657 Required equipment A Metal clamp inside lower arm B Process cable package cables C Process cable package hose D Cable guide E Metal clamp F Connectors at base G Customer plate H Rear cover plate J Earth Equipment Spare part no Art no Note Process cable package 1 3 MH 3HAC027104 001 Robot var...

Page 158: ...by step instruc tions below These procedures include references to the tools required Circuit diagram 3HAC029940 001 Equipment Spare part no Art no Note Action Note 1 Move the robot to the calibration position 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 3 CAUTION The cable package is sensitive to mechanical damage They must be handled with care espec...

Page 159: ... 2008 ABB All rights reserved 5 Disconnect the hose from the customer plate xx0700000643 Parts A Customer plate B Hose connector R1 PROC1 6 Disconnect the cable connectors from the customer plate xx0700000645 Parts A Connector R1 CP CS B Connector R1 SP R3 FP7 Action Note Continued Continues on next page ...

Page 160: ...xx0700000646 Parts A Metal clamp bracket robot cable package B Metal clamp bracket process cable package C Position for prev torque nuts 8 Pull the lower end of the process cable package out through the centrum hole in gearbox axis 1 Order of removal 1 Hose 2 Cables 9 Remove the prev torque nuts securing the process cable package on the inside of the lower arm xx0700000649 Parts A Position for pre...

Page 161: ...hment plate B Attachment screws M10x16 quality 8 8 A3F 2 pcs C Strap velcro D Connectors 11 Pull the process cable package gently out off the lower arm NOTE Perform this carefully in order not to damage the cable harness of the robot Action Note Action Note 1 Push the process cable package gently down through the lower arm Make sure that the cables are not twisted with each other NOTE Perform this...

Page 162: ...chment screws M10x16 quality 8 8 A3F 2 pcs C Strap velcro D Connectors 3 Refit the prev torque nuts securing the process cable package on the inside of the lower arm xx0700000649 Parts A Position for prev torque nuts B Process cable package 4 Push the process cable package gently down through the cable guide in the centrum hole in gearbox axis 1 Order of refitting 1 Cables 2 Hose Action Note Conti...

Page 163: ... package B Metal clamp bracket process cable package C Position for prev torque nuts 6 Connect all connectors at the customer plate xx0700000645 Parts A Connector R1 CP CS B Connector R1 SP R3 FP7 7 Refit the rear cover plate Shown in the figure Location of Process cable package 1 3 MH on page 155 8 Update the revolution counter 9 DANGER Make sure all safety requirements are met when performing th...

Page 164: ...le harness lower end axes 1 3 on page 147 Location of cable harness axes 4 6 The cable harness for axes 4 to 6 is run throughout the upper arm and wrist unit as shown in the figure below xx0700000071 Required equipment A Cable harness axes 1 6 B Cable bracket upper arm tube C Cable bracket wrist unit D Cable starps outdoor E Attachment screws cable attachment armhouse M10x16 quality 8 8 2 pcs F At...

Page 165: ...1 See chapter Circuit diagram Equipment etc Spare part no Art no Note Action Note 1 In order to facilitate refitting of the cable harness run the robot to the specified positions Axis 1 0 Axis 2 0 Axis 3 0 Axis 4 0 Axis 5 90 Axis 6 no significance NOTE Axis 5 must be oriented in the correct position 90 to allow the cover of motor axis 6 to open 2 DANGER Turn off all electric power hydraulic and pn...

Page 166: ...P6 and R2 FB6 from motor axis 6 Shown in the figure Location of cable harness axes 4 6 on page 162 8 Disconnect all connectors at motor axis 6 R2 MP6 and R2 FB6 Shown in the figure Location of cable harness axes 4 6 on page 162 9 Loosen the cable bracket in the upper arm tube by undoing its two attachment screws on top of the tube 10 Disconnect the two connectors R2 FB5 and R2 MP5 inside the tube ...

Page 167: ...ower end axes 1 3 on page 147 2 Insert the cable harness gently from the rear into the upper arm Arrange the cable harness as shown in the figure Location of cable harness axes 4 6 on page 162 3 Refit the cable gland securing the cables to the armhouse Make sure not to twist the harness xx0700000041 4 Connect the two connectors inside the upper arm tube R2 MP5 and R2 FB5 and secure the cable brack...

Page 168: ...axes 4 6 on page 162 10 Refit cover motor axis 6 11 Refit the metal clamps on the armhouse Shown in the figure Location of cable harness axes 4 6 on page 162 12 Refit the cover wrist unit xx0700000140 A Cover wrist unit 13 If the connection between the SMB battery and the SMB unit has been broken the revolution counters must be updated Detailed in the section Updating revolution counters on page 2...

Page 169: ... Motor axis 5 with connectors R4 FB5 and R4 MP5 B Connectors R3 FB5 and R3 MP5 A Cable cover B Motor axis 5 with connectors R4 FB5 and R4 MP5 C Connectors R3 FB5 and R3 MP5 Equipment Spare part no Note Cable harness axis 5 3HAC14139 1 Circuit diagram 3HAC025744 001 Standard toolkit The content is defined in section Standard toolkit on page 280 Other tools and procedures may be required See referen...

Page 170: ...nect all connectors at motor axis 5 5 Remove the cable gland cover at the cable exit by unscrewing its two attachment screws 6 Remove the cable axis 5 Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Reconnect all connectors at motor axis 5 3 Refit the cable gland cover at the cable exit with its two attachment screws 4 Refit the cover of mo...

Page 171: ...7 001 Revision A Copyright 2007 2008 ABB All rights reserved 7 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 33 Action Note Continued ...

Page 172: ...omplete robot except for the base and gearbox axis 1 This is shown in the figure below A more detailed view of the component and its position may be found in chapter Spare parts and exploded views on page 285 xx0700000073 Robot variant IRB 6660 130 3 1 A Upper arm B Lower arm C Motor axis 1 D Frame E Base F Gearbox axis 1 G Attachment screws base M12x70 quality 12 9 Gleitmo 24 pcs H Calibration pl...

Page 173: ... G Base H Calibration plate axis 1 Equipment etc Art no Note Lifting device robot 3HAC15607 1 Instruction 3HAC15971 2 is enclosed Guide pins M12 x 130 3HAC022637 001 Used to guide the complete arm system when refitting Always use the guide pins in pairs In order to make the refitting easier it is recommended to use two guide pins of different lengths Notice that longer guide pins than 140 mm will ...

Page 174: ...kit on page 280 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Equipment etc Art no Note Action Note 1 Make sure the robot is positioned as shown in figure to the right If it is not position it that way Release the brakes if necessary as detailed in section Manually relea...

Page 175: ... gearbox axis 1 on page 120 4 Loosen the cable connectors from the base and pull up the cabling from the base through the hole in the center of the frame Detailed in section Replacement of cable harness lower end axes 1 3 on page 147 Detailed in section Replacement of Process cable package 1 3 MH 5 Remove the motor axis 1 Detailed in section Replacement of motor axis 1 on page 222 6 Run the overhe...

Page 176: ...page 171 Make sure the lift is done completely level How to adjust the lift is described in the enclosed instruction to the lifting device Follow the instructions before lifting xx0700000004 Robot variant IRB 6660 130 3 1 xx0700000427 Robot variant IRB 6660 205 1 9 A Load hook B Swiveling lifting eyes 4 pcs C Shortening hook D Chain E Lifting eye M12 F Lifting device s eye I Lifting slings 4 pcs L...

Page 177: ...TION The complete arm system weighs Robot variant IRB 6660 130 3 1 1500 kg Robot variant IRB 6660 205 1 9 1330 kg 1 1 Lift the arm system carefully and secure it in a safe area Always move the robot at very low speeds making sure it does not tip Continue lifting even if the arm system turns out to be unbalanced despite earlier adjustments The risk of damaging the interfaces is bigger if the load i...

Page 178: ...76 Copyright 2007 2008 ABB All rights reserved Refitting arm system The procedure below details how to lift and refit the complete arm system Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Continued Continues on next page ...

Page 179: ...71 Make sure the lift is done completely level How to adjust the lift is described in the enclosed instruction to the lifting device Follow the instructions before lifting xx0700000004 Robot variant IRB 6660 130 3 1 xx0700000427 Robot variant IRB 6660 205 3 1 A Load hook B Swiveling lifting eyes 4 pcs C Shortening hook D Chain E Lifting eye M12 F Lifting device s eye I Lifting slings L Hook Action...

Page 180: ... Fit the two guide pins to the frame attachment holes as shown in the figure to the right x0600002632 The figure above shows the frame view from below A Attachment holes for the guide pins M12 6 Look through the empty mounting hole of motor 1 to assist in aligning the assembly during refitting of the arm system Lower the arm system with guidance from the guide pins previously fitted to the frame N...

Page 181: ...r axis 1 Detailed in section Replacement of motor axis 1 on page 222 11 Refit the cabling in the base Detailed in section Replacement of cable harness lower end axes 1 3 on page 147 12 Perform a leak down test of the gearbox axis 1 Detailed in section Performing a leak down test on page 142 13 Refill the gearbox axis 1 with lubricating oil Detailed in section Oil change gearbox axis 1 on page 120 ...

Page 182: ...d views on page 285 xx0700000163 Required equipment A Wrist unit B Turning disk C Attachment screws turning disk 12 pcs D Oil plug draining E Oil plug filling F Cooling elements only robot variant IRB6660 130 3 1 Equipment etc Spare part no Art no Note Turning disk dia 200 3HAC13752 1 O rings are not included O ring 3HAB3772 64 1 pc 3HAB3772 61 12 pcs Must be replaced when replacing the turning di...

Page 183: ...e robot to a position where the oil plug draining of axis 6 gearbox faces downwards Shown in the figure Location of turning disk on page 180 4 Drain the oil from gearbox 6 Detailed in section Oil change gearbox axis 6 on page 130 5 Remove the turning disk by unscrewing its attachment screws Shown in the figure Location of turning disk on page 180 Action Note 1 Lubricate the turning disk o ring wit...

Page 184: ...crew joints on page 276 before fitting 3 Perform a leak down test of the gearbox axis 6 Detailed in section Performing a leak down test on page 142 4 Refill the gearbox 6 with oil Detailed in section Oil change gearbox axis 6 on page 130 5 Refit any equipment removed during disassem bly to the turning disk 6 DANGER Make sure all safety requirements are met when performing the first test run These ...

Page 185: ...he component and its position may be found in chapter Spare parts and exploded views on page 285 xx0700000069 Robot variant IRB 6660 130 3 1 xx0700000635 Robot variant IRB 6660 205 1 9 A Wrist unit B Turning disk C Cover wrist unit D Cover upper arm tube E Connectors upper arm tube with cable bracket R3 FB5 R3 MP5 F Cable bracket G Attachment point for lifting tool wrist unit H Attachment screws a...

Page 186: ... procedures in the step by step instructions below These procedures include references to the tools required Circuit diagram 3HAC025744 001 See chapter Circuit diagram Action Note 1 Remove all equipment fitted to the turning disk 2 Turn axis 4 to a position where the cover upper arm tube and wrist unit faces upwards Also turn axis 5 so that the turning disk faces to the side in order to allow acce...

Page 187: ...by disconnecting the two connectors in the upper arm tube R3 FB5 R3 MP5 Shown in the figure Location of wrist unit on page 183 11 Fit the lifting tool to the wrist unit Art no is specified in Required equipment on page 184 12 CAUTION The complete wrist unit weighs 130 kg All lifting equipment used must be sized accordingly 13 Slightly raise the wrist unit to unload the screw joint facilitating rem...

Page 188: ...276 before fitting 7 Remove the guide pins and secure the two remaining attachment screws as detailed above 8 Remove the lifting tool from the wrist unit 9 Reconnect the motor axis 5 by connecting the two connectors inside the upper arm tube R3 FB5 R3 MP5 and secure the cable bracket with the two attachment screws to the tube Shown in the figure Location of wrist unit on page 183 10 NOTE Axis 5 mu...

Page 189: ...3 Reconnect the connectors to motor axis 6 and refit the motor cover 14 Refit the cover upper arm tube Shown in the figure Location of wrist unit on page 183 15 Refit the cover wrist unit Shown in the figure Location of wrist unit on page 183 16 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is incl...

Page 190: ...arm Location of upper arm The upper arm is located as shown in the figures below A more detailed view of the component and its position may be found in chapter Spare parts and exploded views on page 285 xx0700000059 Robot variant IRB 6660 130 3 1 A Upper arm B Motor axis 4 C Balancing device D Lower arm E Parallel rod Continues on next page ...

Page 191: ...cement of upper arm 189 3HAC028197 001 Revision A Copyright 2007 2008 ABB All rights reserved xx0700000636 Robot variant IRB 6660 205 1 9 A Upper arm B Upper arm C Lower arm D Parallel rod Continued Continues on next page ...

Page 192: ...r arm Seen from above The letters in the figures are being referred to in the step by step procedures below xx0700000058 Robot variant IRB 6660 130 3 1 A Shaft axis 2 B Shaft axis 3 C Set screw cup point M10 x 20 quality 45H A3F D Lubricant paste Molycote 1000 E Sealing ring V ring F Sealing ring G Taper roller bearing H O ring I Sealing ring J Sealing assembly K Lock nut KM 12 L O ring Di 54 2 mm...

Page 193: ...6660 205 1 9 A Shaft axis 2 B Shaft axis 3 C Set screw cup point M10x20 quality 45H A3F D Surfaces where to apply lubricant paste Molycote 1000 E Sealing ring V ring F Sealing ring G Taper roller bearing H O ring I Sealing ring J Sealing assembly including support ring K Lock nut KM12 L O ring Di 54 2 mm t 5 7 mm Continued Continues on next page ...

Page 194: ...pper arm axis 4 3HAC029161 001 Robot variant IRB 6660 205 1 9 Grease filling tool KM12 socket 3HAC5347 1 Standard toolkit The content is defined in section Standard toolkit on page 280 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Circuit diagram 3HAC025744 001 See chapt...

Page 195: ...rn off all electric power hydraulic and pneumatic pressure supplies to the robot 4 Secure the upper arm with lifting slings in an overhead crane 5 Drain the oil from axis 4 Detailed in section Oil change gearbox axis 4 on page 126 6 Remove the cable harness in the upper arm Detailed in section Replacement of cable harness upper end on page 162 7 CAUTION The complete upper arm weighs 380 kg without...

Page 196: ...f the upper arm components on page 190 Perform the removal with care Threads can otherwise be damaged 14 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 Shown in the figure View of the assembly of the upper arm components on page 190 15 Put the shafts in a clean and safe place 16 Remove the upper arm Acti...

Page 197: ...ft the upper arm with an overhead crane and move it to its mounting position Make sure that the upper arm is placed in a horizontal position xx0700000137 Robot variant IRB 6660 130 3 1 xx0700000518 Robot variant IRB 6660 205 1 9 4 NOTE Refit the axis 3 side first 5 Carefully refit the shaft axis 3 B by hand only Don t use force since the threads can be damaged if fitting is not done in the correct...

Page 198: ...m components on page 190 Loctite 243 Tightening torque 90 Nm 12 The refit the axis 2 side in the same order with the exception of the lock nut K Follow the steps for refitting shaft axis 3 above Shown in the figure View of the assembly of the upper arm components on page 190 13 Apply locking liquid on the lock nut K and refit it NOTE The order of the tightening torques is very important NOTE The f...

Page 199: ...the robot variant IRB 6660 205 1 9 Refit the balancing device Detailed in section Replacement of balancing device on page 218 19 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration informa tion 20 DANGER Make sure all safety requirements are met when performing the firs...

Page 200: ...found in chapter Spare parts and exploded views on page 285 xx0700000064 Required equipment A Robot variant IRB 6660 205 1 9 B Robot variant IRB 6660 130 3 1 C Parallel rod Equipment etc Spare part no Art no Note Parallel rod 3HAC021084 004 Robot variant IRB 6660 130 3 1 Parallel rod 3HAC028641 001 Robot variant IRB 6660 205 1 9 Mounting Demounting tool 3HAC5021 1 Locking liquid Loctite 243 Standa...

Page 201: ... references to these procedures in the step by step instructions below These procedures include references to the tools required Equipment etc Spare part no Art no Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Secure the upper arm with a roundsling in a crane 3 Remove the upper lock screw and washer locking the parallel rod in positi...

Page 202: ... the thrust washer F See figure above 6 Remove the parallel rod C backwards from its upper connection point and let it rest against frame and base See figure above and Location of parallel rod on page 198 7 Continue by removing 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 thrus...

Page 203: ...by pushing it through the parallel bar Press the shaft in position See figure above 5 Apply locking liquid in the hole of the lock screw Loctite 243 6 Refit the lock screw and plain washer xx0700000066 Parts A Lock screw M6x16 upper B Lock screw M6x16 lower 7 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration infor...

Page 204: ...vision A 202 Copyright 2007 2008 ABB All rights reserved 8 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 33 Action Note Continued ...

Page 205: ...ent and its position may be found in chapter Spare parts and exploded views on page 285 xx0700000067 Required equipment A Lower arm B Parallel arm Equipment etc Spare part no Art no Note Lower arm 3HAC021464 004 Robot variant IRB 6660 130 3 1 Lower arm 3HAC028617 001 Robot variant IRB 6660 205 1 9 Crank 3HAC023132 001 Lock screw M16x90 Lifting tool lower arm complete 3HAC8446 1 Standard toolkit Th...

Page 206: ...d pneumatic pressure supplies to the robot 2 Secure the lower arm with a lock screw in the hole as shown in the figure to the right xx0600002736 A Hole for lock screw M16x90 3 Not applicable to robot variant IRB 6660 205 1 9 Remove the balancing device Detailed in section Replacement of balancing device on page 218 4 Remove the parallel rod Detailed in sectionReplacement of parallel rod on page 19...

Page 207: ... screws holding the lower arm on both sides 12 Push the lower arm and parallel arm together with the help of an iron bar or similar If the parts are not pushed together it will be difficult to remove the complete lower arm 13 Remove the complete lower arm including the parallel arm How to replace the parallel arm is detailed in section Replacement of parallel arm on page 208 Action Note Action Not...

Page 208: ... the remaining screws 10 Secure the lower arm by fitting a lock screw xx0600002736 A Hole for lock screw M16x90 11 Refit gearbox axis 2 3 Detailed in section Replacement of gearbox axes 2 3 on page 251 12 Refit motor axes 2 3 Detailed in section Replacement of motor axes 2 and 3 on page 227 13 Refit the complete upper arm Detailed in section Replacement of upper arm on page 188 14 Refit the cable ...

Page 209: ...detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration infor mation 19 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 33 Action Note Continued ...

Page 210: ...ow A more detailed view of the component and its position may be found in chapter Spare parts and exploded views on page 285 xx0700000067 Required equipment A Lower arm B Parallel arm Equipment etc Spare part no Art no Note Parallel arm 3HAC023026 003 Bearing grease 3HAB 3537 1 Pressing tool lower arm 3HAC023092 001 Lifting device parallel arm 3HAC023098 001 Lifting tool lower arm complete 3HAC844...

Page 211: ...ower hydraulic and pneumatic pressure supplies to the robot 2 Remove the complete lower arm Detailed in section Replacement of complete lower arm on page 203 3 Put the complete lower arm on a workbench Removal of the parallel arm is best perfomed on a workbench 4 Remove the two VK covers 5 Fit the lifting device parallel arm on the parallel arm Art no is specified in Required equipment on page 208...

Page 212: ...ed in Required equipment on page 208 11 CAUTION The parallel arm weighs 92 kg 12 Lift the parallel arm and put it in mounting position with the lower arm 13 Carefully press the parallel arm onto the lower arm with the pressing tool lower arm Art no is specified in Required equipment on page 208 14 Refit the big and small VK covers 15 Refit the complete lower arm Detailed in section Replacement of ...

Page 213: ...re below xx0600002621 Required equipment Removal SMB unit The procedure below details how to remove the SMB unit A SMB cover B SMB unit C Battery cable D SMB battery E SMB battery cover Equipment etc Spare part no Art no Note SMB unit 3HAC022286 001 Battery pack 3HAC16831 1 Standard toolkit The content is defined in section Standard toolkit on page 280 Circuit Diagram 3HAC025744 001 See chapter Ci...

Page 214: ...m the brake release board if need of more space 6 Remove the nuts and washers from the pins securing the board Shown in the figure Location of SMB unit on page 211 7 Gently disconnect the connectors from the SMB unit when pulling the board out Connectors R1 SMB1 3 R1 SMB4 6 and R2 SMB 8 Disconnect the battery cable from the SMB unit Shown in the figure Location of SMB unit on page 211 Action Note ...

Page 215: ...nit to the pins with the nuts and washers 6 If disconnected reconnect the connectors X8 X9 and X10 to the brake release board 7 Secure the SMB cover with its attachment screws Shown in the figure Location of SMB unit on page 211 8 Update the revolution counter Detailed in chapter Calibration section Updating revolution counters on page 265 9 DANGER Make sure all safety requirements are met when pe...

Page 216: ... figure below xx0600002621 Required equipment A SMB cover B SMB unit C Battery cable D SMB battery E SMB battery cover Equipment etc Art no Note Brake release unit with buttons 3HAC16035 1 Located together with the SMB unit at the left hand side of the frame Standard toolkit The content is defined in section Standard toolkit on page 280 Other tools and procedures may be required See references to ...

Page 217: ...ver Shown in the figure Location of brake release unit on page 214 The guard must be removed to ensure a correct refitting of the brake release unit 4 Open the SMB cover by unscrewing the attachment screws Let the battery stay connected to avoid the need of synchronization of the robot Shown in the figure Location of brake release unit on page 214 5 Remove the complete brake release unit including...

Page 218: ...ety information in section WARNING The unit is sensitive to ESD on page 35 3 Fasten the brake release unit on the bracket with the attachment screws Make sure the unit is positioned as straight as possible on the bracket The push buttons can otherwise get jammed when the SMB cover is refitted Shown in the figure Location of brake release unit on page 214 Art no is specified in Required equipment o...

Page 219: ...ormation in section WARNING The brake release buttons may be jammed after service work on page 34 8 Refit the push button guardand thecover push button guard to the SMB cover Shown in the figure Location of brake release unit on page 214 9 If the battery has been disconnected the revolution counter must be updated Detailed in the Calibration chapter section Updating revolution counters on page 265...

Page 220: ... below A more detailed view of the component and its position may be found in chapter Spare parts and exploded views on page 285 xx0700000019 Required equipment A Balancing device B Piston rod C Guide ring not visible in this figure Equipment etc Spare part no Art no Note Balancing device 3HAC024779 001 Auxiliary shaft 3HAC5281 1 For fitting the inner rings of the bearings Auxiliary shaft long 3HA...

Page 221: ...res include references to the tools required Equipment etc Spare part no Art no Note Action Note 1 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 The balancing device must be placed in a 90 angle from the floor in order the be lifted in the most secure way Shown in section Location balancing device on pa...

Page 222: ...rdingly 11 Carefully remove the balancing device from its upper and lower attachment 12 Remove the balancing device and put it in a safe place 13 Remove the inner rings of the bearings 14 Remove the sealing rings and support washers Action Note Action Note 1 Apply sealing compound on the surface for the sealing ring 2 Refit the inner sealing rings and support washers 3 Refit the inner ring of the ...

Page 223: ...nipple Continue until grease excudes behind the inner sealing 11 Remove the lubricating tool and wipe off protruding grease 12 Remove the auxiliary shafts 13 Apply locking liquid on the lock nuts Loctite 243 14 Refit the lock nuts and support washers Tightening torque 120 Nm 15 Check play min 0 1 mm between support washers and bearing seat at both bearings 16 Remove the M12x50 screw to restore the...

Page 224: ...ed equipment A Motor axis 1 B Motor attachment screws and washers C Cable gland cover located on the lower side of the motor D Motor cover Equipment etc Spare part no Art no Note Motor axis 1 3HAC028861 001 Includes motor pinion o ring Old o ring must be replaced when replacing the motor Grease 3HAB3537 1 Used to lubricate the o ring Power supply 24 VDC max 1 5 A For releasing the brakes Standard ...

Page 225: ...res include references to the tools required Circuit diagram 3HAC025744 001 See chapter Circuit diagram Equipment etc Spare part no Art no Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Remove the motor cover in order to get access to the connectors on top of the motor by unscrewing its four attachment screws Shown in the figure Locat...

Page 226: ...1 pin 2 pin 5 6 Remove the motor by unscrewing its four attachment screws and plain washers Shown in the figure Location of motor on page 222 7 If required press the motor out of position by fitting two screws in the holes on the motor for pressing out the motor Always use the removal screws in pairs 8 CAUTION The motor weighs 29 kg All lifting equipment used must be sized accordingly 9 Lift the m...

Page 227: ... supply Connect to connector R2 MP1 pin 2 pin 5 4 Fit the motor making sure the motor pinion is properly mated to the gearbox of axis 1 Make sure the motor is turned the right way that is connections on the left hand side Make sure the motor pinion does not get damaged 5 Secure the motor with its four attachment screws and plain washers M10 x 40 Shown in the figure Location of motor on page 222 Ti...

Page 228: ... B Attachment screws C Cable gland 10 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration infor mation 11 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or ...

Page 229: ...shers D Cable gland cover located on the lower side of the motor E Motor cover F Hole for lock screw Equipment etc Spare part no Art no Note Motor axis 2 3 3HAC021030 001 Includes motor pinion o ring The o ring must be replaced when the motor is replaced Grease 3HAB3537 1 For lubricating the o ring Guide pins M10 x 150 3HAC13120 2 For guiding the motor Guide pins are to be used in pairs Lifting to...

Page 230: ...bot 4 Lock the lower arm by inserting the lock screw into the hole Shown in the figure Location of motors axes 2 and 3 on page 227 5 Drain the oil from gearbox axes 2 3 Detailed in Oil change gearbox axes 2 3 on page 123 6 Remove the motor cover by unscrewing its four attachment screws Shown in the figure Location of motors axes 2 and 3 on page 227 7 Remove the cable gland cover at the cable exit ...

Page 231: ...placed the motor pinion must also be replaced Action Note Action Note 1 Make sure the o ring on the circumference of the motor is seated properly Lightly lubricate the o ring with grease 2 In order to release the brake connect the 24 VDC power supply Connect to connector R2 MP1 pin 2 pin 5 3 Fit the lifting tool motor axes 2 3 to the motor Art no is specified in Required equipment on page 227 4 Fi...

Page 232: ...e 12 Reconnect all connectors beneath the motor cover Connect in accordance with markings on connectors 13 Refit the cable gland cover at the cable exit with its two attachment screws Shown in the figure Location of motors axes 2 and 3 on page 227 Replace the gasket 14 Refit the motor cover with its four attachment screws and washers Make sure the cover is tightly sealed 15 Remove the lock screw f...

Page 233: ... Must be replaced when reas sembling motor Lifting tool motor ax 1 4 5 3HAC14459 1 Grease 3HAC3537 1 Used to lubricate the o ring Removal tool motor M10x 3HAC14972 1 Always use the removal tools in pairs Guide pins M8 x 100 3HAC15520 1 For guiding the motor Guide pins M8 x 150 3HAC15520 2 For guiding the motor Rotation tool 3HAC17105 1 Used to rotate the motor pinion when mating it to the gear whe...

Page 234: ...umatic pressure supplies to the robot 3 Remove the cable gland cover at the cable exit of the motor by unscrewing its two attachment screws Shown in the figure Location of motor on page 231 Make sure the gasket is not damaged 4 Remove the cover on top of the motor by unscrewing its four attachment screws 5 Disconnect all connectors beneath the motor cover 6 In order to release the brake connect th...

Page 235: ... in Required equipment on page 231 Shown in the figure Location of motor on page 231 6 Fit the motor with guidance of the pins making sure the motor pinion is properly mated to the gear of gearbox 4 Make sure the motor pinion does not get damaged 7 Use the rotation tool in order to rotate the motor pinion when mating it to the gear Fit the motor making sure the motor pinion is properly mated to th...

Page 236: ... Perform a leak down test if gearbox has been drained Detailed in section Performing a leak down test on page 142 15 Refill the gearbox with oil if drained 16 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration informa tion 17 DANGER Make sure all safety requirements ar...

Page 237: ... 205 1 9 C Wrist unit D Motor axis 5 Inside upper arm tube E Upper arm tube Equipment etc Spare part no Art no Note Motor 3HAC17484 10 Does not include pinion Use the pinion from the motor to be replaced Includes o ring 21522012 430 Set of shim motor 3HAC7941 28 Used to obtain the correct distance between motor flange and outer surface of motor pinion O ring 21522012 430 Must be replaced when reas...

Page 238: ...ferences to these procedures in the step by step instruc tions below These procedures include references to the tools required Circuit Diagram 3HAC025744 001 See chapter Circuit diagram Equipment etc Spare part no Art no Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Drain the oil from gearbox axis 5 Detailed in section Oil change gea...

Page 239: ...he brake release voltage Make sure the motor pinion is not damaged 13 Remove the motor by gently lifting it straight out Keep track of the shims between the motor flange and the wrist housing Action Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Make sure the o ring on the circumference of the motor is seated properly Lightly lubricat...

Page 240: ...s tightly sealed 11 Perform a leak down test Detailed in section Performing a leak down test on page 142 12 Refit the wrist unit 13 Refill the gear with oil Detailed in section Oil change gearbox axis 5 on page 128 14 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration ...

Page 241: ...axis 6 Figure shows robot variant IRB 6660 130 3 1 There are no cooling elements on the motor on variant IRB 6660 205 1 9 B Gearbox axis 6 C Attachment screws and washers gearbox 18 pcs D Attachment screws turning disk 12 pcs Equipment etc Spare part no Art no Note Motor axis 6 3HAC028889 001 Includes motor pinion o ring 21522012 430 Motor axis 6 IRB6660 205 1 9 3HAC15988 1 Includes motor pinion o...

Page 242: ...es may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Circuit Diagram 3HAC025744 001 See chapter Circuit diagram Equipment etc Spare part no Art no Note Action Note 1 Move the robot to a position where the motor in axis 6 is pointed straight up This position enables the motor to be replaced without dra...

Page 243: ...pinion away from the gear and disconnect the brake release voltage Make sure the motor pinion is not damaged 10 Remove the motor by gently lifting it straight out Action Note Action Note 1 Make sure the o ring on the circumference of the motor is seated properly Lightly lubricate the o ring with grease Art no is specified in Required equipment on page 239 2 In order to release the brake connect th...

Page 244: ...the motor cover 10 Refit the cover on top of the motor with its five attachment screws Make sure the cover is tightly sealed 11 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration infor mation 12 DANGER Make sure all safety requirements are met when performing the first...

Page 245: ...e found in chapter Spare parts and exploded views on page 285 xx0700000074 Required equipment A Gearbox axis 1 B Frame C Base D Attachment screws gearbox axis 1 M12x70 quality 12 9 UNBRAKO 24 pcs E Attachment screws gearbox axis 1 M16x90 quality 12 9 UNBRAKO 18 pcs Equipment etc Spare part no Art no Note Gearbox 3HAC10828 1 Includes gearbox all o rings and sealing rings O ring 3HAB3772 54 Replace ...

Page 246: ...Lifting device base 3HAC15560 1 Lifting tool chain 3HAC15556 1 Standard toolkit The content is defined in section Standard toolkit on page 280 Other tools and procedures may be required See references to these procedures in the step by step instruc tions below These procedures include references to the tools required Equipment etc Spare part no Art no Note Continued Continues on next page ...

Page 247: ...60 130 3 1 xx0700000518 Robot variant IRB 6660 205 1 9 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 3 Drain the oil from gearbox 1 Detailed in section Oil change gearbox axis 1 on page 120 4 Disconnect all cabling in the rear of the robot base and remove the cable support plate inside of the base Detailed in section Replacement of cable harness lower ...

Page 248: ... base and gearbox weighs 510 kg together All lifting equipment must be used accordingly 10 Lift the robot base to allow fitting the support base and gear 1 on each sides of the base Art no is specified in Required equipment on page 243 11 Fit the support base Make sure the base remains in a stable position before performing any work underneath the base 12 Remove the bottom plate from underneath th...

Page 249: ...ashers 3 pcs 14 Remove the cable guide in the center of gearbox 1 by unscrewing its attachment screws xx0200000256 A Location for attachment screws cable guide cable guide removed in the figure 15 CAUTION The gearbox weighs 200 kg All lifting equipment used must be sized accordingly 16 Lift the gearbox away with the already mounted lifting tools Action Note Action Note 1 If the base is not support...

Page 250: ...C O ring 3HAB 3772 54 D O ring 3HAB 3772 55 E Sealing ring 3HAC 11581 4 3 Refit the cable guide in the center of gearbox 1 with its attachment screws xx0200000256 A Location for attachment screws cable guide cable guide removed in figure 4 Fit the lifting device base and the lifting tool chain to the gearbox Art no is specified in Required equipment on page 243 5 Lift the gearbox to its mounting p...

Page 251: ...xis 1 18 pcs C Washers 3 pcs 8 Refit the bottom plate underneath the robot base by pushing it into the groove and fitting the attachment screw If removed also refit the rear connector plate NOTE Direct the bends on the bottom plate downwards 1 screw M6 x 8 xx0300000612 A Bottom plate B Rear connector plate C Attachment screw D Groove 9 CAUTION The base and gearbox weighs 510 kg together All liftin...

Page 252: ...acement of cable harness lower end axes 1 3 on page 147 14 Perform a leak down test Detailed in section Performing a leak down test on page 142 15 Refill the gearbox with oil Detailed in section Filling oil axis 1 on page 122 16 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section C...

Page 253: ...5 1 9 is the same xx0700000063 Required equipment A Gearbox axis 2 B Gearbox axis 3 C Hole for lockscrew Equipment etc Spare part no Art no Note Gearbox axes 2 3 3HAC022644 001 Sealing axes 2 3 3HAC022379 001 Lock screw M16x90 Guide pins Use guide pins in pairs Lifting tool gearbox axes 2 3 3HAC023240 001 Standard toolkit The content is defined in section Standard toolkit on page 280 Other tools a...

Page 254: ...ic and pneumatic pressure supplies to the robot 4 Drain the gearbox axis 2 3 from oil Detailed in section Oil change gearbox axes 2 3 on page 123 NOTE Time consuming activity 5 Remove the motor cables of motor axes 2 3 and protect the cables from getting damaged and from oil spill 6 Remove one gearbox at a time 7 DANGER Secure the weight of the lower arm properly before releasing the brakes of mot...

Page 255: ... sized accord ingly 15 If required apply two M12 screws to the holes in the gearbox in order to press it free 16 Remove the gearbox axis 2 3 using an overhead crane or similar with guidance from the fitted guide pins 17 Remove the sealing from the lower arm and clean it Action Note Action Note 1 Make sure that the o ring is fitted to the gearbox axis 2 3 Lightly lubricate it with grease 2 Fit the ...

Page 256: ...achment screws and washers Tightening torque 24 Nm 11 Refit the motors axes 2 3 Detailed in section Replacement of motor axes 2 and 3 on page 227 12 Perform a leakdown test 13 Refill the gearbox axes 2 3 with oil Detailed in section Oil change gearbox axes 2 3 on page 123 14 Remove the locking screw lower arm 15 Recalibrate the robot Calibration is detailed in a separate calibration manual enclose...

Page 257: ...E Oil plug draining F Oil plug filling G Cooling elements Equipment etc Spare part no Art no Note Gearbox 3HAC028121 001 Includes o ring 3HAB3772 57 Washers 3HAA1001 172 Not included in gearbox Replace only when damaged O ring 3HAB3772 64 3HAB3772 61 Must be replaced when reas sembling gearbox Grease 3HAB3537 1 For lubricating the o ring Standard toolkit The content is defined in section Standard ...

Page 258: ...section Oil change gearbox axis 6 on page 130 3 Remove the turning disk Detailed in section Removal turning disk on page 181 4 Remove the gearbox by unscrewing its 18 attachment screws Shown in the figure Location of gearbox on page 255 5 If required apply M8 screws to the holes shown in the figure beside to press the gearbox out xx0200000220 A M8 holes for pressing out the gearbox 6 Remove the ge...

Page 259: ...the gears of the motor 5 Secure the gearbox with the attachment screws and washers Shown in the figure Location of gearbox on page 255 8 pcs M8 x 40 12 9 quality UNBRAKO Tightening torque 30 Nm Reused screws may be used providing they are lubricated as detailed in section Screw joints on page 276 before fitting 6 Refit the turning disk Detailed in section Refitting turning disk on page 181 7 Perfo...

Page 260: ...vision A 258 Copyright 2007 2008 ABB All rights reserved 10 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 33 Action Note Continued ...

Page 261: ...obot has Absolute Accuracy calibration it is also recommended but not always needed to be calibrated for new Absolute Accuracy The resolver values will change when parts affecting the calibration position are replaced on the robot for example motors or parts of transmission Contents of the revolution counter memory are lost If the contents of the revolution counter memory are lost the counters mus...

Page 262: ...separate file Calibration Pendulum standard method Absolute Accuracy calibration optional Based on standard calibration and besides positioning the robot at home position the Absolute Accuracy calibration also compensates for mechanical tolerances in the robot structure deflection due to load Absolute Accuracy calibration focuses on positioning accuracy in the Cartesian coordinate system for the r...

Page 263: ...e method and the different routines further CalibWare Absolute Accuracy calibration In order to achieve a good positioning in the Cartesian coordinate system Absolute Accuracy is used as a TCP calibration The tool CalibWare guides through the calibration process and calculates new compensation parameters This is further detailed in the application manual Absolute Accuracy Calibware 2 0 If a servic...

Page 264: ...s and or correct axis position for all robot models Calibration scales marks IRB 6660 The figure below shows the positions of the calibration marks on the robot The figure shows robot variant IRB 6660 130 3 1 but the position of the calibration marks are the same on robot variant IRB 6660 205 1 9 xx0700000148 A Calibration plate axis 1 B Calibration tab on robot C Calibration mark axis 2 D Calibra...

Page 265: ...libration information 5 3 Calibration scales and correct axis position 263 3HAC028197 001 Revision A Copyright 2007 2008 ABB All rights reserved F Calibration mark axis 5 G Calibration mark axis 6 Continued ...

Page 266: ...erved 5 4 Calibration movement directions for all axes Overview When calibrating the axis must consistently be run towards the calibration position in the same direction in order to avoid position errors caused by backlash in gears etc Positive directions are shown in the figure below This is normally handled by the robot calibration software ...

Page 267: ...g the revolution counter setting with the FlexPendant This procedure details the second step when updating the revolution counter storing the revolution counter setting with the FlexPendant RobotWare 5 0 Action Note 1 Select axis by axis motion mode 2 Jog the robot to place the calibration marks within the tolerance zone Shown in section Calibration scales and correct axis position on page 262 3 W...

Page 268: ...lect the axis to have its revolution counter updated by Ticking in the box to the left Tapping Select all to update all axes Then tap Update 5 A dialog box is displayed warning that the updating operation cannot be undone Tap Update to proceed with updating the revolution counters Tap Cancel to cancel updating the revolution counters Tapping Update updates the ticked revolution counters and remove...

Page 269: ... the following program MoveAbsJ 0 0 0 0 0 0 9E9 9E9 9E9 9E9 9E9 9E9 NoEOffs v1000 z50 Tool0 5 Run the program in manual mode 6 Check that the calibration marks for the axes align correctly If they do not update the revolution counters The calibration marks are shown in section Calibration scales and correct axis position on page 262 How to update the revolution counters is detailed in section Upda...

Page 271: ...anterials General All used grease oils and dead batteries must be disposed of in accordance with the current legislation of the country in which the robot and the control unit is installed If the robot or the control unit is partially or completely disposed of the various parts must be grouped together according to their nature that is all iron together and all plastic together and disposed of acc...

Page 272: ...l regulations Do no dispose of oil and grease near lakes ponds ditches down drains or on to soil Incineration must be carried out under controlled conditions in accordance with local regulations Also note that Spills may form a film on water surfaces causing damage to organisms Oxygen transfer could also be impaired Spillage may penetrate the soil causing ground water contamination Material Exampl...

Page 273: ...lancing 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 Equipment Art no Note Standard toolkit The content is defined in section Standard toolkit on page 280 Cutting torch For opening housing and cutting coils Other tools and procedures may be required See references to these ...

Page 274: ...alancing device The device also contains some grease 2 Place the device on a workbench or similar Make sure it is clamped in position with a vice or similar 3 Open a hole in the side of the housing as shown in the figure Use a cutting torch The measurements shown below are maximum values xx07000000155 4 Cut the coils of the three springs inside the housing as specified below Outer spring cut at le...

Page 275: ...3HAC028197 001 Revision A Copyright 2007 2008 ABB All rights reserved 7 Reference information 7 1 Introduction General This chapter includes general information complementing the more specific information in the different procedures in the manual ...

Page 276: ...t of machines Part 1 General requirements EN 1050 Principles for risk assessment ANSI RIA 15 06 1999 Industrial robots safety requirements DIN 19258 Interbus S International Standard Standards robot cell The following standards are applicable when the robot is part of a robot cell EN 953 Fixed and moveable guards EN 811 Safety distances to prevent danger zones being reached by the lower limbs EN 3...

Page 277: ...07 2008 ABB All rights reserved 7 3 Unit conversion Converter table Use the table below to convert units used in this manual Quantity Units Length 1 m 3 28 ft 39 37 in Weight 1 kg 2 21 lb Pressure 1 bar 100 kPa 14 5 psi Force 1 N 0 738 lbf Moment 1 Nm 0 738 lbf tn Volume 1 L 0 264 US gal ...

Page 278: ...mo is a special surface treatment to reduce the friction when tightening the screw joint Screws treated with Gleitmo may be reused 3 4 times before the coating disappears After this the screw must be discarded and replaced with a new one When handling screws treated with Gleitmo protective gloves of nitrile rubber type should be used Screws lubricated in other ways Screws lubricated with Molycote ...

Page 279: ...Maximum allowed total deviation from the specified value is 10 The table below specifies the recommended standard tightening torque for oil lubricated screws with slotted or cross recess head screws The table below specifies the recommended standard tightening torque for oil lubricated screws with Allen head screws The table below specifies the recommended standard tightening torque for Molycote l...

Page 280: ...rque for water and air connectors when one or both connectors are made of brass M16 235 280 M24 790 950 Dimension Tightening torque Nm Nominal Tightening torque Nm Min Tightening torque Nm Max 1 8 12 8 15 1 4 15 10 20 3 8 20 15 25 1 2 40 30 50 3 4 70 55 90 Dimension Tightening torque Nm Class 10 9 Molycote lubricated Tightening torque Nm Class 12 9 Molycote lubricated Continued ...

Page 281: ...cified All components exceeding 22 kg 50 lbs are high lighted in this way To avoid injury ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg A wide range of lifting tools and devices are available for each manipulator model Example Below is an example of how a weight specification is presented inside a procedure table Action Note CAUTION The motor we...

Page 282: ...olkit and defined in the table below This way the tools required are the sum of the Standard Toolkit and any tools listed in the instruction Contents standard toolkit Qty Tool Rem 1 Ring open end spanner 8 19 mm 1 Socket head cap 5 17 mm 1 Torx socket no 20 60 1 Box spanner set 1 Torque wrench 10 100 Nm 1 Torque wrench 75 400 Nm 1 Ratchet head for torque wrench 1 2 2 Hexagon headed screw M10x100 1...

Page 283: ...at are used for the current robot model This toolkit is necessary primarly when removing and refitting the motors The tools are also listed directly in the instructions Description Art no Note Calibration Pendulum toolkit 3HAC15716 1 Complete kit that also includes operating manual Description Art no Note Oil exchange equipment 3HAC021745 001 Includes vacuum pump with regulator hose and coupling c...

Page 284: ...oisting block 1 Support base and gearbox axis 1 1 3HAC15535 1 Lifting tool gearbox axis 1 1 3HAC15556 1 Lifting eye used together with lifting tool 3HAC15556 1 3HAC025333 005 Lifting tool motor 1 3HAC14586 1 Lifting tool gearbox axes 2 3 1 3HAC023240 001 Lifting tool frame 1 3HAC023308 001 Lifting tool complete robot 1 3HAC15607 1 User instruction 3HAC15971 1 Lifting tool parallel arm 1 3HAC023098...

Page 285: ...General Many repair and maintenance activities require different pieces of lifting equipment which are specified in each procedure The use of each piece of lifting equipment is not detailed in the activity procedure but in the instruction delivered with each piece of lifting equipment This implies that the instructions delivered with the lifting equipment should be stored for later reference ...

Page 287: ...ws 8 1 Introduction 285 3HAC028197 001 Revision A Copyright 2007 2008 ABB All rights reserved 8 Spare parts and exploded views 8 1 Introduction Definitions This chapter specifies all spare parts and replacement articles of the robot ...

Page 288: ...pcs 90 1 9 3HAC11526 1 Stud screw M6x150 quality PSH 5 8 fzb 2 pcs 90 1 10 3HAC022286 001 Serial measurement unit DSQC 633 1 90 1 11 9ADA267 6 Hexagon nut M6 quality 8 A2F 4 pcs 90 1 12 9ADA312 6 Plain washer 6 4x12x1 6 quality A2F 2 pcs 90 1 13 3HAC15619 1 Cable FB7 SMB 1 7 1 90 1 14 9ADA183 25 Hex socket head cap screw M6x20 quality 8 8 A2F 10 pcs 90 1 15 3HAC021349 003 Cover SMB 1 90 1 16 3HAC1...

Page 289: ...d Exploded view xx0700000232 90 1 31 3HAC12129 1 Cover plate 2 pcs 90 1 32 9ADA183 24 Hex socket head cap screw M6x16 quality 8 8 A2F 12 pcs 90 1 33 9ADA183 48 Hex socket head cap screw M10x16 quality 8 8 A3F 2 pcs 90 1 34 3HAB3409 26 Hex socket head cap screw M6x25 quality steel Gleitmo 610 1 Item Article no Description Qty Continued ...

Page 290: ... Magnetic plug 1 69 3HAC16721 1 Magnetic plug 1 70 3HAC032140 001 Lubricating oil Kyodo Yushi TMO150 8000 ml 71 3HAC12671 6 Block for calibration 1 72 3HAC14024 1 Protection screw 1 73 9ADA618 57 Torx pan head screw M6x20 quality 8 8 A2F 3 pcs 74 3HAC021287 001 Sync plate 1 75 9ADA618 56 Torx pan head screw M6x16 quality 8 8 A2F 2 pcs 76 3HAC12812 2 Mech stop ax 1 assembly 1 77 3HAC10499 7 Cover s...

Page 292: ...s 106 3HAC11732 2 Washer T 3 3 pcs 107 3HAB3409 88 Hex socket head cap screw M16x70 quality 12 9 Gleitmo 610 18 pcs 107 3HAB7700 5 Hex socket head cap screw M16x70 quality UNBRAKO 12 9 Gleitmo 610 18 pcs 108 3HAC14453 1 Hose with flange 1 109 3HAC11529 1 Rubber lined clip D 28 1 110 9ADA618 56 Torx pan head screw M6x16 quality 8 8 A2F 1 111 3HAC4428 2 Hose Clip 1 112 3HAC14453 2 Plug 1 113 3HAC122...

Page 294: ...409 71 Hex socket head cap screw M12x60 quality 12 9 Gleitmo 610 24 pcs 24 3HAB7700 71 Hex socket head cap screw M12x60 quality UNBRAKO 12 9 Gleitmo 610 24 pcs 25 3HAA1001 134 Washer 13x19x1 5 24 pcs 26 3HAC021663 003 Cover machined 1 27 9ADA183 39 Hex socket head cap screw M8x35 quality 8 8 A2F 16 pcs 28 9ADA312 7 Plain washer 8 4x16x1 6 16 pcs 29 3HAB3772 84 O ring 1 30 3HAC021030 001 Motor Inc ...

Page 295: ...ights reserved Exploded view xx0700000239 38 3HAA1001 134 Washer 13x19x1 5 21 pcs 39 3HAC032140 001 Lubricating oil Kyodo Yushi TMO150 5000 ml 40 3HAC16721 1 Magnetic plug 3 pcs 41 3HAC16721 1 Magnetic plug 3 pcs 42 3HAC032140 001 Lubricating oil Kyodo Yushi TMO150 5000 ml Item Spare part no Article no Description Qty Continued ...

Page 296: ...VK Cover VK 35x8 Not shown in this figure 1 304 3HAB3537 1 Bearing grease Shell Alvania WR2 10 g 305 3HAC4435 1 Spacing sleeve 2 pcs 306 3HAB4169 1 Sealed spherical bearing 2 pcs 310 3HAA2166 23 VK Cover VK 120x12 1 311 3HAC022338 001 Damper 2 pcs 312 9ADA183 37 Hex socket head cap screw M8x25 quality 8 8 A2F 4 pcs 313 9ADA312 7 Plain washer 8 4x16x1 6 4 pcs 314 3HAB7116 1 Locking liquid Loctite 2...

Page 297: ... and exploded views 8 6 Spare parts Lower arm system 295 3HAC028197 001 Revision A Copyright 2007 2008 ABB All rights reserved Exploded view robot variant IRB6660 130 3 1 and IRB 6660 205 1 9 xx0700000236 Continued ...

Page 298: ...cle no Description Qty 201 3HAC021084 004 Parallel rod machining Robot variant IRB6660 130 3 1 1 201 3HAC028641 001 Parallel rod machining Robot variant IRB6660 205 1 9 1 202 3HAB3537 1 Bearing grease Shell Alvania WR2 4 g 203 3HAC4331 1 Thrust washer 2 pcs 204 3HAC3715 1 Sealed spherical bearing 2 pcs 205 3HAC4332 1 Cover washer 2 pcs 206 3HAC4330 1 Shaft 2 pcs Continues on next page ...

Page 300: ... 1 9 Item Article no Description Qty 4 3HAC024779 001 Balancing device 1 4 6 3HAC3476 1 Guiding ring 1 4 8 3HAC3311 1 Adjust Needle bearing 2 pcs 4 10 3HAC3530 1 Circlip 1 58 12360012 202 Sealing compound 4 ml 59 3HAC7343 1 Ring 2 pcs 60 3HAC7253 1 Support washer 4 pcs 61 3HAA1001 124 Support ring 2 pcs 62 3HAB3537 1 Bearing grease Shell Alvania RW2 10 g 63 3HAC7349 1 Lock nut 2 pc 64 3HAB7116 1 L...

Page 302: ...0 205 1 9 1 44 3HAC026627 001 Shaft axes 2 3 robot variant IRB 6660 205 1 9 1 45 11712016 618 Lubricant paste 5 ml 46 3HAB3772 29 O ring 2 pcs 47 2216264 16 Sealing ring 2 pcs 48 3HAC022581 001 Sealing ring 2 pcs 49 3HAB3537 1 Bearing grease 10 g 50 22133802 8 Taper roller bearing 2 pcs 51 3HAC7817 1 Sealing assembly 2 pcs 52 3HAC6627 1 Sealing ring 2 pcs 53 3HAA1001 658 O ring 2 pcs 54 3HAB7116 1...

Page 303: ...3 301 3HAC028197 001 Revision A Copyright 2007 2008 ABB All rights reserved Exploded view The figure shows robot variant IRB 6660 130 3 1 The only difference in robot variant IRB 6660 205 1 9 are the shafts on axes 2 and 3 See part list above xx0700000235 Continued ...

Page 304: ... Rot ac motor incl pinion 1 3HAC028839 001 Spacer 1 3HAC026249 001 Gasket motor axis 6 2 pcs 6 4 5 9ADA312 7 Plain washer 8 4x16x1 6 4 pcs 6 4 6 9ADA183 37 Hex socket head cap screw M8x25 quality 8 8 A2F 4 pcs 6 4 7 3HAA1001 172 Washer 8 4x13x1 5 18 pcs 6 4 8 2522122 1 Magnetic plug 2 pcs 6 4 9 3HAC032140 001 Lubrication oil Kyodo Yushi TMO150 450 ml 6 4 10 3HAB7116 1 Locking liquid Loctite 243 2 ...

Page 305: ... 303 3HAC028197 001 Revision A Copyright 2007 2008 ABB All rights reserved Exploded view of both robot variants IRB 6660 130 3 1 IRB 6660 205 1 9 xx0700000238 82 9ADA618 56 Torx pan head screw M6x16 quality 8 8 A2F 11 pcs Item Spare part no Article no Description Qty Continued ...

Page 306: ...s 8 11 Spare parts Labels 3HAC028197 001 Revision A 304 Copyright 2007 2008 ABB All rights reserved 8 11 Spare parts Labels Parts list Item Article no Description Qty 3HAC027176 001 Labels and plate set 1 3HAC021505 003 Oil labels 1 ...

Page 307: ...allation procedure for the equipment is detailed Option no Equipment Installation is detailed in 159 1 Fork lift set including all required equipment Lifting robot with fork lift on page 43 87 1 Cooling fan axis 1 Installation of cooling fan for motors axis 1 or 2 option on page 72 Cabling cooling fan axis 1 29 2 Mechanical stop for axis 1 7 5 Mechanically restricting the working range of axis 1 o...

Page 309: ...ircuit diagram 9 1 Introduction 307 3HAC028197 001 Revision A Copyright 2007 2008 ABB All rights reserved 9 Circuit diagram 9 1 Introduction Overview This chapter includes the circuit diagram for the robot ...

Page 311: ...rs that may appear in this document Except as may be expressly stated anywhere in this document nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses damages 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 document This document and parts thereof mus...

Page 312: ...ge Page description ABB Contents1 1 COPYRIGHT page 2 Table of contents 1 150 3 Valid For 4 Connection point location IRB 6600 6640 6650 7600 5 Connection point location IRB 6660 9 Legend IRB 66XX 7600 10 Brake Release Unit IRB 66XX 7600 20 Serial Measuring Board IRB 66XX 7600 30 Axis 1 IRB 66XX 7600 40 Axis 2 IRB 66XX 7600 50 Axis 3 Incl optional signal lamp IRB 66XX 76 60 Axis 4 IRB 66XX 7600 70 ...

Page 313: ...1 Manipulator harness axis 5 IRB 6600 6640 6650 6650S 3HAC11440 1 Manipulator harness axis 5 6 IRB 7600 3HAC023717 001 Manipulator harness axis 5 6 IRB 6600 ID 6640 ID 6650 ID 3HAC15930 1 UL signal lamp IRB 6600 6640 6650 6600 ID 6640 ID 6650 ID 6650S 7600 3HAC12498 1 Pos SW 3 functions IRB 6600 6640 6650 6600 ID 6640 ID 6650 ID 6650S 7600 3HAC12587 1 Pos SW 2 functions IRB 6600 6650 6600 ID 6650 ...

Page 314: ...7 8 R1 G R1 SMB1 7 R3 FAN2 R2 FB7 R2 G R2 SMB R1 SMB1 3 R1 SMB4 6 R2 SW2 X8 X9 X10 R2 MP2 R2 FB2 R2 MP4 R2 FB4 R3 FAN3 R2 FB3 R2 MP3 R2 H1 R2 H2 R2 M5 6 IRB7600 6600 ID 6640 ID 6650 ID R2 MP1 R2 FB1 R3 MP5 IRB 7600 6600 ID 6640 ID 6650 ID R3 FB5 IRB 7600 6600 ID 6640 ID 6650 ID R3 MP6 R3 FB6 R3 MP5 IRB 6600 6640 6650 6650S R3 FB5 IRB 6600 6640 6650 6650S R4 MP5 IRB 6600 6640 6650 6650S R4 FB5 IRB ...

Page 315: ...opyright 2003 ABB Page 5 21 Total IRB 6660 3HAC025744 001 Latest revision Approved by date Connection point location Location Plant Sublocation IRB6660 Manipulator Document no Next Rev Ind 02 Lab Office Status APPROVED 1 2 3 4 5 6 7 8 R3 MP6 R3 FB6 R3 MP5 R3 FB5 R2 MP3 R2 FB3 R2 H1 R2 H2 R2 MP1 R2 FB1 R1 MP R1 SMB R1 CP CS R2 MP4 R2 FB4 R2 MP2 R2 FB2 R1 SMB1 3 R1 SMB4 6 R2 SMB X8 X9 X10 R2 CP CS ...

Page 316: ...revision Approved by date Legend Location Plant Sublocation IRB66XX 7600 Manipulator Document no Next Rev Ind 02 Lab Office Status APPROVED 2005 10 17 1 2 3 4 5 6 7 8 M B PTC R G BU FB SMB FAN SW Keypin Motor Brake Temp sensor PTC resistor Resolver Battery Pack Brake Release Unit Feedback unit Serial Measurment Board Fan Position switch Location pin to avoid mismatch Protective Earth Twisted wires...

Page 317: ... Circuit Brake Bleed Circuit Brake Bleed Circuit Brake Bleed Circuit Brake Bleed Circuit Brake Bleed Circuit 9 1 Key Pin Key Pin BU Brake Release Simplified R1 MP 13 4 3 5 2 X8 1 X8 1 5 3 11 12 X10 1 3 5 X9 4 8 10 X10 1 3 5 X9 4 8 10 Brake Release Brake PB 2 1 R1 MP R1 MP R1 MP R1 MP R1 MP R1 MP 5 6 7 8 9 10 0V 4 BU M1 Axis 1 30 2 BU M2 Axis 2 40 2 BU M3 Axis 3 50 2 BU M4 Axis 4 60 2 BU M5 7600 Ax...

Page 318: ...otal IRB 66XX 7600 3HAC025744 001 Latest revision Approved by date Serial Measuring Board Location Plant Sublocation 66XX 7600 SMB Document no Next Rev Ind 02 Lab Office Status APPROVED 2005 10 17 1 2 3 4 5 6 7 8 A B C D E F L KEYPIN M R1 SMB 9 5 8 4 3 7 R2 SMB SDI SDI N SDO SDO N 0V 24V BK WHBK BN WHBN RD WHRD OG SMB 9 5 8 4 3 7 2 1 R2 SMB 2 1 R1 G X3 R1 G X3 G 0V Axis 3 50 3 0V EXT LAMP Axis 3 5...

Page 319: ...xt Rev Ind 02 Lab Office Status APPROVED 2005 10 17 1 2 3 4 5 6 7 8 M 3 S V T W R U PE R2 MP1 1 6 7 9 2 5 Brake MU1 RD WH BK GNYE BU BU R2 MP1 1 6 7 9 12 2 17 18 19 R1 MP M1R M1S M1T BU M1 BU 0V M1 1 3 5 GNYE 9 10 R2 FB1 6 1 7 2 8 3 Resolver FB1 RD BK BU YE WHBK WHYE WHRD R2 FB1 6 1 7 2 8 3 2 14 3 15 6 18 R1 SMB1 3 BK WHBK BN WHBN RD WHRD X1 0V X1 Y1 0V Y1 0V EXC1 EXC1 2 14 3 15 6 18 R1 SMB1 3 SMB...

Page 320: ...02 Lab Office Status APPROVED 2005 10 17 1 2 3 4 5 6 7 8 SMB R1 SMB1 3 4 16 5 17 7 19 R1 MP 32 31 30 4 16 5 17 7 19 R1 SMB1 3 BK WHBK BN WHBN RD WHRD M2R M2S M2T BU M2 BU 0V M2 1 2 4 GNYE 9 10 X2 0V X2 Y2 0V Y2 0V EXC1 EXC1 R2 MP2 1 6 7 9 2 5 R2 FB2 6 1 7 2 8 3 FB2 MU2 R2 MP2 1 6 7 9 2 5 R2 FB2 6 1 7 2 8 3 RD BK BU YE WHBK WHYE WHRD RD WH BK GNYE BU BU M 3 S V T W R U PE Brake Resolver 4 3 10 12 R...

Page 321: ...4 5 6 7 8 SMB R1 SMB1 3 9 21 10 22 8 20 R1 MP 3 5 7 9 21 10 22 8 20 R1 SMB1 3 BK WHBK BN WHBN RD WHRD M3R M3S M3T PE PE BU M3 1 2 3 GNYE GNYE 9 X3 0V X3 Y3 0V Y3 0V EXC1 EXC1 R2 MP3 1 6 7 9 12 2 R2 FB3 6 1 7 2 8 3 FB3 MU3 R2 MP3 1 6 7 9 2 5 R2 FB3 6 1 7 2 8 3 RD BK BU YE WHBK WHYE WHRD RD WH BK GNYE BU BU M 3 S V T W R U PE Brake Resolver KEYPIN B KEYPIN A A K 1 2 R2 H1 R2 H2 R2 H1 R2 H2 OG R3 H S...

Page 322: ...v Ind 02 Lab Office Status APPROVED 2005 10 17 1 2 3 4 5 6 7 8 SMB R1 SMB4 6 2 14 3 15 6 18 R1 MP 1 2 10 2 14 3 15 6 18 R1 SMB4 6 BK WHBK BN WHBN RD WHRD M4R M4S M4T PE BU M4 BU 0V M4 1 2 3 GNYE 6 7 X4 0V X4 Y4 0V Y4 0V EXC2 EXC2 R2 MP4 1 3 7 9 2 5 R2 FB4 6 1 7 2 8 3 FB4 MU4 R2 MP4 1 3 7 9 2 5 R2 FB4 6 1 7 2 8 3 RD BK BU YE WHBK WHYE WHRD RD WH BK GNYE BU BU M 3 S V T W R U PE Brake Resolver PTC4 ...

Page 323: ...5 17 7 19 R1 SMB4 6 BK WHBK BN WHBN RD WHRD M5R M5S M5T PE BU M5 BU 0V M5 1 2 3 GNYE 6 7 X5 0V X5 Y5 0V Y5 0V EXC2 EXC2 R3 MP5 1 3 7 9 2 5 R3 FB5 6 1 7 2 8 3 FB5 MU5 R3 MP5 1 3 7 9 2 5 R3 FB5 6 1 7 2 8 3 RD BK BU YE WHBK WHYE WHRD RD WH BK GNYE BU BU M 3 S V T W R U PE Brake Resolver C1 C2 C3 GND B9 B1 B7 B8 8 11 C1 C2 C3 GND B9 B1 B7 8 11 PTC5 1 2 BU BK M5R M5S M5T PE BU M5 BU 0V M5 1 2 3 GNYE 6 ...

Page 324: ... 16 5 17 7 19 20 28 29 R1 SMB4 6 R1 MP BK WHBK BN WHBN RD WHRD M5R M5S M5T PE BU M5 BU 0V M5 PTC M5 5 1 2 3 GNYE 6 7 4 X5 0V X5 Y5 0V Y5 0V EXC2 EXC2 A B C D E F A B C D E F R3 FB5 R3 MP5 1 2 3 GND C D A B BK WHBK BN WHBN RD WHRD 1 2 3 GND C D A B M5R M5S M5T PE BU M5 BU 0V M5 PTC M5 PTC M6 X5 0V X5 Y5 0V Y5 0V EXC2 EXC2 1 2 3 GNYE 6 7 4 5 R4 FB5 6 1 7 2 8 3 R4 MP5 1 3 7 9 2 5 8 11 FB5 R4 FB5 6 1 ...

Page 325: ...6XX 7600 BU 10 2 BU 0V M5 66XX 7600 Axis 4 60 2 PTC M5 20 28 29 15 4 16 5 17 7 19 PTC 0V R1 SMB4 6 5 BK WHBK BN WHBN RD WHRD M5R M5S M5T PE BU M5 BU 0V M5 PTC M5 X5 0V X5 Y5 0V Y5 0V EXC2 EXC2 1 2 3 GNYE 6 7 4 R2 M5 6 C1 C2 C3 GND B9 B1 B7 A1 A7 A2 A8 A3 A9 C1 C2 C3 GND B9 B1 B7 A1 A7 A2 A8 A3 A9 R2 M5 6 BN WHBN RD WHRD OG WHOG M5R M5S M5T PE BU M5 BU 0V M5 PTC M5 PTC M6 1 2 3 GNYE 9 11 7 X5 0V X5...

Page 326: ... 20 R1 MP 9 8 16 9 21 10 22 8 20 R1 SMB4 6 BK WHBK BN WHBN RD WHRD M6R M6S M6T PE BU M6 BU 0V M6 1 2 3 GNYE 6 7 X6 0V X6 Y6 0V Y6 0V EXC2 EXC2 R3 MP6 1 3 7 9 2 5 R3 FB6 6 1 7 2 8 3 FB6 MU6 R3 MP6 1 3 7 9 2 5 R3 FB6 6 1 7 2 8 3 RD BK BU YE WHBK WHYE WHRD RD WH BK GNYE BU BU M 3 S V T W R U PE Brake Resolver 8 11 BU BK PTC6 1 2 8 11 R2 M5 6 C4 C5 C6 GND B11 B12 B10 C4 C5 C6 GND B11 B12 B10 M6R M6S M...

Page 327: ... 6 Document no Next Rev Ind 02 Lab Office Status APPROVED 2005 10 17 1 2 3 4 5 6 7 8 SMB R1 SMB4 6 9 21 10 22 8 20 R1 MP 9 8 16 9 21 10 22 8 20 R1 SMB4 6 BK WHBK BN WHBN RD WHRD M6R M6S M6T PE BU M6 BU 0V M6 1 2 3 GNYE 6 7 X6 0V X6 Y6 0V Y6 0V EXC2 EXC2 R3 MP6 1 3 7 9 2 5 R3 FB6 6 1 7 2 8 3 FB6 MU6 R3 MP6 1 3 7 9 2 5 R3 FB6 6 1 7 2 8 3 RD BK BU YE WHBK WHYE WHRD RD WH BK GNYE BU BU M 3 S V T W R U...

Page 328: ...9 21 10 22 8 20 9 21 10 22 8 20 R1 MP 66XX 7600 BU 10 7 BU M6 9 8 16 R1 SMB4 6 BK WHBK BN WHBN RD WHRD M6R M6S M6T PE BU M6 X6 0V X6 Y6 0V Y6 0V EXC2 EXC2 1 2 3 GNYE 6 R2 M5 6 C4 C5 C6 GND B11 B10 R2 M5 6 A4 A10 A5 A11 A6 A12 C4 C5 C6 GND B11 B10 A4 A10 A5 A11 A6 A12 M6R M6S M6T PE BU M6 BU 0V M6 PTC 0V BK WHBK BN WHBN RD WHRD 1 2 3 GNYE 6 7 5 X6 0V X6 Y6 0V Y6 0V EXC2 EXC2 PTC M6 4 R3 FB6 6 1 7 2...

Page 329: ...0 17 1 2 3 4 5 6 7 8 SW1 1 22 21 14 13 SW1 2 22 21 14 13 SW1 3 22 21 14 13 SW1 4 22 21 14 13 SW1 5 22 21 14 13 SW1 6 22 21 14 13 A B D C E F H G J K M L N P S R T U W V X Y a Z Position switches Axis 1 Power 1 1 1 Power 1 1 2 Signal 1 1 1 Signal 1 1 2 Power 1 2 1 Power 1 2 2 Signal 1 2 2 Signal 1 2 1 Power 1 3 1 Power 1 3 2 Signal 1 3 2 Signal 1 3 1 Power 1 4 1 Power 1 4 2 Signal 1 4 2 Signal 1 4 ...

Page 330: ... A B D C E F H G J K M L Power 2 1 1 Power 2 1 2 Signal 2 1 2 Signal 2 1 1 Power 2 2 1 Power 2 2 2 Signal 2 2 2 Signal 2 2 1 Power 2 3 1 Power 2 3 2 Signal 2 3 2 Signal 2 3 1 1 2 4 3 5 6 8 7 9 10 12 11 SW2 1 22 21 14 13 SW2 2 22 21 14 13 SW2 3 22 21 14 13 Position switches Axis 2 R1 SW2 3 A B D C E F H G J K M L A B D C E F H G J K M L R2 SW2 Power 2 1 1 Power 2 1 2 Signal 2 1 2 Signal 2 1 1 Power...

Page 331: ...8 T U W V X Y a Z b c e d f h g R1 SW2 3 Power 3 1 1 Power 3 1 2 Signal 3 1 2 Signal 3 1 1 Power 3 2 1 Power 3 2 2 Signal 3 2 2 Signal 3 2 1 Power 3 3 1 Power 3 3 2 Signal 3 3 2 Signal 3 3 1 1 2 4 3 5 6 8 7 9 10 12 11 13 15 14 A B D C E F H G J K M L A B D C E F H G J K M L R2 SW3 Power 3 1 1 Power 3 1 2 Signal 3 1 2 Signal 3 1 1 Power 3 2 1 Power 3 2 2 Signal 3 2 2 Signal 3 2 1 Power 3 3 1 Power ...

Page 332: ... 0 1 23 3 4 5 5 6 2 70 2 888 2 9 6 0 9 9 2 A 8B C D 9 8 B ...

Page 333: ... 2 3 4 5 5 6 2 70 2 888 2 9 6 0 9 9 1 EF 2 888 2 9 6 9 9 8 B ...

Page 334: ... 9 0G 06 6 2 4 5 5 6 99 0 9 9 H H H 0 1 23 3 0 2 3 0 0G 06 6 0 06 99 066 0 10I 0 06 98 066 0 10I 0 I 0 236 6 I 0 I 0 236 6 I 0 I 0 236 6 I 0 I 0 236 0G2 I 0 I 0 236 0G2 I 0 9 I 0 236 0G2 I 0 9 I 0 236 0 9 I 0 236 0 ...

Page 335: ...98 99 2 888 7 066 0 10I 4 5 5 06 6 2 70 2 888 2 9 6 0 9 9 263 6 0 I 7 263 6 0 I 7 E 7 F G E 7 F B 9 8 B B 9 B 9 B B B B 9 9 8 B 9 B 0I 2 I G E F 9 8 B ...

Page 336: ... 98 2 888 7 066 0 10I 4 5 5 06 6 2 70 2 888 2 9 6 0 9 9 G E 7 F E 7 F 9 8 B ...

Page 337: ... 6 I 0 I62 206 2 G0 6 26 26 B9 E F E F B88 G 00 6 B 8 B 8 2 888 0 6 0 0 26 J 8 8 J 9 J J 9 J 8 8 8 8 8 B 3671 3671 J J 9 9 G G GB B G G G G 3671 I 6 3671 03 36 1 62 I 0 7 8 8 3 3 K K 9 8 3671 3671 9 8 J2 7 8 7 9 9 7 7 I7 6 03 1 36 I 8 3671 L L I L 263 8 B 3671 9 8 B ...

Page 338: ... E F E F B88 G 00 6 B 8 B 8 2 888 0 6 0 0 26 J 9 J 9 J 9 8 8 B 736 36 7 6 6 7 I I 703 03 J 9 9 8 8 B B 7 I 736 36 7 6 6 7 I I 703 03 7 62 I 0 7 9 9 8 8 B B 9 8 79 7 7 6 7 7 7 6 6 7 703 03 71 1 6 78 G G G J2 7 9 8 B 7 7 6 7 6 9 J 7 J 7 J 7 1 7 1 7 J 7 6 L I L 263 L 736 36 7 6 6 7 I I 703 03 9 8 B ...

Page 339: ... J 9 B B J 9 B B 8 8B 8B 8B 8 8 8 9 8 8 8 8 B 8B9 8B8 8B 8B 8BB 8B 8 8 8B 8 I 8 888 88 88B 88 J 9 9 8 8 B B 8 8 B B G G 9 9 G G 9 9 03 36 6 31 I 03 36 6 I I 03 36 6 62 I 0 7 9 9 8 8 B B 8 8 B B 9 9 9 9 8 8 79 736 36 7 I I 7 731 31 7 703 03 7 6 6 7 7 7 6 6 9 8 B 1 1 36 36 36 36 78 J2 7 9 8 B 8 B 9 9 8 5 6 6 6H 6H 03 1 36 31 7 7 6 7 703 31 7 I 7 6 71 736 7 703 I 71 736 7 I 7 731 L I L 263 L 67 7 7 9...

Page 340: ...36 0G2 I 0 I62 206 2 G0 6 26 26 B9 E F E F B8B G 00 6 BB 8 B 8 2 888 0 6 0 0 26 J 8 8 J 9 J J 9 J 8 8 8 8 8 B 3671 3671 J J 9 9 G G GB B G G G G 3671 I 3671 03 36 1 62 I 0 7 8 8 3 3 K K 9 8 3671 3671 9 8 J2 7 9 9 7 8 7 7 I7 6 03 1 36 I 3671 L I L 263 L 8 B 3671 9 8 B ...

Page 341: ...9 E F E F B8B G 00 6 BB 8 B 8 2 888 0 6 0 0 26 J 9 J 9 J 9 736 36 7 6 6 8 8 B 7 I I 703 03 J 9 9 8 8 B B 97 736 36 7 6 6 7 I I 703 03 I 97 62 I 0 9 9 8 8 7 B B 9 8 979 7 6 6 7 703 03 71 1 7 7 7 6 7 6 G G G 978 J2 9 8 B 7 7 7 6 7 6 9 1 7 1 7 J 7 J 7 J 7 J 7 6 L I L 263 L 736 36 7 6 6 7 I I 703 03 9 8 B ...

Page 342: ...B J 9 8 8B 8B 8B 8 8 8 9 8 8 8 8 B 8B9 8B8 8B 8B 8BB 8B 8B 8 8 8 8 36 888 88 88B 88 J 9 9 8 8 B B 8 8 B B 9 9 G9 9 G8 8 9 9 7 03 36 6 31 I 03 36 6 31 I 03 36 36 6 7 62 I 0 7 9 9 8 8 B B 8 8 B B 9 9 9 9 8 8 79 736 36 7 I I 7 731 31 7 703 03 7 6 6 7 7 7 6 6 9 8 B 1 1 36 36 36 36 78 J2 7 9 8 B 8 B 9 9 9 9 8 8 J 7 J J 7 J 6 03 1 36 31 7 7 6 7 703 31 7 I 7 6 7 703 71 736 71 736 36 7 I 7 731 L I L 263 L...

Page 343: ... 8 8 8 8B 8B 8B 8 8 8 9 8 8 8 8 B 8B9 8B8 8 8 8 8 8 8 B 736 36 7 6 6 7 I I 703 03 L I 3671 6 03 1 36 I 6 736 36 7 6 6 7 I I 703 03 03 1 36 31 7 7 6 7 703 31 L 263 3671 J 9 9 8 8 B B 9 9 8 8 B B 8 8 7 3671 I 736 36 7 6 6 7 I I 703 03 03 36 6 31 I 03 7 5 62 I 0 7 8 8 9 8 B B 9 9 8 8 B B 8 8 79 703 03 3671 703 03 71 1 736 36 7 I I 7 731 31 7 78 5 J2 7 8 B 9 8 B 8 3671 9 8 B ...

Page 344: ...9 0 6 9 9 L 0 0 26 J 9 J 9 B B J 9 J 9 J 9 B B J 9 B B 8B 8B 8BB 8B 8B 8 8 8 8 888 88 88B 88 L I 7 7 6 7 703 71 736 71 736 7 I 7 731 67 L I 263 J 9 9 9 B B 7 36 6 31 I 7 62 I 0 9 9 7 B B 79 703 03 7 6 6 78 J2 7 B 9 B 9 B 03 03 03 03 039 038 361 361 9 8 B ...

Page 345: ...ndation loads 38 requirements 39 G gearbox axis 1 replacement 243 gearbox axis 6 replacement 255 I installation mechanical stop axis 1 79 L lifting equipment 279 lifting of robot with lifting slings 52 lifting robot with fork lift 43 lifting slings robot 52 loads on foundation 38 M mechanical stop axis 1 79 motion of axes 41 motor axis 4 replacement 231 motor axis 5 replacement 235 motor axis 6 re...

Page 346: ...onditions robot 39 symbols safety 30 sync marks 262 T testing brakes 24 tightening torque mechanical stop axis 1 80 tools Calibration Pendulum equipment 281 for service 281 oil exchange equipment 281 turning disk replacement 180 type of motion 41 U updating revolution counters 265 V Validity and responsibility 14 W weight base plate 58 62 gearbox 247 253 lower arm 205 motor 224 225 robot 48 51 55 ...

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Page 348: ...ABB AB Robotics Products S 721 68 VÄSTERÅS SWEDEN Telephone 46 0 21 344000 Telefax 46 0 21 132592 3HAC028197 001 Revision A en ...

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