Page 1 ROBOTICS Product manual IRB 6660...
Page 2 Trace back information: Workspace R18-2 version a18 Checked in 2018-11-20 Skribenta version 5.3.012...
Page 3 Product manual IRB 6660 - 100/3.3 IRB 6660 - 130/3.1 IRB 6660 - 205/1.9 IRC5 Document ID: 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved. Specifications subject to change without notice.
Page 4 The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.
Page 5: Table Of Contents
2.3.8 Fitting equipment on robot ............... 2.3.9 Installation of chip protection - IRB 6660 - 205/1.9 ......... 2.3.10 Installation of cooling fan for motors (option) ..........2.3.11 Installation of Foundry Plus Cable guard (option no. 908-1) ......2.3.12 Loads fitted to the robot, stopping time and braking distances ......
Page 6 Replacement of parallel arm ..............Frame and base ....................4.5.1 Replacing the SMB unit ................4.5.2 Replacing the brake release board ............. 4.5.3 Replacing the balancing device ..............Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 7 Standard tools ....................Special tools ....................Lifting accessories and lifting instructions .............. Spare part lists Spare part lists and illustrations ................Circuit diagram Circuit diagrams ....................Index Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
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Page 9: Overview Of This Manual
ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Product manual scope The manual covers covers all variants and designs of the IRB 6660. Some variants and designs may have been removed from the business offer and are no longer available for purchase.
Page 10 Revision Description First edition This revision includes the following additions and/or changes: • Robot version IRB 6660 - 205/1.9 added which includes new upper arm and new lower arm, as well as Chip protection. • Process cable package added. •...
Page 11 Information about restricting and extending the working range of axis 1 is now separated, see Mechanically restricting the working range of Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 12 6 on page 336. This revision includes the following updates: • New variant IRB 6660 - 100/3.3 is added. • Added turning radius and wrist center positions to the working range information, see Working range and type of motion on page •...
Page 13 Moved position of customer cabling plate at robot base to new location, Replacement of process cable package 1 - 3 MH on page 189. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 14 Published in release R18.2. The following updates are made in this revision: • Removed doubled information. Published in release R18.2. The following updates are made in this revision: • Updated references. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 15: Product Documentation
Product documentation Categories for user documentation from ABB Robotics The user documentation from ABB Robotics is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.
Page 16 The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 17: How To Read The Product Manual
Likewise, certain work methods or general information that is valid for several robot models, can be illustrated with illustrations that show a different robot model than the one that is described in the current manual. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
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Page 19: Safety
Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment that can influence the safety of the entire system.
Page 20 Unauthorized modifications of the originally delivered robot are prohibited. Without the consent of ABB, it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength of the robot could be affected.
Page 21: Protective Stop And Emergency Stop
1.1.2 Protective stop and emergency stop 1.1.2 Protective stop and emergency stop Overview The protective stops and emergency stops are described in the product manual for the controller. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 22: Safety Actions
1.2 Safety actions 1.2.1 Fire extinguishing Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the manipulator or controller. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 23: Emergency Release Of The Robot Axes
When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways. Make sure no personnel is near or beneath the robot. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 24: Make Sure That The Main Power Has Been Switched Off
To avoid these personal injuries, switch off the main power on the controller before proceeding work. Note Switch off all main power switches in a MultiMove system. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 25: Safety Risks
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. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 26 ABB is not liable for damages caused by the use of non-original spare parts and special equipment. ABB is not liable for damages or injuries caused by unauthorized modifications to the robot.
Page 27: Moving Robots Are Potentially Lethal
The hold-to-run function is used in manual mode, not in automatic mode. Make sure no personnel are present within the working range of the robot before pressing the start button. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 28: First Test Run May Cause Injury Or Damage
If maintenance or repair has been done, pay special attention to the function of the part that was serviced. Collision risks CAUTION When programming the movements of the robot, always identify potential collision risks before the first test run. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 30: Enabling Device And Hold-To-Run Functionality
How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 31: Risks Associated With Live Electric Parts
The power supply for the motors (up to 800 VDC). • The user connections for tools or other parts of the installation (max. 230 VAC). Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 32 Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 33: The Unit Is Sensitive To Esd
The mat must be grounded through a current-limit- ing resistor. Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 34: Hot Parts May Cause Burns
Wait until the potentially hot component has cooled if it is to be removed or handled in any other way. Do not put anything on hot metal surfaces, e.g. paper or plastic. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 35: Safety Risks Related To Pneumatic/Hydraulic Systems
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 prevent tools, etc., from falling due to gravity. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 36: Brake Testing
3 Inspect and verify that the axis maintains its position. If the robot does not change position as the motors are switched off, then the brake function is adequate. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 37: Safety Risks During Handling Of Batteries
Risk of fire or explosion. Operating temperatures are listed in Pre-installation procedure on page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 38: Safety Risks During Work With Gearbox Lubricants (Oil Or Grease)
Possible pressure build-up in gearbox Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 39 The magnetic oil plugs will take Contaminated oil in care of any remaining metal gear boxes chips. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 40: Safety Signals And Symbols
ELECTROSTATIC Warns for electrostatic hazards which could result DISCHARGE (ESD) in severe damage to the product. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 41 Symbol Designation Significance NOTE Describes important facts and conditions. Describes where to find additional information or how to do an operation in an easier way. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 42: Safety Symbols On Product Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 43 Brake release Pressing this button will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 44 Tip risk when loosening bolts The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 45 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 xx1500002616 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 46 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 47 Shut off with handle Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
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Page 49: Installation And Commissioning
Safety on page 19 before performing any installation work. Note If the IRB 6660 is connected to power, always make sure that the robot is connected to protective earth before starting any installation work. For more information see: • Product manual - IRC5...
Page 50: Unpacking
It also contains information useful during later re-installation of the robot. Prerequisites for installation personnel Installation personnel working with an ABB product must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work • conform to all national and local codes.
Page 51 The values also never reach their maximum at the same time! WARNING The robot installation is restricted to the mounting options given in following load table(s). Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 52 ± 7.9 kN (IRB 6660 - 205/1.9) ± 14.9 kN (IRB 6660 - 205/1.9) Force z 18.5 ± 3.7 kN (IRB 6660 - 100/3.3) 18.5 ± 7.4 kN (IRB 6660 - 100/3.3) 18.8 ± 8.4 kN (IRB 6660 - 130/3.1) 18.8 ±12.8 kN (IRB 6660 - 130/3.1)
Page 53 The table shows the available protection types of the robot, with the corresponding protection class. Protection type Protection class Manipulator, protection type Standard IP 67 Manipulator, protection type Foundry Plus IP 67 Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 54: Working Range And Type Of Motion
Axis 2 angle (de- Axis 3 angle (de- ber, see figure grees) grees) above 2055.5 2374,5 2629 1125 1189 -734 3343 2834 2501 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 55 Axis 2 angle (de- Axis 3 angle (de- ber, see figure grees) grees) above 1805.5 2374.5 2544 1306 1065 -518 3102 2596 2415 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 56 1193 1794.5 1903.2 751.5 1162.7 632.2 351.1 793.3 -37.9 1932.4 914.8 1579.6 1833 1043.4 2083.2 997.3 -60.4 107.4 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 57 Radius B IRB 6660 - 100/3.3 710 mm 3343 mm IRB 6660 - 130/3.1 710 mm 3102 mm IRB 6660 - 205/1.9 710 mm 1932 mm Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 58: Risk Of Tipping/Stability
Do not change the robot position before securing it to the foundation! Shipping and transportation position This figure shows the robot in its shipping position and transportation position. xx0700000001 IRB 6660 - 130/3.1, IRB 6660 - 100/3.3 IRB 6660 - 205/1.9 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S ©...
Page 59 2 Installation and commissioning 2.2.3 Risk of tipping/stability Continued WARNING The robot is likely to be mechanically unstable if not secured to the foundation. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 60: On-Site Installation
See figure Fork lift set, 3HAC023044-001 hardware on page Standard toolkit Content is defined in section Standard tools on page 381. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 61 Horizontal attachment screws (4 pcs / fork lift pocket) Attachment screw for adapter (1 pc / adapter) Vertical attachment screws (2 pcs) Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 62 Manually releasing the brakes on page xx0700000517 • A: IRB 6660 - 100/3.3, IRB 6660 - 130/3.1 • B: IRB 6660 - 205/1.9 Fit the two adapters to the robot and secure. Attachment points are shown in figure Attachment points on robot on page Attachment screws, 2 pcs, M16 x 90.
Page 63 However, they are tightened with different torque! xx0500002279 A Horizontal attachment screws, 4 pcs, M16 x 60. Tightening torque: 60 Nm. B Adapter Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 64 Attachment points on robot on page Double-check that pockets are properly se- cured to the robot! Insert fork lift forks into the pockets. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 65 Action Note CAUTION Note The IRB 6660 robot weighs 1950 kg. If the robot is equipped with fork lift pockets an extra weight of 90 kg must All lifting accessories used must be sized ac- be added to the robot weight!
Page 66: Lifting Robot With Roundslings
CAUTION Note The IRB 6660 robot weighs 1950 kg. If the robot is equipped with fork lift pockets an extra weight of 90 kg must be All lifting accessories used must be sized added to the robot weight!
Page 67 2 Installation and commissioning 2.3.2 Lifting robot with roundslings Continued The illustration is similar with the label attached to the robot’s lower arm. IRB 6660 - 130/3.1, IRB 6660 - 100/3.3 xx0700000002 Roundsling 2 m Roundsling 2 m Roundsling 2 m...
Page 68 2 Installation and commissioning 2.3.2 Lifting robot with roundslings Continued IRB 6660 - 205/1.9 xx0700000426 Roundsling 2 m Roundsling 2 m Roundsling 2 m Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 69: Lifting Robot With Lifting Slings
Attempting to lift a robot in any other position may result in the robot tipping over, causing severe damage or injury! Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 70 2.3.3 Lifting robot with lifting slings Continued Illustration, lifting slings The figure below shows how to lift the complete robot with lifting slings. IRB 6660 - 130/3.1, IRB 6660 - 100/3.3 xx0700000004 Load hook Swivelling lifting eyes, 4 pcs Shortening hook...
Page 71 Load hook Swivelling lifting eyes, 4 pcs Shortening hook Chain Lifting eye, M12 Eye for lifting accessory Lifting slings, 4 pcs Hook Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 72 CAUTION Note The IRB 6660 robot weighs 1950 kg. If the robot is equipped with fork lift pockets an extra weight of 90 kg must All lifting accessories used must be sized ac-...
Page 73: Manually Releasing The Brakes
The brake will function again as soon as the button is released. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 74 Incorrect connections, such as supplying power to the wrong pin, may cause all brakes to be released simultaneously! Supply 0V on pin 12 and 24V on pin 11. xx0600002937 Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 75: Lifting The Base Plate
Fit lifting slings to the eyes and to the lifting accessory. CAUTION Lift and move the base plate very slowly. If the base plate starts to swing it is a risk for injuries or damage. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 76: Securing The Base Plate
E, F, G, H Common tolerance zone (accuracy all over the base plate from one contact surface to the other) Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 77 2 Installation and commissioning 2.3.6 Securing the base plate Continued xx0400000715 Four holes for alternative clamping, 4x Ø18 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 78 The illustration below shows the orienting grooves and attachment holes for leveling bolts in the base plate. xx1500000312 Orienting grooves (3 pcs) Levelling bolts, attachment holes (4 pcs) Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 79 Base plate This section details how to secure the base plate to the foundation. Action Note Make sure the foundation is levelled. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 80 0.3 mm. If it is not, use pieces of sheet metal or similar to bring the base plate to a levelled position. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 81: Orienting And Securing The Robot
M24 x 140 Quality: Quality 8.8 Suitable washer: Thickness: 4 mm Outer diameter: 44 mm Inner diameter: 25 mm Tightening torque: 725 Nm Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 82 Note Lightly lubricate screws before as- sembly! Tighten bolts in a criss-cross pattern to ensure that the base is not distorted. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 83 This illustration shows the hole configuration used when securing the robot. xx0300000046 Cross section, guide sleeve hole This illustration shows the cross section of the guide sleeve holes. xx0100000109 Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 84: Fitting Equipment On Robot
IRB 6660 - 130/3.1 1497.5 mm 190 mm 490 mm 128 mm IRB 6660 - 205/1.9 885 mm 190 mm 490 mm 128 mm Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 85 2 Installation and commissioning 2.3.8 Fitting equipment on robot Continued xx0700000014 xx0700000674 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 86 Illustration, fitting of extra equipment on frame The mounting holes available for fitting extra equipment on the frame are shown below. Illustrations show robot variant IRB 6660 - 130/3.1 but all shown measurements are the same on all variants. xx0700000013...
Page 87 12.9. Standard screws with quality 8.8 may be used when fitting other equipment to the mounting holes on the upper arm house or frame. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 88: Installation Of Chip Protection - Irb 6660
2.3.9 Installation of chip protection - IRB 6660 - 205/1.9 Note This section is only applicable to the robot variant IRB 6660 - 205/1.9. Location of chip protection The chip protection is installed on the lower arm as shown in the figure below.
Page 89 2 Installation and commissioning 2.3.9 Installation of chip protection - IRB 6660 - 205/1.9 Continued Installation, chip protection The procedure below details how to install the chip protection on the lower arm of the robot. Action Note DANGER Turn off all electric power, hydraulic and...
Page 90: Installation Of Cooling Fan For Motors (Option)
The figure shows IRB 7600 but the principle fitting is the same. xx1800000169 xx1800000170 Cooling fan, axis 1 Cooling fan, axis 2 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 91 • fan axes 1 & 2 cable harness • plate, customer • attachment screws and nuts. Cable harness inside control- 3HAC025488-001 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 92 Plate for customer connections, at base xx0500002301 Plate for customer connections Attachment screws, 3 pcs, M6x16 quality 8.8-A2F Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 93 Tighten them properly so that the box is firmly attached to the motor. Install the cabling and make adjustments in RobotWare, as described in the following procedures. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 94 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 95 Cable is specified in section ler. cables (option) on page 106. Also make adjustments in RobotWare, as de- scribed in the following procedure. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 96 Modifying options dialogue, by using the Modify Controller System Wizard in the Sys- tem Builder of RobotStudio. Read more about modifying the system in Operating manual - RobotStudio. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 97: Installation Of Foundry Plus Cable Guard (Option No. 908-1)
Separate instructions for IRB 2600, 4600, 6620, 6640, 6650S, 6660 and 7600 are available in English, German, French, Spanish and Italian and can be found for registered users on myABB Business Portal (www.myportal.abb.com) and delivered with the Cable guard, article number 3HAC035933-001.
Page 98: Loads Fitted To The Robot, Stopping Time And Braking Distances
The performance of the motor brake depends on if there are any loads attached to the robot. For more information, see product specification for the robot. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 99: Signal Lamp (Option)
The lamp is active in MOTORS ON mode. Further information Further information about the MOTORS ON/MOTORS OFF mode may be found in the product manual for the controller. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 100: Restricting The Working Range
This section describes how to install hardware that restricts the working range. Note Adjustments must also be made in the robot configuration software (system parameters). References to relevant manuals are included in the installation procedures. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 101: Mechanically Restricting The Working Range Of Axis 1
Includes attachment screws and an assembly drawing. Standard toolkit Technical reference manual - System Article number is specified in parameters section References on page Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 102 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 103: Extended Working Range, Axis 1 (Option 561-1)
Boundand Lower Joint Bound must be reference manual - System parameters. changed to 3.84 respectively -3.84. The values are in radians, that is 3.84 radians = 220 degrees. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 104: Electrical Connections
Robot cable, power: 7 m 3HAC026787-001 Robot cable, power: 15 m 3HAC026787-002 Robot cable, power: 22 m 3HAC026787-003 Robot cable, power: 30 m 3HAC026787-004 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 105 There is a grounding/bonding point on the manipulator base. The grounding/bonding point is used for potential equalizing between control cabinet, manipulator and any peripheral devices. xx1600001000 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 106 Harness - cooling, 22 m 3HAC022723-005 Distributing cable: R1.FAN.SW2/3 Inside cabinet: A43.X10 and A43.X11 Harness - cooling, 30 m 3HAC022723-006 Distributing cable: R1.FAN.SW2/3 Inside cabinet: A43.X10 and A43.X11 Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 107: Start Of Robot In Cold Environments
If the program consists of large wrist movements, it is possible that the reorientation velocity, which is always high in predefined velocities, needs to be included in the ramping up. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
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Page 109: Maintenance
Safety on page 19 before performing any service work. Note If the IRB 6660 is connected to power, always make sure that the IRB 6660 is connected to protective earth before starting any maintenance work. For more information see: •...
Page 110: Maintenance Schedule And Component Life
40000 hours. ABB Connected Services and its Assessment tools can help you to identify the real stress level of your robot, and define the optimal ABB support to maintain your robot working. Contact your local ABB Customer Service to get more information.
Page 111: Maintenance Schedule
The following table specifies the required maintenance activities and intervals. Maintenance activity Equipment Interval Cleaning Robot Cleaning the IRB 6660 on page 169 Inspection Oil level in axis-1 gearbox Every 12 months. Inspection Oil level in axis-2 gearbox Every 12 months.
Page 112 1 12 months Inspection Motor fan Every 12 Inspect the fan for contam- months ination that could hinder the air supply. Clean if ne- cessary. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 113: Expected Component Life
5 is not calculated by SIS (See the Operating manual - Service Information System). In some applications, such as Foundry or Washing, the robot can be exposed to chemicals, high temperature or humidity, which can have an effect on the lifetime of the gearboxes. Contact the local ABB Robotics Service team for more information.
Page 114: Inspection Activities
144. Do not mix with other oils! Standard toolkit Content is defined in section Standard tools on page 381. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 115 Further information about how to fill with oil is found in section Changing oil, axis-1 gearbox on page 146. Refit the oil plug. Tightening torque:24 Nm Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 116: Inspecting, Oil Level Gearbox Axes 2 - 3
The gearboxes axes 2-3 are located in the lower arm rotational center, underneath the motor attachment. xx0500002482 Gearbox, axis 2 Oil plug, draining Oil plug, filling Ventilation hole, gearbox axis 2 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 117 Before proceeding, please read the safety inform- ation in the section Safety risks during work with gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 118 Filling of oil is detailed further in section Changing oil, gearbox axes 2 and 3 on page 149. Refit oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 119: Inspecting The Oil Level In Axis-4 Gearbox
These procedures include refer- be required. See references to ences to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 120 Further information about how to fill the oil may be found in the section Filling, oil on page 154. Refit the oil plug. Tightening torque:24 Nm Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 121: Inspecting The Oil Level In Axis-5 Gearbox
Before proceeding, please read the safety inform- ation in the section Safety risks during work with gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 122 Further information about how to fill the oil may be found in the section Filling, oil, axis 5 on page 157. Refit the oil plug. Tightening torque:24 Nm Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 123: Inspecting The Oil Level In Axis-6 Gearbox
The axis-6 gearbox is located in the wrist unit as shown in this figure. The figure shows the gearbox for robot variant IRB 6660 - 100/3.3 and IRB 6660 - 130/3.1. The axis-6 motor on variant IRB 6660 - 205/1.9 has no cooling elements.
Page 124 C Gearbox oil the oil surface. This will avoid surface tension from stopping air to enter into the gearbox. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 125 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 126: Inspecting, Balancing Device Bearings And Piston Rod Guide Ring
3.3.6 Inspecting, balancing device bearings and piston rod guide ring 3.3.6 Inspecting, balancing device bearings and piston rod guide ring Note This section is not applicable to robot variant IRB 6660-205/1.9. Location of balancing device The figure shows the location of the balancing device.
Page 127 Art. no. is specified in Required equipment lower axes of balancing device. on page 126. The shafts should be tightened to their bottom position. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 128 Apply locking liquid on the lock nuts Tightening torque on the lock nuts: (KM10) and refit them. • 120 Nm Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 129 B Circlip Note If there is a risk of metallic contact between the piston rod and the end cover, the guide ring must be replaced! Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 130: Inspection, Cable Harness
The robot cable harness, axes 1-6 is located as shown in the figures below: xx0700000022 Cable guide, axis 2 Metal clamp (4 pcs) Connectors at base Cable guide Cable harness Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 131 3 Maintenance 3.3.7 Inspection, cable harness Continued xx0700000631 Cable guide, axis 1 Cable gland, SMB unit Cable guide, axis 2 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 133 Detailed in sections Replacement damage is detected. of cable harness, lower end (axes 1-3) on page 181 Replacement of cable harness, upper end on page 196. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 134: Inspecting The Information Labels
Warning label concerning risk of tipping Information labels at gearboxes and at robot base, specifying which oil is used in gearboxes. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 135 Inspect the labels, located as shown in the figures. Replace any missing or damaged labels. Article numbers for the labels and plate set is specified in Spare part lists on page 387. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 136: Inspecting The Axis-1 Mechanical Stop Pin
• electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 137 The expected life of gearboxes can be reduced after collision with the mechanical stop. Make sure the mechanical stop pin can move in both directions. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 138: Inspecting The Additional Mechanical Stops
Mechanical stop axis 1 3HAC11076-2 Limits the robot working range by 15°. Standard toolkit Content is defined in section Standard tools on page 381. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 139 If any damage is detected, the mechanical stops must Article number is specified in be replaced. Required equipment on page 138. Correct attachment screws: • Axis 1: M16 x 35, quality 12.9. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 140: Inspecting The Damper On Axes 2-5
Location of dampers The figure below shows the location of all the dampers to be inspected. The figure shows the robot variant IRB 6660 - 130/3.1. Dampers and the position of the dampers are the same on all variants. xx0700000024...
Page 141 If any damage is detected, the damper must be re- Art. no. is specified in Required placed with a new one! equipment on page 140. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 142: Inspecting, Signal Lamp (Option)
Use this procedure to inspect the function of the signal lamp. Action Note Check that signal lamp is lit when motors are put in operation ("MOTORS ON"). Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 143 • Checking cable connections. • Measuring the voltage in connectors motor axis 3 (=24V). • Checking the cabling. Replace cabling if a fault is detected. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 144: Replacement/Changing Activities
Before starting any inspection, maintenance, or changing activities of lubrication, always contact the local ABB Service organization for more information. For ABB personnel: Always check ABB Library for the latest revision of the manual Technical reference manual - Lubrication in gearboxes, in order to always get the latest information of updates about lubrication in gearboxes.
Page 145 Includes pump with outlet pipe. Use the suggested dispenser or a similar one: • Orion OriCan article number 22590 (pneumatic) Nipple for quick connect fitting, with o-ring Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 146: Changing Oil, Axis-1 Gearbox
144. oil in gear- Do not mix with other oils! boxes on page 144. Oil collecting vessel Capacity: 8,000 ml. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 147 146. Remove oil plug, filling in order to drain oil Shown in figure Location of oil plugs quicker! on page 146. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 148 114. on page 144. Note Do not mix Kyodo Yushi TMO 150 with other oil types! Refit the oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 149: Changing Oil, Gearbox Axes 2 And 3
The figure shows the position of gearbox, axis 2. xx0500002482 Gearbox axis 2 Oil plug, draining Oil plug, filling Ventilation hole plug, gearbox axis 2 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 150 Content is defined in section ment Special tools on page 382. Standard toolkit Content is defined in section Standard tools on page 381. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 151 • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 152 Refit oil plug,filling and ventilation hole plug. Shown in Location of oil plugs on page 149. Tightening torque: 24 Nm. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 153: Changing Oil, Axis-4 Gearbox
Special tools on page 382. Oil collecting vessel Capacity: 9,000 ml. Standard toolkit Content is defined in section Standard tools on page 381. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 154 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 155 119. amount is detailed in Type and amount of oil in gearboxes on page 144. Refit the oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 156: Changing Oil, Axis-5 Gearbox
Required equipment on page 156. Action Note Run axis 4 to a position where the oil plug for draining is facing downwards. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 157 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 158 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 144. Refit the oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 159: Changing Oil, Axis-6 Gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below. The figure shows the axis-6 gearbox for robot variant IRB 6660 - 100/3.3 and IRB 6660 - 130/3.1, and includes cooling elements on motor. There are no cooling elements on the axis-6 motor on robot variant IRB 6660 - 205/1.9.
Page 160 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 161 Refit the oil plug. Tightening torque: 24 Nm. Inspect the oil level. Detailed in the section Inspecting the oil level in axis-6 gearbox on page 123. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 162: Replacing The Smb Battery
Battery pack with a 2-pole battery contact (DSQC) xx0700000029 SMB battery cover SMB battery pack with 2-pole battery contact. Battery cable Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 163 Equipment, etc. Spare part no. Note Battery unit For spare part no. Battery includes protection circuits. Only re- see: place with a specified spare part or an ABB- • Spare part approved equivalent. lists on page 387 Standard toolkit Content is defined in section...
Page 164 Shown in figure Location of SMB Battery includes protection circuits. Only replace battery on page 162. with a specified spare part or with an ABB- ap- proved equivalent. Refitting, battery Use this procedure to refit the SMB battery. Action Note...
Page 165 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 166: Lubrication Activities
3.5.1 Lubricating balancing device bearings and piston rod 3.5 Lubrication activities 3.5.1 Lubricating balancing device bearings and piston rod Note This section is not applicable to the robot variant IRB 6660-205/1.9 Overview This procedure details how to lubricate bearings and piston rod of the balancing device.
Page 167 Remove lubricating tool and clean threads on shaft Also clean from old grease on ends free from grease. the inner side! Apply some grease on the support washers. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 168 Before entering the robot working area. Clean piston rod with isopropanol before applying new grease. Apply new grease. Type of grease is specified in Required equipment on page167. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 169: Cleaning Activities
General To secure high uptime it is important that the IRB 6660 is cleaned regularly. The frequency of cleaning depends on the environment in which the product works. Different cleaning methods are allowed depending on the type of protection of the IRB 6660.
Page 170 Typical tap water pressure and flow Instructions for steam or high pressure water cleaning ABB robots with protection types Foundry Plus, Wash, or Foundry Prime can be cleaned using a steam cleaner or high pressure water cleaner. The following list defines the prerequisites: •...
Page 171 Cooling fans Inspect the air supply inlet of the the motor cooling fans. Clean to remove any contamination that could hinder the air supply. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 172 This page is intentionally left blank...
Page 173: Repair
Make sure to read through the chapter Safety on page 19 before commencing any service work. Note If the IRB 6660 is connected to power, always make sure that the IRB 6660 is connected to earth before starting any repair work. For more information see: •...
Page 174: General Procedures
Spray any suspected leak areas with the leak detec- tion spray. Bubbles indicate a leak. When the leak has been localized, take the necessary measures to correct the leak. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 175: Mounting Instructions For Bearings
Make sure the bearing is properly aligned as this will directly affect the durab- ility of the bearing. Greasing of bearings Note This instruction is not valid for solid oil bearings. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 176 Grooved ball bearings must be filled with grease from both sides. • Tapered roller bearings and axial needle bearings must be greased in the split condition. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 177: Mounting Instructions For Seals
Never hammer directly on the seal as this may result in leakage. Make sure no grease left on the robot surface. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 178 If the flange surfaces are defective, the parts may not be used because leakage could occur. Clean the surfaces properly in accordance with the recommendations of ABB. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.
Page 179: Cut The Paint Or Surface On The Robot Before Replacing Parts
Carefully grind the paint edge that is left on the structure to a smooth surface. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 180: The Brake Release Buttons May Be Jammed After Service Work
If a button gets jammed in the depressed position, the alignment of the brake release unit must be adjusted so that the buttons can move freely in their tubes. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 181: Complete Robot
Cable guide, axis 2 Metal clamp Connector at base Cable guide, axis 1 Cable harness, axes 1-6 Cover plate Rear cover plate Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 182 Circuit diagram 3HAC025744-001 See chapter Circuit dia- gram on page 389. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 183 Remove the motor cover, axis 1, 2, 3 by remov- ing its attachment screws, in order to reach the connectors. Disconnect all connectors at motor 1, 2 and 3. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 184 SMB recess. xx0600002701 • A: Cable gland, SMB • B: Attachment screws (4 pcs) Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 185 Continue removal of the cable harness in the Detailed in Replacement of cable har- upper arm. ness, upper end on page 196. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 186 SMB recess. xx0600002701 • A: Cable gland, SMB • B: Attachment screws, (4 pcs) Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 187 Before continuing any service work, please observe the safety information in section brake release buttons may be jammed after service work on page 180! Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 188 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 189: Replacement Of Process Cable Package 1 - 3 Mh
Process cable package, cables Process cable package, hose Cable guide Metal clamp Connectors at base Customer plate Rear cover plate Earth Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 191 B: Hose connector R1.PROC1 Disconnect the cable connectors from the customer plate. xx0700000645 Parts: • A: Connector R1.CP/CS • B: Connector R1.SP/R3.FP7 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 192 Parts: • A: Position for prev. torque nuts • B: Process cable package Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 193 Note Perform this carefully in order not to damage the cable harness of the robot. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 194 Push the process cable package gently Order of refitting: down through the cable guide in the 1 Cables centrum hole in gearbox axis 1. 2 Hose Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 195 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 196: Replacement Of Cable Harness, Upper End
Attachment screw (cable attachment rear), M6x25 quality 12.9 Gleitmo Required equipment Equipment, etc. Note Cable harness axes 1-6 Spare part lists on page 387. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 197 The procedure below details how to remove the cable harness. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 198 Make sure not to lose the washers placed in the holes of the foundry gasket. xx0700000140 • A : Cover, wrist unit xx1400002580 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 199 Disconnect all connectors at motor axis 4 Shown in the figure Location of cable (R2.MP4, R2.FB4). harness on page 196 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 200 Connect the two connectors inside the up- per arm tube, (R2.MP5 and R2.FB5) and secure the cable bracket with its two attach- ment screws to the tube. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 201 Refit cover motor, axis 6. Refit the metal clamps, on the armhouse. Standard Fit the wrist cover. xx0700000140 • A : Cover, wrist unit Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 202 Replace if damaged. Foundry Plus Make sure the gasket on the adapter ring is undamaged. Replace if damaged. xx1400002581 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 203 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 204: Replacement Of Cabling, Axis 5 Motor
Location of cabling The separate cables for the axis 5 motor are located inside the upper arm tube, as shown in the figure below. IRB 6660 - 100/3.3, IRB 6660 - 130/3.1 xx0700000055 Motor axis 5 with connectors R4.FB5 and R4.MP5 Connectors R3.FB5 and R3.MP5...
Page 205 Refit the cover of motor, axis 5. Refit the complete wrist unit. Detailed in section: • Refitting, wrist unit on page 225. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 206 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 207: Replacement Of Complete Arm System
This is shown in the figure below. A more detailed view of the component and its position may be found in Spare part lists on page 387. IRB 6660 - 100/3.3, IRB 6660 - 130/3.1 xx0700000073 Upper arm Lower arm Motor, axis 1...
Page 208 140 mm will not be possible to remove from the frame be- cause lack of space after refitting! Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 209 Use this procedure to lift and remove the complete arm system. Action Note Decide which calibration routine to use, and take actions accord- ingly prior to beginning the re- pair procedure. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 210 How to replace the cabling is detailed in Replacement through the center of the axis-1 of cable harness, lower end (axes 1-3) on page 181. gearbox. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 211 Make sure the lift is done completely level! How to instructions. adjust the lift is described in the enclosed instruction to the lifting accessory! Follow the instructions before lifting! IRB 6660 - 130/3.1, IRB 6660 - 100/3.3 xx0700000004 IRB 6660 - 205/1.9 xx0700000427 A: Load hook...
Page 212 208. CAUTION The complete arm system weighs 1330 - 1520 kg! All lifting equipment used must be sized accordingly! Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 213 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 214 Make sure the lift is done completely level! How to adjust the lift is described in the enclosed instruction to the lifting access- ory! Follow the instructions before lifting! IRB 6660 - 130/3.1, IRB 6660 - 100/3.3 xx0700000004 IRB 6660 - 205/3.1 xx0700000427 •...
Page 215 Make sure the lifting accessory is adjusted prior to refitting of arm system. Refit 22 of the 24 attachment screws before the arm system is completely lowered. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 216 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 217: Upper And Lower Arms
The turning disk is located in the front of the wrist housing as shown in the figure below. The figure shows the axis-6 gearbox for robot variant IRB 6660 - 100/3.3 and IRB 6660 - 130/3.1, and includes cooling elements on motor. There are no cooling elements on the axis-6 motor on robot variant IRB 6660 - 250/1.9.
Page 218 217. Remove the turning disk. Foundry Plus: Remove old flange sealant residues and other con- tamination from the contact surfaces. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 219 Also fit the 12 o-rings, when refitting the attach- ment screws. xx0200000218 • A: Sealing surface, o-ring Foundry Plus: Apply Loctite 574 flange sealant on the contact surface. xx1400000995 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 220 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 221: Replacement Of Complete Wrist Unit
The wrist unit is located on the upper arm as shown in the figure below. A more detailed view of the component and its position may be found in Spare part lists on page 387. IRB 6660 - 100/3.3, IRB 6660 - 130/3.1 xx0700000069 Wrist unit Turning disk Cover, wrist unit Cover, upper arm tube Connectors, upper arm tube, with cable bracket (R3.FB5, R3.MP5)
Page 223 Turn axis 4 to a position where the cover, upper arm tube and wrist unit, faces upwards. Turn axis 5 to +90°. xx0200000185 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 224 Shown in the figure Location of wrist the two connectors in the upper arm tube unit on page 221. (R3.FB5, R3.MP5). Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 225 Remove the lifting tool from the wrist unit. Note Axis 5 must be oriented in the correct position (+90º) to allow the motor 6 cover to open! Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 226 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 227: Replacement Of Upper Arm
4 Repair 4.4.3 Replacement of upper arm 4.4.3 Replacement of upper arm Location of upper arm The upper arm is located as shown below. IRB 6660 - 100/3.3, IRB 6660 - 130/3.1 xx0700000059 Upper arm Motor, axis 4 Balancing device...
Page 228 4 Repair 4.4.3 Replacement of upper arm Continued IRB 6660 - 205/1.9 xx0700000636 Upper arm Upper arm Lower arm Parallel rod Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 229 Shown below is a cut away view of how the upper arm is fitted to the lower arm (seen from above). The letters are being referred to in the following step by step procedures. IRB 6660 - 100/3.3, IRB 6660 - 130/3.1 xx0700000058 Shaft, axis 2...
Page 230 Taper roller bearing O-ring Sealing ring Sealing assembly (including support ring) Lock nut (KM12) O-ring (Di = 54.2 mm, t = 5.7 mm) Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 231 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 232 Remove all equipment fitted to the turning disk. IRB 6660 - 130/3.1, IRB 6660 - 100/3.3 Move the upper arm to a horizontal position. Rotate axis 4 so that the attachment hole for lifting eye is facing upwards.
Page 233 Use a suitable lifting accessory to avoid in- jury to personnel! Raise the lifting equipment to take the weight of the upper arm. (Not applicable to robot variant IRB 6660 Detailed in section Replacing the balan- - 205/1.9! ) cing device on page 266 Remove the balancing device.
Page 234 The complete upper arm weighs 380 kg without any additional equipment fitted! Use a suitable lifting accessory to avoid in- jury to personnel! Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 235 4.4.3 Replacement of upper arm Continued Action Note IRB 6660 - 130/3.1, IRB 6660 - 100/3.3 Lift 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.
Page 236 Axis Calibration is described in Calibrating with Axis Calibration method on page 352. General calibration information is included in section Calibration on page 341. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 237 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 238: Replacing The Parallel Rod
4.4.4 Replacing the parallel rod Location of parallel rod The parallel rod is located as shown in the figure. xx0700000064 Robot variant IRB 6660 - 205/1.9 Robot variant IRB 6660 - 130/3.1, IRB 6660 - 100/3.3 Parallel rod Required equipment Equipment, etc. Art.no.
Page 239 Secure the upper arm with a roundsling in an overhead crane or similar, in order to avoid accidents. Foundry Plus: Remove the protection plugs Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 240 C Parallel rod D Sealed spherical bearing E Bearing grease F Thrust washer Remove the thrust washer (F). See figure above! Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 241 Apply rust preventive on the highlighted areas. Note Rust preventive should be applied in both ends of the parallel rod. xx1400001126 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 242 Refit the lock screw and plain washer. xx0700000066 Parts: • A: Lock screw M6x16, (upper) • B: Lock screw M6x16 (lower) Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 243 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 244: Replacing The Complete Lower Arm
Used to keep the axes 2/3 sealing in place during refitting of lower arm. Crank 3HAC023132-001 Lock screw M16x90 Lifting tool, lower arm com- 3HAC8446-1 plete Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 245 The procedure below details how to remove the lower arm. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 246 Replacing the gearbox, axes 2- 3 on page 324. CAUTION The robot lower arm weighs 160 kg (IRB 6660 - 100/3.3, IRB 6660 - 130/3.1) / 110 kg (IRB 6660 - 205/1.9). All lifting accessories used must be sized accord-...
Page 247 CAUTION The parallel arm system weighs 92 kg. All lifting accessories used must be sized accord- ingly! Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 248 CAUTION The robot lower arm weighs 160 kg (IRB 6660 - 100/3.3, IRB 6660 - 130/3.1) / 110 kg (IRB 6660 - 205/1.9). All lifting accessories used must be sized accord-...
Page 249 Fit the parallel arm to the lower arm. Replacement of parallel arm on page 252. CAUTION The robot lower arm weighs 160 kg (IRB 6660 - 100/3.3, IRB 6660 - 130/3.1) / 110 kg (IRB 6660 - 205/1.9). All lifting accessories used must be sized accord- ingly!
Page 250 Change the position of the lower arm in order to reach the remaining attachment holes, and fit the remaining screws. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 251 Refit the cable harness. See . Refit the parallel rod. Replacing the parallel rod on page 238 ( Not applicable to robot variant IRB 6660 - Replacing the balancing device 205/1.9 ! ) on page 266. Refit the balancing device.
Page 252: Replacement Of Parallel Arm
Location of parallel arm The parallel arm is located as shown in the figure below. xx0700000067 Robot variant IRB 6660 - 205/1.9 Robot variant IRB 6660 - 130/3.1, IRB 6660 - 100/3.3 Parallel arm Lower arm Required equipment Equipment, etc.
Page 253 Use this procedure to remove the parallel arm. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 254 Removal of the parallel arm is best performed on a workbench. xx1000001024 Remove the two VK covers. xx1000001371 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 255 The parallel arm system weighs 92 kg. All lifting accessories used must be sized accord- ingly! Remove the parallel arm. xx1000001018 If needed, change the bearings. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 256 Refit a bearing on each shaft with pressing tool, Art. no. is specified in Required lower arm. equipment on page 252 xx1000001377 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 257 Apply some grease in the holes in the lower arm (thick blue arrows). Note Do not put grease on the surfaces for the VK covers (thin red arrow)! xx1000001380 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 258 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in the section First test run may cause injury or damage on page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 259: Frame And Base
For spare part number, see: Spare part lists on page 387. Battery pack For spare part number, see: Spare part lists on page 387. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 260 Disconnect the battery cable by pressing down the upper lip of the R2.G connector to release the lock while pulling the connector upwards. xx1700000993 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 261 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 262: Replacing The Brake Release Board
These procedures include references be required. See references to to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 263 Remove the complete brake release board (including brake release board and bracket) from the SMB recess, by removing its two at- tachment screws. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 264 Screened cables must not get in contact with the brake release board after installation. Eliminate all risks of contact between screened cables and the brake release board. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 265 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 266: Replacing The Balancing Device
4.5.3 Replacing the balancing device 4.5.3 Replacing the balancing device Note This section is only applicable to robot variant IRB 6660 - 100/3.3, IRB 6660 - 130/3.1. Location, balancing device The balancing device is located as shown in the figure.
Page 267 • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 268 266 Fit the short auxiliary shaft on the upper shaft and the longer on the lower shaft. Stretch the roundsling. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 269 Remove the balancing device and put it in a safe place. Remove the inner rings of the bearings. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 270 266 Fit the short auxiliary shaft on the upper shaft and the longer on the lower shaft. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 271 0.1 mm too long. If the distance is too long the bearings may be damaged when erecting the balancing device. xx1000001111 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 272 Refit the lock nuts and support washers. Tightening torque: 120 Nm xx1000001113 Check play (min. 0.1 mm) between support washers and bearing seat at both bearings. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 273 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 274: Motors
O-ring 21522012-430 Replace if damaged. Grease 3HAB3537-1 Used to lubricate the o-ring Loctite 574, Flange sealant 12340011-116 Option Foundry Plus Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 275 Use this procedure to remove the axis-1 motor. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 276 In order to release the brake, connect the 24 Connect to connector R2.MP1 VDC power supply. • + : pin 2 • -: pin 5 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 277 Foundry Plus: Remove old Loctite 574 flange sealant residues and other contamination from the contact sur- faces on both motor and gearbox. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 278 • + : pin 2 • -: pin 5 Foundry Plus: Apply Loctite 574 flange sealant on the contact surface. xx1400000986 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 279 Position of Cable gland cover Refit the motor cover with its attachment screws. Note Make sure the cover is tightly sealed! xx1000001092 Part: Motor cover Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 280 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 281: Replacing Motors, Axes 2 And 3
Guide pins are to be used in pairs! Lifting tool, motor axes 2-3 3HAC14586-1 Lock screw M16x90 For securing the lower arm. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 282 Use this procedure to remove motors axes 2 and 3. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 283 Drain the oil from gearbox. See section • Draining, axes 2 and 3 on page 151 Remove the motor cover. xx1000001102 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 284 VDC power supply. • + : pin 2 • -: pin 5 Unscrew attachment screws and washers of the motor. xx1000001104 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 285 2-3 to the motor. equipment on page 281. CAUTION The motor weighs 32 kg! All lifting equipment used must be sized accordingly! Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 286 Remove old Loctite 574 flange sealant residues and other contamination from the contact sur- faces on both motor and gearbox. xx1400000988 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 287 Art. no. is specified in Required equipment on page 281. Foundry Plus: Apply Loctite 574 flange sealant on the contact surface. xx1400000987 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 288 Remove the lifting tool and allow the motor to rest on the guide pins. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 289 Refit the cable gland cover at the cable exit with its two attachment screws. Note Use a new gasket! Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 290 Calib- rating with Axis Calibration method on page 352. General calibration information is in- cluded in section Calibration on page 341. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 291 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 292: Replacement Of Motor, Axis 4
24 VDC, max. 1,5 A For releasing the brakes. Standard toolkit Content is defined in section Standard tools on page 381. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 293 The procedure below details how to remove the motor, axis 4. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 294 Foundry Plus: Remove old Loctite 574 flange sealant residues and other contamination from the contact surfaces on both motor and gearbox. xx1400000989 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 295 Make sure the motor pinion does not get making sure the motor pinion is properly damaged! mated to the gear of gearbox 4. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 296 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 297: Replacement Of Motor, Axis 5
A more detailed view of the component and its position may be found in Spare part lists on page 387. xx0700000062 Robot variant IRB 6660 - 100/3.3, IRB 6660 - 130/3.1 Robot variant IRB 6660 - 205/1.9 Wrist unit Motor, axis 5 (Inside upper arm tube) Upper arm tube Required equipment Equipment, etc.
Page 298 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 299 • +: pin C • -: pin D Remove the motor by unscrewing its four attach- ment screws and plain washers. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 300 -: pin 5 - connector R3.MP5 (on the separate cable, if not removed): • +: pin C • -: pin D Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 301 Foundry Plus Make sure that the gasket is undamaged. Also the small gasket fitted in the cover recess. Replace if damaged. xx1400002579 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 302 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 303: Replacement Of Motor, Axis 6
Axis-6 motor. Figure shows a motor with cooling elements. (There are no cooling elements on the motor on variant IRB 6660 - 205/1.9.) Axis-6 gearbox Attachment screws and washers gearbox (18 pcs) Attachment screws, turning disk (12 pcs) Required equipment Equipment, etc.
Page 304 Read more about reference calibration for then reference calibration is not possible. Pendulum Calibration in Operating manu- al - Calibration Pendulum. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 305 In order to release the brake, connect the 24 VDC Connect to connector R3.MP6 power supply. • +: pin 2 • -: pin 5 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 306 4 Repair 4.6.5 Replacement of motor, axis 6 Continued Action Note (Not applicable to robot variant IRB 6660 - 205/1.9 If needed, loosen the strap securing the cooling elements in order to reach the attachment screws securing motor axis 6. xx0700000164 •...
Page 307 4 Repair 4.6.5 Replacement of motor, axis 6 Continued Action Note (Not applicable to robot variant IRB 6660 - 205/1.9!) Refit the strap securing the cooling elements. xx0700000164 • A: Strap • B: Cooling elements Disconnect the brake release voltage.
Page 308 6 and forwards in Removal, motor on page 305. Note Keep the old rear motor cover with the air nipple. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 309 F: Washer • G: Rear motor cover • H: Sealing • J: Loctite 574 Apply Mercasol 3106 on the motor end cover. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 310 Apply Loctite 574 flange sealant on the contact surface. xx1400000992 Apply grease on the o-ring on the motor. Continue to refit the new motor according to section, Refitting, motor on page 306. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 311: Gearboxes
3HAB3772-54 Replace if damaged! O-ring 3HAB3772-55 Replace if damaged! Sealing ring 3HAC11581-4 Replace if damaged! Grease 3HAB3537-1 For lubricating the o-rings. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 312 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 313 Use this procedure to remove gearbox, axis 1. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 314 4 Repair 4.7.1 Replacing the axis 1 gearbox Continued Action Note IRB 6660 - 130/3.1, IRB 6660 - 100/3.3 Move the robot to its most stable position, shown in the figure to the right. xx0700000137 IRB 6660 - 205/1.9 xx0700000518...
Page 315 Make sure the base remains in a stable position before performing any work under- neath the base! xx1000000364 A Support base (4 pcs) Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 316 A view from below: • A: Oil drain hose • B: Attachment screws, gearbox axis 1, 18 pcs • C: Washers, 3 pcs Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 317 Turn the gearbox, and remove the protec- tion pipe by unscrewing two attachment screws. Note Move the protective pipe over to the new gearbox. xx1400000786 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 318 • A: Guide pin • C: O-ring 3HAB 3772-54 • D: O-ring 3HAB 3772-55 • E: Sealing ring 3HAC 11581-4 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 319 311. CAUTION The gearbox weighs 200 kg. All lifting accessories used must be sized ac- cordingly! Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 320 Lift gearbox axis 1 onto the guide pins and Always use guide pins in pairs! lower it carefully to its mounting position. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 321 1, 18 pcs • C: Washers, 3 pcs Refit the cable guide in the center of gearbox 1 with its attachment screws. xx1000001393 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 322 Calibrat- ing with Axis Calibration method on page 352. General calibration information is in- cluded in section Calibration on page 341. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 323 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 324: Replacing The Gearbox, Axes
Location of gearbox, axes 2-3 The axis-2 and axis-3 gearboxes are located on either side of the frame as shown in the figure. The figure shows robot variant IRB 6660 - 130/3.1. The location of the gearboxes is the same on all variants. xx0700000063...
Page 325 Use this procedure to remove the axis-2 or axis-3 gearbox. Note Do not replace both gearboxes at the same time, unless the complete arm system is already removed! Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 327 Remove the two plastic screws in the upper end of the balancing device. Note Keep the plastic screws. They will be refit- ted later. xx1000001111 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 328 Remove all remaining attachment screws that secure the gearbox to the lower arm system. Axis 2: M16 and M12. Axis 3: M12. xx1000001405 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 330 Remove the sealing from the lower arm and clean it. Note The sealing can hang onto the gearbox, sticking to the oil. xx1200000630 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 331 Fit the lifting accessory to the gearbox and Specified in Required equipment on lift it with an overhead crane. page 324. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 332 Note Do not apply grease closer than 20 mm from the edge of the holes in the sealing. xx1400000993 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 333 M12 screws. • Tightening torque: 120 Nm. Secure the gearbox to the frame. M12, quality 8.8-A2F Tightening torque: 120 Nm. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 334 Refit the motors axes 2-3. Replacing motors, axes 2 and 3 on page 281 Perform a leakdown test. Performing a leak-down test on page 174. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 335 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 336: Replacement Of Gearbox, Axis
4.7.3 Replacement of gearbox, axis 6 Location of gearbox The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below. The figure shows the motor for robot variant IRB 6660 - 130/3.1 (with cooling elements). xx0700000165 Strap...
Page 337 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 338 A: M8 holes for pressing out the gearbox Foundry Plus: Remove old Loctite 574 flange sealant residues and other contamination from the contact sur- faces. xx1400001123 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 339 Detailed in the section Manually releasing the brakes on page Foundry Plus: Apply Loctite 574 flange sealant on the contact surface. xx1400001122 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 340 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 341: Calibration
Term Definition Calibration method A collective term for several methods that might be available for calibrating the ABB robot. Each method contains calibration routines. Synchronization position Known position of the complete robot where the angle of each axis can be checked against visual synchronization marks.
Page 342: Calibration Methods
Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant. If no data is found related to standard calibration, Calibration Pendulum is used as default. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 343 Axis Calibration method Axis Calibration is a standard calibration method for calibration of IRB 6660 and is the most accurate method for the standard calibration. It is the recommended method in order to achieve proper performance.
Page 344: When To Calibrate
The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration, according to information in this manual. If the robot has absolute accuracy calibration, it is also recommended, but not always necessary to calibrate for new absolute accuracy.
Page 345: Synchronization Marks And Axis Movement Directions
This section shows the position of the synchronization marks and the synchronization position for each axis. Synchronization marks, IRB 6660 The figure shows robot variant IRB 6660 - 130/3.1 but the position of the marks are the same on all IRB 6660 robot variants. xx0700000148...
Page 346 5.2.1 Synchronization marks and synchronization position for axes Continued Synchronization mark, axis 2 Synchronization mark, axis 3 Synchronization mark, axis 4 Synchronization mark, axis 5 Synchronization mark, axis 6 Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 347: Calibration Movement Directions For All Axes
Note! The graphic shows an IRB 7600. The positive direction is the same for all 6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in the opposite direction! xx0200000089 Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 349 All mechanical units connected to the system are shown with their calibration status. Tap the mechanical unit in question. xx1500000943 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 350 Calibration method used at factory for each axis is shown, as well as calibration method used during last field calibration. Tap Manual Method (Advanced). xx1500000944 A screen is displayed, tap Rev. Counters. en0400000771 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 351 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 365. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 352: Calibrating With Axis Calibration Method
FlexPendant. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. WARNING The calibration tool must be fully inserted into the calibration bushing, until the steel spring ring snaps into place.
Page 353 A benefit with reference calibration is that the current state of the robot is stored and not the state when the robot left the ABB factory. The reference value will be named according to tool name, date etc.
Page 354: Calibration Tools For Axis Calibration
There is no risk for bad calibrations as long as the calibration tool is in one piece. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. Equipment, etc. Article number...
Page 355 It is possible to make the calibration tool identifiable with, for example, an RFID chip. The procedure of how to install an RFID chip is described below. Note The tool identifier is NOT delivered from ABB, it is a customized solution. Action Note It is possible to use any RFID solution, with the correct dimensions.
Page 356: Installation Locations For The Calibration Tools
Replace damaged parts with new, if needed. Spare part Article number Note Protection cover and plug set 3HAC056806-001 Contains replacement calibration pin covers and protective plugs for the bushing. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 357: Axis Calibration - Running The Calibration Procedure
WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration holes may cause severe damage to the robot and/or personnel. Equipment, etc.
Page 358 Use this procedure to call for the Axis Calibration method on the FlexPendant. Action Note On the ABB menu, tap Calibration. xx1500000942 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 359 The three-position enabling device on the Press and hold the three-position enabling FlexPendant has been released during robot device and press Play. movement. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 360 Confirm unsynchronized state by pressing Ac- knowledge to continue Axis Calibration proced- ure. Restart Axis Calibration procedure by pressing Play. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 361 SafeMove generates the message "Unsynchron- ized time limit expired" (anytime). xx1500002482 Press OK to continue Axis Calibration procedure. Restart Axis Calibration procedure by pressing Play. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 362 Ensure that the sealing is not damaged. Replace the plug and the sealing with new spare part, if missing or damaged. xx1500000952 Protection cover and plug set: 3HAC056806-001. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 363: Calibrating With Calibration Pendulum Method
Where to find information for Calibration Pendulum Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 364: Verifying The Calibration
345. Write down the values on a new label and stick it on top of the calibration label. Remove any calibration equipment from the robot. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 365: Checking The Synchronization Position
If they do not, up- ization position for axes on page 345 date the revolution counters. Updating revolution counters on page 348. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
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Page 367: Decommissioning
These parts must also be disposed of in accordance with the current legislation of the country in which the robot and control unit are installed. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 368: Environmental Information
Spills can form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. • Spillage can penetrate the soil causing ground water contamination. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 369: Scrapping Of Robot
• When motors are removed from the robot, the robot will collapse if it is not properly supported before the motor is removed. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 370: Decommissioning Of Balancing Device
6.4 Decommissioning of balancing device 6.4 Decommissioning of balancing device Note This section is not applicable to robot variant IRB 6660 - 205/1.9. General There is much energy stored in the balancing device. Therefore a special procedure is required to dismantle it. The coil springs inside the balancing device exert a potentially lethal force unless dismantled properly.
Page 371 Cut a hole in the housing as shown in the Use a cutting torch with a long shaft. figure. The measurements shown below are maxim- um values! xx0700000155 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 372 • Inner spring: cut at least four coils! Double-check the number of coils cut and make sure all the tension in the springs are removed. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 373: Reference Information
7.1 Introduction 7 Reference information 7.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 374: Applicable Standards
Terminology and general principles EN 574:1996 + A1:2008 Safety of machinery - Two-hand control devices - Functional aspects - Principles for design Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 375 Safety requirements for industrial robots and robot systems ANSI/UL 1740 Safety standard for robots and robotic equipment CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require- ments Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 376: Unit Conversion
1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 377: Screw Joints
UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below) and is extremely resistant to fatigue.
Page 378 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 379 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm - Nominal Min. Max. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 380: Weight Specifications
All components exceeding 22 kg (50 lbs) are highlighted in this way. To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.
Page 381: Standard Tools
To be shortened to 12 mm Hex bit socket head cap no. 6 socket 40 mm L=145 mm Hex bit socket head cap no. 6 socket 40mm bit L=220 mm Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 382: Special Tools
3HAC055412- Delivered as a set of calibration tools. ibration Required if Axis Calibration is the valid calibration method for the robot. Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 383 Lifting chain (used together with the hoisting block) Support, base and gearbox axis 1 3HAC15535-1 Lifting tool, gearbox axis 1 3HAC15556-1 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 384 Auxiliary shaft, long 3HAC5275-1 Auxiliary shaft, short 3HAC5276-1 Support shaft/bearing race 3HAC5281-1 Tool for lubrication 3HAC5222-1 Adapter for shaft axis 3 3HAC023916-001 Guide sleeves 3HAC14446-1 Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 385: Lifting Accessories And Lifting Instructions
This implies that the instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
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Page 387: Spare Part Lists
Spare parts and exploded views are not included in the manual but delivered as a separate document for registered users on myABB Business Portal, www.mypo- rtal.abb.com. Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
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Page 389: Circuit Diagram
Circuit diagram - IRB 6400RF 3HAC8935-1 Circuit diagram - IRB 6600 type A 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6600 type B 3HAC13347-1 3HAC025744-001 Continues on next page Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 390 3HAC029940-001 Circuit diagram - IRB 6700 3HAC043446-005 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 Circuit diagram - Product.ProductName 3HAC050778-003 Circuit diagram - IRB 910SC 3HAC056159-002 Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 391 Absolute Accuracy type, 342 foundation rough, 348 requirements, 52 standard type, 342 frame verification, 364 dimensions, 86 when to calibrate, 344 calibration, Absolute Accuracy, 343 Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 392 166 motor axis 4, 292 lubrication motor axis 5, 297 amount in gearboxes, 144 motor axis 6, 303 type of lubrication, 144 Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 393 40 restricting axis 1, 101 wrist unit, replacement, 221 replacing, 259 SMB battery extension of lifetime, 162, 259 zero position replacing, 162, 259 checking, 365 Product manual - IRB 6660 3HAC028197-001 Revision: S © Copyright 2007-2018 ABB. All rights reserved.
Page 396 PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics and Motion 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2007-2018 ABB. All rights reserved. Specifications subject to change without notice.

This manual is also suitable for:

Irb 6660 - 100/3.3 Irb 6660 - 130/3.1 Irb 6660 - 205/1.9

ABB IRB 6660 Product Manual

1 Safety

2 Installation and Commissioning

3 Maintenance

4 Repair

5 Calibration

6 Decommissioning

7 Reference Information

8 Spare Part Lists

9 Circuit Diagram

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