Page 1 ROBOTICS Product manual IRB 660...
Page 2 Trace back information: Workspace 20C version a3 Checked in 2020-09-14 Skribenta version 5.3.075...
Page 3 Product manual IRB 660 - 180/3.15 IRB 660 - 250/3.15 IRC5 Document ID: 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved. Specifications subject to change without notice.
Page 4 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, damage to persons or property, fitness for a specific purpose or the like.
Page 5: Table Of Contents
Maintenance Introduction ...................... Maintenance schedule and expected component life ..........3.2.1 Specification of maintenance intervals ............3.2.2 Maintenance schedule ................3.2.3 Expected component life ................. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 6 Replacing motor, axis 6 ................Gearboxes ....................... 4.7.1 Replacing the axis 1 gearbox ..............4.7.2 Replacing the gearbox, axes 2- 3 ............... 4.7.3 Replacing gearbox axis 6 ................Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 7 Standard tools ....................Special tools ....................Lifting accessories and lifting instructions .............. Spare part lists Spare part lists and illustrations ................Circuit diagrams Circuit diagrams ....................Index Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 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 660. Some variants and designs may have been removed from the business offer and are no longer available for purchase.
Page 10 Reference to the circuit diagram for the robot. References Document name Document ID Product specification - IRB 660 3HAC023932-001 Product manual, spare parts - IRB 660 3HAC049102-001 Safety manual for robot - Manipulator and IRC5 or OmniCore 3HAC031045-001 controller Circuit diagram - IRB 660...
Page 11 New revision on Circuit diagrams. This revision includes the following addtions and/or changes: • Section "Securing the robot" in Installation chapter has been re- moved. Content is not applicable to IRB 660. • Section What is an emergency stop? added to chapter Safety •...
Page 12 Some general tightening torques have been changed/added, see updated values in Screw joints on page 343. • Added information about batteries. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 13 New standard calibration method is introduced (Axis Calibration). Calibration on page 305. • Information about grounding point added. See Robot cabling and connection points on page Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 14 191 and increased the torque span for standard torque wrench, see Standard tools on page 347. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 15 Changed tightening torques on the wrist oil plugs. • Removed lifting tool for axis-2 and axis-3 gearbox from the special tools list (lifting method was changed in previous revision). Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 16: 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 17 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 18: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 19: Safety
The installation and/or use of non-original spare parts and equipment can negatively affect the safety, function, performance, and structural properties of the robot. ABB is not liable for damages caused by the use of non-original spare parts and equipment.
Page 20: Requirements On Personnel
The plant liable must make sure that the personnel is trained on the robot, and on responding to emergency or abnormal situations. Personal protective equipment Use personal protective equipment, as stated in the product manual. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 21: Safety Signals And Symbols
NOTE Signal word used to indicate important facts and conditions. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 22 1.2.1 Safety signals in the manual Continued Symbol Designation Significance Signal word used to indicate where to find additional information or how to do an operation in an easier way. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 23: Safety Symbols On Manipulator Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 24 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 25 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 26 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 27 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 28 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 29: Robot Stopping Functions
The protective stops and emergency stops are described in the product manual for the controller. For more information see: • Product manual - IRC5 • Product manual - IRC5 Panel Mounted Controller Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 30: Installation And Commissioning
When the robot is installed at a height, hanging, or other than mounted directly on the floor, there will be additional hazards. Electrical safety The mains power must be installed to fulfill national regulations. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 31 The risk assessment should also consider other hazards, such as, but not limited • Water • Compressed air • Hydraulics Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 32 Before the robot system is put into operation, verify that the safety functions are working as intended and that any remaining hazards identified in the risk assessment are mitigated to an acceptable level. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 33: Operation
Never stay beneath a robot arm. Gravity and the release of braking devices can create additional hazards. A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 35 Operating temperatures are listed in Operating conditions, robot on page See safety instructions for the batteries in Material/product safety data sheet - Battery pack (3HAC043118-001). Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 36 WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Related information See also the safety information related to installation and operation. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 37: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 38: Brake Testing
3 Inspect and verify that the axis maintains its position. If the manipulator does not change position as the motors are switched off, then the brake function is adequate. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 39: Troubleshooting
The manipulator can move unexpectedly at any time. DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers. A risk assessment must be done to address both robot and robot system specific hazards.
Page 40: Decommissioning
Never stay beneath a robot arm. Gravity and the release of braking devices can create additional hazards. A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 41: Installation And Commissioning
Note If the IRB 660 is connected to power, always make sure that the robot is connected to protective earth and a residual current device (RCD) before starting any installation work. For more information see: •...
Page 42: 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 43 The robot installation is restricted to the mounting options given in following load table(s). Floor mounted Force Endurance load (in operation) Max. load (emergency stop) Force xy ± 8.0 kN ± 11.7 kN Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 44 (gaseous only) Operating conditions, robot The table shows the allowed operating conditions for the robot: Parameter Value Minimum ambient temperature 0° C Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 45 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 Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 46: Working Range And Type Of Motion
(dimensions in mm). IRB 660 - 180/3.15 and IRB 660 - 250/3.15 The illustration below shows the unrestricted working range of IRB 660 - 180/3.15 and IRB 660 - 250/3.15.
Page 47 Rotation motion -180° to +180° Arm motion -42° to +85° Arm motion -20° to +120° Arm motion 20° to 160° Turn motion -300° to +300° Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 48: Risk Of Tipping/Stability
This figure shows the robot in its shipping position and transportation position. xx0500002275 WARNING The robot will be mechanically unstable if not properly secured to the foundation. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 49: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 50: On-Site Installation
See figure Fork lift set, 3HAC023044-001 hardware on page Standard toolkit Content is defined in section Standard tools on page 347. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 51 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 52 Attachment screws, 2 pcs, M16 x 90. Tightening torque: 270 Nm. Strap up axis 2 motor cable on the adapter. xx0500002278 • A: Strap, velcro Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 53 Make sure the securing screw is removed from the fork lift pocket! It is only used for robot model IRB 6650S. xx0700000655 A Securing screw Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 54 Double-check that pockets are properly se- cured to the robot! Insert fork lift forks into the pockets. CAUTION The IRB 660 robot weighs 1750 kg. All lifting accessories used must be sized ac- cordingly! Carefully lift the robot and move it to its install- ation site.
Page 55: Lifting Robot With Roundslings
Position robot in a secure transport position. Attach roundslings to robot according to fig- Attachment points on page CAUTION The IRB 660 robot weighs 1750 kg. All lifting accessories used must be sized accordingly! WARNING Personnel must not, under any circum-...
Page 56 The illustration is similar with the label attached to the robot’s frame. xx0500002285 Chain sling with shortener Roundsling, robot Roundsling, upper arm. Used to secure against rotation. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 57 2 Installation and commissioning 2.3.2 Lifting robot with roundslings Continued Note! No sharp edges! Shackle Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 58: Lifting Robot With Lifting Slings
Eye for lifting accessory Swivelling lifting eyes, 3 pcs Chain Lifting sling, short. Secures against rotation. Lifting slings, long Hook Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 59 Article number is specified in Required scribed in the enclosed instruction! equipment on page CAUTION The IRB 660 robot weighs 1750 kg. All lifting accessories used must be sized ac- cordingly! WARNING Personnel must not, under any circumstances, be present under the suspended load! Raise overhead crane to lift the robot.
Page 60: Manually Releasing The Brakes
Make sure no personnel is near or beneath the ro- bot. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 61 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 62: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 63: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 64 325 (2x) 241,1 250,5 225,8 138,4 109,1 xx1000001054 ¤ Four holes for alternative clamping, 4x Ø18 Color: RAL 9005. Thickness: 80-100 µm Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 65 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 66 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 67 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 68: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 69 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 70 This illustration shows the hole configuration used when securing the robot. xx0600002628 Cross section, guide sleeve hole This illustration shows the cross section of the guide sleeve holes. xx0600002629 Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 71: Fitting Equipment On Robot
10 kg. Max. extra weight on the upper arm: • IRB 660 - 180/3.15 = 35 kg • IRB 660 - 250/3.15 = 35 kg Note! The weight of the extra equipment on the upper arm must be deducted from the maximal handling capacity.
Page 72 Illustration, fitting of extra equipment on frame The illustration below shows the mounting holes available for fitting extra equipment on the frame. xx0500002505 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 73 Illustration, fitting on turning disk The illustration below shows the mounting holes available for fitting equipment on the turning disk. xx0500002292 Mounting flange. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 74 When fitting tools on the turning disk (see the figures above), only use screws with quality 12.9. When fitting other equipment to mounting holes standard screws with quality 8.8 may be used. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 75: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 76: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 77: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 78: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 79 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 80: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 81: Installation Of Position Switch, Axis 1 (Option)
The position switch sets may be delivered in one of two ways: • Fitted by ABB on delivery. In this case, the cams must still be fitted and locked by the user. For axis 1, the cover for the cams must also be fitted.
Page 82 Required equipment on page Further information about cables and connection points, see section Robot cabling and connection points on page Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 83 • 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 84 B: Connection point R1.SW1 • C: Notch for cable • D: Position switch, axis 1 Refit the rear cover to the robot base. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 85 Fit the cam with the M5 screw and nut. Tighten Shown in the figure Illustration, adjust the M5 screw to secure the cam. and secure cams on page Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 86 Cam stop, M5 nut and M5 x 6 set screw Adjustable cam Profile Illustration, cutting the cam The illustration below shows how to cut the position switch cam. xx0100000114 Remove the gray section Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 87: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 88: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 89 There is a grounding/bonding point on the manipulator base. The grounding/bonding point is used for potential equalizing between control cabinet, manipulator and any peripheral devices. xx1600001007 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 90 1 inside point 2 inside cabinet cabinet Bracket in the cabinet wall (M2004) 3HAC020813-082 Harness position switch axis 1 3HAC021117-001 XT8.1 and XT8.2 (M2004) Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 91: Maintenance
Note If the IRB 660 is connected to power, always make sure that the IRB 660 is connected to protective earth and a residual current device (RCD) before starting any maintenance work. For more information see: •...
Page 92: Maintenance Schedule And Expected 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 93: Maintenance Schedule
First change when DTC reads: • 6,000 hours Second change when DTC reads: • 24,000 hours Following changes: • Every 24,000 hours Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 94 Equipment Interval Inspection Signal lamp Every: 12 months Inspection Additional mechanical stop Every: axis 1 12 months Inspection Position switches, axis 1 Every: 12 months Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 95: 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 96: Inspection Activities
122. Do not mix with other oils! Standard toolkit Content is defined in section Standard tools on page 347. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 97 Further information about how to fill with oil is found in section Changing oil, axis-1 gearbox on page 123. Refit the oil plug. Tightening torque: Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 98: Inspecting, Oil Level Gearbox Axes
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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 99 Use this procedure to inspect the oil level in gearbox axes 2 - 3. Action Note WARNING Handling gearbox oil involves several safety risks, Gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 100 Filling of oil is detailed further in section Changing oil, gearbox axes 2 and 3 on page 126. Refit oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 101: Inspecting, Oil Level Gearbox Axis
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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 103: Inspecting, Balancing Device Bearings And Piston Rod Guide Ring
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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 104 Art. no. is specified in Required equipment lower axes of balancing device. on page 103. The shafts should be tightened to their bottom position. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 105 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 106 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 107: Inspecting, Cable Harness
The axes-1-6 cable harness is shown below. xx0500002497 Cable harness robot, axes 1-6 Connectors at base Motor cables Cable guide, axis 2 Metal clamps Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 108 Check the metal clamps on the lower arm. Shown in figure Location of cable har- ness, axes 1-6 on page 107 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 109 Detailed in section: is detected! Replacing cable harness, lower end (axes 1-3) on page 150. Replacing the cable harness, upper end (incl. axis 6) on page 158. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 110: Inspecting The Information Labels
Warning label concerning extended working range (option) Information labels at gearboxes and at robot base, specifying which oil is used in gearboxes. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 111 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 353. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 112: Inspecting The Axis-1 Mechanical Stop Pin
Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 113 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 114: Inspecting The Additional Mechanical Stops
3.3.8 Inspecting the additional mechanical stops Location of mechanical stops This figure shows the location of the additional mechanical stops on axis 1. (The figure shows IRB 7600 but the location on axis 1 is the same on IRB 660.) xx0300000049 Additional mechanical stop...
Page 115 If any damage is detected, the mechanical stops must Article number is specified in be replaced. Required equipment on page 114. Correct attachment screws: • Axis 1: M16 x 35, quality 12.9. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 116: Inspection, Dampers
Damper, lower arm, lower (1 pc) Damper, axis 2 (2 pcs) Damper, axis 3 (2 pcs). Not visible in this view. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 117 Check attachment screws for deformation. If any damage is detected, the damper must be Art.no. is specified in Required replaced with a new one. equipment on page 117. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 118: Inspection, Position Switch Axis
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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 119 Check that the area inside of the sheets is clean enough not to interfere with the function of the position switch. If any damage is detected, the position switch must be replaced! Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 120: Inspecting The Signal Lamp (Option)
Use this procedure to inspect the function of the signal lamp. Action Note Inspect that signal lamp is lit when motors are put in operation ("MOTORS ON"). Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 121 • measuring the voltage in the connectors of motor axis 6 (=24V). • inspecting the cabling. Replace the cabling if a fault is detected. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 122: Replacement/Changing Activities
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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 123: Changing Oil, Axis-1 Gearbox
122. oil in gear- Do not mix with other oils! boxes on page 122. Oil collecting vessel Capacity: 8,000 ml. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 124 123. Remove oil plug, filling in order to drain oil Shown in figure Location of oil plugs quicker! on page 123. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 126: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 127 Content is defined in section ment Special tools on page 348. Standard toolkit Content is defined in section Standard tools on page 347. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 128 WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 129 Refit oil plug,filling and ventilation hole plug. Shown in Location of oil plugs on page 126. Tightening torque: 24 Nm. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 130: Changing Oil, Gearbox Axis 6
Use this procedure to drain oil from gearbox axis 6. When using oil change equipment, follow the instructions enclosed with kit. Action Note Put tilt house in a suitable position. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 131 Correct oil level is detailed in section Inspection, oil level axis-6 gearbox on page 102. Refit the oil plug. Tightening torque: 20 Nm Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 132: Replacing The Smb Battery
Battery pack with a 2-pole battery contact (DSQC) xx0500002486 SMB battery cover SMB battery pack Battery cable Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 133 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 353 Standard toolkit Content is defined in section...
Page 134 Shown in figure Location of SMB Battery includes protection circuits. Only replace battery on page 132. with a specified spare part or with an ABB- ap- proved equivalent. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W...
Page 135 Detailed in chapter Calibration - section Updating revolution coun- ters on page 311. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 136: Lubrication Activities
Note! Balancing device must be fitted on robot when lubricating bearings! xx0500002489 Ear (bearing located inside) Support washer Lock nut Piston rod Guide ring (not visible in this view) Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 137 Apply locking liquid on the lock nuts (KM10). Tightening torque on lock nuts: • 120 Nm Note Do not apply locking liquid on the shafts! Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 138 Clean piston rod with isopropanol before applying new grease. Apply new grease. Type of grease is specified in Required equipment on page137. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 139: Cleaning Activities
General To secure high uptime it is important that the IRB 660 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 660.
Page 140 Cleaning with water and steam Instructions for rinsing with water ABB robots with protection types Standard, Foundry Plus, Wash, or Foundry Prime can be cleaned by rinsing with water (water cleaner). The following list defines the prerequisites: •...
Page 141: Repair
Repair activities not described in this chapter must only be carried out by ABB. Report replaced units Note When replacing a part on the IRB 660, report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit.
Page 142: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 143: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 144 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 145: Mounting Instructions For Sealings
If the sealing is without dust lip, just lubricate the main lip with a thin layer of grease. xx2000000071 A Main lip B Grease C Dust lip Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 146 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 147 Lubricate the o-ring with grease. Tighten the screws evenly while assembling. Check that the o-ring is not squashed outside the o-ring groove. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 148: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 149: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 150: Complete Robot
Connector R1.MP Connector R1.SMB Attachment point for earth lug Cover plate Rear cover plate Cable gland, SMB Cable guide, axis 2 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 151 Connector at base Cable guide, axis 1 Cable harness, axes 1-6 Cover plate Rear cover plate Attachment point for earth lug Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 152 Note Move the robot to the calibration position. This is done in order to facilitate updat- ing of the revolution counter. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 153 Unscrew the screws of the motor covers for axes 1, 2 and 3 and lift away the covers. This is done in order to reach the motor connectors. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 154 Perform this removal with care, in order not to damage any of the components inside the SMB recess. xx1000001330 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 155 1 in the center of the frame. CAUTION Make sure the cables are not twisted with each other or with customer harness (if any)! xx1000001331 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 156 Reconnect connectors R2.SMB, R1.SMB1-3, R1.SMB6 of the SMB unit. Reconnect X8, X9 and X10 to the brake release unit. Reconnect R1.G. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 157 Update the revolution counter! See section Updating revolution counters on page 311. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 158: Replacing The Cable Harness, Upper End (Incl. Axis 6)
Rear cover plate Cable gland, SMB Cable guide, axis 2 Metal clamp, frame Metal clamp, lower arm Metal clamp, upper arm Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 159 Action Note Move the robot to the calibration position. This is done in order to facilitate updating of the revolution counter. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 160 Make sure the gasket is not damaged! xx0600002694 • A: Screw securing the cable gland Disconnect connectors at axis 6 motor. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 161 (2 + 2 pcs). xx1000001338 Carefully pull out the cable harness from the upper and lower arm. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 162 (2 + 2 pcs) from the outside of the upper arm. xx1000001338 Refit the metal clamp at the tilthouse with its nuts. xx1000001336 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 163 Update the revolution counter! Detailed in section Updating revolution counters on page 311. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 164: Replacing The Base, Including Axis 1 Gearbox
Parallel rod Linkage Complete upper arm (incl. tilthouse) Balancing device Frame Gearbox, axis 1 Base Base attachment screws Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 165 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 167 Make sure the lift is done completely described in the enclosed user instructions. level. This is detailed in section Lifting robot with lifting slings on page Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 168 Refit the axis 1 gearbox, if it has been re- Replacing the axis 1 gearbox on moved. page 276. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 169 A: Attachment holes for the guide pins, M12 Dimension is specified in Required equipment on page 165. Note Always use guide pins in pairs. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 170 Replacing cable harness, lower end frame. (axes 1-3) on page 150. Refit the axis 1 motor. Replacing motor, axis 1 on page 251. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 171 General calibration information is included in section Calibration on page 305. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 172: Upper And Lower Arm
For spare part no. O-rings are not included! see: Spare part lists on page 353. O-ring 3HAB3772-65 (1pc) For robot v. IRB 660 180/3.15, 250/3.15 Wrist, type 1 21520431-20 (6 pcs) Must be replaced when replacing the turning disk! Grease 3HAC042536-001 Shell Gadus S2 Used to lubricate the o-rings.
Page 173 172. 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 174 See section • Changing oil, gearbox axis 6 on page 130 Refit any equipment removed during disas- sembly to the turning disk. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 175 4 Repair 4.4.1 Replacing the turning disk Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 176: Replacement Of Tilthouse Unit
The tilthouse unit is located as shown in the figure below. xx0600002616 Tilthouse unit Upper arm Upper rod Screw M6x10 Washer 6.4x12x1.6 Ballplug Protection cap Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 177 The figure below shows a cut away view of how the tilthouse unit is fitted to the upper arm. The letters in the figure are being referred to in the step by step procedures below. xx0600002742 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 179 Bushing, 3HAC 023075-006 Screw M6x25, 2 pcs (MC6S) Threaded washer, 3HAC 5507-1 Press washer, 3HAC 023075-002 Threaded bar, M16 L = 300 mm Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 180 Press housing, 3HAC 023080-004 Support housing, 3HAC 023080-003 Screw M6x14, 2pcs (MC6S) Flange lock nut, M16 Threaded bar, M16 L=435 mm Nut M16 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 181 • 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 182 (incl. axis Place the motor cables in a way that it will not 6) on page 158 be damaged. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 183 VK cover in order to catch it. CAUTION Only a very low air pressure is needed! xx1000001072 Parts: M6 screw in hole for filling grease VK cover Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 184 C: Upper arm Remove the small VK cover from the inside with the help of a punch. xx1000001073 Remove the lock nut. xx1000001074 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 185 Press out the shaft. xx1000001075 A Shaft Remove the press tool, mounting axis 6 and the shaft. xx1000001076 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 186 Cut away view of outside of the tilthouse. Use a plastic hammer the assembly of the tilthouse unit on or similair. page 177. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 187 179. Art.no. is specified in Required equipment on page 178. Fit the pressing tool and press the parts togeth- Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 188 178. parts with the flange locknut (F). Shown in the figure Press tool mount- ing axis 6 on page 180. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 190 General calibration information is in- cluded in section Calibration on page 305. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 191: Replacement Of Upper Arm
The upper arm is located as shown below. xx0600002609 Upper arm Motor axis 6 Balancing device Lower arm Parallel rod Linkage Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 192 Sealing ring Taper roller bearing O-ring Sealing ring Sealing assembly Lock nut (KM12) O-ring (Di = 54.2 mm, t = 5.7 mm) Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 193 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 194 Replacement of linkage - link on page 209 Remove the parallel rod. Detailed in section Replacing the parallel rod on page 216 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 195 The adapter is not needed on this shaft! Put the shafts in a clean and safe place. Remove the upper arm. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 196 Fill the bearings (G) with bearing grease. Shown in the figure View of the assembly Use grease filling tool. of the upper arm components on page 192. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 197 The complete upper arm with weighs 170 kg (without any additional equipment fitted). Use a suitable lifting accessory to avoid in- jury to personnel! Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 198 7 Apply locking liquid (Loctite 243) on the lock nut (K) and refit it using a KM12 socket. Tightening torque 90 Nm. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 199 Axis Calibration is described in Calibrating with Axis Calibration method on page 315. General calibration information is included in section Calibration on page 305. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 200 4 Repair 4.4.3 Replacement of upper arm Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 201: Replacement Of Linkage - Upper Rod
3HAC3311-1 Replace if damaged. Bearing grease 3HAC042536-001 Shell Gadus S2 Used to lubricate the bear- ings. Locking liquid 3HAB7116-1 Loctite 243 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 202 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot work- ing area. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 203 Spare part no. is specified in Required equipment on page 201. Note The bearings are sensitive for pushes. Make sure they are not damaged! Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 204 Refit the lock nuts on the link and tilthouse, Tightening torque: 120 Nm. using locking liquid. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 205: Replacing The Linkage - Lower Rod
Link Required equipment Equipment Art no. Note Lower rod For spare part no. see: • Spare part lists on page 353 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 206 This is done in order to prevent the link from moving if both the upper rod and lower rod are removed. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 207 (The same distance from bearing to the edge of the lower rod on both sides.) Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 208 Refit the lock nuts on the shaft ends. Use a Tightening torque: 120 Nm. KM10 socket. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 209: Replacement Of Linkage - Link
Cut away view of the assembly of the link The figure shows a cut view of how the link is fitted. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 210 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 211 - lower rod on page 205 Fit the auxiliary shaft on the shaft. Art.no. is specified in Required equipment on page 210 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 212 Put one hand with some paper on top of the VK cover in order to catch it when re- leased. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 213 Place the outer rings of the bearings in the link. Use the pressing tool and fit the outer rings Art.no. is specified in Required equipment on page 210 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 214 The recommended order of tightening the lock nut is important to follow to avoid future problems with the shaft. Refit the VK cover. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 215 General calibration information is included in section Calibration on page 305. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 216: Replacing The Parallel Rod
Mercasol 3110 Waxcoat Protection plug 3HAC4836-2 F21 28x22, 4x12x9 Standard toolkit Content is defined in section Standard tools on page 347. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 217 Remove the protection plugs Remove the upper lock screw and washer, that secure the parallel rod in position. xx0600002741 • A: Lock screw M6x16 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 218 3 Remove the thrust washer (F). Remove the parallel rod from the robot. Replace the bearings (D), if necessary. See figure above! Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 219 E Bearing grease F Thrust washer Put the cover washer (B) on the axis 3 side See figure above! of the parallel rod. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 220 Foundry Plus: Refit the protection plugs. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 221: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 222 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 223 Remove the axes 2 and 3 gearboxes. Also see CAUTION The robot lower arm weighs 65 kg. All lifting accessories used must be sized accord- ingly! Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 224 CAUTION The parallel arm system weighs 118 kg. All lifting accessories used must be sized accord- ingly! Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 225 Remove the complete lower arm (including the parallel arm). xx1000001358 How to replace the parallel arm is detailed in section Replacement of parallel arm on page 229. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 226 Art. no. is specified in Required to the lower arm and put the sealings on them. equipment on page 221. See figure. xx1000001368 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 227 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 228 General calibration information is in- cluded in section Calibration on page 305. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 229: Replacement Of Parallel Arm
Bearing grease 3HAC042536-001 Shell Gadus S2 Rust preventive 3HAC034903-001 Mercasol 3110 Waxcoat Pressing tool, lower arm 3HAC023092-001 Lifting accessory, parallel 3HAC023098-001 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 230 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 231 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 232 The parallel arm system weighs 118 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 233 Refit a bearing on each shaft with pressing tool, Art. no. is specified in Required lower arm. equipment on page 229 xx1000001377 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 234 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 235 General calibration information is included in section Calibration on page 305. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 236: Frame And Base
Hole for lock screw Required equipment Equipment, etc. Art.no. Note Balancing device For spare part num- ber, see Spare part lists on page 353. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 237 236. Lock the lower arm by inserting the lock screw into the hole. CAUTION Tighten by hand! xx1000001101 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 238 Attach a lifting accessories to the balancing device. Use the hole in the lifting ear. xx1000001112 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 239 See figure! xx1000001115 CAUTION The balancing device weighs 70 kg. All lifting accessories used must be sized ac- cordingly! Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 240 Remove residual grease. Refitting, balancing device use this procedure to refit the balancing device. Action Note Check the bearings. Replace if needed. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 241 All lifting accessories used must be sized ac- cordingly! Attach lifting accessory to the balancing device and lift it on to the auxiliary shafts. xx1000001112 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 242 Remove the auxiliary shafts. Apply locking liquid on the threads of the lock Specified in section Required equip- nuts. ment on page 236. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 243 Remove the M12x50 screws from the balancing device to restore the springforce. Remove the lock screw. xx1000001101 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 244: Replacing The Smb Unit
For spare part number, see: Spare part lists on page 353. Standard toolkit Content is defined in section Standard tools on page 347. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 245 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 246 6 Nm. Update the revolution counters. Updating revolution counters on page 311. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 247: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 248 Location of the brake release unit is shown in the figure Location of brake release board on page 247. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 249 Refit the push button guard to the SMB cover. Shown in the figure Location of brake release board on page 247. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 250 Updating revolution counters on page 311. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 251: Motors
Grease 3HAC042536-001 Shell Gadus S2 For lubricating the o-ring. Bits extension 3HAC12342-1 Used to reach the attachment screws for the motor. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 252 Use this procedure to remove motor 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 253 VDC power supply. • + : pin 2 • -: pin 5 Remove the attachment screws of the motor. Use the bits extension. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 254 Be careful not to damage the pinion in the pro- cess! Disconnect the brake release voltage. Check the pinion. If there is any damage, the pinion must be replaced. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 255 Make sure the motor is turned the right way. See figure. Note Make sure the motor pinion does not get dam- aged! Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 256 Calib- rating with Axis Calibration method on page 315. General calibration information is in- cluded in section Calibration on page 305. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 257 4 Repair 4.6.1 Replacing motor, axis 1 Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 258: Replacing Motors, Axes 2 And 3
2-3 Lock screw M16x90 For securing the lower arm. Bits extension 3HAC12342-1 Used to reach the attachment screws for the motor. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 259 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 260 Drain the oil from gearbox. See section • Changing oil, gearbox axes 2 and 3 on page 126. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 261 In order to release the brake, connect the 24 Connect to connector R2.MP2 VDC power supply. • + : pin 2 • -: pin 5 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 262 Fit two guide pins in two of the motors attach- Art. no. is specified in Required ment holes. equipment on page 258. xx1000001131 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 263 Make sure the pinion does not get damaged! xx1000001105 Remove the motor by gently lifting it straight out and place it on a secure surface. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 264 -: pin 5 Fit the lifting tool, motor axes 2-3 to the motor. Art. no. is specified in Required equipment on page 258. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 265 Remove the lifting tool and allow the motor to rest on the guide pins. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 266 50 Nm Disconnect the brake release voltage. Reconnect all connectors beneath the motor Connect in accordance with markings cover. on connectors. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 267 142. Refill the gearbox with oil. See section Changing oil, gearbox axes 2 and 3 on page 126. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 268 General calibration information is in- cluded in section Calibration on page 305. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 269: Replacing Motor, Axis 6
These procedures include refer- may be required. See refer- ences to the tools required. ences to these procedures in the step-by-step instruc- tions below. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 270 6 when stand- ing in front of the robot. Note The motor axis 6 can be replaced without draining the gear oil. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 271 A Signal lamp (UL lamp) B Cable straps, outdoor C Cable D Connection point to the cable gland Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 272 Disconnect the brake release voltage. Remove the motor by gently lifting it straight up and place it on a secure surface. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 273 Make sure the motor is turned the correct way. See figure! xx1000001108 Remove the guide pins. Apply locking liquid (Loctite 243) on the attach- ment screws. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 274 Refit the connections to the UL lamp, if the ro- bot is equipped with one. Check the gasket. If damaged, replace it. xx1000001224 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 275 General calibration information is in- cluded in section Calibration on page 305. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 276: Gearboxes
Guide pins 2 pcs, M16x150. Used for guiding the gearbox into place in the base. Always use guide pins in pairs! Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 277 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 278 Replacing the base, including axis 1 gearbox on page 164. Unfasten the robot base from the foundation by removing the base attachment screws. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 279 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 280 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 281 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 282 • 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 283 276. CAUTION The gearbox weighs . All lifting accessories used must be sized ac- cordingly! Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 284 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 285 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 286 General calibration information is in- cluded in section Calibration on page 305. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 287: Replacing The Gearbox, Axes 2- 3
Guide sleeves 3HAC14628-1/2 Use to keep the sealing in place. Grease Use to lubricate surfaces on the gearbox for easier assembly. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 288 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 290 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 291 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 293 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 294 Fit the lifting accessory to the gearbox and Specified in Required equipment on lift it with an overhead crane. page 287. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 295 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 296 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 297 Refit the motors axes 2-3. Replacing motors, axes 2 and 3 on page 258 Perform a leakdown test. Performing a leak-down test on page 142. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 298 General calibration information is included in section Calibration on page 305. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 299: Replacing Gearbox Axis 6
O-ring (type 2) 12 pcs 3HAB3772-61 Must be replaced when reas- sembling gearbox. 13.1x1.6 Grease 3HAC042536-001 Shell Gadus S2 Used to lubricate the o-ring Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 300 Jog the robot to a position where the tilt- house unit is placed in an appropriate ser- vice position. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 301 If required apply two M8 screws in the holes shown in the figure, and press out the gearbox. xx0200000220 A: M8 holes for pressing out the gearbox Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 302 • 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 303 142. Refill the gearbox with oil. See section • Changing oil, gearbox axis 6 on page 130 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 304 General calibration information is included in section Calibration on page 305. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 305: 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 306: Calibration Methods
Axis Calibration method Axis Calibration is a standard calibration method for calibration of IRB 660 and is the most accurate method for the standard calibration. It is the recommended method in order to achieve proper performance.
Page 307 The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including the Operating manual - Calibration Pendulum, which describes the method and the different routines further. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 308: When To Calibrate
The resolver values are changed If resolver values are changed, the robot must be re-calibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration, according to information in this manual. The resolver values will change when parts affecting the calibration position are replaced on the robot, for example motors or parts of the transmission.
Page 309: Synchronization Marks And Axis Movement Directions
One of the marks is more narrow than the other and should be positioned within the limits of the wider mark. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 310: Calibration Movement Directions For All Axes
Manual movement directions, 4 axes Note! The graphic shows an IRB 260. The positive direction is the same for all 4-axis robots xx0500001927 Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 312 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 313 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 314 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 331. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 315: 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 316 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 317 Axis to be calibrated Unrestricted. Axis is allowed to be jogged to other position than 0 degrees. Axis must be put in position 0 degrees. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 318: 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 319 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 321 Replace damaged parts with new. 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 322: 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 323 Use this procedure to start the Axis Calibration routine on the FlexPendant. Action Note On the ABB menu, tap Calibration. xx1500000942 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 324 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 325 Replace the cover with new spare part, if missing or damaged. xx1600002102 Protection cover and plug set: 3HAC056806-001. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 326 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 327: Reference Calibration
(step 5, see Brief introduction to Reference Calibration on page 327). Example "Adjust axis 4": 1 Create a backup. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 328 10 Check again against the verification position. 11 Repeat the manual tuning if needed. 12 Create a new reference if the intention is to use the reference in the future. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 329: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 330: Verifying The Calibration
Write down the values on a new label and stick it on top of the calibration label. The label is located on the lower arm. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 331: Checking The Synchronization Position
If they do not, up- ization position for axes on page 309 date the revolution counters. Updating revolution counters on page 311. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 332 This page is intentionally left blank...
Page 333: Decommissioning
Incineration must be carried out under controlled conditions in accordance with local regulations. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 334 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 335: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 336: Decommissioning Of Balancing Device
The following procedure contains useful information about decommissioning. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 337 Cut a hole in the housing as shown in the Use a cutting torch with a long shaft. figure. xx1100000096 * Minimum measure, in millimeters. ** Maximum measure, in millimeters. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 338 Double-check the number of coils cut and make sure all the tension in the spring is removed. Cut more coils if there is still tension in the spring. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 339: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 340: Applicable Standards
Degrees of protection provided by enclosures (IP code) Only robots with protection Clean Room. Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots. Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 341 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 342: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 343: Screw Joints
7.4 Screw joints 7.4 Screw joints General This section describes how to tighten the various types of screw joints on ABB robots. The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials.
Page 344 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 345 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 346: 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 347: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 348: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 349 Lifting tool, complete robot 3HAC15607-1 Lifting tool, parallel arm 3HAC023098-001 Lifting tool, turning device gearbox ax.1 3HAC14406-1 Lifting tool, base 3HAC14868-1 Continues on next page Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 350 Auxiliary shaft, short 3HAC5276-1 Support shaft/bearing race 3HAC5281-1 Axis 1 pinion 3HAC022436-001 Tool for lubrication 3HAC5222-1 Adapter for shaft axis 3 3HAC071308-001 Guide sleeves 3HAC14446-1 Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 351: Lifting Accessories And Lifting Instructions
This implies that the instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 352 This page is intentionally left blank...
Page 353: 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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 354 This page is intentionally left blank...
Page 355: Circuit Diagrams
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 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 356 Circuit diagram - IRB 6700 / IRB 6790 3HAC043446-005 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 14000 3HAC050778-003 Circuit diagram - IRB 910SC 3HAC056159-002 Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 357 2, 126 calibration manuals, 307 oil change axis 3, 126 calibration marks, 309 oil change axis 6, 130 Calibration Pendulum gearbox axis 1, replacement, 276 Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 358 19 lubrication restricting amount in gearboxes, 122 working range axis 1, 78, 80 type of lubrication, 122 revolution counters storing on FlexPendant, 312 Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 359 87 working range, 46 stability, 48 restricting axis 1, 78 standards, 340 ANSI, 341 CAN, 341 zero position EN, 341 checking, 331 EN IEC, 340 Product manual - IRB 660 3HAC025755-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 362 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 2006-2020 ABB. All rights reserved. Specifications subject to change without notice.

ABB IRB 660 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 Diagrams

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