irb_6660

ROBOTICS
Product manual
IRB 6660
Trace back information:
Workspace R18-2 version a18
Checked in 2018-11-20
Skribenta version 5.3.012
Product manual
IRB 6660 - 100/3.3
IRB 6660 - 130/3.1
IRB 6660 - 205/1.9
IRC5
Document ID: 3HAC028197-001

Revision: S
© Copyright 2007-2018 ABB. All rights reserved.

Specifications subject to change without notice.
The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.

ABB AB, Robotics
Robotics and Motion
Se-721 68 Västerås
Sweden
Table of contents
Table of contents
Overview of this manual ................................................................................................................... 9
Product documentation .................................................................................................................... 15
How to read the product manual ...................................................................................................... 17
1 Safety 19
1.1 General safety information .................................................................................. 19
1.1.1 Limitation of liability ................................................................................. 19
1.1.2 Protective stop and emergency stop ........................................................... 21
1.2 Safety actions ................................................................................................... 22
1.2.1 Fire extinguishing .................................................................................... 22
1.2.2 Emergency release of the robot axes .......................................................... 23
1.2.3 Make sure that the main power has been switched off .................................... 24
1.3 Safety risks ...................................................................................................... 25
1.3.1 Safety risks during installation and service work on robots .............................. 25
1.3.2 Moving robots are potentially lethal ............................................................ 27
1.3.3 First test run may cause injury or damage .................................................... 28
1.3.4 Work inside the working range of the robot .................................................. 29
1.3.5 Enabling device and hold-to-run functionality ............................................... 30
1.3.6 Risks associated with live electric parts ....................................................... 31
1.3.7 The unit is sensitive to ESD ....................................................................... 33
1.3.8 Hot parts may cause burns ....................................................................... 34
1.3.9 Safety risks related to pneumatic/hydraulic systems ...................................... 35
1.3.10 Brake testing .......................................................................................... 36
1.3.11 Safety risks during handling of batteries ...................................................... 37
1.3.12 Safety risks during work with gearbox lubricants (oil or grease) ....................... 38
1.4 Safety signals and symbols ................................................................................. 40
1.4.1 Safety signals in the manual ...................................................................... 40
1.4.2 Safety symbols on product labels ............................................................... 42
2 Installation and commissioning 49

2.1 Introduction ...................................................................................................... 49
2.2 Unpacking ....................................................................................................... 50
2.2.1 Pre-installation procedure ......................................................................... 50
2.2.2 Working range and type of motion .............................................................. 54
2.2.3 Risk of tipping/stability ............................................................................. 58
2.3 On-site installation ............................................................................................ 60
2.3.1 Lifting robot with fork lift ........................................................................... 60
2.3.2 Lifting robot with roundslings .................................................................... 66
2.3.3 Lifting robot with lifting slings .................................................................... 69
2.3.4 Manually releasing the brakes ................................................................... 73
2.3.5 Lifting the base plate ................................................................................ 75
2.3.6 Securing the base plate ............................................................................ 76
2.3.7 Orienting and securing the robot ................................................................ 81
2.3.8 Fitting equipment on robot ....................................................................... 84
2.3.9 Installation of chip protection - IRB 6660 - 205/1.9 ......................................... 88
2.3.10 Installation of cooling fan for motors (option) ................................................ 90
2.3.11 Installation of Foundry Plus Cable guard (option no. 908-1) ............................. 97
2.3.12 Loads fitted to the robot, stopping time and braking distances ......................... 98
2.3.13 Signal lamp (option) ................................................................................. 99
2.4 Restricting the working range .............................................................................. 100
2.4.1 Axes with restricted working range ............................................................. 100
2.4.2 Mechanically restricting the working range of axis 1 ...................................... 101
2.4.3 Extended working range, axis 1 (option 561-1) ............................................. 103
2.5 Electrical connections ........................................................................................ 104
2.5.1 Robot cabling and connection points .......................................................... 104
2.6 Start of robot in cold environments ...................................................................... 107
Product manual - IRB 6660 5

3HAC028197-001 Revision: S
Table of contents
3 Maintenance 109
3.1 Introduction ...................................................................................................... 109
3.2 Maintenance schedule and component life ............................................................. 110
3.2.1 Specification of maintenance intervals ........................................................ 110
3.2.2 Maintenance schedule ............................................................................. 111
3.2.3 Expected component life ......................................................................... 113
3.3 Inspection activities ........................................................................................... 114
3.3.1 Inspecting the oil level in axis-1 gearbox ..................................................... 114
3.3.2 Inspecting, oil level gearbox axes 2 - 3 ....................................................... 116
3.3.6 Inspecting, balancing device bearings and piston rod guide ring ...................... 126
3.3.7 Inspection, cable harness ......................................................................... 130
3.3.8 Inspecting the information labels ................................................................ 134
3.3.9 Inspecting the axis-1 mechanical stop pin ................................................... 136
3.3.10 Inspecting the additional mechanical stops ................................................. 138
3.3.11 Inspecting the damper on axes 2-5 ............................................................. 140
3.3.12 Inspecting, signal lamp (option) ................................................................. 142
3.4 Replacement/changing activities .......................................................................... 144
3.4.1 Type of lubrication in gearboxes ................................................................ 144
3.4.2 Changing oil, axis-1 gearbox ..................................................................... 146
3.4.3 Changing oil, gearbox axes 2 and 3 ........................................................... 149
3.4.7 Replacing the SMB battery ........................................................................ 162
3.5 Lubrication activities .......................................................................................... 166
3.5.1 Lubricating balancing device bearings and piston rod .................................... 166
3.6 Cleaning activities ............................................................................................. 169
3.6.1 Cleaning the IRB 6660 .............................................................................. 169
4 Repair 173
4.1 Introduction ...................................................................................................... 173
4.2 General procedures ........................................................................................... 174
4.2.1 Performing a leak-down test ...................................................................... 174
4.2.2 Mounting instructions for bearings ............................................................. 175
4.2.3 Mounting instructions for seals .................................................................. 177
4.2.4 Cut the paint or surface on the robot before replacing parts ............................ 179
4.2.5 The brake release buttons may be jammed after service work ......................... 180
4.3 Complete robot ................................................................................................. 181
4.3.1 Replacement of cable harness, lower end (axes 1-3) ...................................... 181
4.3.2 Replacement of process cable package 1 - 3 MH .......................................... 189
4.3.3 Replacement of cable harness, upper end ................................................... 196
4.3.4 Replacement of cabling, axis 5 motor .......................................................... 204
4.3.5 Replacement of complete arm system ......................................................... 207
4.4 Upper and lower arms ........................................................................................ 217
4.4.1 Replacing the turning disk ........................................................................ 217
4.4.2 Replacement of complete wrist unit ............................................................ 221
4.4.3 Replacement of upper arm ........................................................................ 227
4.4.4 Replacing the parallel rod ......................................................................... 238
4.4.5 Replacing the complete lower arm .............................................................. 244
4.4.6 Replacement of parallel arm ...................................................................... 252
4.5 Frame and base ................................................................................................ 259
4.5.1 Replacing the SMB unit ............................................................................ 259
4.5.2 Replacing the brake release board ............................................................. 262
4.5.3 Replacing the balancing device .................................................................. 266
6 Product manual - IRB 6660

Table of contents
4.6 Motors ............................................................................................................ 274

4.6.1 Replacing motor, axis 1 ............................................................................ 274
4.6.2 Replacing motors, axes 2 and 3 ................................................................. 281
4.6.3 Replacement of motor, axis 4 .................................................................... 292
4.6.4 Replacement of motor, axis 5 ................................................................... 297
4.6.5 Replacement of motor, axis 6 .................................................................... 303
4.7 Gearboxes ....................................................................................................... 311
4.7.1 Replacing the axis 1 gearbox ..................................................................... 311
4.7.2 Replacing the gearbox, axes 2- 3 ............................................................... 324
4.7.3 Replacement of gearbox, axis 6 ................................................................. 336
5 Calibration 341
5.1 Introduction to calibration ................................................................................... 341
5.1.1 Introduction and calibration terminology ...................................................... 341
5.1.2 Calibration methods ................................................................................. 342
5.1.3 When to calibrate ................................................................................... 344
5.2 Synchronization marks and axis movement directions ............................................. 345
5.2.1 Synchronization marks and synchronization position for axes ......................... 345
5.2.2 Calibration movement directions for all axes ................................................ 347
5.3 Updating revolution counters ............................................................................... 348
5.4 Calibrating with Axis Calibration method ............................................................... 352
5.4.1 Description of Axis Calibration .................................................................. 352
5.4.2 Calibration tools for Axis Calibration ........................................................... 354
5.4.3 Installation locations for the calibration tools ............................................... 356
5.4.4 Axis Calibration - Running the calibration procedure ...................................... 357
5.5 Calibrating with Calibration Pendulum method ........................................................ 363
5.6 Verifying the calibration ...................................................................................... 364
5.7 Checking the synchronization position .................................................................. 365
6 Decommissioning 367
6.1 Introduction ...................................................................................................... 367
6.2 Environmental information .................................................................................. 368
6.3 Scrapping of robot ............................................................................................. 369
6.4 Decommissioning of balancing device ................................................................... 370
7 Reference information 373

7.1 Introduction ...................................................................................................... 373
7.2 Applicable standards ......................................................................................... 374
7.3 Unit conversion ................................................................................................. 376
7.4 Screw joints .................................................................................................... 377
7.5 Weight specifications ......................................................................................... 380
7.6 Standard tools .................................................................................................. 381
7.7 Special tools .................................................................................................... 382
7.8 Lifting accessories and lifting instructions .............................................................. 385
8 Spare part lists 387

8.1 Spare part lists and illustrations ........................................................................... 387
9 Circuit diagram 389

9.1 Circuit diagrams ................................................................................................ 389
Index 391

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Overview of this manual

About this manual
This manual contains instructions for:
• mechanical and electrical installation of the robot
• maintenance of the robot
• mechanical and electrical repair of the robot.
The manual also contains reference information for all procedures detailed in the
manual.
Usage
This manual should be used during:
• installation, from lifting the robot to its work site and securing it to the
foundation, to making it ready for operation
• maintenance work
• repair work and calibration.
Who should read this manual?

This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
Maintenance/repair/installation personnel working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
Product manual scope

The manual covers covers all variants and designs of the IRB 6660. Some variants
and designs may have been removed from the business offer and are no longer
available for purchase.
Organization of chapters
The manual is organized in the following chapters:
Chapter Contents
Safety Safety information that must be read through before performing
any installation or service work on the robot. Contains general
safety aspects as well as more specific information on how to
avoid personal injuries and damage to the product.
Installation and commis- Required information about lifting and installation of the robot.
sioning
Maintenance Step-by-step procedures that describe how to perform mainten-
ance of the robot. Based on a maintenance schedule that may
be used to plan periodical maintenance.
Continues on next page

Continued
Chapter Contents
Repair Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.
Calibration Calibration procedures and general information about calibration.
Decommissioning Environmental information about the robot and its components.
Reference information Useful information when performing installation, maintenance
or repair work. Includes lists of necessary tools, additional doc-
uments, safety standards etc.
Spare part / part list Complete spare part list and complete list of robot components,
shown in exploded views.
Exploded views Detailed illustrations of the robot with reference numbers to the
part list.
Circuit diagram Reference to the circuit diagram for the robot..
References
Reference Document ID
Product specification - IRB 6660 3HAC028207-001
Product manual, spare parts - IRB 6660 3HAC049112-001
Circuit diagram - DressPack 6660 3HAC029940-001
Circuit diagram - IRB 6660 Circuit diagram - IRB 6660
Product manual - IRC5 3HAC021313-001
IRC5 with main computer DSQC 639.
Product manual - IRC5 3HAC047136-001
IRC5 with main computer DSQC1000.
Operating manual - IRC5 with FlexPendant 3HAC050941-001
Operating manual - Calibration Pendulum 3HAC16578-1
Operating manual - Service Information System 3HAC050944-001
Application manual - Additional axes and stand alone controller 3HAC051016-001
Technical reference manual - Lubrication in gearboxes 3HAC042927-001
Technical reference manual - System parameters 3HAC050948-001
Application manual - Electronic Position Switches 3HAC050996-001
Application manual - CalibWare Field 5.0 3HAC030421-001
Revisions
Revision Description
- First edition
A This revision includes the following additions and/or changes:
• Robot version IRB 6660 - 205/1.9 added which includes new upper arm
and new lower arm, as well as Chip protection.
• Process cable package added.
• Option Base spacers no longer available for this robot model. Section
is removed from the manual.
• Prerequisites in section Overview changed.
• Oil change intervals for Shell Tivela S 150 is changed.

Continued
• New product name Mobilgear 600 XP 320 (old name Mobile Gearlube
X 320). Art. no. remains the same.
• Procedure for Process cable package 1-3 MH added.
B This revision includes the following additions and/or changes:
• The product name RobotStudio Online is changed to RobotStudio.
• Section "WARNING! - Mixed oils may cause severe damage to gear-
boxes" in chapter Safety, has been integrated in section "Type of oil
in gearboxes" in Maintenance chapter.
• The oil Shell Tivela S150 has been replaced by Kyodo Yushi TMO150.
• Section Type of oil in gearboxes in chapter Maintenance has been
updated according to changes made in oil types.
• Section What is an emergency stop? added to chapter Safety.
• Section Maintenance schedule in chapter Maintenance: Intervals for
inspection activities and oilchanges have been revised.
• Section Maintenance schedule in chapter Maintenance: Overhaul of
robot is new.
• Section Maintenance schedule in chapter Maintenance: The information
about Service Information System (SIS) has been updated.
• Section Maintenance schedule in chapter Maintenance: Intervals for
replacement of battery pack changed
• Section Expected lifetime in chapter Maintenance: The lifetime of certain
parts has been revised.
• Section Cleaning of robot updated.
C This revision include the following addition:
• New WARNING! added in chapter Safety section Work inside the ro-
bot´s working range.
• New WARNING! added in Safety chapter section WARNING! - Safety
risks during work with gearbox oil.
• The text in the introductions to chapters Installation, Maintenance and
Repair has been updated concerning the robot being connected to
earth when power connected.
• Section Expected component life in chapter Maintenance : The lifetime
of certain parts has been updated.
• Section Foundry Plus,Cable guard added to chapter Installation.
D This revision includes the following additions and/or changes:
• The lifetime of certain parts has been updated, see Expected compon-
ent life on page 113.
• Circuit diagrams are not included in this document but delivered as
separate files. See Circuit diagram on page 389.
• List of standards updated, see Applicable standards on page 374.
The chapter Safety updated with:
• Updated safety signal graphics for the levels Danger and Warning, see
Safety signals in the manual on page 40.
• New safety labels on the manipulators, see Safety symbols on product
labels on page 42.
• Revised terminology: robot replaced with manipulator.
E This revision includes the following updates:
• Maximum deviation changed, see Securing the base plate on page 76.
F This revision includes following additions and/or changes:
• Removed information about lubricating attachment screws, section
Inspecting the additional mechanical stops on page 138.
• Changed tightening torque of fork lift adapters, from 60 Nm to 270 Nm,
see section Lifting robot with fork lift on page 62.
• Information about restricting and extending the working range of axis
1 is now separated, see Mechanically restricting the working range of
Continued
axis 1 on page 101 and the new section Extended working range, axis
1 (option 561-1) on page 103. Also added signal about option 561-1 in
section Inspecting the axis-1 mechanical stop pin on page 136.
G This revision includes the following updates:
• Added section Extended working range, axis 1 (option 561-1) on
page 103.
• A new block, about general illustrations, added in section How to read
the product manual on page 17.
• Added instructions for securing parallel arm and lower arm to each
other before removing the lower arm, see Replacing the complete lower
arm on page 244.
• Added guide sleeves to hold the axes 2/3 sealing in place when refitting
the lower arm, see Replacing the complete lower arm on page 244.
• Made minor corrections and improvements in the complete instruction
for how to replace the lower arm system, see Replacing the complete
lower arm on page 244.
for how to replace the parallel arm, see Replacement of parallel arm
on page 252.
for how to replace the axis 1 gearbox, see Replacing the axis 1 gearbox
on page 311.
• Some general tightening torques have been changed/added, see up-
dated values in Screw joints on page 377.
• Added Safety risks during handling of batteries on page 37.
• The maximum allowed deviation in levelity of the base plate is changed,
see Securing the base plate on page 76.
• Reference to Hilti standard added to the foundation recommendation
for the base plate and class designation for foundation is changed to
european standard C25/C30 (previously Swedish standard K25/K30),
see Securing the base plate on page 76.
• Corrections and improvements are made in the instruction for how to
replace the axis-2 and axis-3 gearbox, see Replacing the gearbox, axes
2- 3 on page 324.
• All data about type of lubrication in gearboxes is moved from the
manual to a separate lubrication manual, see Type and amount of oil
in gearboxes on page 144.
• Corrected the article number for the o-ring in axis-6 gearbox, see Re-
placement of gearbox, axis 6 on page 336.
H This revision includes the following updates:
• New variant IRB 6660 - 100/3.3 is added.
• Added turning radius and wrist center positions to the working range
information, see Working range and type of motion on page 54.
• New spare part number for the cable harness for robot variant IRB
6660 - 130/3.1, see Spare parts - cable harness.
• Added complete axis 4 and upper arm extenders to the spare part list,
and removed upper arm and cooling elements as spare parts, see
Spare parts - upper arm.
• Corrected the method of inspecting oil level in the axis-6 gearbox, see
Inspecting the oil level in axis-6 gearbox on page 123.
• Added o-rings to required equipment lists in Replacing motor, axis 1
on page 274 and Replacing motors, axes 2 and 3 on page 281.
• Corrected the position numbers of axis-3 motor and its attachments,
see Spare parts - frame to lower arm.
• A new SMB unit and battery is introduced, with longer battery lifetime.

Continued
J This revision includes the following updates:
• Instruction for inspection of oil level updated.
• Added cabling to cooling fan for axis-1 and axis-2 motors.
• Added information about risks when scrapping a decommissioned ro-
bot, see Scrapping of robot on page 369.
• Spare parts and exploded views are not included in this document but
delivered as a separate document. See Product manual, spare
parts - IRB 6660
K This revision includes the following updates:
• The maximum allowed deviation in levelness of the base plate and
foundation is changed, see Securing the base plate on page 76.
• Changed dimension of cable holder carrier screw, see Replacement
of cable harness, upper end on page 196.
• Information about option Foundry Plus implemented in chapter Repair.
• Added tightening torque for R1.SMB and 7th axis connector, ses Re-
placement of cable harness, lower end (axes 1-3) on page 181.
• Minor corrections.
L This revision includes the following updates:
• Illustrations of SMB battery RMU improved.
M This revision includes the following updates:
• New standard calibration method is introduced (Axis Calibration). See
Calibration on page 341.
N Published in release R16.2. The following updates are made in this revision:
• Drawing of base plate is not available for purchase, faulty information
removed in Securing the base plate on page 76.
• Corrections due to updates in terminology.
• Information about grounding point added. See Robot cabling and
connection points on page 104.
P Published in release R17.2. The following updates are made in this revision:
• Caution about removing metal residues added in sections about SMB
boards.
• Information about minimum resonance frequency added.
• Bending radius of static floor cables added.
• Updated list of applicable standards.
• Added text regarding overhaul in section specification of maintenance
intervals.
• Section Start of robot in cold environments on page 107 added.
• Updated information regarding replacement of brake release board.
• Updated information regarding disconnecting and reconnecting battery
cable to serial measurement board.
• Updated information regarding replacing the balancing device.
Q Published in release R18.1. The following updates are made in this revision:
• Information added about fatigue to Axis Calibration tool, see Calibration
tools for Axis Calibration on page 354.
• Added sections in General procedures.
• Safety restructured.
• Updated spare parts number brake release board (is DSQC1050, was
DSQC563)
• Note added to calibration chapter to emphasize the requirement of
equally dressed robot when using previously created reference calib-
ration values.
• Moved position of customer cabling plate at robot base to new location,
see Replacement of process cable package 1 - 3 MH on page 189.

Continued
• Information about myABB Business Portal added.
• Changed direction of installed cooling fan on axis-2 motor and removed
a faulty image showing the design of the cooling fan. Also added de-
tailed images to installation procedure for the fan.
R Published in release R18.2. The following updates are made in this revision:
• Removed doubled information.
S Published in release R18.2. The following updates are made in this revision:
• Updated references.

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.
All documents can be found via myABB Business Portal, www.myportal.abb.com.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.
Technical reference manuals

The technical reference manuals describe reference information for robotics
products, for example lubrication, the RAPID language, and system parameters.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
• What is included (for example cables, I/O boards, RAPID instructions, system
parameters, software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.

Continued
Operating manuals
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.

How to read the product manual
How to read the product manual

Reading the procedures
The procedures contain references to figures, tools, material, and so on. The
references are read as described below.
References to figures
The procedures often include references to components or attachment points
located on the manipulator/controller. The components or attachment points are
marked with italic text in the procedures and completed with a reference to the
figure where the current component or attachment point is shown.
The denomination in the procedure for the component or attachment point
corresponds to the denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a
procedure.
Action Note/Illustration
8. Remove the rear attachment screws, gearbox. Shown in the figure Location of
gearbox on page xx.
References to required equipment

The procedures often include references to equipment (spare parts, tools, etc.)
required for the different actions in the procedure. The equipment is marked with
italic text in the procedures and completed with a reference to the section where
the equipment is listed with further information, that is article number and
dimensions.
The designation in the procedure for the component or attachment point
corresponds to the designation in the referenced list.
The table below shows an example of a reference to a list of required equipment
from a step in a procedure.
3. Fit a new sealing, axis 2 to the gearbox. Art. no. is specified in Required
equipment on page xx.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 19.
Illustrations
The robot is illustrated with general figures that does not take painting or protection
type in consideration.
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.

1 Safety
1.1.1 Limitation of liability
1 Safety
1.1 General safety information
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial robot will not cause injury or damage even if
all safety instructions are complied with.
The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment that can influence the safety of
the entire system.
In particular, liability cannot be accepted if injury/damage has been caused for any
of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed.
• Non-authorized design modifications made in or around the robot.
• Repairs carried out by in-experienced or non-qualified personnel.
• Foreign objects.
• Force majeure.
Nation/region specific regulations

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

The integrator is responsible that the safety devices necessary to protect people
working with the robot system are designed and installed correctly.
When integrating the robot with external devices and machines:
• The supplier of the complete system must ensure that all circuits used in the
safety function are interlocked in accordance with the applicable standards
for that function.
• The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance
with the applicable standards for the emergency stop function.

1 Safety
Continued
The integrator of the final application is required to perform an assessment of the

hazards and risks (HRA).
Note
The integrator is responsible for the safety of the final application.
Safe access
The robot system shall be designed to allow safe access to all areas where
intervention is necessary during operation, adjustment, and maintenance.
Where it is necessary to perform tasks within the safeguarded space there shall
be safe and adequate access to the task locations.
Safety zones, which must be crossed before admittance, must be set up in front
of the robot's working space. Light beams or sensitive mats are suitable devices.
Turntables or the like should be used to keep the operator out of the robot's working
space.
A safety fence is recommended to ensure safeguarded space. Sufficient space
must be provided around the manipulator to protect those working with or on it
from hazards such as crushing.
The fence or enclosure must be dimensioned to withstand the force created if the
load being handled by the robot is dropped or released at maximum speed.
Determine the maximum speed from the maximum velocities of the robot axes and
from the position at which the robot is working in the work cell (see the section
Robot motion in the Product specification).
Also consider the maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the robot.
Safe handling
Users shall not be exposed to hazards, including slipping, tripping, and falling
hazards.
It must be possible to safely turn off tools, such as milling cutters, etc. Make sure
that guards remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
Emergency stop buttons must be positioned in easily accessible places so that
the robot can be stopped quickly. If any of the buttons do not stop all the robot
workcell motion, each emergency stop button must be marked, if more than one
is provided, to indicate its designated safety function.
Grippers/end effectors must be designed so that they do not drop work pieces/tools
in the event of a power failure or a disturbance to the controller.
Unauthorized modifications of the originally delivered robot are prohibited. Without
the consent of ABB, it is forbidden to attach additional parts through welding,
riveting, or drilling of new holes into the castings. The strength of the robot could
be affected.

1 Safety
1.1.2 Protective stop and emergency stop
1.1.2 Protective stop and emergency stop
Overview
The protective stops and emergency stops are described in the product manual
for the controller.

1 Safety
1.2.1 Fire extinguishing
1.2 Safety actions
1.2.1 Fire extinguishing
Note
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the

manipulator or controller.

1 Safety
1.2.2 Emergency release of the robot axes
1.2.2 Emergency release of the robot axes
Description
In an emergency situation, the brakes on a robot axis can be released manually
by pushing a brake release button.
How to release the brakes is described in the section:
• Manually releasing the brakes on page 73.
The robot may be moved manually on smaller robot models, but larger models
may require using an overhead crane or similar equipment.
Increased injury
Before releasing the brakes, make sure that the weight of the robot does not
increase the pressure on the trapped person, further increasing any injury.
DANGER
When releasing the holding brakes, the robot axes may move very quickly and
sometimes in unexpected ways.
Make sure no personnel is near or beneath the robot.

1 Safety
1.2.3 Make sure that the main power has been switched off
1.2.3 Make sure that the main power has been switched off
Description
Working with high voltage is potentially lethal. Persons subjected to high voltage
may suffer cardiac arrest, burn injuries, or other severe injuries. To avoid these
personal injuries, switch off the main power on the controller before proceeding
work.
Note
Switch off all main power switches in a MultiMove system.

1 Safety
1.3.1 Safety risks during installation and service work on robots
1.3 Safety risks
Requirements on personnel
Only persons who know the robot and are trained in the operation and handling
of the robot are allowed to maintain the robot. Persons who are under the influence
of alcohol, drugs or any other intoxicating substances are not allowed to install,
maintain, repair, or use the robot.
• Those in charge of operations must make sure that safety instructions are
available for the installation in question.
• Those who install or service/maintain the robot must have the appropriate
training for the equipment in question and in any safety matters associated
with it.
• Personnel should be trained on responding to emergency or abnormal
situations.
General risks during installation and service

The instructions in the product manual must always be followed.
Never turn the power on to the robot before it is properly fixed and bolted to its
foundation/support.
Make sure that no one else can turn on the power to the controller and robot while
you are working with the system. A good method is to always lock the main switch
on the controller cabinet with a safety lock.
you are working with the system. A good method is to remove the power cable to
the controller.
If the robot is installed at a height, hanging, or other than standing directly on the
floor, there may be additional risks than those for a robot standing directly on the
floor.
Energy stored in the robot for the purpose of counterbalancing certain axes may
be released if the robot, or parts thereof, are dismantled.
Never use the robot as a ladder, which means, do not climb on the controller,
motors, or other parts during service work. There is a risk of slipping because of
the high temperature of the motors and oil spills that can occur on the robot. There
is also a risk of the robot being damaged.
To avoid damaging the product, make sure that there are no loose screws, turnings,
or other parts inside the product after work has been performed.
Safety risks during operational disturbances

Corrective maintenance must only be carried out by qualified personnel who are
familiar with the entire installation as well as the special risks associated with its
different parts.

1 Safety
Continued
If the working process is interrupted, extra care must be taken due to risks other
than those associated with regular operation. Such an interruption may have to be
rectified manually.
Spare parts and special equipment

ABB does not supply spare parts and special equipment which have not been
tested and approved by ABB. The installation and/or use of such products could
negatively affect the structural properties of the robot and as a result of that affect
the active or passive safety operation. ABB is not liable for damages caused by
the use of non-original spare parts and special equipment. ABB is not liable for
damages or injuries caused by unauthorized modifications to the robot.
Connection of external safety devices

Apart from the built-in safety functions, the robot is also supplied with an interface
for the connection of external safety devices. An external safety function can
interact with other machines and peripheral equipment via this interface. This
means that control signals can act on safety signals received from the peripheral
equipment as well as from the robot.
Personal protective equipment

Always use suitable personal protective equipment, based on the risk assessment
for the installation.
Allergenic material
See Environmental information on page 368 for specification of allergenic materials
in the product, if any.

1 Safety
1.3.2 Moving robots are potentially lethal
1.3.2 Moving robots are potentially lethal
Description
Any moving robot is a potentially lethal machine.
When running, the robot may perform unexpected and sometimes irrational
movements. Moreover, all movements are performed with great force and may
seriously injure any personnel and/or damage any piece of equipment located
within the working range of the robot.
Safe handling
Action Note
1 Before attempting to run the robot, make Emergency stop equipment such as gates,
sure all emergency stop equipment is cor- tread mats, light curtains, etc.
rectly installed and connected.
2 Usually the hold-to-run function is active How to use the hold-to-run function is de-
only in manual full speed mode. To in- scribed in section How to use the hold-to-
crease safety it is also possible to activate run function in the Operating manual - IRC5
hold-to-run for manual reduced speed with with FlexPendant.
a system parameter.
The hold-to-run function is used in manual
mode, not in automatic mode.
3 Make sure no personnel are present within
the working range of the robot before
pressing the start button.

1 Safety
1.3.3 First test run may cause injury or damage
1.3.3 First test run may cause injury or damage
Description
After installation and performing service activities, there are several safety risks
to take into consideration before the first test run.
Safe handling
Use this procedure when performing the first test run after installation, maintenance,
or repair.
DANGER
Running the robot without fulfilling the following aspects, may involve a risk of
injury and cause severe damage to the robot.
Action
1 Remove all tools and foreign objects from the robot and its working area.
2 Verify that the robot is properly secured to its position by all screws, before it is powered
up.
3 Verify that any safety equipment installed to secure the position or restrict the robot
motion during service activity is removed.
4 Verify that the fixture and work piece are well secured, if applicable.
5 Install all safety equipment properly.
6 Make sure all personnel are standing at a safe distance from the robot, and is out of
its reach behind safety fences, or similar.
7 If maintenance or repair has been done, pay special attention to the function of the
part that was serviced.
Collision risks
CAUTION
When programming the movements of the robot, always identify potential collision
risks before the first test run.

1 Safety
1.3.4 Work inside the working range of the robot
1.3.4 Work inside the working range of the robot
WARNING
If work must be carried out within the work area of the robot, then the following
points must be observed:
• The operating mode selector on the controller must be in the manual mode
position to render the three-position enabling device operational and to block
operation from a computer link or remote control panel.
• The maximum speed of the robot is limited to 250 mm/s when the operating
mode selector is in the position Manual mode with reduced speed. This
should be the normal position when entering the working space.
The position Manual mode with full speed (100%) may only be used by
trained personnel who are aware of the risks that this entails. Manual mode
with full speed (100%) is not available in USA or Canada.
• Pay attention to the rotating axes of the robot. Keep away from axes to not
get entangled with hair or clothing. Also, be aware of any danger that may
be caused by rotating tools or other devices mounted on the robot or inside
the cell.
• Keep clear of moving parts so that limbs, hands, or fingers do not get trapped
or crushed by the robot.
• To prevent anyone else from taking control of the robot, always put a safety
lock on the cell door and bring the three-position enabling device with you
when entering the working space.
WARNING
NEVER, under any circumstances, stay beneath any of the robot's axes! There
is always a risk that the robot will move unexpectedly when robot axes are moved
using the three-position enabling device or during other work inside the working
range of the robot.

1 Safety
1.3.5 Enabling device and hold-to-run functionality
1.3.5 Enabling device and hold-to-run functionality
Three-position enabling device

The three-position enabling device is a manually operated, constant pressure
push-button which, when continuously activated in one position only, allows
potentially hazardous functions but does not initiate them. In any other position,
hazardous functions are stopped safely.
The three-position enabling device is of a specific type where you must press the
push-button only half-way to activate it. In the fully in and fully out positions,
operating the robot is impossible.
Note
The three-position enabling device is a push-button located on the teach pendant

which, when pressed halfway in, switches the system to MOTORS ON. When
the enabling device is released or pushed all the way in, the manipulator switches
to the MOTORS OFF state.
To ensure safe use of the teach pendant, the following must be implemented:
• The enabling device must never be rendered inoperational in any way.
• During programming and testing, the enabling device must be released as
soon as there is no need for the robot to move.
• Anyone entering the working space of the robot must always hold the teach
pendant. This is to prevent anyone else from taking control of the robot
without his/her knowledge.
Hold-to-run function
The hold-to-run function allows movement when a button connected to the function
is actuated manually and immediately stops any movement when released. The
hold-to-run function can only be used in manual mode.
How to operate the hold-to-run function for IRC5 is described in Operating
manual - IRC5 with FlexPendant.

1 Safety
1.3.6 Risks associated with live electric parts
Voltage related risks, general

Work on the electrical equipment of the robot must be performed by a qualified
electrician in accordance with electrical regulations.
Although troubleshooting may, on occasion, need to be carried out while the power
supply is turned on, the robot must be turned off (by setting the main switch to
OFF) when repairing faults, disconnecting electric leads, and disconnecting or
connecting units.
The main supply to the robot must be connected in such a way that it can be turned
off from outside the working space of the robot.
you are working with the system. A good method is to always lock the main switch
on the controller cabinet with a safety lock.
The necessary protection for the electrical equipment and robot during installation,
commissioning, and maintenance is guaranteed if the valid regulations are followed.
Voltage related risks, IRC5 controller

A danger of high voltage is associated with, for example, the following parts:
• Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in
the controller.
• Units such as I/O modules, can be supplied with power from an external
source.
• The main supply/main switch
• The transformers
• The power unit
• The control power supply (230 VAC)
• The rectifier unit (262/400-480 VAC and 400/700 VDC. Note: capacitors!)
• The drive unit (400/700 VDC)
• The drive system power supply (230 VAC)
• The service outlets (115/230 VAC)
• The customer power supply (230 VAC)
• The power supply unit for additional tools, or special power supply units for
the machining process.
• The external voltage connected to the controller remains live even when the
robot is disconnected from the mains.
• Additional connections.
Voltage related risks, manipulator

A danger of low voltage is associated with the manipulator in:
• The power supply for the motors (up to 800 VDC).
• The user connections for tools or other parts of the installation (max. 230
VAC).

1 Safety
Continued
Voltage related risks, tools, material handling devices, etc.

Tools, material handling devices, etc., may be live even if the robot system is in
the OFF position. Power supply cables which are in motion during the working
process may be damaged.

1 Safety
1.3.7 The unit is sensitive to ESD
1.3.7 The unit is sensitive to ESD
Description
ESD (electrostatic discharge) is the transfer of electrical static charge between two
bodies at different potentials, either through direct contact or through an induced
electrical field. When handling parts or their containers, personnel not grounded
may potentially transfer high static charges. This discharge may destroy sensitive
electronics.
Safe handling
Action Note
1 Use a wrist strap. The wrist strap Wrist straps must be tested frequently to ensure
button is located inside the control- that they are not damaged and are operating cor-
ler. rectly.
• Product manual - IRC5
2 Use an ESD protective floor mat. The mat must be grounded through a current-limit-
ing resistor.
3 Use a dissipative table mat. The mat should provide a controlled discharge of
static voltages and must be grounded.

1 Safety
1.3.8 Hot parts may cause burns
1.3.8 Hot parts may cause burns
Description
During normal operation, many parts become hot. Touching these may cause
burns.
There is also a risk of fire if flammable materials are put on hot surfaces.
Safe handling
Always use your hand, at some distance, to feel if heat is radiating from the
potentially hot component before actually touching it.
Wait until the potentially hot component has cooled if it is to be removed or handled
in any other way.
Do not put anything on hot metal surfaces, e.g. paper or plastic.

1 Safety
1.3.9 Safety risks related to pneumatic/hydraulic systems
1.3.9 Safety risks related to pneumatic/hydraulic systems
General
Special safety regulations apply to pneumatic and hydraulic systems.
Note
All components that remain pressurized after separating the machine from the
power supply must be provided with clearly visible drain facilities and a warning
sign that indicates the need for pressure relief before adjustments or performing
any maintenance on the robot system.
Residual energy
Residual energy can be present in these systems. After shutdown, particular care
must be taken.
The pressure must be released in the complete pneumatic or hydraulic systems
before starting to repair them.
Work on hydraulic equipment may only be performed by persons with special
knowledge and experience of hydraulics.
All pipes, hoses, and connections have to be inspected regularly for leaks and
damage. Damage must be repaired immediately.
Splashed oil may cause injury or fire.
Safe design
Gravity may cause any parts or objects held by these systems to drop.
Dump valves should be used in case of emergency.
Shot bolts should be used to prevent tools, etc., from falling due to gravity.

1 Safety
1.3.10 Brake testing
1.3.10 Brake testing
When to test
During operation, the holding brake of each axis normally wears down. A test can
be performed to determine whether the brake can still perform its function.
How to test
The function of the holding brake of each axis motor may be verified as described
below:
1 Run each robot axis to a position where the combined weight of the robot
arm and any load is maximized (maximum static load).
2 Switch the motor to the MOTORS OFF.
3 Inspect and verify that the axis maintains its position.
If the robot does not change position as the motors are switched off, then
the brake function is adequate.

1 Safety
1.3.11 Safety risks during handling of batteries
1.3.11 Safety risks during handling of batteries
Description
Under normal conditions of use, the electrode materials and liquid electrolyte in
the batteries are not exposed to the outside, provided the battery integrity is
maintained and seals remain intact.
There is a risk of exposure only in case of abuse (mechanical, thermal, electrical)
which leads to the activation of safety valves and/or the rupture of the battery
container. Electrolyte leakage, electrode materials reaction with moisture/water or
battery vent/explosion/fire may follow, depending upon the circumstances.
Note
Appropriate disposal regulations must be observed.
Safe handling
Use safety glasses when handling the batteries.
In the event of leakage, wear rubber gloves and chemical apron.
In the event of fire, use self-contained breathing apparatus.
Do not short circuit, recharge, puncture, incinerate, crush, immerse, force discharge
or expose to temperatures above the declared operating temperature range of the
product. Risk of fire or explosion.
Operating temperatures are listed in Pre-installation procedure on page 50.

1 Safety
1.3.12 Safety risks during work with gearbox lubricants (oil or grease)
Description
When handling gearbox lubricants, there is a risk of both personal injury and
product damage occurring. The following safety information must be regarded
before performing any work with lubricants in the gearboxes.
Note
When handling oil, grease, or other chemical substances the safety information
of the manufacturer must be observed.
Note
When aggressive media is handled, an appropriate skin protection must be

provided. Gloves and goggles are recommended.
Note
Appropriate disposal regulations must be observed.
Note
Take special care when handling hot lubricants.
Safe handling
Warning Description Elimination/Action

Changing and draining gearbox Make sure that protective gear
oil or grease may require hand- like goggles and gloves are al-
ling hot lubricant heated up to ways worn during this activity.
90 °C.
Hot oil or grease
When working with gearbox lub- Make sure that protective gear
ricant there is a risk of an allergic like goggles and gloves are al-
reaction. ways worn.
Allergic reaction
When opening the oil or grease Open the plug carefully and keep
plug, there may be pressure away from the opening. Do not
present in the gearbox, causing overfill the gearbox when filling.
lubricant to spray from the
opening.
Possible pressure
build-up in gearbox

1 Safety
Continued
Warning Description Elimination/Action

Overfilling of gearbox lubricant Make sure not to overfill the
can lead to internal over-pres- gearbox when filling it with oil or
sure inside the gearbox which in grease.
turn may: After filling, verify that the level
• damage seals and gas- is correct.
Do not overfill kets
• completely press out
seals and gaskets
• prevent the robot from
moving freely.
Mixing types of oil may cause When filling gearbox oil, do not
severe damage to the gearbox. mix different types of oil unless
specified in the instructions. Al-
ways use the type of oil specified
by the manufacturer.
Do not mix types of oil
Warm oil drains quicker than When changing gearbox oil, first
cold oil. run the robot for a time to heat
up the oil.
Heat up the oil

The specified amount of oil or After filling, verify that the level
grease is based on the total is correct.
volume of the gearbox. When
changing the lubricant, the
amount refilled may differ from
the specified amount, depending
Specified amount de- on how much has previously
pends on drained been drained from the gearbox.
volume
When draining the oil make sure
that as much oil as possible is
drained from the gearbox. The
reason for this is to drain as
much oil sludge and metal chips
as possible from the gearbox.
The magnetic oil plugs will take
Contaminated oil in care of any remaining metal
gear boxes chips.

1 Safety
1.4.1 Safety signals in the manual
1.4 Safety signals and symbols
Introduction to safety signals

This section specifies all safety signals used in the user manuals. Each signal
consists of:
• A caption specifying the danger level (DANGER, WARNING, or CAUTION)
and the type of danger.
• A brief description of what will happen if the the danger is not eliminated.
• Instruction about how to eliminate danger to simplify doing the work.
Danger levels
The table below defines the captions specifying the danger levels used throughout
this manual.
Symbol Designation Significance
DANGER Warns that an accident will occur if the instructions
are not followed, resulting in a serious or fatal injury
and/or severe damage to the product. It applies to
warnings that apply to danger with, for example,
contact with high voltage electrical units, explosion
or fire risk, risk of poisonous gases, risk of crushing,
impact, fall from height, and so on.
WARNING Warns that an accident may occur if the instructions
are not followed that can lead to serious injury, pos-
sibly fatal, and/or great damage to the product. It
applies to warnings that apply to danger with, for
example, contact with high voltage electrical units,
explosion or fire risk, risk of poisonous gases, risk
of crushing, impact, fall from height, etc.
ELECTRICAL Warns for electrical hazards which could result in
SHOCK severe personal injury or death.
CAUTION Warns that an accident may occur if the instructions

are not followed that can result in injury and/or
damage to the product. It also applies to warnings
of risks that include burns, eye injury, skin injury,
hearing damage, crushing or slipping, tripping, im-
pact, fall from height, etc. Furthermore, it applies to
warnings that include function requirements when
fitting and removing equipment where there is a risk
of damaging the product or causing a breakdown.
ELECTROSTATIC Warns for electrostatic hazards which could result
DISCHARGE (ESD) in severe damage to the product.

1 Safety
Continued
Symbol Designation Significance

NOTE Describes important facts and conditions.
TIP Describes where to find additional information or

how to do an operation in an easier way.

1 Safety
1.4.2 Safety symbols on product labels
Introduction to labels
This section describes safety symbols used on labels (stickers) on the product.
Symbols are used in combinations on the labels, describing each specific warning.
The descriptions in this section are generic, the labels can contain additional
information such as values.
Note
The safety and health symbols on the labels on the product must be observed.
Additional safety information given by the system builder or integrator must also
be observed.
Types of labels
Both the manipulator and the controller are marked with several safety and
information labels, containing important information about the product. The
information is useful for all personnel handling the robot, for example during
installation, service, or operation.
The safety labels are language independent, they only use graphics. See Symbols
on safety labels on page 42.
The information labels can contain information in text (English, German, and
French).
Symbols on safety labels
Symbol Description
Warning!
Warns that an accident may occur if the instructions are not
followed that can lead to serious injury, possibly fatal, and/or
great damage to the product. It applies to warnings that apply
xx0900000812
to danger with, for example, contact with high voltage electrical
units, explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height, etc.
Caution!
Warns that an accident may occur if the instructions are not
followed that can result in injury and/or damage to the product.
It also applies to warnings of risks that include burns, eye injury,
skin injury, hearing damage, crushing or slipping, tripping, im-
xx0900000811 pact, fall from height, etc. Furthermore, it applies to warnings
that include function requirements when fitting and removing
equipment where there is a risk of damaging the product or
causing a breakdown.
Prohibition
Used in combinations with other symbols.
xx0900000839

1 Safety
Continued
Symbol Description
See user documentation
Read user documentation for details.
Which manual to read is defined by the symbol:
• No text: Product manual.
• EPS: Application manual - Electronic Position Switches.
xx0900000813
Before disassemble, see product manual
xx0900000816
Do not disassemble
Disassembling this part can cause injury.
xx0900000815
Extended rotation
This axis has extended rotation (working area) compared to
standard.
xx0900000814
Brake release
Pressing this button will release the brakes. This means that
the robot arm can fall down.
xx0900000808

1 Safety
Continued
Symbol Description
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

1 Safety
Continued
Symbol Description
Heat
Risk of heat that can cause burns. (Both signs are used)
xx0900000818
!
3HAC 4431-1/06
xx1300001087
Moving robot
4 6 The robot can move unexpectedly.
3 5
1
xx0900000819
xx1000001141
2 3
xx1500002616

1 Safety
Continued
Symbol Description
Brake release buttons
xx0900000820
xx1000001140
Lifting bolt
xx0900000821
Chain sling with shortener
xx1000001242
Lifting of robot
xx0900000822
Oil
Can be used in combination with prohibition if oil is not allowed.
xx0900000823
Mechanical stop
xx0900000824

1 Safety
Continued
Symbol Description
No mechanical stop
xx1000001144
Stored energy
Warns that this part contains stored energy.
Used in combination with Do not disassemble symbol.
xx0900000825
Pressure
Warns that this part is pressurized. Usually contains additional
text with the pressure level.
xx0900000826
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

2 Installation and commissioning
2.1 Introduction

2.1 Introduction
General
This chapter contains assembly instructions and information for installing the IRB
6660 at the working site.
More detailed technical data can be found in the Product specification for the IRB
6660, such as:
• Load diagram
• Permitted extra loads (equipment), if any
• Location of extra loads (equipment), if any.
Safety information
Before any installation work is commenced, it is extremely important that all safety
information is observed.
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 19 before performing any installation
work.
Note
If the IRB 6660 is connected to power, always make sure that the robot is
connected to protective earth before starting any installation work.
For more information see:

2.2.1 Pre-installation procedure
2.2 Unpacking
Introduction
This section is intended for use when unpacking and installing the robot for the
first time. 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.
Checking the pre-requisites for installation
Action
1 Make a visual inspection of the packaging and make sure that nothing is damaged.
2 Remove the packaging.
3 Check for any visible transport damage.
Note
Stop unpacking and contact ABB if transport damages are found.
4 Clean the unit with a lint-free cloth, if necessary.

5 Make sure that the lifting accessory used (if required) is suitable to handle the weight
of the robot as specified in: Weight, robot on page 50
6 If the robot is not installed directly, it must be stored as described in: Storage condi-
tions, robot on page 53
7 Make sure that the expected operating environment of the robot conforms to the
specifications as described in: Operating conditions, robot on page 53
8 Before taking the robot to its installation site, make sure that the site conforms to:
• Loads on foundation, robot on page 51
• Protection classes, robot on page 53
• Requirements, foundation on page 52
9 Before moving the robot, please observe the stability of the robot: Risk of tipping/sta-
bility on page 58
10 When these prerequisites are met, the robot can be taken to its installation site as
described in section: On-site installation on page 60
11 Install required equipment, if any.
• Signal lamp (option) on page 99
Weight, robot
The table shows the weight of the robot.
Robot model Weight
IRB 6660 1950 kg

Continued
Note
The weight does not include tools and other equipment fitted on the robot.
Loads on foundation, robot

The illustration shows the directions of the robots stress forces.
The directions are valid for all floor mounted, suspended and inverted robots.
Txy
Fz
Fxy
Tz
xx1100000521
Fxy Force in any direction in the XY plane

Fz Force in the Z plane
Txy Bending torque in any direction in the XY plane
Tz Bending torque in the Z plane
The table shows the various forces and torques working on the robot during different
kinds of operation.
Note
These forces and torques are extreme values that are rarely encountered during
operation. The values also never reach their maximum at the same time!
WARNING
The robot installation is restricted to the mounting options given in following load
table(s).

Continued
Floor mounted
Force Endurance load (in operation) Max. load (emergency stop)

Force xy ± 7.6 kN (IRB 6660 - 100/3.3) ± 12.8 kN (IRB 6660 - 100/3.3)
± 8.5 kN (IRB 6660 - 130/3.1) ± 16.1 kN (IRB 6660 - 130/3.1)
± 7.9 kN (IRB 6660 - 205/1.9) ± 14.9 kN (IRB 6660 - 205/1.9)
Force z 18.5 ± 3.7 kN (IRB 6660 - 100/3.3) 18.5 ± 7.4 kN (IRB 6660 - 100/3.3)
18.8 ± 8.4 kN (IRB 6660 - 130/3.1) 18.8 ±12.8 kN (IRB 6660 - 130/3.1)
18.0 ± 4.4 kN (IRB 6660 - 205/1.9) 18.0 ±7.7 kN (IRB 6660 - 205/1.9)
Torque xy ± 24.4 kNm (IRB 6660 - 100/3.3) ± 33.4 kNm (IRB 6660 - 100/3.3)
± 25.6 kNm (IRB 6660 - 130/3.1) ± 37.2 kNm (IRB 6660 - 130/3.1)
± 19.6 kNm (IRB 6660 - 205/1.9) ± 32.4 kNm (IRB 6660 - 205/1.9)
Torque z ± 7.6 kNm (IRB 6660 - 100/3.3) ± 14.5 kNm (IRB 6660 - 100/3.3)
± 10.3 kNm (IRB 6660 - 130/3.1) ± 19.3 kNm (IRB 6660 - 130/3.1)
± 7.1 kNm (IRB 6660 - 205/1.9) ± 14.7 kNm (IRB 6660 - 205/1.9)
Requirements, foundation
The table shows the requirements for the foundation where the weight of the
installed robot is included:
Requirement Value Note
Flatness of foundation 0.3 mm Flat foundations give better repeatability of the
surface resolver calibration compared to original settings
on delivery from ABB.
The value for levelness aims at the circumstance
of the anchoring points in the robot base.
In order to compensate for an uneven surface,
the robot can be recalibrated during installation.
If resolver/encoder calibration is changed this
will influence the absolute accuracy.
Maximum tilt 5°
Minimum resonance 22 Hz The value is recommended for optimal perform-
frequency ance.
Note Due to foundation stiffness, consider robot mass
including equipment. i
It may affect the For information about compensating for founda-
manipulator life- tion flexibility, see Application manual - Control-
time to have a ler software IRC5, section Motion Process Mode.
lower resonance
frequency than
recommended.
i The minimum resonance frequency given should be interpreted as the frequency of the robot
mass/inertia, robot assumed stiff, when a foundation translational/torsional elasticity is added, i.e.,
the stiffness of the pedestal where the robot is mounted. The minimum resonance frequency should
not be interpreted as the resonance frequency of the building, floor etc. For example, if the equivalent
mass of the floor is very high, it will not affect robot movement, even if the frequency is well below
the stated 25 Hz. The robot should be mounted as rigid as possibly to the floor.
Disturbances from other machinery will affect the robot and the tool accuracy. The robot has
resonance frequencies in the region 10 – 20 Hz and disturbances in this region will be amplified,
although somewhat damped by the servo control. This might be a problem, depending on the
requirements from the applications. If this is a problem, the robot needs to be isolated from the
environment.

Continued
Storage conditions, robot

The table shows the allowed storage conditions for the robot:
Parameter Value
Minimum ambient temperature -25° C
Maximum ambient temperature +55° C
Maximum ambient temperature (less than 24 hrs) +70° C
Maximum ambient humidity 95% at constant temperature
(gaseous only)
Operating conditions, robot

The table shows the allowed operating conditions for the robot:
Parameter Value
Minimum ambient temperature +5° C
Maximum ambient temperature +50° C i
Maximum ambient humidity 95% at constant temperature
i In a high speed presstending application, max ambient temperature is +40° C.
Protection classes, robot

The table shows the available protection types of the robot, with the corresponding
protection class.
Protection type Protection class
Manipulator, protection type Standard IP 67
Manipulator, protection type Foundry Plus IP 67

2.2.2 Working range and type of motion
Working range
The following figures show the working ranges of the robot variants. The extreme
positions of the robot arm are specified at the wrist center (dimensions in mm).
IRB 6660 - 100/3.3

1211 (A) 997
1131 (B) 1755,5 200

B
G
A
2834
1125
2629
2958
2501
3092 (C)
2374,5
C
1189
814,5
742
D
23
300
734
851
645
E
940
3343
xx1200000979
(A) Mechanical stop

(B) Max. working range
(C) Max. working range
Positions at wrist center
Position num- X position (mm) Z position (mm) Axis 2 angle (de- Axis 3 angle (de-
ber, see figure grees) grees)
above
A 2055.5 2374,5 0 0
B 997 2629 -42 -20
C 1125 1189 -42 28
D 645 -23 50 120
E 940 -734 85 120
F 3343 742 85 15
G 2834 2501 50 -20

Continued
IRB 6660 - 130/3.1

1619
Z
1211 (A) 763
1131 (B) 1505.5 200
B
G
A
3005 (C)
2596
2873
904
C
2544
2375
2415
F
1306
814.5
807
194
D
X
300
605.3
518
770
E
1065
3102
1575
xx1000000662
(A) Max. working range

(B) Mechanical stop
(C) Max. working range
above
A 1805.5 2374.5 0 0
B 763 2544 -42 -20
C 904 1306 -42 28
D 770 194 50 120
E 1065 -518 85 120
F 3102 807 85 15
G 2596 2415 50 -20

Continued
IRB 6660 - 205/1.9
xx1000000663
(A) Max. working range

(B) Max. working range
above
A 1193 1794.5 0 0
B 575 1903.2 -42 -20
C 751.5 1162.7 -42 28
D 632.2 351.1 50 120
E 793.3 -37.9 85 120
F 1932.4 914.8 85 15
G 1579.6 1833 50 -20
H 1043.4 2083.2 0 -20
K 997.3 -60.4 85 107.4

Continued
Type of motion
Axis Type of motion Range of movement Note

1 Rotation motion +180° to -180°
2 Arm motion +85° to -42°
3 Arm motion +120° to -20°
2-3 Arm motion +20° to +160°
4 Wrist motion +300° to -300°
5 Bend motion +120° to -120°
6 Turn motion +300° to -300°
Turning radius
xx1200000980
Robot variant Radius A (axis-3 motor) Radius B

IRB 6660 - 100/3.3 710 mm 3343 mm
IRB 6660 - 130/3.1 710 mm 3102 mm
IRB 6660 - 205/1.9 710 mm 1932 mm

2.2.3 Risk of tipping/stability
Risk of tipping
If the robot is not fastened to the foundation while moving the arm, the robot is not
stable in the whole working area. Moving the arm will displace the center of gravity,
which may cause the robot to tip over.
The shipping position is the most stable position.
Do not change the robot position before securing it to the foundation!
Shipping and transportation position

This figure shows the robot in its shipping position and transportation position.
42°
28°
xx0700000001
A IRB 6660 - 130/3.1, IRB 6660 - 100/3.3

B IRB 6660 - 205/1.9

Continued
WARNING
The robot is likely to be mechanically unstable if not secured to the foundation.

2.3.1 Lifting robot with fork lift
2.3 On-site installation
General
The robot may be moved using a fork lift, provided that available special aids are
used.
This section describes how to attach the fork lift equipment to the robot.
Attachment points on robot

The attachment points for the fork lift equipment are shown in this figure.
xx0500002276
A Attachment points on adapter and horizontal attachment screws

B Attachment points, horizontal attachment screws
C Attachment points, vertical attachment screws
Required equipment
Equipment, etc. Art. no. Note

Fork lift set, incl. all required 3HAC023044-001 See figure Fork lift set, 3HAC023044-001
hardware on page 61.
Standard toolkit - Content is defined in section Standard
tools on page 381.

Continued
Fork lift set, 3HAC023044-001

The fork lift set 3HAC023044-001, is fitted to the robot as shown in the figure below.
xx0500002277
A Fork lift pocket (2 pcs, one long and one short)

B Adapter (2 pcs)
C Horizontal attachment screws (4 pcs / fork lift pocket)
D Attachment screw for adapter (1 pc / adapter)
E Vertical attachment screws (2 pcs)

Continued
Lifting robot with fork lift

This section details how to secure the fork lift set to the robot in order to lift and
move the robot using the fork lift ONLY!
Action Note
1 If a cooling fan for the axis 1 motor is used, it
must be removed in order to use the fork lift
device!
2 Position the robot as shown in the figure to the Release the brakes if required as de-
right! tailed in section Manually releasing the
brakes on page 73.
xx0700000517
• A: IRB 6660 - 100/3.3, IRB 6660

- 130/3.1
• B: IRB 6660 - 205/1.9
3 Fit the two adapters to the robot and secure. Attachment points are shown in figure
Attachment points on robot on page 60.
Attachment screws, 2 pcs, M16 x 90.
Tightening torque: 270 Nm.

Continued
Action Note
4 Strap up axis 2 motor cable on the adapter.
xx0500002278
• A: Strap, velcro
5
CAUTION
The fork lift pocket weighs 60 kg!
6 Secure the longer fork lift pocket to the adapter Always use original screws (or replace-
and frame with four of the horizontal attachments of equivalent quality: M16, qual-
ment screws and washers. ity 12.9)!
Attachment points on the robot are
Note
shown in figure Attachment points on
robot on page 60.
The screws, which are attached horizontally
and vertically, are identical. However, they are
tightened with different torque!
xx0500002279
A Horizontal attachment screws, 4

pcs, M16 x 60. Tightening torque:
60 Nm.
B Adapter

Continued
Action Note
7 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
8 Secure fork lift pocket to robot with two vertical
attachment screws and washers.
Note
Vertically and the horizontally attached screws

are identical, but tightened with different
torques!
xx0500002284
A Vertical attachment screws, 2

pcs, M16x60. Tightening torque:
270 Nm.
Always use original screws (or replace-
ments of equivalent quality: M16, qual-
ity 12.9)!
Attachment points on robot are shown
in figure Attachment points on robot on
page 60.
9
CAUTION
The fork lift pocket weighs 22 kg!
10 Secure the shorter fork lift pocket on the other 4 pcs, M16x60.
side of the robot with the four remaining hori- Tightening torque: 60 Nm.
zontal attachment screws.
Always use original screws (or replace-
ments of equivalent quality: M16, qual-
ity 12.9)!
Attachment points on robot are shown
in figure Attachment points on robot on
page 60.
11 Double-check that pockets are properly se-
cured to the robot! Insert fork lift forks into the
pockets.

Continued
Action Note
12
CAUTION Note
The IRB 6660 robot weighs 1950 kg. If the robot is equipped with fork lift
All lifting accessories used must be sized ac- pockets an extra weight of 90 kg must
cordingly! be added to the robot weight!
13 Carefully lift the robot and move it to its install-

ation site.
14
WARNING
Personnel must not, under any circumstances,

be present under the suspended load!
15 Refit the cooling fan to the motor, if any.

2.3.2 Lifting robot with roundslings
General
The robot can be lifted with roundslings according to this section.
Sling specification
Sling type Qty Lifting capacity Length / Note

Roundsling, robot 3 pcs 3 000 kg 2m
Lifting with roundslings
Action Note
1 Position robot in a secure transport position.
2 Attach roundslings to robot according to fig-
ure Attachment points on page 66.
3
Note
Make sure that the roundslings do not lie

against sensitive parts, for example harness
and customer equipment!
4 When attaching the roundsling A on the up- Shown in the figure Attachment points
per arm, put it in a U-shape through the hole on page 66.
in the wrist.
5
CAUTION Note
All lifting accessories used must be sized pockets an extra weight of 90 kg must be
accordingly! added to the robot weight!
6
WARNING
Personnel must not, under any circum-

stances, be present under the suspended
load!
Attachment points
This figure shows how to attach the roundslings to the robot.

Continued
The illustration is similar with the label attached to the robot’s lower arm.
IRB 6660 - 130/3.1, IRB 6660 - 100/3.3
xx0700000002
A Roundsling 2 m
B Roundsling 2 m
C Roundsling 2 m

Continued
IRB 6660 - 205/1.9
xx0700000426
A Roundsling 2 m
B Roundsling 2 m
C Roundsling 2 m

2.3.3 Lifting robot with lifting slings
General
This section contains a general overview of how to lift the complete robot using
special lifting equipment. More detailed instructions are included with the equipment.
Note
Move the robot to the recommended position shown in the figure and in the
instruction!
Attempting to lift a robot in any other position may result in the robot tipping
over, causing severe damage or injury!

Continued
Illustration, lifting slings

The figure below shows how to lift the complete robot with lifting slings.
IRB 6660 - 130/3.1, IRB 6660 - 100/3.3
xx0700000004
A Load hook
B Swivelling lifting eyes, 4 pcs
C Shortening hook
D Chain
E Lifting eye, M12
F Eye for lifting accessory
I Lifting slings, 4 pcs
L Hook

Continued
IRB 6660 - 205/1.9
xx0700000427
A Load hook
B Swivelling lifting eyes, 4 pcs
C Shortening hook
D Chain
E Lifting eye, M12
F Eye for lifting accessory
J Lifting slings, 4 pcs
L Hook

Continued
Required equipment
Equipment Article number Note

Lifting accessory, robot 3HAC15607-1 Includes user instructions 3HAC15971-2
Slings attached directly onto robot

This section details how to lift and move the robot using lifting slings when these
are attached directly onto the robot frame.
Action Note
1 Run the overhead crane to a position above
the robot.
2 Position the robot as detailed in enclosed in- Article number is specified in Required
struction! equipment on page 72.
Release the brakes, if required, as de-
tailed in section Manually releasing the
brakes on page 73.
3 Shown in the figure Illustration, lifting
Note slings on page 70.
If the robot is equipped with forklift pockets,

it is necessary to remove these in order to
reach the lower holes in the frame. These are
used to attach the hooks of the lifting slings.
4 Fit the lifting accessory to the robot as de- Article number is specified in Required
scribed in the enclosed instruction! equipment on page 72.
5
CAUTION Note
All lifting accessories used must be sized ac- pockets an extra weight of 90 kg must
cordingly! be added to the robot weight!
6
WARNING
Personnel must not, under any circumstances,

be present under the suspended load!
7 Raise overhead crane to lift the robot. Make sure all hooks and attachments
maintain their correct positions while
lifting the robot!
Always move the robot at very low
speeds, making sure it does not tip.

2.3.4 Manually releasing the brakes
Introduction to manually releasing the brakes

This section describes how to release the holding brakes for the motors of each
axis.
Location of brake release unit

The internal brake release unit is located as shown in the figure.
xx0700000005
Releasing the brakes

This procedure details how to release the holding brakes when the robot is equipped
with an internal brake release unit.
Action Note
1 The internal brake release unit is equipped with Buttons are shown in figure Loca-
buttons for controlling the axes brakes. The buttons tion of brake release unit on
are numbered according to the numbers of the page 73.
axes.
If the robot is not connected to the controller, power
must be supplied to the connector R1.MP according
to the section Supplying power to connector R1.MP
on page 74.
2
DANGER
When releasing the holding brakes, the robot axes

may move very quickly and sometimes in unexpec-
ted ways.
Make sure no personnel is near or beneath the ro-
bot.
3 Release the holding brake on a particular robot

axis by pressing the corresponding button on the
internal brake release unit.
The brake will function again as soon as the button
is released.

Continued
Supplying power to connector R1.MP

If the robot is not connected to the controller, power must be supplied to connector
R1.MP on the robot, in order to enable the brake release buttons.
Action Note
1
DANGER
Incorrect connections, such as supplying

power to the wrong pin, may cause all
brakes to be released simultaneously!
2 Supply 0V on pin 12 and 24V on pin 11.
xx0600002937

2.3.5 Lifting the base plate
2.3.5 Lifting the base plate
Required equipment

Lifting eye, M16 3HAC14457-4 3 pcs
Lifting slings Length: approx. 2 m
Hole configuration
xx0200000096
A Attachment holes for lifting eyes (x3)
Lifting, base plate
Action Note
1
CAUTION
The base plate weighs 353 kg. All lifting accessories

used must be sized accordingly.
2 Fit lifting eyes in specified holes. Shown in figure Hole configur-

ation on page 75.
3 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.

2.3.6 Securing the base plate
Base plate, dimensions

D G H
2x R525
598,31
560,85
B 487,01
(Ø 8 455
00)
950
243,5
F 2x 450
12x M24 A E
Ø1 A
A
0
73,84
231,5
111,30
C C
560,85
634,68
502,04
73,84
0
132,64
317,3
2x 50x45º
857,3
1020
48
4x
(4x)
6,3
)
(48
(2 3x
) 45
º
0.3 Common Zone
E, F, G, H
13
1,6
A
(2)
1,6
)
(2
13
3x
A-A 45
Ø 45P7 º B-B
Ø1.5
47 +0
0 ,5
c
K7
3x R1
45
52,
0,25 c
5º
(2
) (2x R22,5)
4
3x
3x 90º 1,6
C-C D
xx1000001053
E, F, G, H Common tolerance zone (accuracy all over the base plate from one contact
surface to the other)

Continued
xx0400000715
A Four holes for alternative clamping, 4x Ø18

Continued
Base plate, orienting grooves and leveling bolts

The illustration below shows the orienting grooves and attachment holes for leveling
bolts in the base plate.
B A
B
B
A
xx1500000312
A Orienting grooves (3 pcs)

B Levelling bolts, attachment holes (4 pcs)

Continued
Base plate, guide sleeve holes

The illustration below shows the orienting grooves and guide sleeve holes in the
base plate.
xx0300000045
A Guide sleeve holes (2 pcs)
Required equipment

Base plate 3HAC12937-7 Includes
• guide sleeves, 3HAC12937-3
• levelling screws, 9ADA120-79
• attachment screws and washers
for securing the robot to the
base plate.
tools on page 381.
Other tools and procedures may These procedures include references
be required. See references to to the tools required.
these procedures in the step-by-
step instructions below.
Base plate
This section details how to secure the base plate to the foundation.
Action Note
1 Make sure the foundation is levelled.

Continued
Action Note
2
CAUTION
The base plate weighs 353 kg! All lifting

equipment used must be sized accordingly!
3 Position base plate in relation to the robot Shown in figure Base plate, orienting
work location using the grooves in the base grooves and leveling bolts on page 78.
plate.
4 Lift the base plate to its mounting position. Detailed in section Lifting the base plate
on page 75.
5 Use the base plate as a template and drill at- Attachment holes: 16 pcs.
tachment holes as required by the selected
bolt dimension.
6 Fit the base plate and use the levelling bolts Shown in figure Base plate, orienting
to level the base plate. grooves and leveling bolts on page 78.
7 If required, fit strips of sheet metal underneath
the base plate to fill any gaps.
8 Secure the base plate to the foundation with
screws and sleeves.
9 Recheck the four contact surfaces on the Maximum allowed deviation all over the
base plate to make sure the base plate is base plate, from one contact surface to
levelled and flat. the other: 0.3 mm.
If it is not, use pieces of sheet metal or similar
to bring the base plate to a levelled position.

2.3.7 Orienting and securing the robot
General
This section details how to orient and secure the robot to the base plate in order
to run the robot safely.
Illustration, robot fitted to base plate

This illustration shows the robot base fitted to the base plate.
xx0100000107
A Robot attachment bolts and washers, 12 pcs (M24 x 140)

B Orienting grooves in the robot base and in the base plate
C Levelling screws
D Base plate attachment screws
Attachment screws
The table below specifies the type of securing screws and washers to be used for
securing the robot to the base plate/foundation.
Suitable screws, lightly lubricated: M24 x 140
Quality: Quality 8.8
Suitable washer: Thickness: 4 mm
Outer diameter: 44 mm
Inner diameter: 25 mm
Tightening torque: 725 Nm

Continued
Securing the robot

Use this procedure to secure robot to base plate after fitting plate to the foundation.
Action Note
1 Lift the robot. See section Lifting robot with lifting
slings on page 69.
See section Lifting robot with round-
slings on page 66.
2 Move robot to the vicinity of its installation loca-
tion.
3 Fit two guide sleeves to the guide sleeve holes Shown in figure Base plate, guide
in the base plate. sleeve holes on page 79.
Note
One of the guide sleeve holes is

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

sembly!
6 Tighten bolts in a criss-cross pattern to ensure

that the base is not distorted.

Continued
Hole configuration, base

This illustration shows the hole configuration used when securing the robot.
xx0300000046
Cross section, guide sleeve hole

This illustration shows the cross section of the guide sleeve holes.
xx0100000109

2.3.8 Fitting equipment on robot
General
The robot features mounting holes for additional equipment.
Access to any of the following mounting holes may be obstructed by any additional
cabling, equipment, etc., fitted by the robot user. Make sure the required mounting
holes are accessible when planning the robot cell.
Note
All equipment and cables used on the robot, must be designed and fitted not to
damage the robot and/or its parts.
Note
No extra equipment may be fitted on the lower arm of the robot.
Illustration, fitting of extra equipment on upper arm

The illustrations below shows the mounting holes available for fitting extra
equipment on the upper arm.
xx0700000015
Number Robot variant A B C D

1 IRB 6660 - 100/3.3 1747.5 mm 190 mm 490 mm 128 mm
IRB 6660 - 130/3.1 1497.5 mm 190 mm 490 mm 128 mm
2 IRB 6660 - 205/1.9 885 mm 190 mm 490 mm 128 mm

Continued
xx0700000014
xx0700000674

Continued
Illustration, fitting of extra equipment on frame

The mounting holes available for fitting extra equipment on the frame are shown
below.
Illustrations show robot variant IRB 6660 - 130/3.1 but all shown measurements
are the same on all variants.
xx0700000013
xx0700000012

Continued
Illustration, fitting on turning disc

The illustration below shows the mounting holes available for fitting equipment on
the turning disc.
xx0200000197
- Turning disk (type 2) for all robot versions.
Fastener quality
When fitting tools on the turning disk (see the figures above), only use screws with
quality 12.9.
Standard screws with quality 8.8 may be used when fitting other equipment to the
mounting holes on the upper arm house or frame.

2.3.9 Installation of chip protection - IRB 6660 - 205/1.9
Note
This section is only applicable to the robot variant IRB 6660 - 205/1.9.
Location of chip protection

The chip protection is installed on the lower arm as shown in the figure below.
xx0700000630
A Bracket
B Attachment screws M6x16 quality 8.8-A2F (2 pcs per side)
C Attachment screws M6x16 quality 8.8-A2F (4 pcs)
D Protection
Required equipment
Equipment Art. no. Note

Chip protection 3HAC030124-001
Locking liquid - Loctite 243
For locking screws.
Standard toolkit Content is defined in section
Standard tools on page 381.
Other tools and procedures may These procedures include
be required. See references to references to the tools re-
these procedures in the step-by- quired.

Continued
Installation, chip protection

The procedure below details how to install the chip protection on the lower arm of
the robot.
Action Note
1
DANGER
Turn off all electric power, hydraulic and

pneumatic pressure supplies to the robot!
2 Place the chip protection around the lower As shown in the figure Location of chip
arm. protection on page 88.
3 Fit the bracket on the chip protection with Art. no. is detailed in Required equipment
its attachment screws - two screws on each on page 88.
side of the lower arm.
Lock screws with locking liquid.
4 Let the protection hang down in front of As shown in the figure Location of chip
the lower arm and base of the robot. protection on page 88.

2.3.10 Installation of cooling fan for motors (option)
General
A cooling fan can be installed on motor axis 1 and/or axis 2!
Location of cooling fans

The fan can be installed on motor axis 1 and/or axis 2, as shown in the figure below.
The figure shows IRB 7600 but the principle fitting is the same.
xx1800000169 xx1800000170
A Cooling fan, axis 1

B Cooling fan, axis 2

Continued
Cooling fan
The details of the cooling fan are shown in the figure below.
xx0500002158
A Fanbox
B Attachment screws, fanbox plates (9 pcs)
C Groove in the connector
D Tightening screws, fanbox (3 pcs)
Required equipment

Cooling fan 3HAC15374-1
Cabling, cooling fan, axes 1 3HAC046362-001 Choose this cabling if equipping the robot
and 2 with cooling fans on both axis 1 and 2.
Plate for customer connec- 3HAC025778-001 An additional connection plate must be
tions fitted to the robot base, if not already in-
stalled. The plate is shown in the figure
Plate for customer connections, at base
on page 92.
Additional cabling to the - Specified in section Fan cables (option)
controller on page 106.
Material set fan axes 1 and 3HAC023999-001 The set includes:
2 • fan axes 1 & 2 cable harness
• plate, customer
• attachment screws and nuts.
Cable harness inside control- 3HAC025488-001
ler

Continued

Locking liquid - Loctite 243. Used for the three tightening
screws.
tools on page 381.
Circuit diagram 3HAC025744-001 See chapter Circuit diagram on page 389.
Other tools and procedures These procedures include references to
may be required. See refer- the tools required.
ences to these procedures
in the step-by-step instruc-
tions below.
Plate for customer connections, at base
xx0500002301
A Plate for customer connections

B Attachment screws, 3 pcs, M6x16 quality 8.8-A2F

Continued
Installation, fan
The procedure below details how to install the cooling fan on motors, axes 1 or 2
.
Action Note
1
DANGER
Turn off all:

• electric power supply to the robot
• hydraulic pressure supply to the robot
• air pressure supply to the robot
Before entering the robot working area.
2 Prepare the fanbox for installation: Shown in the figure Cool-

• disassemble the two parts of the box by removing the ing fan on page 91.
nine attachment screws
• loosen the three tightening screws, to avoid damaging
the surfaces of the motor when fitting the fanbox
• turn the connector to the correct position; axis 1:
groove pointing inwards, as shown in the figure
Cooling fan on page 91.
3 Temporarily lift the motor cabling out of the way of the current
motor to make room for the fanbox.
4 Fit the parts of the fanbox to the motor and reassemble with
the nine attachment screws.
5 Lift the box (axis 1) so that it does not rest directly on the
robot and secure the box with the three tightening screws,
using locking liquid. Tighten them properly so that the box
is firmly attached to the motor.
6 Install the cabling and make adjustments in RobotWare, as
described in the following procedures.

Continued
Separate cabling for axis 1 or 2

The figure below shows the cabling used for the fan on axis 1 or 2.
xx0700000669
A Cable bracket (to be removed)

B Connector R1.SW2/3, connected to the robot base
C Connector R3.FAN2, connected to the fan of axis 1 or 2.
Installation, separate fan cabling axis 1 or 2

The procedure below details how to install the separate cabling for the cooling fan
of axis 1 or 2.
Action Note
1 Move the robot to its calibration position. This is detailed in section Syn-
chronization marks and synchron-
ization position for axes on
page 345.
2
DANGER
Turn off all:


Continued
Action Note
3 Remove the rear cover plate from the robot base.
xx1800000161
4 Remove the cable bracket (A) Shown in the figure Separate

cabling for axis 1 or 2 on page 94
5 Fit the plate for customer connections, if not Art. no. is specified in Required
already fitted, to the connection plate of the robot equipment on page 91.
base.
xx1800000162
6 Run the cabling up through the base and frame.

7 Run the cable underneath the robot cabling and
out through the side of the frame, at motor, axis
1 or 2.
Strap the fan cable to the cable of the motor axis
1 or 2, close to the motor.
Note
The fan cable must not be strapped to the motor

cable along the part of the cable that is twisted
when the robot is in operation.
8 Connect the connector R3.FAN2 to the fan of axis

1.
9 Connect the connector R1.SW2/3 to the base of
the robot. Make sure that the cabling, run through
the frame and base, is not twisted and runs freely
from the robot cabling.
10 Refit the rear cover plate to the robot base.
11 Install additional cabling to and inside the control- Cable is specified in section Fan
ler. cables (option) on page 106.
Also make adjustments in RobotWare, as de-
scribed in the following procedure.

Continued
Adjustments in RobotWare
Action Note
1 Modify the settings in RobotWare to RobotWare 5.0: change the settings in the
include the cooling fans. Modifying options dialogue, by using the
Modify Controller System Wizard in the Sys-
tem Builder of RobotStudio. Read more about
modifying the system in Operating manual -
RobotStudio.

2.3.11 Installation of Foundry Plus Cable guard (option no. 908-1)
2.3.11 Installation of Foundry Plus Cable guard (option no. 908-1)
Introduction
How to install the Foundry Plus Cable guard is described in the instruction delivered
with the cable guard.
Separate instructions for IRB 2600, 4600, 6620, 6640, 6650S, 6660 and 7600 are
available in English, German, French, Spanish and Italian and can be found for
registered users on myABB Business Portal (www.myportal.abb.com) and delivered
with the Cable guard, article number 3HAC035933-001.

2.3.12 Loads fitted to the robot, stopping time and braking distances
2.3.12 Loads fitted to the robot, stopping time and braking distances
General
Any loads mounted on the robot must be defined correctly and carefully (with
regard to the position of center of gravity and mass moments of inertia) in order
to avoid jolting movements and overloading motors, gears and structure.
CAUTION
Incorrectly defined loads may result in operational stops or major damage to the
robot.
References
Load diagrams, permitted extra loads (equipment) and their positions are specified
in the product specification. The loads must be defined in the software.
• Operating manual - IRC5 with FlexPendant
Stopping time and braking distances

The performance of the motor brake depends on if there are any loads attached
to the robot. For more information, see product specification for the robot.

2.3.13 Signal lamp (option)
2.3.13 Signal lamp (option)
Description
A signal lamp with a yellow fixed light can be mounted on the robot, as a safety
device.
Installation
See the assembly instruction delivered with the signal lamp.
Function
The lamp is active in MOTORS ON mode.
Further information
Further information about the MOTORS ON/MOTORS OFF mode may be found in
the product manual for the controller.

2.4.1 Axes with restricted working range
2.4 Restricting the working range
2.4.1 Axes with restricted working range
General
When installing the robot, make sure that it can move freely within its entire working
space. If there is a risk that it may collide with other objects, its working space
should be limited.
The working range of the following axes may be restricted:
• Axis 1, hardware (mechanical stop) and software.
• Axis 2, software.
• Axis 3, software.
As standard configuration, axis 1 is allowed to move ± 180º.
This section describes how to install hardware that restricts the working range.
Note
Adjustments must also be made in the robot configuration software (system

parameters). References to relevant manuals are included in the installation
procedures.

2.4.2 Mechanically restricting the working range of axis 1
General
The working range of axis 1 is limited by fixed mechanical stops and adjustment
of the system parameter configuration. The working range can be reduced by
adding additional mechanical stops giving 7.5 or 15 graduation, between 22.5°
and 135° in both directions.
Mechanical stops, axis 1

The illustration shows the mounting position of the stop pin and one of the additional
mechanical stops available for axis 1.
xx0300000049
A Additional mechanical stop

B Stop pin
Required equipment
Equipment, etc. Article number Note

Mechanical stop for axis 1, 7.5° 3HAC11076-1 Includes attachment screws and
an assembly drawing.
Mechanical stop for axis 1, 15° 3HAC11076-2 Includes attachment screws and
an assembly drawing.
Standard toolkit -
Technical reference manual - System - Article number is specified in
parameters section References on page 10.

Continued
Installation, mechanical stops axis 1

Use this procedure to fit the additional mechanical stops to axis 1 of the robot. An
assembly drawing is also enclosed with the product.
Action Note
1
DANGER
Turn off all:

2 Fit the additional mechanical stop to the Tightening torque: 120 Nm.
frame according to the figure Mechanical
stops, axis 1 on page 101.
3 Adjust the software working range limitations The system parameters that must be
(system parameter configuration) to corres- changed (Upper joint bound and Lower
pond to the mechanical limitations. joint bound) are described in Technical
reference manual - System parameters.
4
WARNING
If the mechanical stop pin is deformed after

a hard collision, it must be replaced!
Deformed movable stops and/or additional
stops as well as deformed attachment
screws must also be replaced after a hard
collision.

2.4.3 Extended working range, axis 1 (option 561-1)
2.4.3 Extended working range, axis 1 (option 561-1)
Overview
The working range of axis 1 can be increased from standard range to extended ±
220º.
Extending the working range
1 Remove the mechanical stop pin from axis
1 (A).
xx0400001034
2 Redefine the software working range limit- The system parameters that must be
ations in the system parameters, topic changed (Upper joint bound and Lower
Motion. The Arm parameters Upper Joint joint bound) are described in Technical
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.

2.5.1 Robot cabling and connection points
2.5 Electrical connections
Introduction
Connect the robot and controller to each other after securing them to the foundation.
The lists below specify which cables to use for each respective application.
Main cable categories

All cables between the robot and controller are divided into the following categories:
Cable category Description
Robot cables Handles power supply to and control of the robot's motors
as well as feedback from the serial measurement board.
Specified in the table Robot cables on page 104.
Fan cables (option) Handles supply to and feedback from any cooling fan on
the robot.
Specified in the table Fan cables (option) on page 106.
Customer cables (option) Handles communication with equipment fitted on the robot
by the customer, low voltage signals and high voltage power
supply + protective ground.
The customer cables also handle databus communication.
See the product manual for the controller, see document
number in References on page 10.
External axes cables (option) Handles power supply to and control of the external axes'
motors as well as feedback from the servo system.
See the Application manual - Additional axes and stand
alone controller (M2004), see document number in Refer-
ences on page 10.
Robot cables
These cables are included in the standard delivery. They are completely
pre-manufactured and ready to plug in.
Cable sub-category Description Connection Connection
point, cabinet point, robot
Robot cable, power Transfers drive power from the XS1 R1.MP
drive units in the control cabinet
to the robot motors.
Robot cable, signals Transfers resolver data from XS2 R1.SMB
and power supply to the serial
measurement board.
Robot cable, power
Cable Art. no.

Robot cable, power: 7 m 3HAC026787-001

Continued
Robot cable, signals
Cable Art. no.

Robot cable signal, shielded: 7 m 3HAC7998-1
Bending radius for static floor cables

The minimum bending radius is 10 times the cable diameter for static floor cables.
A
B
xx1600002016
A Diameter
B Diameter x10
Grounding and bonding point on manipulator

There is a grounding/bonding point on the manipulator base. The grounding/bonding
point is used for potential equalizing between control cabinet, manipulator and any
peripheral devices.
xx1600001000

Continued
Fan cables (option)

These cables are not included in the standard delivery, but are included in the
delivery if the fan option is ordered. The cables are completely pre-manufactured
and ready to plug in.
Cabling to be installed on the robot is specified in section Installation of cooling
fan for motors (option) on page 90.
Cabling between robot base and control cabinet, cooling fans, M2004
The cables specified below are specific for the IRC5 controller and used when the
robot is equipped with cooling fans. The cabling for the cooling fans runs all the
way from the robot base to the inside of the cabinet. Fans can also be ordered
without cables.
If equipping the robot with cooling fans, use the cabling specified below. The cables
for cooling fans listed below are used together with a distributing cable, also
specified below.
Cable Art. no. Connection point
Harness - cooling, 7 m 3HAC022723-001 Distributing cable: R1.FAN.SW2/3
Inside cabinet: A43.X10 and A43.X11

2.6 Start of robot in cold environments
2.6 Start of robot in cold environments
Introduction
This section describes how to start the robot in a cold environment if it is not starting
the normal way.
Problems with starting the robot

Event message from Motion Supervision
Use this procedure if an event message indicates a problem with Motion supervision
at start-up. More information about Motion Supervision is found in Technical
reference manual - System parameters.
Action Note
1 Turn off Motion Supervision.
2 Start the robot.
3 When the robot has reached normal working temper-
ature, the Motion Supervision can be turned on
again.
Robot stopping with other event message

Use this procedure if the robot is not starting.
Action Note
1 Start the robot with its normal program but The speed can be regulated with the
with reduced speed. RAPID instruction VelSet.
Adjusting the speed and acceleration during warm-up

Depending on how cold the environment is and what program is being used, the
speed might need to be ramped up until reached maximum. The table shows
examples of how to adjust the speed:
Work cycles AccSet Speed/velocity
3 Work cycles 20, 20 v100 (100 mm/s)
5 Work cycles 40, 40 v400 (400 mm/s)
5 Work cycles 60, 60 v600 (600 mm/s)
5 Work cycles 100, 100 v1000 (1000 mm/s)
More than 5 Work cycles 100, 100 Max.
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.

3 Maintenance
3.1 Introduction
3 Maintenance
3.1 Introduction
Structure of this chapter

This chapter describes all the maintenance activities recommended for the IRB
6660.
It is based on the maintenance schedule found at the beginning of the chapter.
The schedule contains information about required maintenance activities including
intervals, and refers to procedures for the activities.
Each procedure contains all the information required to perform the activity,
including required tools and materials.
The procedures are gathered in different sections and divided according to the
maintenance activity.
Safety information
Observe all safety information before conducting any service work.
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 19 before performing any service
work.
Note
If the IRB 6660 is connected to power, always make sure that the IRB 6660 is
connected to protective earth before starting any maintenance work.

3 Maintenance
3.2.1 Specification of maintenance intervals
3.2 Maintenance schedule and component life
3.2.1 Specification of maintenance intervals
Introduction
The intervals are specified in different ways depending on the type of maintenance
activity to be carried out and the working conditions of the IRB 6660:
• Calendar time: specified in months regardless of whether the system is
running or not.
• Operating time: specified in operating hours. More frequent running means
more frequent maintenance activities.
• SIS: specified by the robot's SIS (Service Information System). A typical
value is given for a typical work cycle, but the value will differ depending on
how hard each part is run. The SIS used in M2004 is further described in the
Operating manual - Service Information System.
Overhaul
Depending on application and operational environment a complete overhaul may
be necessary in average around 40000 hours.
ABB Connected Services and its Assessment tools can help you to identify 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.

3 Maintenance
3.2.2 Maintenance schedule
General
The robot must be maintained regularly to ensure proper function. The maintenance
activities and intervals are specified in the following table.
Non-predictable situations also give rise to inspections of the robot. Any damages
must be attended to immediately!
The inspection intervals do not specify the life of each component. Values for these
are specified in the section Expected component life on page 113
Instructions for how to perform the different maintenance activities are found in
sections:
• Inspection activities on page 114
• Replacement/changing activities on page 144
• Cleaning activities on page 169
Activities and intervals, standard equipment

The following table specifies the required maintenance activities and intervals.
Maintenance activity Equipment Interval
Cleaning Robot Cleaning the IRB 6660 on page 169
Inspection Oil level in axis-1 gearbox Every 12 months.
Inspection Balancing device Every 6 months.
Inspection Robot harness Every 12 months i .
Inspection Information labels Every 12 months.
Inspection Dampers Every 12 months.
Inspection Mechanical stop Every 12 months.
Change Oil in axis-1 gearbox First change when DTC ii reads:
• 6,000 hours
Second change when DTC ii reads:
• 24,000 hours
Following changes:
• Every 24,000 hours.
• 6,000 hours
• 24,000 hours
Following changes:

3 Maintenance
Continued
Maintenance activity Equipment Interval

• 6,000 hours
• 24,000 hours
Following changes:
Change Oil in axis-4 gearbox Every 24,000 hours.
Change Oil in axis-5 gearbox Every 24,000 hours.
Change Oil in axis-6 gear First change when DTC ii reads:
• 6,000 hours
• 24,000 hours
Following changes:
Overhaul Robot Every:
• 40,000 hours iii .
Replacement Battery pack, measurement 36 months or battery low alert iv
system of type RMU101 or
RMU102 (3-pole battery con-
tact)
Replacement Battery pack, measurement Battery low alert v
system with 2-pole battery
contact, e.g. DSQC633A
Lubrication Balancing device bearings Every 12,000 hours vi
i Replace when damage or cracks is detected or life limit is approaching that specified in section
Expected component life on page 113.
ii DTC = Duty Time Counter. Shows the operational time of the robot.
iii If the robot is run in presstending applications, typically 36 months.
iv The battery low alert (38213 Battery charge low) is displayed when the battery needs to be replaced.
The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned
on until the battery is to be replaced.
See the replacement instruction for more details.
v The battery low alert (38213 Battery charge low) is displayed when remaining backup capacity
(robot powered off) is less than 2 months. The typical lifetime of a new battery is 36 months if the
robot is powered off 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime
can be extended with a battery shutdown service routine. See Operating manual - IRC5 with
FlexPendant for instructions.
vi Always lubricate the front eye bearing after refitting the shaft of the balancing device.
Activities and intervals, optional equipment

The following table specifies the required maintenance activities and intervals for
common optional equipment. The maintenance of other external equipment for the
robot is detailed in separate documents.
Maintenance activity Equipment Interval Note
Inspection Signal lamp Every:
12 months
Inspection Additional mechanical Every:
stop axis 1 12 months
Inspection Motor fan Every 12 Inspect the fan for contam-
months ination that could hinder
the air supply. Clean if ne-
cessary.

3 Maintenance
3.2.3 Expected component life
3.2.3 Expected component life
General
The expected life of a specific component of the robot can vary greatly depending
on how hard it is run.
Expected component life - protection type Standard
Component Expected life Note

Cable harness 40,000 hours ii Not including:
Normal usage i • Possible SpotPack
harnesses
• Optional upper arm
harnesses
Cable harness 20,000 hours ii Not including:
Extreme usage iii • Possible SpotPack
harnesses
• Optional upper arm
harnesses
Balancing device 40,000 hours iv
Gearboxes v 40,000 hours
i Examples of "normal usage" in regard to movement: most material handling applications.
ii Severe chemical or thermal environments, or similar environments, can result in shortened life
expectancy.
iii Examples of "extreme usage" in regard to movement: press tending, very severe palletizing
applications, major use of axis 1 movement.
iv The given life for the balancing device is based on a test cycle of 4,000,000 cycles that starts from
the initial position and goes to maximum extension, and back. Deviations from this cycle will result
in differences in expected life!
v Depending on application, the lifetime can vary. The Service Information System (SIS) that is
integrated in the robot software can be used as guidance when planning gearbox service for the
individual robot. This applies to gearboxes on axes 1, 2, 3 and 6. The lifetime of gearbox axes 4
and 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.
The SIS for an IRC5 system is described in the Operating manual - Service Information System.

3 Maintenance
3.3.1 Inspecting the oil level in axis-1 gearbox
3.3 Inspection activities
Location of gearbox
The axis-1 gearbox is located between the frame and base. See oil plugs in the
following figure.
E
xx0500002479
A Oil plug, inspection

B Gearbox, axis 1
C Oil plug filling
D Motor, axis 1
E Drain hose (Behind cover)
Required equipment

Lubricating oil See Type and
amount of oil in Note
gearboxes on
page 144. Do not mix with other oils!
Standard toolkit - Content is defined in section


3 Maintenance
Continued

Other tools and procedures may These procedures include refer-
be required. See references to ences to the tools required.
Inspecting the oil level in axis-1 gearbox

Use this procedure to inspect the oil level in the axis-1 gearbox.
Action Note
1
WARNING
Handling gearbox oil involves several safety risks.

Before proceeding, please read the safety informa-
tion in the section Safety risks during work with
gearbox lubricants (oil or grease) on page 38.
2
DANGER
Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working area.
3 Make sure that the oil temperature is +25°C ±10°C. This is a precaution to reduce the
temperature dependency of the
measurement.
4 Open the oil plug, inspection. Shown in figure Location of gear-
box on page 114.
5 Measure the oil level. A
Required oil level: max. 10 mm below the oil plug
hole.
C
xx1400002785
A Oil plug hole

B Required oil level
C Gearbox oil
6 Adjust the oil level, if required. Where to find type of oil and total
amount is detailed in Type of lub-
rication in gearboxes on page 144.
Further information about how to
fill with oil is found in section
Changing oil, axis-1 gearbox on
page 146.
7 Refit the oil plug. Tightening torque:24 Nm

3 Maintenance
3.3.2 Inspecting, oil level gearbox axes 2 - 3
Location of gearbox, axes 2-3

The gearboxes axes 2-3 are located in the lower arm rotational center, underneath
the motor attachment.
xx0500002482
A Gearbox, axis 2
B Oil plug, draining
C Oil plug, filling
D Ventilation hole, gearbox axis 2

3 Maintenance
Continued
xx0500002483
A Gearbox, axis 3
C Oil plug, filling
D Ventilation hole, gearbox axis 3
Required equipment
Equipment etc. Art.no. Note

amount of oil in Note
gearboxes on
page 144. Do not mix with other oils!

step instructions below
Inspecting, oil level gearbox 2 - 3

Use this procedure to inspect the oil level in gearbox axes 2 - 3.
Action Note
1
WARNING

Before proceeding, please read the safety inform-
ation in the section Safety risks during work with

3 Maintenance
Continued
Action Note
2
DANGER
Turn off all:

3 Open oil plug, filling See Location of gearbox, axes 2-3

on page 116.
4 Measure oil level at the oil plug, filling.
Required oil level: max. 5 mm below oil plug hole.
5 Add oil if required. Art.no. is specified in Required
equipment on page 117.
Filling of oil is detailed further in
section Changing oil, gearbox axes
2 and 3 on page 149.
6 Refit oil plug, filling. Tightening torque: 24 Nm.

3 Maintenance
Location of gearbox
The axis-4 gearbox is located in the rear part of the upper arm as shown in the
figure.
xx0700000018
A Oil plug, filling and inspection

Required equipment

amount of oil in
gearboxes on
page 144.
Standard toolkit - Content is defined in section Stand-
ard tools on page 381.

3 Maintenance
Continued

Action Note
1
WARNING
Handling gearbox oil involves several safety

risks. Before proceeding, please read the
safety information in the section Safety risks
during work with gearbox lubricants (oil or
grease) on page 38.
2 Move the robot to the calibration position. This is detailed in section Synchroniza-
tion marks and synchronization posi-
tion for axes on page 345.
3
DANGER
Turn off all:

4 Make sure that the oil temperature is +25°C This is a precaution to reduce the tem-
±10°C. perature dependency of the measure-
ment.
5 Open the oil plug, filling and inspection. Shown in the figure Location of gear-
box on page 119.
6 Measure the oil level. A
Required oil level: 0-10 mm
C
xx1400002785
A Oil plug hole

B Required oil level
C Gearbox oil
amount is detailed in Type and amount
of oil in gearboxes on page 144.
Further information about how to fill the
oil may be found in the section Filling,
oil on page 154.

3 Maintenance
Location of gearbox
The axis-5 gearbox is located in the wrist unit as shown in the figure.
xx0200000232
- The figure above shows the wrist unit of IRB 6600 and IRB 6650
A Oil plug, filling and inspection
Required equipment
Equipment etc. Art. no. Note

amount of oil in
gearboxes on
page 144.

Action Note
1
WARNING


3 Maintenance
Continued
Action Note
2 Move the robot upper arm to a horizontal position.
3 Turn the wrist unit in a way that both oil plugs are
facing upwards.
4
DANGER
Turn off all:

5 Make sure that the oil temperature is +25°C This is a precaution to reduce the
±10°C. temperature dependency of the
measurement.
6 Open the oil plug, filling and inspection. Shown in the figure Location of
gearbox on page 121.
7 Measure the oil level.
Required oil level to the upper edge of the filling
and inspection oil plug hole (a): 30 mm
xx0500002222
amount is detailed in Type and
amount of oil in gearboxes on
page 144.
Further information about how to fill
the oil may be found in the section
Filling, oil, axis 5 on page 157.

3 Maintenance
Location of gearbox
The axis-6 gearbox is located in the wrist unit as shown in this figure.
The figure shows the gearbox for robot variant IRB 6660 - 100/3.3 and IRB 6660 -
130/3.1. The axis-6 motor on variant IRB 6660 - 205/1.9 has no cooling elements.
xx0700000161
A Strap (securing cooling elements)

B Axis-6 gearbox
C Oil plug, draining
D Oil plug, filling
E Cooling element (IRB 6660 - 100/3.3 and IRB 6660 - 130/3.1)
Required equipment

amount of oil in
gearboxes on
page 144.

3 Maintenance
Continued

Action Note
1
WARNING

risks. Before proceeding, please read the safety
information in the section Safety risks during
work with gearbox lubricants (oil or grease) on
page 38.
2 Move axes 3 and 5 to a horizontal position, and

make sure that the oil plug, filling and inspection
is facing upwards.
3
DANGER
Turn off all:

4 Make sure that the oil temperature is +25°C This is a precaution to reduce the
±10°C. temperature dependency of the
measurement.
5 Remove the oil plug, filling and inspection.
xx1300002447
6 Slowly turn axis 4 until the axis-4 angle reads

+72.5° to +77.5°.
7 Inspect the oil level in the hole for the oil plug, A
filling and inspection. B
The oil should reach all the way up to the extern-
al edge of the thread for the oil plug, filling and C
inspection.
xx1400002786
Note
A Oil plug hole
If needed, use a clean, narrow object, for ex- B Required oil level
ample an oil stick or a cable tie, to gently poke C Gearbox oil
the oil surface. This will avoid surface tension
from stopping air to enter into the gearbox.

3 Maintenance
Continued
Action Note
page 144.
Further information about how to fill
the oil may be found in the section
Filling, oil, axis 6 on page 160.
9 Refit the oil plug. Tightening torque: 24 Nm.
10
WARNING
Do not mix oil types! If wrong oil is refilled, the

gearbox must be rinsed as detailed in Technical
reference manual - Lubrication in gearboxes.

3 Maintenance
3.3.6 Inspecting, balancing device bearings and piston rod guide ring
Note
This section is not applicable to robot variant IRB 6660-205/1.9.
Location of balancing device

The figure shows the location of the balancing device.
xx0700000019
A Balancing device
B Piston rod
C Guide ring (not visible in this figure)
Required equipment
Equipment Art.no Note

Grease 3HAB3537-1
Auxiliary shaft, upper 3HAC5276-1
Auxiliary shaft, lower 3HAC5275-1

3 Maintenance
Continued
Equipment Art.no Note

Inspecting, bearings
Use this procedure to inspect the bearings, balancing device.
Action Note
1 Move axis 2 to calibration position.
2
DANGER
Turn off all:

• hydraulic pressure supply to the
robot
3 Remove locknuts (KM10), sealing rings

and support washers.
xx0500002496
A Ear (adjustable needle bearing located

inside)
B Support washer
C Lock nut KM10 (with sealing ring)
D Piston rod
E Guide ring (not visible in this view)
F Inner ring
4 Fit the auxiliary shafts on upper and Art. no. is specified in Required equipment
lower axes of balancing device. on page 126.
The shafts should be tightened to their
bottom position.

3 Maintenance
Continued
Action Note
5 Remove the protection hood from the
M12 hole on top of the balancing device.
xx0600002687
A Attachment (seen from above)

B Protection hood
6 Unload the bearings using a M12x50
screw, in the hole for the protective hood,
at the cylinder top.
7 Pull out the cylinder a little, in order to Shown in previous figure in this procedure.
be able to inspect the inner rings without
removing the balancing cylinder.
8 Wipe the inner rings clean and check that
there are no pressure marks or other Note
similar deformations.
It is quite normal for the bearing races to
have a darker color than the surrounding
material.
9 Inspect the bearings, support washers Shown in previous figure.

and sealing rings.
10 If any of the parts looks abnormal, re- Detailed in section Replacing the balancing
place. device on page 266.
11 Lubricate the shafts, if needed.
12 Push the cylinder back in. Make sure that the inner support washers
and sealing rings get in the correct position.
13 Remove the auxiliary shafts.
14 Remove the M12x50 screw.
Put back the protection hood in the hole. Note
Don´t forget to remove the screw!

If the screw isn´t removed it may damage the
balancing device, when the robot starts op-
erating.
15 Apply locking liquid on the lock nuts Tightening torque on the lock nuts:
(KM10) and refit them. • 120 Nm

3 Maintenance
Continued
Inspecting, piston rod guide ring

Use this procedure to inspect the piston rod guide ring for wear.
Action Note
1 Move axis 2 to a position where the balancing
device is in a horizontal position.
2
DANGER
Turn off all:

3 Check the guide ring for wear.

Replace if necessary.
xx0600002689
A Guide ring
B Circlip
4
Note
If there is a risk of metallic contact between the

piston rod and the end cover, the guide ring
must be replaced!

3 Maintenance
3.3.7 Inspection, cable harness
Location of cable harness

The robot cable harness, axes 1-6 is located as shown in the figures below:
xx0700000022
A Cable guide, axis 2

B Metal clamp (4 pcs)
C Connectors at base
D Cable guide
E Cable harness

3 Maintenance
Continued
xx0700000631

B Cable gland, SMB unit
C Cable guide, axis 2

3 Maintenance
Continued
xx0700000021
A Cable strap, outdoor

B Attachment screw, M10x16 quality 8.8 (2 pcs)
C Cable strap, outdoor
D Cable fixing bracket
E Attachment screw, metal clamp M6x25 quality steel 12.9 Gleitmo
Required equipment

Cable harness For spare part
number, see Spare
part lists on
page 387.
Other tools and procedures may be re- These procedures include
quired. See references to these proced- references to the tools re-
ures in the step-by-step instructions be- quired.
low.
Circuit diagram - See chapter Circuit diagram
on page 389.

3 Maintenance
Continued
Inspection, cable harness

The procedure below details how to inspect the cable harness axes 1-6.
Action Note
1
DANGER
Turn off all electric power, hydraulic and pneumat-

ic pressure supplies to the robot!
2 Make an overall visual inspection of the cable

harness in order to detect wear and damage.
3 Check the connectors at the base. Shown in the figure Location of
cable harness on page 130.
4 Check the metal clamps at the rear of the upper Shown in the figure Location of
arm and in the upper arm tube. cable harness on page 130.
5 Check that the velcro straps and the mounting
plate are properly attached to the frame.
6 Check the cabling leading into the lower arm.
Make sure it is attached by the straps and not
damaged.
7 Replace the cable harness if wear, cracks or Detailed in sections Replacement
damage is detected. of cable harness, lower end (axes
1-3) on page 181 and Replacement
of cable harness, upper end on
page 196.

3 Maintenance
3.3.8 Inspecting the information labels
Location of labels
These figures show the location of the information labels to be inspected. The
symbols are described in section Safety symbols on product labels on page 42.
xx0700000047
A Warning label concerning high temperature (2 pcs)

B Warning label, symbol of flash (located on motor cover) (2 pcs)
C Instruction label
E Instruction label concerning lifting the robot
F Warning label concerning risk of tipping
- Information labels at gearboxes and at robot base, specifying which oil is used
in gearboxes.

3 Maintenance
Continued
xx0700000048
A Warning label concerning high temperature (2 pcs)

B Warning label, symbol of a flash (located on motor cover) (1 pcs)
D Warning label concerning brake release
G Serial no. from rating label
H Warning label concerning stored energy
I Label calibration
J Warning label concerning shutting off power
K Abs-Acc information sign
L Danger label concerning clamping risk
Required tools and equipment

Visual inspection, no tools are required.
Inspecting, labels
Action Note
1
DANGER
Turn off all:

2 Inspect the labels, located as shown in the figures.

3 Replace any missing or damaged labels. Article numbers for the labels and
plate set is specified in Spare part
lists on page 387.

3 Maintenance
3.3.9 Inspecting the axis-1 mechanical stop pin
WARNING
Mechanical stop pin can not be fitted onto robot if option 810-1 Electronic Position
Switch is used.
Location of mechanical stop pin

The axis-1 mechanical stop is located as shown in the figure.
xx0200000151
A Mechanical stop pin
Required equipment
Visual inspection, no tools are required.
Inspecting, mechanical stop pin

Use this procedure to inspect the axis-1 mechanical stop pin.
Action Note
1
DANGER
Turn off all:

to the robot, before entering the robot working
area.

3 Maintenance
Continued
Action Note
2 Inspect the axis-1 mechanical stop pin.
If the mechanical stop pin is bent or damaged, it
must be replaced.
Note
The expected life of gearboxes can be reduced

after collision with the mechanical stop.
3 Make sure the mechanical stop pin can move in

both directions.

3 Maintenance
3.3.10 Inspecting the additional mechanical stops
Location of mechanical stops

This figure shows the location of the additional mechanical stop on axis 1.
Additional mechanical stops are not provided for axis 2 and 3.
xx0300000049
A Additional mechanical stop

B Stop pin
Required equipment
Equipment etc. Article number Note

Mechanical stop axis 1 3HAC11076-1 Limits the robot working range by 7.5°.
Mechanical stop axis 1 3HAC11076-2 Limits the robot working range by 15°.
tools on page 381.

3 Maintenance
Continued
Inspecting, mechanical stops

Use this procedure to inspect the additional mechanical stops.
Action Note
1
DANGER
Turn off all:

2 Make sure no additional stops are damaged. Shown in figure Location of

mechanical stops on page 138.
3 Make sure the stops are properly attached.
Correct tightening torque, additional mechanical
stops:
• Axis 1 = 120 Nm.
4 If any damage is detected, the mechanical stops must Article number is specified in
be replaced. Required equipment on page 138.
Correct attachment screws:
• Axis 1: M16 x 35, quality 12.9.

3 Maintenance
3.3.11 Inspecting the damper on axes 2-5
Location of dampers
The figure below shows the location of all the dampers to be inspected.
The figure shows the robot variant IRB 6660 - 130/3.1. Dampers and the position
of the dampers are the same on all variants.
xx0700000024
A Damper (2 pcs)
B Damper, axis 2 (2 pcs)
C Damper, axis 3 (2 pcs). Not visible in this view.
D Damper (1 pcs)
E Damper, axis 4 (1 pcs), inside armhouse
F Damper, axis 5 (2 pcs)
Required equipment
A damper must be replaced if damaged!
Equipment Spare part/ art. no. Note
Damper axis 2 3HAC12991-1
Damper 3HAC022338-001
Damper 3HAC022339-001
Standard toolkit 3HAC15571-1 Content is defined in section Standard
tools on page 381.

3 Maintenance
Continued
Inspection, dampers
The procedure below details how to inspect the dampers, axes 2-5.
Action Note
1
DANGER
Turn off all:

2 Check all dampers for damage, and for cracks or Shown in the figure Location of
existing impressions larger than 1 mm. dampers on page 140.
To inspect the damper axis 4, remove the two covers
on top of the upper arm!
3 Check attachment screws for deformation.
4 If any damage is detected, the damper must be re- Art. no. is specified in Required
placed with a new one! equipment on page 140.

3 Maintenance
3.3.12 Inspecting, signal lamp (option)
Location of signal lamp

The signal lamp is located as shown in figure below. Note that the position can
differ depending on how the customer harness for axis 4-6 is mounted. See
assembly drawing on the current harness for alternative positioning.
xx0700000056
A Signal lamp
B Metal clamp
C Cable strap, outdoor
Required equipment

Signal lamp 3HAC028196-001 To be replaced in case of detected
damage.
Inspecting, signal lamp

Use this procedure to inspect the function of the signal lamp.
Action Note
1 Check that signal lamp is lit when motors are put in
operation ("MOTORS ON").

3 Maintenance
Continued
Action Note
2
DANGER
Turn off all:

3 If the lamp is not lit, trace the fault by: Art. no. is specified in Required
• Checking whether the signal lamp is broken. equipment on page 142.
If so, replace it.
• Checking cable connections.
• Measuring the voltage in connectors motor
axis 3 (=24V).
• Checking the cabling. Replace cabling if a fault
is detected.

3 Maintenance
3.4.1 Type of lubrication in gearboxes
3.4 Replacement/changing activities
Introduction
This section describes where to find information about the type of lubrication,
article number and the amount of lubrication in the specific gearbox. It also
describes the equipment needed when working with lubrication.
Type and amount of oil in gearboxes

Information about the type of lubrication, article number as well as the amount in
the specific gearbox can be found in Technical reference manual - Lubrication in
gearboxes available for registered users on myABB Business Portal, www.mypo-
rtal.abb.com.
Before starting any inspection, maintenance, or changing activities of lubrication,
always contact the local ABB Service organization for more information.
For ABB personnel: Always check ABB Library for the latest revision of the manual
Technical reference manual - Lubrication in gearboxes, in order to always get the
latest information of updates about lubrication in gearboxes. A new revision will
be published on ABB Library immediately after updates.
Location of gearboxes
The figure shows the location of the gearboxes.
xx0700000026
A Gearbox, axis 1

3 Maintenance
Continued
B Gearbox, axis 2
C Gearbox, axis 3
D Gearbox, axis 4
E Gearbox, axis 5
F Gearbox, axis 6
Equipment
Equipment Note
Oil dispenser 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

3 Maintenance
3.4.2 Changing oil, axis-1 gearbox
Location of oil plugs

The axis-1 gearbox is located between the frame and base. See oil plugs in the
following figure.
trueThe oil is drained through a hose, which is located at the rear of the robot base.
E
xx0500002479
A Oil plug, inspection

B Gearbox axis 1
C Oil plug, filling
D Motor, axis 1
E Drain hose
Required equipment
Equipment, etc. Art. no. Amount Note

Lubricating oil See Type and See Type
amount of oil in and Note
gearboxes on amount of
page 144. oil in gear- Do not mix with other oils!
boxes on
page 144.
Oil collecting vessel - Capacity: 8,000 ml.
3 Maintenance
Continued

Oil exchange equip- 3HAC021745-001 Content is defined in section
ment Special tools on page 382.
Draining oil, axis-1 gearbox

Use this procedure to drain the oil in gearbox axis 1.
When using oil exchange equipment, follow the instructions enclosed with the kit.
Art. no. for the kit is specified in Required equipment on page 146.
Action Note
1
DANGER
Turn off all:

area.
2
WARNING

page 38.
3 Remove rear cover on the base by unscrewing

its attachment screws.
4 Pull out the draining hose from the rear of the
base.
xx0200000237
The hose is located beneath the base,

seen from below.
A Oil draining hose
5 Place an oil vessel close to hose end. Vessel capacity is specified in Re-
quired equipment on page 146.
6 Remove oil plug, filling in order to drain oil Shown in figure Location of oil plugs
quicker! on page 146.

3 Maintenance
Continued
Action Note
7 Open the hose end and drain the oil into a
vessel. Note
CAUTION Draining is time-consuming. Elapsed

time depends on the temperature of
Drain as much oil as possible. See Safety risks the oil.
grease) on page 38.
8 Close the oil drain hose, and put it back inside

the base.
9 Refit rear cover by securing it with its attach-
ment screws.
Filling oil, axis-1 gearbox

Use this procedure to fill gearbox axis 1 with oil.
Action Note
1
DANGER
Turn off all:

2
WARNING

Before proceeding, please read the safety information
in the section Safety risks during work with gearbox
lubricants (oil or grease) on page 38.
3 Open the oil plug, filling. Shown in figure Location of oil

plugs on page 146.
4 Refill the gearbox with clean lubricating oil. Where to find type of oil and
The correct oil level is detailed in section Inspecting total amount is detailed in Type
the oil level in axis-1 gearbox on page 114. and amount of oil in gearboxes
on page 144.
5
Note
Do not mix Kyodo Yushi TMO 150 with other oil types!
6 Refit the oil plug, filling. Tightening torque: 24 Nm.

3 Maintenance
3.4.3 Changing oil, gearbox axes 2 and 3
Location of oil plugs

Gearboxes, axes 2 and 3, are located in lower arm rotational center, underneath
motor attachment.
The figure shows the position of gearbox, axis 2.
xx0500002482
A Gearbox axis 2
C Oil plug, filling
D Ventilation hole plug, gearbox axis 2

3 Maintenance
Continued
The figure shows position of gearbox, axis 3.
xx0500002483
A Gearbox, axis 3
C Oil plug, filling
D Ventilation hole plug, gearbox axis 3
Required equipment
Equipment etc. Art. no. Amount Note

Lubricating oil See Type and See Type and
amount of oil in amount of oil in Note
gearboxes on gearboxes on
page 144. page 144. Do not mix with other oils!
Oil collecting vessel Capacity: 6,000 ml


3 Maintenance
Continued
Draining, axes 2 and 3

Use this procedure to drain oil in gearbox axes 2 and 3.
When using oil change equipment, follow the instructions enclosed with kit.
Action Note
1
DANGER
Turn off all:

area.
2
WARNING

grease) on page 38.
3 Remove the ventilation hole plug. Shown in Location of oil plugs on

page 149.
4 Remove the oil plug, draining, and drain gear- Shown in Location of oil plugs on
box using a hose with a nipple and an oil col- page 149.
lecting vessel. Vessel capacity is specified in Re-
Draining is time-consuming.
Elapsed time varies depending on the
temperature of the oil.
5 Refit the oil plug, draining. Tightening torque: 24 Nm.
Filling, axes 2 and 3

Use this procedure to fill gearboxes of axes 2 and 3 with oil.
When using oil change equipment, follow the instructions enclosed with kit.
Action Note
1
DANGER
Turn off all:

area.

3 Maintenance
Continued
Action Note
2
WARNING

grease) on page 38.
3 Remove the oil plug, filling. (Ventilation hole Shown in Location of oil plugs on
plug should also be removed.) page 149.
4
Note
Don´t mix Kyodo Yushi TMO 150 with other oil

types!
5 Refill gearbox with lubricating oil. Art.no. and total amount are specified
The amount of oil to be filled depends on the in Required equipment on page 150.
amount that was previously drained.
6 Refit oil plug,filling and ventilation hole plug. Shown in Location of oil plugs on
page 149.

3 Maintenance
Location of gearbox
The axis 4 gearbox is located in the rearmost part of the upper arm as shown in
the figure below.
xx0700000018
A Oil plug, filling

Required equipment

Lubricating oil See Type and See Type
amount of oil in and
gearboxes on amount of
page 144. oil in gear-
boxes on
page 144.
Oil exchange equipment 3HAC021745-001 Content is defined in section
Special tools on page 382.

3 Maintenance
Continued
Draining, oil
The procedure below details how to drain the oil in the gearbox, axis 4.
When using the oil exchange equipment, follow the instructions enclosed with the
kit. Art. no. for the kit is specified in Required equipment on page 153.
Action Note
1 Run the upper arm -45° from the calibration
position.
2
DANGER
Turn off all:

3
WARNING

page 38.
4 Remove the oil plug, filling.

5 Drain the oil from the gearbox into a vessel by Shown in the figure Location of gear-
opening the oil plug, draining. box on page 153.
Vessel capacity is specified in Re-
6 Run the upper arm back to its calibration posi- This is detailed in section Synchroniz-
tion (horizontal position). ation marks and synchronization pos-
ition for axes on page 345.
Filling, oil
The procedure below details how to fill the oil in the gearbox, axis 4.
Action Note
1
DANGER
Turn off all:


3 Maintenance
Continued
Action Note
2
WARNING

grease) on page 38.
3 Refill the gearbox with clean lubricating oil. Shown in the figure Location of gear-
The correct oil level is detailed in section In- box on page 153.
specting the oil level in axis-4 gearbox on Where to find type of oil and total
page 119. amount is detailed in Type and amount
of oil in gearboxes on page 144.

3 Maintenance
Location of gearbox
The axis 5 gearbox is located in the wrist unit as shown in the figure below.
xx0200000232
- Wrist unit of IRB 6600 and IRB 6650

A Oil plug, filling
Required equipment

amount of oil in amount of oil in
page 144. page 144.
Oil exchange equipment 3HAC021745-001 Content is defined in sec-
tion Special tools on
page 382.
Standard toolkit - Content is defined in sec-
tion Standard tools on
page 381.
Draining, oil, axis 5

The procedure below details how to change the oil in gearbox, axis 5.
Action Note
1 Run axis 4 to a position where the oil plug for
draining is facing downwards.

3 Maintenance
Continued
Action Note
2
DANGER
Turn off all:

3
WARNING

4 Remove the oil plug, filling.

5 Drain the oil from the gearbox by opening the oil Shown in the figure Location of
plug, draining. gearbox on page 156.
Vessel capacity is specified in Re-
Filling, oil, axis 5

The procedure below details how to change the oil in gearbox, axis 5.
Action Note
1 Run axis 4 to a position where the oil plug, filling,
is facing upwards.
2
WARNING

3
DANGER
Turn off all:


3 Maintenance
Continued
Action Note
4 Refill the gearbox with clean lubricating oil. Shown in the figure Location of
The correct oil level is detailed in section Inspect- gearbox on page 156.
ing the oil level in axis-5 gearbox on page 121. Where to find type of oil and total
page 144.

3 Maintenance
Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure
below.
The figure shows the axis-6 gearbox for robot variant IRB 6660 - 100/3.3 and IRB
6660 - 130/3.1, and includes cooling elements on motor. There are no cooling
elements on the axis-6 motor on robot variant IRB 6660 - 205/1.9.
xx0700000161
A Strap
B Gearbox, axis 6
C Oil plug, draining
D Oil plug, filling
E Cooling elements (IRB 6660 - 100/3.3, IRB 6660 - 130/3.1)
Required equipment

amount of oil in amount of oil in Note
page 144. page 144. Do not mix with other oils!

Oil collecting vessel - Vessel capacity:
500 ml

3 Maintenance
Continued
Draining, oil, axis 6

The procedure below details how to drain oil from the gearbox, axis 6.
Action Note
1 Run the robot to a position where the oil plug, Shown in the figure Location of
filling of axis 6 gearbox is facing downwards. gearbox on page 159.
2
DANGER
Turn off all:

3
WARNING

4 Drain the oil from the gearbox into a vessel by Vessel capacity is specified in Re-
removing the oil plug. quired equipment on page 159.
Measure the amount of oil drained. The amount of oil to be refilled de-
pends on the amount previously
drained.
Filling, oil, axis 6

The procedure below details how to fill oil into the gearbox, axis 6.
Action Note
1
DANGER
Turn off all:


3 Maintenance
Continued
Action Note
2
WARNING

3 Remove the oil plug, filling. Shown in the figure Location of

4 Refill the gearbox with clean lubricating oil. Where to find type of oil and total
The correct oil level is detailed in section Inspect- amount is detailed in Type and
ing the oil level in axis-6 gearbox on page 123. amount of oil in gearboxes on
page 144.
5 Refit the oil plug. Tightening torque: 24 Nm.
Inspect the oil level. Detailed in the section Inspecting
the oil level in axis-6 gearbox on
page 123.

3 Maintenance
3.4.7 Replacing the SMB battery
Note
The battery low alert (38213 Battery charge low) is displayed when the battery
needs to be replaced. The recommendation to avoid an unsynchronized robot
is to keep the power to the controller turned on until the battery is to be replaced.
For a SMB board with 3-pole battery contact (RMU101 3HAC044168-001 or
RMU102 3HAC043904-001), the lifetime of a new battery is typically 36 months.
For a SMB board with 2-pole battery contact (DSQC), the typical lifetime of a new
battery is 36 months if the robot is powered off 2 days/week or 18 months if the
robot is powered off 16 h/day. The lifetime can be extended for longer production
breaks with a battery shutdown service routine. See Operating manual - IRC5
with FlexPendant for instructions.
WARNING
See instructions for batteries, Safety risks during handling of batteries on page 37.
Location of SMB battery

The SMB battery (SMB = serial measurement board) is located on the left hand
side of the frame as shown in the figure.
Battery pack with a 2-pole battery contact (DSQC)
xx0700000029
A SMB battery cover

B SMB battery pack with 2-pole battery contact.
C Battery cable

3 Maintenance
Continued
Battery pack with a 3-pole battery contact (RMU)
A B C D E F G
xx1400002574
A Battery pack RMU

B Holder for battery
C SMB cover
D Battery cable
E Battry holder
F Guide pin (2 pcs)
G SMB unit
Required equipment
Note
There are two variants of SMB units and batteries. One with 2-pole battery contact
(DSQC) and one with 3-pole battery contact (RMU). The variant with the 3-pole
battery contact has longer lifetime for the battery.
It is important that the SMB unit uses the correct battery. Make sure to order the
correct spare parts. Do not exchange battery contacts!
Equipment, etc. Spare part no. Note

Battery unit For spare part no. Battery includes protection circuits. Only re-
see: place with a specified spare part or an ABB-
• Spare part approved equivalent.
lists on
page 387
Standard toolkit - Content is defined in section Standard tools
on page 381.

3 Maintenance
Continued
Equipment, etc. Spare part no. Note

Circuit diagram - See chapter Circuit diagram on page 389.
Removing, battery
Use this procedure to remove the SMB battery.
Action Note
1 Move the robot to its calibration position. This is done in order to facilitate
updating of the revolution counter.
2
DANGER
Turn off all:

3
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the

unit please read the safety information in the sec-
tion The unit is sensitive to ESD on page 33
4 Remove the SMB battery cover by unscrewing the Shown in figure Location of SMB
attachment screws. battery on page 162.
CAUTION
Clean cover from metal residues before opening.

Metal residues can cause shortage on the boards
which can result in hazardous failures.
5 Pull out the battery and disconnect the battery Shown in figure Location of SMB
cable. battery on page 162.
6 Remove the SMB battery. Shown in figure Location of SMB
Battery includes protection circuits. Only replace battery on page 162.
with a specified spare part or with an ABB- ap-
proved equivalent.
Refitting, battery
Use this procedure to refit the SMB battery.
Action Note
1
DANGER
Turn off all:

area.

3 Maintenance
Continued
Action Note
2

unit please read the safety information in the sec-
tion The unit is sensitive to ESD on page 33
3 Reconnect the battery cable and install the battery Art. no. is specified in Required
pack into the SMB/battery recess. equipment on page 163.
Shown in figure Location of SMB
Note battery on page 162.
C
RMU batteries are installed together with a battery
holder to be properly secured inside the recess.
See figure.
Strap the battery cable to the holder.
A
D B
xx1300000307
A Battery pack RMU

B Battery holder
C Battery cable
D Strap
4 Secure the SMB battery cover with its attachment Shown in figure Location of SMB
screws. battery on page 162.
5 Update the revolution counters. Detailed in chapter Calibration -
section Updating revolution coun-
ters on page 348.
6
DANGER
Make sure all safety requirements are met when

performing the first test run. These are further
detailed in the section First test run may cause
injury or damage on page 28.

3 Maintenance
3.5.1 Lubricating balancing device bearings and piston rod
3.5 Lubrication activities
Note
This section is not applicable to the robot variant IRB 6660-205/1.9
Overview
This procedure details how to lubricate bearings and piston rod of the balancing
device.
Location of bearing and piston rod

This figure shows the location of bearings and piston rod.
Note! Balancing device must be fitted on robot when lubricating bearings.
xx0500002489
A Ear (bearing located inside)

B Support washer

3 Maintenance
Continued
C Lock nut
D Piston rod
E Guide ring (not visible in this view)
Required equipment
Equipment Art.no. Note

Lubrication tool 3HAC5222-1
Bearing grease 3HAB3537-1 Equivalent:
• Shell Alvania WR 2
Cleaning agent - Isopropanol
Piston rod grease - Choose any of following equivalents:
• Shell: SRS Grease 4000
• Preem: Novatex Heavy EP 2
• Castrol: Entrepenadfett
• Statoil: Uniway 2X2N
tools on page 381.
Lubricating, bearings
Use this procedure to lubricate the balancing device bearings.
Action Note
1 Move axis 2 to calibration position.
2
DANGER
Turn off all:

3 Remove locknut. Be careful not to loose the sup-

port washer in the process.
4 Fit the lubricating tool. It should be tightened to the
bottom, by hand only.
5 Grease through nipple on the lubricating tool.
6 Continue filling grease until clean grease exudes be-
hind the inner sealing ring.
Repeat this procedure at the other bearing!
7 Remove lubricating tool and clean threads on shaft Also clean from old grease on
ends free from grease. the inner side!
8 Apply some grease on the support washers.

3 Maintenance
Continued
Action Note
9 Apply locking liquid on the lock nuts (KM10). Tightening torque on lock nuts:
• 120 Nm
Note
Do not apply locking liquid on the shafts!
10 Check play between support washer and bearings at Minimum play:

both bearings. • 0.1 mm
Lubricating, piston rod

Use this procedure to lubricate the balancing device piston rod.
Action Note
1 Move axis 2 to a position where the balancing device
is in horizontal position and the piston rod extended
as much as possible.
2
DANGER
Turn off all:

3 Clean piston rod with isopropanol before applying

new grease.
4 Apply new grease. Type of grease is specified in
Required equipment on page167.

3 Maintenance
3.6.1 Cleaning the IRB 6660
3.6 Cleaning activities
WARNING
Turn off all electrical power supplies to the manipulator before entering its work
space.
General
To secure high uptime it is important that the IRB 6660 is cleaned regularly. The
frequency of cleaning depends on the environment in which the product works.
Different cleaning methods are allowed depending on the type of protection of the
IRB 6660.
Note
Always verify the protection type of the robot before cleaning.
Oil spills
Oil spills from gearboxes
Use the following procedure if any oil spills are detected that can be suspected to
originate from a gearbox.
1 Inspect that the oil level in the suspected gearbox is according to the
recommendations, see Inspection activities on page 114.
2 Write down the oil level.
3 Inspect the oil level again after, for example, 6 months.
4 If the oil level is decreased then replace the gearbox.
Special cleaning considerations

This section specifies some special considerations when cleaning the robot.
• Always use cleaning equipment as specified. Any other cleaning equipment
may shorten the life of the robot.
• Always check that all protective covers are fitted to the robot before cleaning.
• Never point the water jet at connectors, joints, sealings, or gaskets.
• Do not use compressed air to clean the robot.
• Never use solvents that are not approved by ABB to clean the robot.
• Do not spray from a distance closer than 0.4 m.
• Do not remove any covers or other protective devices before cleaning the
robot.

3 Maintenance
Continued
Cleaning methods
The following table defines what cleaning methods are allowed depending on the
protection type.
Protection Cleaning method
type
Vacuum Wipe with cloth Rinse with water High pressure water or
cleaner steam
Standard Yes Yes. With light Yes. It is highly re- No
cleaning deter- commended that
gent. the water contains
a rust-prevention
solution and that
the manipulator is
dried afterwards.
Foundry Plus Yes Yes. With light Yes. It is highly re- Yes i .
cleaning deter- commended that It is highly recommended
gent or spirit. the water contains that the water and steam
a rust-prevention contains rust preventive,
solution. without cleaning deter-
gents.
i Perform according to section Cleaning with water and steam on page 170.
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). 1
The following list defines the prerequisites:
• Maximum water pressure at the nozzle: 700 kN/m 2 (7 bar) I
• Fan jet nozzle should be used, min. 45° spread

• Minimum distance from nozzle to encapsulation: 0.4 meters
• Maximum flow: 20 liters/min I
I Typical tap water pressure and flow
Instructions for steam or high pressure water cleaning

ABB robots with protection types Foundry Plus, Wash, or Foundry Prime can be
cleaned using a steam cleaner or high pressure water cleaner. 2
The following list defines the prerequisites:
• Maximum water pressure at the nozzle: 2500 kN/m 2 (25 bar)
• Fan jet nozzle should be used, min. 45° spread
• Minimum distance from nozzle to encapsulation: 0.4 meters
• Maximum water temperature: 80° C
Cables
Movable cables need to be able to move freely:
• Remove waste material, such as sand, dust and chips, if it prevents cable
movement.
1 See Cleaning methods on page 170 for exceptions.
2 See Cleaning methods on page 170 for exceptions.

3 Maintenance
Continued
• Clean the cables if they have a crusty surface, for example from dry release
agents.
Cooling fans
Inspect the air supply inlet of the the motor cooling fans. Clean to remove any
contamination that could hinder the air supply.

4 Repair
4.1 Introduction
4 Repair
4.1 Introduction
Structure of this chapter

This chapter describes all repair activities recommended for the IRB 6660 and any
external unit.
It is made up of separate procedures, each describing a specific repair activity.
Each procedure contains all the information required to perform the activity, for
example spare parts numbers, required special tools, and materials.
WARNING
Repair activities not described in this chapter must only be carried out by ABB.
Otherwise damage to the mechanics and electronics may occur.
Required equipment
The details of the equipment required to perform a specific repair activity are listed
in the respective procedures.
The details of equipment are also available in different lists in the chapter Reference
information on page 373.
Safety information
There are general safety information and specific safety information. The specific
safety information describes the danger and safety risks while performing specific
steps in a procedure. Make sure to read through the chapter Safety on page 19
before commencing any service work.
Note
If the IRB 6660 is connected to power, always make sure that the IRB 6660 is
connected to earth before starting any repair work.

4 Repair
4.2.1 Performing a leak-down test
4.2 General procedures
4.2.1 Performing a leak-down test
When to perform a leak-down test

After refitting any motor and gearbox, the integrity of all seals enclosing the gearbox
oil must be tested. This is done in a leak-down test.
Required equipment

Leak-down tester -
Leak detection spray -
Performing a leak-down test
Action Note
1 Finish the refitting procedure of the motor or gear in
question.
2 Remove the upper oil plug on the gear and replace
it with the leak-down tester.
Regulators, which are included in the leak-down test,
may be required.
3 Use caution, apply compressed air and raise the Correct value:
pressure with the knob until the correct value is 0.2-0.25 bar (20-25 kPa)
shown on the manometer.
CAUTION
The pressure must under no circumstance be higher

than 0.25 bar (20-25 kPa). Also during the time when
the pressure is raised.
4 Disconnect the compressed air supply.

5 Wait for approximately 8-10 minutes and make sure If the compressed air is signific-
that no pressure loss occurs. antly colder or warmer than the
gearbox to be tested, a slight
pressure increase or decrease
may occur. This is quite normal.
6 If any pressure drop occurred, then localize the leak
as described in step 7.
If no pressure drop occurred, then remove the leak-
down tester and refit the oil plug. The test is complete.
7 Spray any suspected leak areas with the leak detec-
tion spray. Bubbles indicate a leak.
8 When the leak has been localized, take the necessary
measures to correct the leak.

4 Repair
4.2.2 Mounting instructions for bearings
General
This section describes how to mount and grease different types of bearings on the
robot.
Equipment

Grease 3HAB3537-1 Used to grease the bearings, if not
specified otherwise.
Assembly of all bearings

Attend to the following instructions while mounting a bearing on the robot.
Action Note
1 To avoid contamination, let a new bearing remain in its wrapping
until it is time for fitting.
2 Ensure that the parts included in the bearing fitting are free from
burrs, grinding waste, and other contamination. Cast components
must be free of foundry sand.
3 Bearing rings, inner rings, and roller elements must not be subjec-
ted to direct impact. The roller elements must not be exposed to
any stresses during the assembly work.
Assembly of tapered bearings

Follow the preceding instructions for the assembly of the bearings when mounting
a tapered bearing on the robot.
In addition to those instructions, the following procedure must be carried out to
enable the roller elements to adjust to the correct position against the race flange.
Action Note
1 Tension the bearing gradually until the recommended pre-tension is achieved.
Note
The roller elements must be rotated a specified number of turns before pre-
tensioning is carried out and also rotated during the pre-tensioning sequence.
2 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.

4 Repair
Continued
The bearings must be greased after assembly according to the following

instructions:
• The bearings must not be completely filled with grease. However, if space
is available beside the bearing fitting, the bearing may be totally filled with
grease when mounted, as excessive grease will be pressed out from the
bearing when the robot is started.
• During operation, the bearing should be filled to 70-80% of the available
volume.
• Ensure that grease is handled and stored properly to avoid contamination.
Grease the different types of bearings as following description:
• Grooved ball bearings must be filled with grease from both sides.
• Tapered roller bearings and axial needle bearings must be greased in the
split condition.

4 Repair
4.2.3 Mounting instructions for seals
General
This section describes how to mount different types of seals.
Equipment

Grease 3HAB3537-1 Used to lubricate the seals.
Rotating seals
The procedure below describes how to fit rotating seals.
CAUTION
Please observe the following before commencing any assembly of seals:

• Protect the sealing surfaces during transport and mounting.
• Keep the seal in its original wrappings or protect it well before actual
mounting.
• The fitting of seals and gears must be carried out on clean workbenches.
• Use a protective sleeve for the sealing lip during mounting, when sliding
over threads, keyways, etc.
Action Note
1 Check the seal to ensure that:
• The seal is of the correct type (provided with cutting
edge).
• There is no damage to the sealing edge (feel with a
fingernail).
2 Inspect the sealing surface before mounting. If scratches
or damage are found, the seal must be replaced since it
may result in future leakage.
3 Lubricate the seal with grease just before fitting. (Not too Article number is specified
early - there is a risk of dirt and foreign particles adhering in Equipment on page 177.
to the seal.)
Fill 2/3 of the space between the dust tongue and sealing
lip with grease. The rubber coated external diameter must
also be greased, unless otherwise specified.
4 Mount the seal correctly with a mounting tool.
Never hammer directly on the seal as this may result in
leakage.
Make sure no grease left on the robot surface.

4 Repair
Continued
Flange seals and static seals

The following procedure describes how to fit flange seals and static seals.
Action
1 Check the flange surfaces. They must be even and free from pores.
It is easy to check flatness using a gauge on the fastened joint (without sealing com-
pound).
If the flange surfaces are defective, the parts may not be used because leakage could
occur.
2 Clean the surfaces properly in accordance with the recommendations of ABB.
3 Distribute the sealing compound evenly over the surface, preferably with a brush.
4 Tighten the screws evenly when fastening the flange joint.
O-rings
The following procedure describes how to fit o-rings.
Action Note
1 Ensure that the correct o-ring size is used.
2 Check the o-ring for surface defects, burrs, Defective o-rings, including damaged
shape accuracy, or deformation. or deformed o-rings, may not be used.
3 Check the o-ring grooves. Defective o-rings may not be used.
The grooves must be geometrically correct and
should be free of pores and contamination.
4 Lubricate the o-ring with grease.
5 Tighten the screws evenly while assembling.
Make sure that no grease is left on the robot
surface.

4 Repair
4.2.4 Cut the paint or surface on the robot before replacing parts
4.2.4 Cut the paint or surface on the robot before replacing parts
General
Follow the procedures in this section whenever breaking the paint of the robot
during replacement of parts.
Required equipment
Equipment Spare parts Note

Cleaning agent Ethanol
Knife
Lint free cloth
Touch up paint Standard/Foundry 3HAC037052-001
Plus, ABB Orange
Removing
Action Description
1 Cut the paint with a knife in the joint between
the part that will be removed and the struc-
ture, to avoid that the paint cracks.
xx0900000121
2 Carefully grind the paint edge that is left on

the structure to a smooth surface.

4 Repair
4.2.5 The brake release buttons may be jammed after service work
4.2.5 The brake release buttons may be jammed after service work
Description
The brake release unit has push-buttons for the brake release of each axis motor.
When service work is performed inside the SMB recess that includes removal and
refitting of the brake release unit, the brake release buttons may be jammed after
refitting.
DANGER
If the power is turned on while a brake release button is jammed in depressed

position, the affected motor brake is released. This may cause serious personal
injuries and damage to the robot.
Elimination
To eliminate the danger after service work has been performed inside the SMB
recess, follow the procedure below.
Action
1 Make sure the power is turned off.
2 Remove the push-button guard, if necessary.
3 Verify that the push-buttons of the brake release unit are working by pressing them
down, one by one.
Make sure none of the buttons are jammed in the tube.
4 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.

4 Repair
4.3.1 Replacement of cable harness, lower end (axes 1-3)
4.3 Complete robot
Overview
The cable harness 1-6 is undivided.
Replacement of the cable harness is detailed in two steps - lower end (axes 1-3)
and upper end (axes 4-6). The procedure below details replacement of lower end
of the cable harness. The procedure for replacing the upper end is detailed in
section Replacement of cable harness, upper end on page 196.
Location of cable harness - lower end (axes 1-3)

The cable harness, lower end (axes 1-3) is located throughout the base, frame and
lower arm as shown in the figure below.
xx0700000070

B Metal clamp
C Connector at base
D Cable guide, axis 1
E Cable harness, axes 1-6
F Cover plate
G Rear cover plate
4 Repair
Continued
H Attachment point for earth lug
The motors axes 2-3 are located on either side of the robot as shown in the figure
below.
xx0600002599
A Motor, axis 2
B Motor, axis 3
C Motor attachment screws and washers
D Cable gland cover (located on the lower side of the motor)
E Motor cover
Required equipment
Equipment, etc. Spare part no. Art.no. Note

Cable harness axes For spare part num-
1-6 ber, see Spare part
lists on page 387.
Gasket 3HAC3537-1 Motor axes 1-5
page 381.
Other tools and pro- These procedures include
cedures may be re- references to the tools re-
quired. See refer- quired.
ences to these pro-
cedures in the step-
by-step instructions
below.
Circuit diagram 3HAC025744-001 See chapter Circuit dia-
gram on page 389.

4 Repair
Continued
Removal, cable harness - lower end (axes 1-3)

The procedure below details how to remove the cable harness, lower end (axes
1-3).
Action Note
1 Move the robot to the calibration position. This is done in order to facilitate updat-
ing of the revolution counter.
2
DANGER
Turn off all:

area.
3 Remove the rear cover plate on the robot by Shown in Location of cable harness -
removing its attachment screws. lower end (axes 1-3) on page 181.
4 Disconnect the earth cable. Shown in Location of cable harness -
lower end (axes 1-3) on page 181.
5 Disconnect connectors R1.MP and R1.SMB. Shown in Location of cable harness -
6 Remove the cable guide axis 2.
xx0600002698
• A: Cable guide ax 2
7 Unscrew the screws in the metal clamps holding Shown in Location of cable harness -
the cable harness in the frame and lower arm. lower end (axes 1-3) on page 181
8 Remove the motor cover, axis 1, 2, 3 by remov-
ing its attachment screws, in order to reach the
connectors.
9 Disconnect all connectors at motor 1, 2 and 3.

4 Repair
Continued
Action Note
10 Open the SMB cover carefully.
The cable (C) between the battery and the SMB
unit may stay connected, in order to avoid an
update of the revolution counter. Be careful not
to let the weight of the cover strain the cable!
In order to remove the cover completely, the
connector R1.G must be disconnected! This
causes a necessary updating of the revolution
counter!
xx0600002700
• A: SMB battery cover

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

• B: Attachment screws (4 pcs)

4 Repair
Continued
Action Note
13 Gently pull the cable harness out of base
through the cable guide, axis 1 and the frame.
xx0700000154

• B: Metal clamp, frame
• C: Cable guide, axis 1
14 Continue removal of the cable harness in the Detailed in Replacement of cable har-
upper arm. ness, upper end on page 196.

4 Repair
Continued
Refitting, cable harness - lower end (axes 1-3)

The procedure below details how to refit the cable harness, lower end (axes 1-3).
Action Note
1 Pull the cable and connectors down through Make sure the cables are not twisted
the cable guide axis 1 in the center of the frame. with each other or with eventual cus-
tomer harness!
xx0700000154

• B: Metal clamp, frame
• C: Cable guide, axis 1
2 Pull out the cables and connectors to the SMB
unit through the frame and refit the cable gland
with its four attachment screws from inside the
SMB recess.
Perform this refitting with care, in order not to
damage any of the components inside the SMB
recess.
xx0600002701

• B: Attachment screws, (4 pcs)

4 Repair
Continued
Action Note
3 Reconnect connectors R1.MP and R1.SMB at Tightening torque for R1.SMB: 10 Nm.
the robot base. Attachment points are shown in the
figure Location of cable harness -
4 Reconnect the earth cable. Attachment point is shown in the fig-
ure Location of cable harness - lower
end (axes 1-3) on page 181
5 Refit the rear cover plate on the robot with its Shown in the figure Location of cable
attachment screws. harness - lower end (axes 1-3) on
page 181
6 Reconnect all connectors at motor 1, 2 and 3.
7 Refit the motor cover, axis 1, 2, 3.
Make sure the cabling is placed correctly when
refitting the cover and does not get jammed.
8 Reconnect connectors R2.SMB, R1.SMB1-3,
R1.SMB4-6 to the SMB unit.
Reconnect X8, X9 and X10 to the brake release
unit.
Reconnect R1.G if it has been disconnected.
9 Secure the SMB cover with its attachment
screws.
If cabling is used for 7th axis (option), refit the
connector R2.FB7 to the SMB cover and tighten
with 6 Nm.
10
WARNING
Before continuing any service work, please

observe the safety information in section The
brake release buttons may be jammed after
service work on page 180!

4 Repair
Continued
Action Note
11 Refit the cable guide, axis 2.
xx0600002698
• A: Cable guide axis 2

12 Pull the cable harness through the lower arm.
13 Refit the metal clamps holding the cable har- Shown in the figure Location of cable
ness in the frame and lower arm with its attach- harness - lower end (axes 1-3) on
ment screws. page 181.
14 Continue refitting of the cable harness in the Detailed in section Replacement of
upper arm. cable harness, upper end on page 196.
15 Update the revolution counter! Detailed in section Updating revolution
counters on page 348.
16
DANGER


4 Repair
4.3.2 Replacement of process cable package 1 - 3 MH
Location of process cable package axes 1 - 3 MH

The process cable package for axes 1 - 3 MH is located throughout the base, frame
and lower arm as shown in the figure below.
xx0700000657
A Metal clamp (inside lower arm)

B Process cable package, cables
C Process cable package, hose
D Cable guide
E Metal clamp
F Connectors at base
G Customer plate
H Rear cover plate
J Earth

4 Repair
Continued
Required equipment
Equipment Art. no Note

Process cable package 1 - 3 MH For spare part number,
see Spare part lists on
page 387.
Other tools and procedures may - These procedures include ref-
be required. See references to erences to the tools required.
Circuit diagram - See Circuit diagram on
page 389.
Removal
The procedure below details how to remove the process cable package 1 - 3 MH.
Action Note
1 Move the robot to the calibration position.
2
DANGER
Turn off all electric power, hydraulic and

pneumatic pressure supplies to the robot!
3
CAUTION
The cable package is sensitive to mechanic-

al damage. They must be handled with care,
especially the connectors, in order to avoid
damaging them.
4 Remove the rear cover plate at the back of Shown in the figure Location of process
the robot base in order to reach the connect- cable package axes 1 - 3 MH on page 189.
ors at the base.

4 Repair
Continued
Action Note
5 Disconnect the hose from the customer
plate.
xx0700000643
Parts:
• A: Customer plate
• B: Hose connector R1.PROC1
6 Disconnect the cable connectors from the
customer plate.
xx0700000645
Parts:
• A: Connector R1.CP/CS
• B: Connector R1.SP/R3.FP7

4 Repair
Continued
Action Note
7 Remove the prev. torque nuts securing the
metal clamp of the process cable package,
to the metal clamp of the robot cable pack-
age, at the SMB recess.
xx0700000646
Parts:
• A: Metal clamp bracket, robot cable
package
• B: Metal clamp bracket, process
cable package
• C: Position for prev. torque nuts
8 Pull the lower end of the process cable Order of removal:
package out through the centrum hole in 1 Hose
gearbox axis 1. 2 Cables
9 Remove the prev. torque nuts securing the
process cable package on the inside of the
lower arm.
xx0700000649
Parts:
• A: Position for prev. torque nuts
• B: Process cable package

4 Repair
Continued
Action Note
10 Disconnect all connectors on the attachment
plate.
xx0700000648
Parts:
• A: Attachment plate
• B: Attachment screws M10x16
quality 8.8-A3F (2 pcs)
• C; Strap, velcro
• D: Connectors
11 Pull the process cable package gently out
off the lower arm. Note
Perform this carefully in order not to

damage the cable harness of the robot.
Refitting
The procedure below details how to refit the process cable package 1 - 3 MH.
Action Note
1 Push the process cable package gently Make sure that the cables are not twisted
down through the lower arm. with each other.
Note
Perform this carefully in order not to

damage the cable harness of the robot.

4 Repair
Continued
Action Note
2 Connect all connectors at the attachment
plate.
xx0700000648
Parts:
• A: Attachment plate
• B: Attachment screws M10x16
quality 8.8-A3F (2 pcs)
• C: Strap, velcro
• D: Connectors
3 Refit the prev. torque nuts securing the
process cable package on the inside of the
lower arm.
xx0700000649
Parts:
• A: Position for prev. torque nuts
• B: Process cable package
4 Push the process cable package gently Order of refitting:
down through the cable guide in the 1 Cables
centrum hole in gearbox axis 1. 2 Hose

4 Repair
Continued
Action Note
5 Secure the metal clamp of the process cable
package, with the prev. torque nuts on the
metal clamp of the robot cable package,
close to the SMB recess.
xx0700000646
Parts:
• A: Metal clamp bracket, robot cable
package
• B: Metal clamp bracket, process
cable package
• C: Position for prev. torque nuts
6 Connect all connectors at the customer
plate.
xx0700000645
Parts:
• A: Connector R1.CP/CS
• B: Connector R1.SP/R3.FP7
7 Refit the rear cover plate. Shown in the figure Location of process
cable package axes 1 - 3 MH on page 189.
8 Update the revolution counter.
9
DANGER
Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section First test
run may cause injury or damage on page 28.

4 Repair
4.3.3 Replacement of cable harness, upper end
Introduction
The cable harness 1-6 is undivided.
Replacing the cable harness is described in two steps:
• lower end (axes 1-3)
• upper end (axes 4-6)
This procedure details how to replace the upper end.
For description of how to replace the lower end, see Replacement of cable harness,
Location of cable harness

The cable harness for the axes 4 to 6 runs throughout the upper arm and wrist unit
as shown in the figure below:
xx0700000071
A Cable harness, axes 1-6

B Cable bracket, upper arm tube
C Cable bracket, wrist unit
D Cable starps, outdoor
E Attachment screws (cable attachment armhouse), M10x16 quality 8.8 (2 pcs)
F Attachment screw (cable attachment rear), M6x25 quality 12.9 Gleitmo
Required equipment
Equipment, etc. Note

Cable harness axes 1-6 See Spare part lists on page 387.

4 Repair
Continued
Equipment, etc. Note

Gasket Motors axes 1-5
See Spare part lists on page 387.
Gasket Motor axis 6. Recommended to be changed
for Foundry Plus.
See Spare part lists on page 387.
Retrofit set Foundry Plus, wrist See Spare part lists on page 387.
Retrofit set Foundry Plus, upper arm axis 4 See Spare part lists on page 387.
Standard toolkit Content is defined in section Standard tools
on page 381.
Other tools and procedures may be required. These procedures include references to the
See references to these procedures in the tools required.
step-by-step instructions below.
Circuit diagram See chapter Circuit diagram on page 389.
Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Action Note
1 Decide which calibration routine to use for
calibrating the robot.
• Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
• Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
If the robot is to be calibrated with refer- Follow the instructions given in the refer-
ence calibration: ence calibration routine on the FlexPendant
Find previous reference values for the axis to create reference values.
or create new reference values. These val- Creating new values requires possibility to
ues are to be used after the repair proced- move the robot.
ure is completed, for calibration of the ro- Read more about reference calibration for
bot. Axis Calibration in Reference calibration
If no previous reference values exist, and routine on page 353.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
Removal
The procedure below details how to remove the cable harness.
Action Note
1 Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.

4 Repair
Continued
Action Note
2 In order to facilitate refitting of the cable
harness, run the robot to the specified pos- Note
itions:
• Axis 1: 0° Axis 5 must be oriented in the correct po-
• Axis 2: 0° sition (+90°) to allow the cover of motor
• Axis 3: 0° axis 6 to open.
• Axis 4: 0°
• Axis 5: +90°
• Axis 6: no significance
3
DANGER
Turn off all:

• hydraulic pressure supply to the ro-
bot
4 Before starting the removal of the axes-4-6 Detailed in the section Replacement of
cable harness, first remove the cable har- cable harness, lower end (axes 1-3) on
ness of axes 1-3. page 181.
5 Remove the cover, wrist unit in order to
reach the cable harness at axes 5 and 6.
Note
Foundry Plus
Make sure not to lose the washers placed
in the holes of the foundry gasket.
xx0700000140
• A : Cover, wrist unit
xx1400002580

4 Repair
Continued
Action Note
6 Remove the cable holder in the wrist unit
by unscrewing the three attachment screws.
Two of the attachment screws (M6x16) are
visibly located at the rear of the cable hold-
er. The third screw (M4x12) is located at the
bottom of the cable holder, securing the
carrier.
xx0600003034
• A : Cable holder
• B : Attachment screws M6x16, 8.8
(2 pcs)
• C : Attachment screw M4x12, 8-
A2F (securing the carrier)
7 Remove the back cover motor, axis 6 by
removing its attachment screws.
8 Pull out the cabling R2.MP6 and R2.FB6 Shown in the figure Location of cable
from motor axis 6 . harness on page 196
9 Disconnect all connectors at motor axis 6 Shown in the figure Location of cable
R2.MP6 and R2.FB6. harness on page 196
10 Loosen the cable bracket in the upper arm
tube by undoing its two attachment screws
on top of the tube.
11 Disconnect the two connectors (R2.FB5 and
R2.MP5) inside the tube.
xx0700000072
Parts:
• A: Motor axis 5 with connectors
R4.FB5 and R4.MP5
• B: Connectors R2.FB5 and R2.MP5
• C: Upper arm tube
12 Remove eventual cable straps from the
harness.
13 Remove the cover motor axis 4 by removing
14 Disconnect all connectors at motor axis 4 Shown in the figure Location of cable
(R2.MP4, R2.FB4). harness on page 196

4 Repair
Continued
Action Note
15 Remove the metal clamps, on the arm-
house.
16 Foundry Plus
Remove the Foundry Plus arm house cover.
xx1400002582
17 Use caution and pull out the cable harness

of the upper arm.
18 Tie the connectors into a bundle, to avoid
damaging them during further removal.
Refitting
The procedure below details how to refit the cable harness.
Action Note
1 Begin by refitting the cable harness lower Detailed in the section Replacement of
end (axes 1-3). cable harness, lower end (axes 1-3) on
page 181.
2 Insert the cable harness gently from the rear Arrange the cable harness as shown in
into the upper arm. the figure Location of cable harness on
page 196
3 Refit the cable gland securing the cables to
the armhouse.
Make sure not to twist the harness.
xx0700000041
4 Connect the two connectors inside the up-

per arm tube, (R2.MP5 and R2.FB5) and
secure the cable bracket with its two attach-
ment screws to the tube.

4 Repair
Continued
Action Note
5 Place the cabling to motor axis 6 correctly Shown in the figure Location of cable
on the upper arm and pull the connectors harness on page 196
carefully through the hole on top of the wrist We recommend changing the gasket on
unit to motor, axis 6. the cover for Foundry Plus robots.
6 Reconnect all connectors at motor axis 4
(R2.MP4,R2.FB4).
7 Refit cover motor axis 4.
8 Refit the cable holder wrist unit with the
three attachment screws.
Two of the attachment screws (M6x16) are
visibly located at the rear of the cable hold-
er. The third screw (M4x10) is located at the
bottom of the cable holder, securing the
carrier.
xx0600003034
• A : Cable holder
• B : Attachment screws M6x16,
quality 8.8 (2 pcs)
• C . Attachment screws M4x10,
quality 8-A2F (securing the carrier)
9 Reconnect the motor cables axis 6 R2.MP6 Shown in the figure Location of cable
and R2.FB6. harness on page 196
10 Refit cover motor, axis 6.
11 Refit the metal clamps, on the armhouse.
12 Standard
Fit the wrist cover.
xx0700000140
• A : Cover, wrist unit

4 Repair
Continued
Action Note
13 Foundry Plus
Make sure the wrist cover gasket and the
small gasket fitted in the recess of the wrist
cover are undamaged. Replace if damaged.
xx1400002579
14 Foundry Plus
Make sure the washers are fitted in the
gasket holes.
xx1400002580
15 Foundry Plus
Fit the wrist cover, Foundry Plus.
Make sure the gasket stays undamaged
after fitting. Replace if damaged.
16 Foundry Plus
Make sure the gasket on the adapter ring is
undamaged. Replace if damaged.
xx1400002581

4 Repair
Continued
Action Note
17 Foundry Plus
Fit the Foundry Plus cover on the adapter
ring.
xx1400002582
18 If the connection between the SMB battery Detailed in the section Updating revolu-
and the SMB unit has been broken, the re- tion counters on page 348.
volution counters must be updated.
19 Make sure the gasket on the adapter ring is
undamaged. Replace if damaged.
20 Recalibrate the robot. Pendulum Calibration is described in Op-
erating manual - Calibration Pendulum,
enclosed with the calibration tools.
Axis Calibration is described in Calibrat-
ing with Axis Calibration method on
page 352.
General calibration information is included
in section Calibration on page 341.
21
DANGER


4 Repair
4.3.4 Replacement of cabling, axis 5 motor
Location of cabling
The separate cables for the axis 5 motor are located inside the upper arm tube, as
shown in the figure below.
IRB 6660 - 100/3.3, IRB 6660 - 130/3.1
xx0700000055
A Motor axis 5 with connectors R4.FB5 and R4.MP5

B Connectors R3.FB5 and R3.MP5
IRB 6660 - 205/1.9
xx0700000632
A Cable cover
B Motor axis 5 with connectors R4.FB5 and R4.MP5
C Connectors R3.FB5 and R3.MP5
Required equipment
Equipment Spare part no. Note

Cable harness axis 5 See Spare part lists
on page 387.

4 Repair
Continued
Equipment Spare part no. Note

Circuit diagram 3HAC025744-001
Standard toolkit Content is defined in section Stand-
Removal, cabling axis 5 motor

The procedure below details how to remove the cabling from the axis 5 motor.
Action Note
1
DANGER
Turn off all:

2 Remove the complete wrist unit. Detailed in section:

• Removal, wrist unit on page 223.
3 Remove the cover of motor, axis 5.
4 Disconnect all connectors at motor, axis 5.
5 Remove the cable gland cover at the cable
exit by unscrewing its two attachment screws.
6 Remove the cable, axis 5.
Refitting, cabling axis 5 motor

The procedure below details how to refit the cabling to the motor of axis 5.
Action Note
1
DANGER
Turn off all:

2 Reconnect all connectors at motor, axis 5.

3 Refit the cable gland cover at the cable exit
with its two attachment screws.
4 Refit the cover of motor, axis 5.
5 Refit the complete wrist unit. Detailed in section:
• Refitting, wrist unit on page 225.

4 Repair
Continued
Action Note
6 Re-calibrate the robot. This is done if a new wrist has been
fitted.
Calibration is detailed in a separate
calibration manual enclosed with the
calibration tools.
General calibration information is in-
cluded in section Calibration on
page 341.
7
DANGER

when performing the first test run. These are
further detailed in the section First test run
may cause injury or damage on page 28.

4 Repair
4.3.5 Replacement of complete arm system
Location of arm system

The complete arm system is defined as the complete robot except for the base
and axis-1 gearbox. This is shown in the figure below.
A more detailed view of the component and its position may be found in Spare part
lists on page 387.
IRB 6660 - 100/3.3, IRB 6660 - 130/3.1
xx0700000073
A Upper arm
B Lower arm
C Motor, axis 1
D Frame
E Base
F Gearbox, axis 1
G Attachment screws base M12x70, quality 12.9 Gleitmo (24 pcs)
H Calibration plate axis 1

4 Repair
Continued
IRB 6660 - 205/1.9
xx0700000633
A Upper arm
B Lower arm
C Frame
D Motor, axis 1
E Gearbox, axis 1
F Attachment screws base M12x70, quality 12.9 Gleitmo (24 pcs)
G Base
H Calibration plate axis 1
Required equipment

Lifting accessory, robot 3HAC15607-1 Instruction 3HAC15971-2 is enclosed!
Guide pins M12 x 130 3HAC022637-001 Used to guide the complete arm system
when lifting it.
Always use the guide pins in pairs!
In order to make the refitting easier, it
is recommended to use two guide pins
of different lengths. Notice that longer
guide pins than 140 mm will not be
possible to remove from the frame be-
cause lack of space after refitting!

4 Repair
Continued

Roundsling 1,5 m Lifting capacity 1,000 kg
Isopropanol - Used for cleaning mounting surfaces.
tools on page 381.
Other tools and procedures These procedures include references
may be required. See refer- to the tools required.
tions below.

Action Note
calibration:
Removal, arm system

Use this procedure to lift and remove the complete arm system.
Action Note
1 Decide which calibration routine
to use, and take actions accord-
ingly prior to beginning the re-
pair procedure.

4 Repair
Continued
Action Note
2 Run the robot to the position Release the brakes if necessary, as detailed in section
shown in the figure to the right. Manually releasing the brakes on page 73.
xx0700000137
42°
xx0700000518
3 Run the overhead crane to a

position above the robot.
4
DANGER
Turn off all:

• electric power supply to
the robot
to the robot
• air pressure supply to the
robot
Before entering the robot work-
ing area.
5 Drain the oil from gearbox axis Detailed in section Changing oil, axis-1 gearbox on
1. page 146.
6 Disconnect the cabling in the
rear of the robot base and re-
move the cable support plate in-
side the base.
7 Pull the disconnected cabling up How to replace the cabling is detailed in Replacement
through the center of the axis-1 of cable harness, lower end (axes 1-3) on page 181.
gearbox.

4 Repair
Continued
Action Note
8 Remove the motor, axis 1. Detailed in section Replacing motor, axis 1 on page 274.
9 Fit the lifting accessory and ad- Art. no. is specified in Required equipment on page 208.
just it as detailed in the enclosed Make sure the lift is done completely level! How to
instructions. adjust the lift is described in the enclosed instruction
to the lifting accessory! Follow the instructions before
lifting!
IRB 6660 - 130/3.1, IRB 6660 - 100/3.3
xx0700000004
IRB 6660 - 205/1.9
xx0700000427
A: Load hook
B: Swiveling lifting eyes (4 pcs)
C: Shortening hook
D: Chain
E: Lifting eye M12
F: Eye of lifting accessory
I: Lifting slings (4 pcs)
L: Hook

4 Repair
Continued
Action Note
10 Remove the block for calibration
and calibration plate axis 1 from
the bottom of the frame.
xx0600002734
• A: Block for calibration

• B: Calibration plate axis 1
11 Unfasten the arm system from Shown in the figure Location of arm system on
the base by unscrewing its 24 page 207.
attachment screws.
xx0600003070
Parts:
• A: Serrated lock washer
• B: Gearbox axis 1
• C: Attachment screws M12x80
12 Fit two guide pins in two oppos- Art. no. is specified in section Required equipment on
ite screw holes. page 208.
13
CAUTION
The complete arm system

weighs 1330 - 1520 kg! All lifting
equipment used must be sized
accordingly!

4 Repair
Continued
Action Note
14 Lift the arm system carefully and Make sure all hooks and attachments stay in the cor-
secure it in a safe area. rect position while lifting the arm system and that the
Always move the robot at very lifting accessory does not wear against sharp edges.
low speeds, making sure it does
not tip.
Continue lifting even if the arm
system turns out to be unbal-
anced despite earlier adjust-
ments! The risk of damaging the
interfaces is bigger if the load is
lowered unbalanced!
Refitting, arm system

The procedure describes how to lift and refit the complete arm system.
Action Note
1
DANGER
Turn off all:


4 Repair
Continued
Action Note
2 Fit the lifting accessory as detailed in en- Art. no. is specified in Required equipment
closed instruction. on page 208.
Make sure the lift is done completely level!
How to adjust the lift is described in the
enclosed instruction to the lifting access-
ory! Follow the instructions before lifting!
IRB 6660 - 130/3.1, IRB 6660 - 100/3.3
xx0700000004
IRB 6660 - 205/3.1
xx0700000427
• A: Load hook
• B: Swiveling lifting eyes (4 pcs)
• C: Shortening hook
• D: Chain
• E: Lifting eye M12
• F: Eye of lifting accessory
• I: Lifting slings
• L: Hook

4 Repair
Continued
Action Note
3
CAUTION
The complete arm system weighs 1330 -

1520 kg! All lifting equipment used must be
sized accordingly!
4 Lift the complete arm system and move it at Make sure all the hooks and attachments
very low speed, making sure it does not tip! stay in the correct position while lifting the
robot!
Make sure the lift is done completely level.
Adjust the length of the chains as detailed
in enclosed instruction .
5 Clean the mounting surfaces with isopropan-
ol.
6 Fit the two guide pins to the frame attach-
ment holes, as shown in the figure to the
right.
xx0600002632
The figure above shows the frame, view

from below.
• A: Attachment holes for the guide
pins, M12
7 Lubricate the outer surface of the gearbox
for easier mating of the gearbox and arm
system.
8 Look through the empty mounting hole of This is a complex task to be performed
motor 1 to assist in aligning the assembly with utmost care in order to avoid injury
during refitting of the arm system. or damage!
Lower the arm system with guidance from
the guide pins previously fitted to the frame.
Note
The refitting must be made completely level!

Make sure the lifting accessory is adjusted
prior to refitting of arm system.
9 Refit 22 of the 24 attachment screws before

the arm system is completely lowered.

4 Repair
Continued
Action Note
10 Remove the guide pins and secure the arm Shown in the figure Location of arm sys-
system to the base with its 24 attachment tem on page 207.
screws and washers. M12 x 70, tightening torque: 115 Nm.
Reused screws may be used, providing
they are lubricated as detailed in section
Screw joints on page 377 before fitting.
11 Refit the block for calibration at the bottom
of the frame.
Also refit the axis 1 calibration plate.
xx0600002734
• A: Block for calibration

• B: Calibration plate axis 1
12 Refit the axis-1 motor. Detailed in section Replacing motor, axis
1 on page 274.
13 Perform a leak-down test of the axis-1 Detailed in section Performing a leak-
gearbox. down test on page 174.
14 Refit the cabling in the base. Detailed in section Replacement of cable
harness, lower end (axes 1-3) on page 181.
15 Refill the gearbox with lubricating oil. Detailed in section Changing oil, axis-1
Axis Calibration is described in Calibrating
with Axis Calibration method on page 352.
17
DANGER


4 Repair
4.4.1 Replacing the turning disk
4.4 Upper and lower arms
Location of turning disk

The turning disk is located in the front of the wrist housing as shown in the figure
below.
The figure shows the axis-6 gearbox for robot variant IRB 6660 - 100/3.3 and IRB
6660 - 130/3.1, and includes cooling elements on motor. There are no cooling
elements on the axis-6 motor on robot variant IRB 6660 - 250/1.9.
xx0700000163
A Wrist unit
B Turning disk
C Attachment screws, turning disk (12 pcs)
D Oil plug, draining
E Oil plug, filling
F Cooling elements (IRB 6660 - 100/3.3, IRB 6660 - 130/3.1)
Required equipment

Turning disk For spare part no.
see: Spare part lists
on page 387.
O-ring 3HAB3772-64 (1 pc) Must be replaced when replacing
Wrist, type 2 3HAB3772-61 (12 the turning disk!
pcs)
Grease 3HAB3537-1 Used to lubricate the o-rings.
Flange sealant 3HAC034903-001 Loctite 574
these procedures in the step-
by-step instructions below.

4 Repair
Continued
Removing, turning disk

Use this procedure to remove the turning disk.
Action Note
1 Run the robot to a position where the oil plug, drain- Shown in the figure Location of
ing of axis 6 gearbox faces downwards. turning disk on page 217.
2
DANGER
Turn off all:

3 Remove any equipment fitted to the turning disk.

4 Drain the axis 6 gearbox. See section
• Changing oil, axis-6 gear-
box on page 159
5 Remove the attachment screws that secure the
turning disk.
xx1400000994
Shown in the figure Location of

turning disk on page 217.
6 Remove the turning disk.
7 Foundry Plus:
Remove old flange sealant residues and other con-
tamination from the contact surfaces.

4 Repair
Continued
Refitting, turning disk

Use this procedure to refit the turning disk.
Action Note
1 Lubricate the o-ring of the turning disk with Art. no. is specified in Required equip-
grease and fit it to the turning disk. ment on page 217.
Also fit the 12 o-rings, when refitting the attach-
ment screws.
xx0200000218
• A: Sealing surface, o-ring

2 Foundry Plus:
Apply Loctite 574 flange sealant on the contact
surface.
xx1400000995

4 Repair
Continued
Action Note
3 Secure the turning disk with its attachment 12 pcs, M12 x 30, 12.9 quality Gleitmo.
screws. Tightening torque: 100 Nm.
xx1400000994

they are lubricated as detailed in sec-
tion Screw joints on page 377 before fit-
ting.
4 Perform a leak-down test of the gearbox axis Detailed in the section Performing a
6. leak-down test on page 174.
5 Refill the axis 6 gearbox with oil. See section
• Changing oil, axis-6 gearbox on
page 159
6 Refit any equipment removed during disas-
sembly to the turning disk.
7
DANGER


4 Repair
4.4.2 Replacement of complete wrist unit
Location of wrist unit

The wrist unit is located on the upper arm as shown in the figure below.
lists on page 387.
IRB 6660 - 100/3.3, IRB 6660 - 130/3.1
xx0700000069
A Wrist unit
B Turning disk
C Cover, wrist unit
D Cover, upper arm tube
E Connectors, upper arm tube, with cable bracket (R3.FB5, R3.MP5)
F Cable bracket
G Attachment point for lifting tool, wrist unit
H Attachment screws and washers, wrist unit
I Upper arm tube

4 Repair
Continued
IRB 6660 - 205/1.9
xx0700000635
A Wrist unit
B Turning disk
C Cover, wrist unit
D Cover, upper arm tube
E Upper arm tube
F Attachment screws and washers, wrist unit
Required equipment
Equipment etc. Art. no. Note

Wrist unit For spare part number,
page 387.
Cover for wrist unit For spare part number,
page 387.
Guide pins M12 x 200 3HAC13056-3 Always use guide pins in pairs!
Lifting accessory, wrist unit 3HAC13605-1
Other tools and procedures These procedures include refer-
may be required. See references to the tools required.
ences to these procedures in
the step-by-step instructions
below.
Circuit diagram See chapter Circuit diagram on
page 389.

4 Repair
Continued

Action Note
calibration:
Removal, wrist unit

The procedure below details how to remove the complete wrist unit.
Action Note
take actions accordingly prior to beginning the
repair procedure.
2 Remove all equipment fitted to the turning disk.
3 Turn axis 4 to a position where the cover, upper
arm tube and wrist unit, faces upwards. Turn
axis 5 to +90°.
xx0200000185

4 Repair
Continued
Action Note
4
DANGER
Turn off all:

5 Remove the cover, wrist unit. Shown in the figure Location of wrist
unit on page 221.
6 Remove the cover, upper arm tube. Shown in the figure Location of wrist
unit on page 221.
7 Remove the cover of motor, axis 6 and discon-
nect all connectors beneath.
8 Loosen the cable bracket, wrist unit on top of Shown in the figure Location of wrist
the wrist by undoing the three attachment unit on page 221.
screws.
Two of the attachment screws are visibly loc-
ated at the rear of the bracket and the third
located at the bottom of the cable bracket, in
the center.
xx0200000254
• B: Attachment screws, rear of

cable bracket (2 pcs)
• C: Attachment screw, bottom of
cable bracket
9 Pick out the cabling from motor, axis 6 and
place it safely on the tube.
10 Fit the lifting accessory to the wrist unit. Art. no. is specified in Required
11
CAUTION
The complete wrist unit weighs 130 kg! All lift-

ing equipment used must be sized accordingly!
12 Slightly raise the wrist unit to unload the screw

joint, facilitating removing the attachment
screws.
13 Remove the wrist unit attachment screws and Shown in the figure Location of wrist
washers. unit on page 221.
14 Pull the wrist unit out, lift it away and place it
on a secure surface.
15 Disconnect the motor axis 5 by disconnecting Shown in the figure Location of wrist
the two connectors in the upper arm tube unit on page 221.
(R3.FB5, R3.MP5).

4 Repair
Continued
Refitting, wrist unit

The procedure below details how to refit the complete wrist unit.
Action Note
1
DANGER
Turn off all:

2 Fit two guide pins, M12 in the upper arm tube, Art. no. is specified in Required equip-
in two of the holes for the wrist unit attachment on page 222.
ment screws. Shown in the figure Location of wrist
unit on page 221.
3 Fit the lifting tool to the wrist unit. Art. no. is specified Location of wrist
unit on page 221.
4
CAUTION
The complete wrist unit weighs 130 kg! All

lifting equipment used must be sized accord-
ingly!
5 Lift the wrist unit and guide it to the upper arm

tube with help of the guide pins.
Make sure the cabling from motor, axis 5 is
safely run into the arm tube and does not get
jammed.
6 Reconnect the motor axis 5 by connecting the Shown in the figure Location of wrist
two connectors inside the upper arm tube unit on page 221.
(R3.FB5, R3.MP5) and secure the cable
bracket with the two attachment screws to the
tube.
7 Secure the wrist unit with 10 of the 12 attach- Shown in the figure Location of wrist
ment screws and washers. unit on page 221.
12 pcs: M12 x 50, 12.9 quality Gleitmo.
ting.
8 Remove the guide pins and secure the two
remaining attachment screws as detailed
above.
9 Remove the lifting tool from the wrist unit.
10
Note
Axis 5 must be oriented in the correct position

(+90º) to allow the motor 6 cover to open!

4 Repair
Continued
Action Note
11 Place the cabling to motor axis 6 correctly on
the upper arm and gently pull the connectors
through the hole on top of wrist unit to motor,
axis 6.
In case of excess of cable length:
• put the excess cable in a loop in the
area shown in the figure and secure
with with cable straps. Cables are
longer in order to fit different upper arm
lengths.
xx0200000185
Parts:
• A: Cable straps
12 Fasten the cable bracket at top of the wrist Shown in the figure Location of wrist
unit with three attachment screws. Two of unit on page 221.
them are visible at the rear attachment point
and the third is located on the bottom of the
cable bracket, in the center.
xx0200000254
• B: Attachment screws, rear at-

tachment point of cable bracket
(2 pcs)
• C: Attachment screw, bottom of
cable bracket
13 Reconnect the connectors to the axis-6 motor
and refit the motor cover.
14 Refit the cover, upper arm tube. Shown in the figure Location of wrist
unit on page 221.
15 Refit the cover, wrist unit. Shown in the figure Location of wrist
unit on page 221.
Tightening torque: 14 Nm±10%. Screw
3HAB3409-25 (with Loctite), Washer
3HAC062379-001.
16 Re-calibrate the robot! Pendulum Calibration is described in
Operating manual - Calibration Pendu-
lum, enclosed with the calibration tools.
page 352.
page 341.
17 Refit any equipment previously removed from
the turning disk.
18
DANGER


4 Repair
4.4.3 Replacement of upper arm
Location of upper arm

The upper arm is located as shown below.
IRB 6660 - 100/3.3, IRB 6660 - 130/3.1
xx0700000059
A Upper arm
B Motor, axis 4
C Balancing device
D Lower arm
E Parallel rod

4 Repair
Continued
IRB 6660 - 205/1.9
xx0700000636
A Upper arm
B Upper arm
C Lower arm
D Parallel rod

4 Repair
Continued
View of the assembly of the upper arm components

Shown below is a cut away view of how the upper arm is fitted to the lower arm
(seen from above). The letters are being referred to in the following step by step
procedures.
IRB 6660 - 100/3.3, IRB 6660 - 130/3.1
xx0700000058
A Shaft, axis 2
B Shaft, axis 3
C Set screw, cup point M10 x 20 quality 45H-A3F
D Lubricant paste (Molycote 1000)
E Sealing ring (V-ring)
F Sealing ring
G Taper roller bearing
H O-ring
I Sealing ring
J Sealing assembly
K Lock nut (KM12)
L O-ring (Di = 54.2 mm, t = 5.7 mm)

4 Repair
Continued
IRB 6660 - 205/1.9
xx0700000637
A Shaft, axis 2
B Shaft, axis 3
C Set screw, cup point M10x20 quality 45H-A3F
D Surfaces where to apply lubricant paste (Molycote 1000)
E Sealing ring (V-ring)
F Sealing ring
G Taper roller bearing
H O-ring
I Sealing ring
J Sealing assembly (including support ring)
K Lock nut (KM12)
L O-ring (Di = 54.2 mm, t = 5.7 mm)

4 Repair
Continued
Required equipment
Equipment, etc. Art.no. Note

Upper arm, axis 4 For spare part part num-
ber, see Spare part lists on
page 387.
Grease filling tool -
Rust preventive 3HAC034903-001 Mercasol 3110 Waxcoat
KM12 socket 3HAC5347-1
Other tools and proced- These procedures include refer-
ures may be required. See ences to the tools required.
references to these proced-
ures in the step-by-step in-
structions below.
Circuit diagram - See chapter Circuit diagram on
page 389.

Action Note
calibration:

4 Repair
Continued
Removal, upper arm

The procedure below details how to remove the upper arm.
Action Note
2 Remove all equipment fitted to the turning
disk.
3 Move the upper arm to a horizontal position. IRB 6660 - 130/3.1, IRB 6660 - 100/3.3
Rotate axis 4 so that the attachment hole
for lifting eye is facing upwards.
xx0700000137
IRB 6660 - 205/1.9
42°
xx0700000518
4
DANGER
Turn off all:

to the robot, before entering the robot
working area.
5 Secure the upper arm with lifting slings in

an overhead crane.

4 Repair
Continued
Action Note
6 Drain the oil from axis 4. Detailed in section Changing oil, axis-4
7 Remove the cable harness in the upper arm. Detailed in section Replacement of cable
harness, upper end on page 196
8
CAUTION
The complete upper arm weighs 380 kg

without any additional equipment fitted!
Use a suitable lifting accessory to avoid in-
jury to personnel!
9 Raise the lifting equipment to take the

weight of the upper arm.
10 (Not applicable to robot variant IRB 6660 Detailed in section Replacing the balan-
- 205/1.9! ) cing device on page 266
Remove the balancing device.
11 Remove the parallel rod. Detailed in section Replacing the parallel
rod on page 238
12 Remove the lock nut (K) on the shaft, axis Shown in the figure View of the assembly
3 (B). of the upper arm components on page 229.
13 Remove the set screw (C) holding the shaft. Shown in the figure View of the assembly
of the upper arm components on page 229.
14 Remove the shaft axis 3 (B). Shown in the figure View of the assembly
Perform the removal with care. Threads
can otherwise be damaged!
15 Then remove the shaft, axis 2 (A) in the Shown in the figure View of the assembly
same order: of the upper arm components on page 229.
1 Remove the lock nut (K)
2 Remove the set screw (C) holding
the shaft
3 Remove the shaft axis 2.
16 Put the shafts in a clean and safe place.
17 Remove the upper arm.
Preparations before refitting, upper arm

The procedure below details the preparations which must be done before refitting
the upper arm.
Action Note
1 Put the shafts (A & B) on a workbench and Shown in the figure View of the assembly
fit the sealing rings (E). of the upper arm components on page 229.
2 Apply some grease on the shafts and sealing
rings. Note
Don´t apply grease on the threads and

cones of the shafts!

4 Repair
Continued
Action Note
3 Fill the bearings (G) with bearing grease. Art. no. is specified Required equipment
Use grease filling tool. on page 231
Shown in the figure View of the assembly
4 Apply lubricant paste (D) on the threads and Molycote 1000.
cones of the shafts. Shown in the figure View of the assembly
of the upper arm components on page 229
5 Foundry Plus:
Apply rust preventive on the surfaces on the
shaft, according to illustration.
Note
Apply rust preventive to the shafts on both

sides of the robot.
xx1400001124
Refitting, upper arm

The procedure below details how to refit the upper arm.
Action Note
1 Secure the upper arm with lifting slings in
an overhead crane.
2
CAUTION
The complete upper arm weighs 380 kg

without any additional equipment fitted!
Use a suitable lifting accessory to avoid in-
jury to personnel!

4 Repair
Continued
Action Note
3 Lift the upper arm with an overhead crane IRB 6660 - 130/3.1, IRB 6660 - 100/3.3
and move it to its mounting position.
Make sure that the upper arm is placed in
a horizontal position.
xx0700000137
IRB 6660 - 205/1.9

42°
xx0700000518
4
Note
Refit the axis 3 side first!
5 Carefully refit the shaft, axis 3 (B) by hand Shown in the figure View of the assembly
only. of the upper arm components on page 229.
Do not use force since the threads can be
damaged if fitting is not done in the correct
way.
6 Secure the shaft. Art.no. is specified in Required equipment
Tightening torque: 400 Nm. on page 231
7 Refit the sealing ring (F) on the shaft. Shown in the figure View of the assembly
8 Refit the bearing (G) on the shaft with the Shown in the figure View of the assembly
pressing tool, upper arm. of the upper arm components on page 229.
9 Fit an o-ring (H) on the sealing ring (I) and Shown in the figure View of the assembly
fit it on the shaft. of the upper arm components on page 229.
Note
The o-ring shall be faced against the bear-

ing.

4 Repair
Continued
Action Note
10 Fit the o-ring (L) on the sealing assembly Shown in the figure View of the assembly
(J) and refit the sealing assembly on the of the upper arm components on page 229.
shaft.
11 Apply locking liquid on the lock nut (K) and Shown in the figure View of the assembly
refit it. of the upper arm components on page 229.
Loctite 243.
Tightening torque 90 Nm.
12 The refit the axis 2 side in the same order Follow the steps for refitting shaft axis 3
with the exception of the lock nut (K). above.
Shown in the figure View of the assembly
13 Apply locking liquid on the lock nut (K) and Shown in the figure View of the assembly
refit it. of the upper arm components on page 229.
Loctite 243.
Note Tightening torque the first time: 300 Nm
Tightening torque the second time: 90
The order of the tightening torques is very
Nm
important!
Note
The fitting of the lock nut on axis 2 is per-

formed in three steps:
1 Fit the lock nut with a tightening
torque of 300 Nm.
2 Unscrew the lock nut.
3 Fit the lock nut once again. This time
with a tightening torque of 90 Nm.
14 Apply locking liquid in the holes for the set Shown in the figure View of the assembly
screws (C) and fit the screws. of the upper arm components on page 229
Loctite 243.
15 Wipe residual grease from the shafts.
16 Refit the parallel rod. Detailed in section Replacing the parallel
rod on page 238
17 Refit the cable harness, upper end. Detailed in section Replacement of cable
harness, upper end on page 196
18 (Not applicable to the robot variant IRB Detailed in section Replacing the balan-
6660 - 205/1.9! ) cing device on page 266
Refit the balancing device.

4 Repair
Continued
Action Note
20
DANGER


4 Repair
4.4.4 Replacing the parallel rod
Location of parallel rod

The parallel rod is located as shown in the figure.
xx0700000064
A Robot variant IRB 6660 - 205/1.9

B Robot variant IRB 6660 - 130/3.1, IRB 6660 - 100/3.3
C Parallel rod
Required equipment

Parallel rod For spare part no. see:
• Spare part lists on
page 387.
Mounting/Demounting tool 3HAC5021-1
Locking liquid 3HAB7116-1 Loctite 243
Protection plug 3HAC4836-2 F21 28x22, 4x12x9

4 Repair
Continued

tions below.
Removing, parallel rod

Use this procedure to remove the parallel rod. The procedure is the same in both
ends of the parallel rod.
Action Note
1
DANGER
Turn off all:

working area.
2
CAUTION
Secure the upper arm with a roundsling in

an overhead crane or similar, in order to
avoid accidents.
3 Foundry Plus:
Remove the protection plugs

4 Repair
Continued
Action Note
4 Remove the upper lock screw and washer,
that secure the parallel rod in position.
xx0700000066
Parts:
• A: Lock screw M6x16, (upper)
• B: Lock screw M6x16, (lower)
5 Remove the upper shaft (A) and cover Art. no. is specified in Required equipment
washer (B), using the fitting/removing tool. on page 238.
xx0700000065
Parts:
A Shaft
B Cover washer
C Parallel rod
D Sealed spherical bearing
E Bearing grease
F Thrust washer
6 Remove the thrust washer (F). See figure above!

4 Repair
Continued
Action Note
7
CAUTION
The parallel rod weighs 45 kg.

All lifting accessories used must be sized
accordingly!
8 Move the parallel rod backwards from its See figure above and Location of parallel
upper connection point and let it rest rod on page 238!
against the frame and base.
9 Secure the parallel rod with a roundsling in
an overhead crane or similar.
10 Remove the lower end of the parallel rod in See figure above!
the same way as the upper end:
1 Remove the lower lock screw and
washer.
2 Remove the lower shaft (A )and cover
washer (B).
3 Remove the thrust washer (F).
11 Remove the parallel rod from the robot.
12 Replace the bearings (D), if necessary. See figure above!
Refitting, parallel rod

Use this procedure to refit the parallel rod. The procedure is the same in both ends
of the parallel rod.
Action Note
1 Start by refitting the lower end.
2 Verify that the bearings are in correct posi-
tion in the parallel rod.
3
CAUTION
The parallel rod weighs 45 kg.

accordingly!
4 Lift the parallel rod to the mounting position

of the lower end, and let it rest on the the
frame and base.
5 Foundry Plus:
Apply rust preventive on the highlighted
areas.
Note
Rust preventive should be applied in both

ends of the parallel rod.
xx1400001126

4 Repair
Continued
Action Note
6 Put the thrust washer (F) on the axis 2 side
of the parallel rod (C).
xx0700000065
Parts:
A Shaft
B Cover washer
C Parallel rod
D Sealed spherical bearing
E Bearing grease
F Thrust washer
7 Put the cover washer (B) on the axis 3 side See figure above!
of the parallel rod.
8 Refit the shaft (A) by pressing it through the Art. no. is specified in Required equip-
parallel bar with the fitting/removing tool. ment on page 238.
See figure above!
9 Apply locking liquid in the hole of the lock Loctite 243
screw.
10 Refit the lock screw and plain washer.
xx0700000066
Parts:
• A: Lock screw M6x16, (upper)
• B: Lock screw M6x16 (lower)

4 Repair
Continued
Action Note
11 Lift the parallel rod up into position for fitting
the upper end.
12 Refit the upper end of the parallel rod in the
same way as the lower end.
13 Foundry Plus:
Refit the protection plugs.
14
DANGER


4 Repair
4.4.5 Replacing the complete lower arm
Location of lower arm

The complete lower arm is located as shown in the figure below.
xx0700000067
A Lower arm
B Parallel arm
Required equipment

Lower arm For spare part no. see:
page 387.
Sealing, axes 2/3 Always change the sealing.
Guide sleeves 3HAC14446-1 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

4 Repair
Continued

below.
page 389.

Action Note
calibration:
Removal, lower arm

The procedure below details how to remove the lower arm.
Action Note
1 Decide which calibration routine to use, and take
actions accordingly prior to beginning the repair
procedure.

4 Repair
Continued
Action Note
2
DANGER
Turn off all:

area.
3 Secure the lower arm with a lock screw in the

hole as shown in the figure to the right.
CAUTION
Tighten by hand!
xx1000001101
4 (Not applicable to robot variant IRB 6660 - See Replacing the balancing device
205/1.9 ! ) on page 266
Remove the balancing device.
5 Remove the parallel rod. See Replacing the parallel rod on
page 238.
6 Remove the cable harness in the upper and See .
lower arm.
Secure the cable harness in a way that it is pro-
tected from oil spill and damage.
7 Remove the complete upper arm. See Replacement of upper arm on
page 227.
8 Remove the axes 2 and 3 motors. See Replacing motors, axes 2 and 3
on page 281.
9 Remove the axes 2 and 3 gearboxes. See Replacing the gearbox, axes 2-
3 on page 324.
10
CAUTION
The robot lower arm weighs 160 kg (IRB 6660 -

100/3.3, IRB 6660 - 130/3.1) / 110 kg (IRB 6660
- 205/1.9).
All lifting accessories used must be sized accord-
ingly!
11 Secure the complete lower arm system (includ- Specified in Required equipment on
ing the parallel arm) with a lifting tool, lower arm page 244.
complete in an overhead crane or similar.

4 Repair
Continued
Action Note
12 Remove the lock screw that secures the lower
arm system.
xx1000001101
13 Remove all M12 and M16 screws that hold the

lower arm, on both sides.
Note
The axis 3 side has no M16 screws!
14
DANGER
Secure the parallel arm to the lower arm before

lifting the lower arm system. If not secured, the
parallel arm can fall down and cause a serious
accident!
xx1000001359
15
CAUTION
The parallel arm system weighs 92 kg.

ingly!

4 Repair
Continued
Action Note
16 Move the parallel arm and secure it to the lower
arm as shown in the figure, to prevent it from
falling down.
xx1000001357
17 The space between the gearboxes is cramp.

Push therefor the lower and parallel arm together Note
with help of an iron bar or similar before remov-
ing them. If the parts are not pushed together,
it will be difficult to remove the com-
plete lower arm.
18
CAUTION

100/3.3, IRB 6660 - 130/3.1) / 110 kg (IRB 6660
- 205/1.9).
ingly!
19 Remove the complete lower arm (including the

parallel arm).
xx1000001358

4 Repair
Continued
Action Note
20 How to replace the parallel arm is detailed in
section Replacement of parallel arm on page 252.
Refitting, lower arm

Use this procedure to refit the lower arm system.
Action Note
1 Fit the parallel arm to the lower arm. See Replacement of parallel arm on
page 252.
2
CAUTION

100/3.3, IRB 6660 - 130/3.1) / 110 kg (IRB 6660
- 205/1.9).
ingly!
3 Fit a lifting tool, lower arm complete, to the lower Specified in Required equipment on
arm system and lift it up. page 244.
DANGER
Secure the parallel arm to the lower arm before

lifting the lower arm system. If not secured, the
parallel arm can fall down and cause a serious
accident!
4 Fit two guide sleeves for the axes 2/3 sealings Art. no. is specified in Required
to the lower arm and put the sealings on them. equipment on page 244.
See figure.
xx1000001368

4 Repair
Continued
Action Note
5 Put the lower arm in its mounting position. Art. no. is specified in Required
If the hole pattern needs to be adjusted, use a equipment on page 244.
crank to move the gears in order to find the cor-
rect hole pattern.
xx1000001370
6
Note
Refit the axis 2 side first!
7 Verify that the sealings are still in place.

8 Refit all screws (both M12 and M16) and wash- Tightening torque M16: 300 Nm
ers, that are possible to fit at this stage, on the Tightening torque M12: 120 Nm
axis 2 side.
9 Push the parallel arm against the axis 3 side with
the help of an iron bar or similar.
10 Refit all screws and washers, that are possible Tightening torque M12: 120 Nm
to fit, on the axis 3 side.
Note
The axis 3 side has no M16 screws!
11 Remove the guide sleeves and secure two

screws more.
12 Change the position of the lower arm in order to
reach the remaining attachment holes, and fit
the remaining screws.

4 Repair
Continued
Action Note
13 Secure the lower arm by fitting a lock screw. Dimension is specified in Required
CAUTION
Tighten by hand!
xx1000001101
14 Refit the axes 2 and 3 gearboxes. See Replacing the gearbox, axes 2-
3 on page 324.
15 Refit the axes 2 and 3 motors. See Replacing motors, axes 2 and 3
on page 281.
16 Refit the complete upper arm. See Replacement of upper arm on
page 227.
17 Refit the cable harness. See .
18 Refit the parallel rod. See Replacing the parallel rod on
page 238
19 ( Not applicable to robot variant IRB 6660 - See Replacing the balancing device
205/1.9 ! ) on page 266.
Refit the balancing device.
20 Remove the lock screw.
21 Recalibrate the robot. Pendulum Calibration is described in
Operating manual - Calibration Pen-
dulum, enclosed with the calibration
tools.
Axis Calibration is described in Calib-
rating with Axis Calibration method
on page 352.
page 341.
22
DANGER


4 Repair
4.4.6 Replacement of parallel arm
Location of parallel arm

The parallel arm is located as shown in the figure below.
xx0700000067
A Robot variant IRB 6660 - 205/1.9

B Robot variant IRB 6660 - 130/3.1, IRB 6660 - 100/3.3
C Parallel arm
D Lower arm
Required equipment

Parallel arm For spare part no. see:
page 387.
VK cover 3HAA2166-23 D=120 mm, T=12 mm
VK cover 3HAA2166-18 D=35 mm, T=8 mm
Bearing grease 3HAB3537-1
Pressing tool, lower arm 3HAC023092-001

4 Repair
Continued

Lifting accessory, parallel 3HAC023098-001
arm
Lifting accessory, lower arm 3HAC8446-1
complete
Level -
below.

Action Note
calibration:
Removal, parallel arm

Use this procedure to remove the parallel arm.
Action Note
procedure.

4 Repair
Continued
Action Note
2
DANGER
Turn off all:

3 Remove the complete lower arm. See Replacing the complete lower
arm on page 244.
4 Put the complete lower arm on a workbench as
shown in the figure.
Tip
Removal of the parallel arm is best performed on a

workbench.
xx1000001024
5 Remove the two VK covers.
xx1000001371

4 Repair
Continued
Action Note
6 Fit the lifting accessory, parallel arm on the parallel Art. no. is specified in Required
arm. Lift the parallel arm to the position shown in equipment on page 252.
the figure.
xx1000001375
7 Disassemble the parallel arm from the lower arm Art. no. is specified in Required
by using the pressing tool, lower arm. equipment on page 252.
8
CAUTION

ingly!
9 Remove the parallel arm.
xx1000001018
10 If needed, change the bearings.

4 Repair
Continued
Refitting, parallel arm

Use this procedure to refit the parallel arm.
Action Note
1 Refitting of the parallel arm is best performed on a
workbench.
2 Apply some grease on the shafts on the parallel Specified in Required equipment
arm. on page 252
3 Refit a spacing sleeve on each shaft.
xx1000001376
4 Refit a bearing on each shaft with pressing tool, Art. no. is specified in Required
lower arm. equipment on page 252
xx1000001377

4 Repair
Continued
Action Note
5 Foundry Plus:
Apply rust preventive on the highlighted areas.
xx1400001127
6 Refit the protection washer on the inner shaft.

7 Refit the lock ring on the inner shaft.
8
CAUTION

ingly!
9 Fit the lifting accessory, parallel arm. Art. no. is specified in Required
10 Lift the parallel arm onto the workbench where the Art. no. is specified in Required
lower arm is placed. equipment on page 252
11 Adjust the lower arm in a way that both holes are
parallel.
Use a level.
12 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

4 Repair
Continued
Action Note
13 Lift the parallel arm, lower it and put it in mounting
position with the lower arm.
xx1000001379
14 Carefully press the parallel arm onto the lower arm Art. no. is specified in Required
using the pressing tool, lower arm. equipment on page 252.
15 Fit the big and small VK cover.
16 Refit the complete lower arm. Detailed in section Replacing the
complete lower arm on page 244.
17 Recalibrate the robot. Pendulum Calibration is described
in Operating manual - Calibration
Pendulum, enclosed with the cal-
ibration tools.
Axis Calibration is described in
Calibrating with Axis Calibration
method on page 352.
General calibration information is
included in section Calibration on
page 341.
18
DANGER

performing the first test run. These are further de-
tailed in the section First test run may cause injury
or damage on page 28.

4 Repair
4.5.1 Replacing the SMB unit
4.5 Frame and base
Location of SMB unit

The SMB unit (SMB = serial measurement board) is located on the left hand side
of the frame as shown in the figure.
xx0600002621
A SMB cover
B SMB unit
C Battery cable
D SMB battery
E SMB battery, cover
Required equipment
Note
There are different variants of SMB units and batteries. The variant with the
3-pole battery contact has longer lifetime for the battery.
It is important that the SMB unit uses the correct battery. Make sure to order the
correct spare parts. Do not replace the battery contact!

SMB unit For spare part number,
see: Spare part lists on
page 387.
Battery pack For spare part number,
see: Spare part lists on
page 387.

4 Repair
Continued

tools on page 381.
page 389.
Removing, SMB unit

Use this procedure to remove the SMB unit.
Action Note
1 Move the robot to the calibration position.
2
DANGER
Turn off all:

3
The unit is sensitive to ESD. Before handling the unit

read the safety information in section The unit is
sensitive to ESD on page 33
4 Remove the SMB cover by unscrewing its attachment Shown in the figure Location of
screws. SMB unit on page 259.
CAUTION
Clean cover from metal residues before opening.

Metal residues can cause shortage on the boards
which can result in hazardous failures.
5 Use caution and remove the connectors X8, X9 and

X10 from the brake release board, if need of more
space.
6 Remove the nuts and washers from the guide pins Shown in the figure Location of
that secure the board. SMB unit on page 259.
7 Use caution and disconnect the connectors from the Connectors R1.SMB1-3,
SMB unit when pulling the board out. R1.SMB4-6 and R2.SMB
8 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

4 Repair
Continued
Refitting, SMB unit

Use this procedure to refit the SMB unit.
Action Note
1
DANGER
Turn off all:

area.
2

unit read the safety information in section The
unit is sensitive to ESD on page 33
3 Connect the battery cable to the SMB unit. Shown in the figure Location of SMB
Make sure the lock on the battery cable connect- unit on page 259.
or R2.G snaps into place during refitting.
4 Connect all connectors to the SMB board: Art. no. is specified in Required
R1.SMB1-3, R1.SMB4-6 and R2.SMB equipment on page 259.
Shown in the figure Location of SMB
unit on page 259.
5 Fit the SMB unit onto the guide pins.
6 Secure the SMB unit to the pins with the nuts
and washers.
7 If disconnected, reconnect the connectors X8,
X9 and X10 to the brake release board.
Be careful not to damage the sockets or pins.
Make sure the connector and its locking arms X8
X10
X9
are snapped down properly.
xx1700000978
8 Secure the SMB cover with its attachment Shown in the figure Location of SMB
screws. unit on page 259.
If cabling is used for 7th axis (option), refit the
7th axis connector to the SMB cover and tighten
with 6 Nm.
9 Update the revolution counter! See Updating revolution counters on
page 348.
10
DANGER


4 Repair
4.5.2 Replacing the brake release board
Location of brake release board

The brake release unit is located together with the SMB unit on the left hand side
of the frame, right next to the gearbox, axis 2, as shown in figure below.
xx0600002621
A SMB cover
B SMB unit
C Battery cable
D SMB battery
E SMB battery, cover
Required equipment

Brake release board 3HAC065020- DSQC1050
001
tools on page 381.

4 Repair
Continued
Removing, brake release board

Use this procedure to remove the brake release board.
Action Note
1
DANGER
Turn off all:

2
ELECTROSTATIC DISCHARGE
(ESD)
The unit is sensitive to ESD. Before handling

the unit read the safety information in section
The unit is sensitive to ESD on page 33
3 Remove the cover for the push button guard.

4 Remove the push button guard from the SMB Shown in the figure Location of brake
cover. release board on page 262.
The guard must be removed to ensure
a correct refitting of the brake release
board.
5 Open the SMB cover by unscrewing the attach- Shown in the figure Location of brake
ment screws. release board on page 262.
Let the battery stay connected, to avoid the
need of synchronization of the robot!
CAUTION
Clean cover from metal residues before

opening.
Metal residues can cause shortage on the
boards which can result in hazardous failures.
6 Take a picture or make notes of how the robot

cabling is positioned in regard to the brake
release board.
7 Remove the complete brake release board
(including brake release board and bracket)
from the SMB recess, by removing its two at-
tachment screws.

4 Repair
Continued
Action Note
8 Disconnect the connectors X8, X9 and X10
from the brake release board.
X8
X10
X9
xx1700000978
Location of the brake release unit is

shown in the figure Location of brake
release board on page 262.
9 Remove the brake release board from the
bracket by removing the four attachment
screws.
Refitting, brake release board

Use this procedure to refit the brake release board.
Action Note
1
The unit is sensitive to ESD. Before handling

the unit read the safety information in section
The unit is sensitive to ESD on page 33
2 Connect the connectors X8, X9 and X10 to the

brake release board.
Be careful not to damage the sockets or pins.
Make sure the connector and its locking arms X8
X10
are snapped down properly. X9
xx1700000978
3 Fasten the brake release board on the bracket Maximum tightening torque: 5 Nm.
with the attachment screws. Shown in the figure Location of brake
Make sure the board is positioned as straight release board on page 262.
as possible on the bracket! The push buttons
can otherwise get jammed when the SMB Art. no. is specified in Required equip-
cover is refitted. ment on page 262.
4 Refit the complete brake release board (includ-

ing brake release board and bracket) to the
SMB recess with the two attachment screws.
5 Verify that the robot cabling is positioned cor-
rectly, according to previously taken pic-
ture/notes.
WARNING
Screened cables must not get in contact with

the brake release board after installation.
Eliminate all risks of contact between screened
cables and the brake release board.

4 Repair
Continued
Action Note
6 Refit the SMB cover with its attachment Shown in the figure Location of brake
screws. release board on page 262.
7
WARNING
Before continuing any service work, follow the

safety procedure in The brake release buttons
may be jammed after service work on page 180.
8 Refit the push button guard to the SMB cover. Shown in the figure Location of brake
release board on page 262.
9 Refit the cover, push button guard.
10 Press the push buttons 1 to 6, one at a time,
to make sure that the buttons are moving
freely and do not stay in a locked position.
11 If the battery has been disconnected the revolu- Detailed in the Calibration chapter -
tion counter must be updated. section Updating revolution counters
on page 348.
12
DANGER


4 Repair
4.5.3 Replacing the balancing device
Note
This section is only applicable to robot variant IRB 6660 - 100/3.3, IRB 6660 -
130/3.1.
Location, balancing device

The balancing device is located as shown in the figure.
xx0700000019
A Balancing device
B Piston rod
C Guide ring (not visible in this figure)
Required equipment

Balancing device For spare part num-
ber, see Spare part
lists on page 387.
Auxiliary shaft 3HAC5281-1 For fitting the inner rings of the bearings
Auxiliary shaft, long 3HAC5275-1

4 Repair
Continued

Auxiliary shaft, short 3HAC5276-1
Lock screw - M16 x 90
For securing the lower arm.
Screw 2 pcs, M12 x 50
For neutralizing the spring force of the
balancing cylinder.
Lubrication tool 3HAC5222-2
Lifting accessories -
Locking liquid 3HAB7116-1 Loctite 243
tools on page 381.
Ball bearing puller -
Removing, balancing device

Use this procedure to remove the balancing device.
Action Note
1 Move the robot to a position close enough to The balancing device must be placed
its calibration position, to allow the lock screw in a 90° angle from the floor, in order
to be inserted into the hole for the lock screw. the be lifted in the most secure way.
See the figure in Location, balancing
device on page 266.
2 Lock the lower arm by inserting the lock screw
into the hole.
CAUTION
Tighten by hand!
xx1000001101
3
DANGER
Turn off all:

area.

4 Repair
Continued
Action Note
4 Remove the protection hood in the upper end
of the balancing device.
5 Insert two screws, M12x50 in the holes to
neutralize the spring force. Screw in the screws
until they have proper contact with the cylinder
inside.
The length of the cylinder is now locked and
the balancing device is unloaded. It should now
be possible to easily rotate the balancing
device.
6 Attach a lifting accessories to the balancing
device.
Use the hole in the lifting ear.
xx1000001112
7 Remove the upper and lower lock nuts and

support washers (2+2 pcs).
Note
Make sure that the shaft between the upper and

lower arm does not rotate when unscrewing the
lock nuts! The lock nut is locked with Loctite
243.
xx1000001113
8 Fit the auxiliary shafts on the upper and lower Art.no. is specified in Required equip-
pivot shaft. ment on page 266
Fit the short auxiliary shaft on the upper shaft
and the longer on the lower shaft.
9 Stretch the roundsling.

4 Repair
Continued
Action Note
10 Apply a ball bearing puller behind the lower ear The figure show IRB 760, but the
of the balancing device. principle is the same.
Note
The ball bearing puller must be applied around

the spacer ring. See figure!
xx1000001115
11
CAUTION
The balancing device weighs 70 kg.

All lifting accessories used must be sized ac-
cordingly!
12 With the help of the ball bearing puller carefully

remove the balancing device from its upper and
lower attachments.
xx1000001114
13 Remove the balancing device and put it in a

safe place.
14 Remove the inner rings of the bearings.

4 Repair
Continued
Action Note
15 Remove upper and lower spacer rings and
support washers (2+2 pcs).
xx1000001116
16 Remove residual grease.
Refitting, balancing device

use this procedure to refit the balancing device.
Action Note
1 Check the bearings. Replace if needed.
2 Refit the inner sealing rings and support
washers in both ends.
xx1000001116
3 Refit the inner ring of the bearings on the upper

and lower pivot shaft with the auxialiary shaft.
4 Fit the auxiliary shafts on the upper and lower Art.no. is specified in section Required
shafts. equipment on page 266
Fit the short auxiliary shaft on the upper shaft
and the longer on the lower shaft.

4 Repair
Continued
Action Note
5
CAUTION
The balancing device weighs 70 kg.

cordingly!
6 Attach lifting accessory to the balancing device

and lift it on to the auxiliary shafts.
xx1000001112
7 Adjust the length between the upper and lower

bearings by means of the M12 screws, used to
neutralize the spring force.
This length should preferably be 0.5 mm too
short than 0.1 mm too long. If the distance is
too long the bearings may be damaged when
erecting the balancing device.
xx1000001111

4 Repair
Continued
Action Note
8 Carefully refit the balancing device on the upper
and lower shafts.
xx1000001271
9 Fit the lubricating tool. Art. no. is specified in section Re-

The tool should be tightened to the bottom po- quired equipment on page 266.
sition by hand power only.
10 Fill the bearings with grease through the nipple.
Continue until grease excudes behind the inner
sealing.
11 Remove the lubricating tool and wipe off pro-
truding grease.
12 Remove the auxiliary shafts.
13 Apply locking liquid on the threads of the lock Specified in section Required equip-
nuts. ment on page 266.
14 Refit the lock nuts and support washers. Tightening torque: 120 Nm
xx1000001113
15 Check play (min. 0.1 mm) between support

washers and bearing seat at both bearings.

4 Repair
Continued
Action Note
16 Remove the M12x50 screws from the balancing
device to restore the springforce.
17 Remove the lock screw.
xx1000001101
18
DANGER


4 Repair
4.6.1 Replacing motor, axis 1
4.6 Motors
Location of motor axis 1

The motor axis 1 is located on the left hand side of the robot as shown in the figure.
xx0600002598
A Motor axis 1
B Motor attachment screws and washers
C Cable gland cover (located on the left hand side of the motor)
D Motor cover
Required equipment
Equipment, etc Art.no. Note

Motor axis 1 See spare part number in Includes:
Spare part lists on • motor
page 387. • pinion
• o-ring (Old o-ring must be re-
placed when replacing the
motor)
O-ring 21522012-430 Replace if damaged.
Grease 3HAB3537-1 Used to lubricate the o-ring
Loctite 574, Flange sealant 12340011-116 Option Foundry Plus

4 Repair
Continued
Equipment, etc Art.no. Note

Power supply - 24 VDC, max. 1,5 A
For releasing the brakes.
Other tools and proced- These procedures include refer-
ures may be required. See ences to the tools required.
references to these proced-
ures in the step-by-step
instructions below.
page 389.

Action Note
calibration:
Removing motor axis 1

Use this procedure to remove the axis-1 motor.
Action Note
repair procedure.

4 Repair
Continued
Action Note
2
DANGER
Turn off all electric power, hydraulic and pneu-

matic pressure supplies to the robot!
3 Remove the motor cover in order to get access

to the connectors on top of the motor.
xx1000001092
Part:
Motor cover
4 Remove the cable gland cover at the motor
cable exit.
Note
Make sure the gasket is undamaged! Replace

if damaged.
xx1000001094
Part:
Position of Cable gland cover
5 Disconnect all connectors beneath the motor
cover.
6 In order to release the brake, connect the 24 Connect to connector R2.MP1
VDC power supply. • + : pin 2
• -: pin 5

4 Repair
Continued
Action Note
7 Remove the attachment screws of the motor.
xx1000001090
Parts:
Motor axis 1
Attachment screw (4 pcs)
Washer (4 pcs)
Pinion
8 If required, press the motor out of position by Always use removal screws and tools
fitting two screws in the holes on the motor for in pairs!
pressing out the motor.
9
CAUTION
The motor weighs 29 kg! All lifting equipment

used must be sized accordingly!
10 Remove the motor by carefully lifting it straight

up to get the pinion away from gear.
CAUTION
Be careful not to damage the pinion in the pro-

cess!
xx1000001021
11 Disconnect the brake release voltage.

12 Check the pinion. If there is any damage, the
pinion must be replaced.
13 Foundry Plus:
Remove old Loctite 574 flange sealant residues
and other contamination from the contact sur-
faces on both motor and gearbox.

4 Repair
Continued
Refitting motor axis 1

This procedure describes how to refit motor axis 1.
Action Note
1 Make sure the o-ring on the circumference of
the motor is seated properly. Lightly lubricate
the o-ring with grease.
xx1000001096
Parts:
Circumference of motor
O-ring
Note
The o-ring must be replaced when re-

placing the motor.
2
CAUTION


• -: pin 5
4 Foundry Plus:
surface.
xx1400000986

4 Repair
Continued
Action Note
5 Gently lower the motor into the gear, making
sure the pinion is properly mated to the gearbox
of axis 1.
Note
Make sure the motor is turned the right way.

See figure.
Note
Make sure the motor pinion does not get dam-

xx1000001090
aged!
Parts:
Motor axis 1
Attachment screw (4 pcs)
Washer (4 pcs)
Pinion
6 Secure the motor with its four attachment M10 x 40
screws and plain washers. Shown in the figure Location of motor
axis 1 on page 274.
Tightening torque:
• 50 Nm
8 Reconnect all connectors beneath the motor
cover.
9 Refit the cable gland cover at the cable exit with
Note
Make sure the cover is tightly sealed!

Replace gasket if damaged.
xx1000001094
Part:
Position of Cable gland cover
10 Refit the motor cover with its attachment
screws.
Note
xx1000001092
Part:
Motor cover

4 Repair
Continued
Action Note
lum, enclosed with the calibration
tools.
rating with Axis Calibration method on
page 352.
page 341.
12
DANGER


4 Repair
4.6.2 Replacing motors, axes 2 and 3
Location of motors, axes 2 and 3

The motors axes 2 and 3 are located on either side of the robot as shown in the
figure.
The procedure is the same for both motors.
xx0600002599
A Motor, axis 2
B Motor, axis 3
C Motor attachment screws and washers
D Cable gland cover (located on the lower side of the motor)
E Motor cover
F Hole for lock screw
Required equipment

Motor axes 2-3 See spare part number in Includes
Spare part lists on • motor
• o-ring (the o-ring must be re-
placed when the motor is re-
placed)
O-ring, motor 21522012-430 Replace if damaged.
Grease 3HAB3537-1 For lubricating the o-ring.
Guide pins 3HAC13120-2 M10x150
For guiding the motor.
Guide pins are to be used in pairs!
Lifting tool, motor axes 2-3 3HAC14586-1
Lock screw M16x90
For securing the lower arm.

4 Repair
Continued

Power supply - 24 VDC, 1.5 A
Rotation tool Used to rotate the motor pinion
when mating it to the gear, when
brakes are released with 24 VDC
power supply.
Standard toolkit Content is defined in section
tions below.
Circuit diagram 3HAC025744-001 See chapter Circuit diagram on
page 389.

Action Note
calibration:
Removing motors axes 2 and 3

Use this procedure to remove motors axes 2 and 3.
Action Note
repair procedure.

4 Repair
Continued
Action Note
2 Run the robot to a position close enough to its
calibration position, to allow the lock screw to
be inserted into the hole for lock screw.
xx1000001101
3 Lock the lower arm by inserting the lock screw See figure above.
into the hole of the frame.
This is done in order to secure axis 2 from col-
lapsing when gearbox axis 2 is being removed.
4
DANGER
Turn off all electric power, hydraulic and pneu-

matic pressure supplies to the robot!
5 Secure the upper arm with roundslings in an

overhead crane.
This is done in order to secure axis 3 from col-
lapsing when gearbox axis 3 is being removed.
6 Drain the oil from gearbox. See section
• Draining, axes 2 and 3 on
page 151
7 Remove the motor cover.
xx1000001102

4 Repair
Continued
Action Note
8 Remove the cable gland cover at the cable exit
.
Note
Make sure the gasket is not damaged! Replace

if damaged.
xx1000001103

cover.
• -: pin 5
11 Unscrew attachment screws and washers of
the motor.
xx1000001104

4 Repair
Continued
Action Note
12 Fit two guide pins in two of the motors attach- Art. no. is specified in Required
ment holes. equipment on page 281.
xx1000001131
13 If required, press the motor out of position by Always use the removal screws and
fitting two screws in the remaining attachment tools in pairs!
holes of the motor, diagonal to each other.
xx1000001184
14 Remove the two screws and fit the lifting tool, Art. no. is specified in Required
motor axes 2-3 to the motor. equipment on page 281.
15
CAUTION


4 Repair
Continued
Action Note
16 Pull out the motor to get the pinion away from
the gear.
Make sure the pinion does not get damaged!
xx1000001105
17 Remove the motor by gently lifting it straight

out and place it on a secure surface.
18 Disconnect the brake release voltage!
19 Check the pinion. If there is any damage, the
motor pinion must be replaced.
20 Foundry Plus:
xx1400000988

4 Repair
Continued
Refitting, motor
Use this procedure to refit the motors for axes 2 and 3.
Action Note
1 Make sure the o-ring on the circumference of
the motor is seated properly. Lightly lubricate
xx1000001096
Parts:
A Circumference
B O-ring
• -: pin 5
3 Fit the lifting tool, motor axes 2-3 to the motor. Art. no. is specified in Required
4 Foundry Plus:
surface.
xx1400000987

4 Repair
Continued
Action Note
5 Fit the two guide pins in the two lower motor Art. no. is specified in Required
attachment holes. equipment on page 281.
xx1000001131
6
CAUTION

7 Lift the motor and guide it on to the guide pins, The figure shows IRB 760 but the
as close to the correct position as possible principle is the same.
without pushing the motor pinion into the gear.
Note
Make sure the motor is turned the right way,

that is connections for the cables facing down-
wards.
xx1000001185
8 Remove the lifting tool and allow the motor to

rest on the guide pins.

4 Repair
Continued
Action Note
9 Use the rotation tool in order to rotate the motor
pinion when mating it to the gear (see figure).
Fit the motor, making sure the motor pinion is
properly mated to the gear of gearbox axis 2-3
and that it doesn´t get damaged.
Note
The rotation tool is used beneath the motor

cover, directly on the motor shaft as shown in
figure above.
xx0200000165
Part:
A Rotation tool
10 Remove the guide pins.
11 Secure the motor with its attachment screws
and plain washers.
xx1000001104
M10 x 40 (4 pcs)
Reused screws may be used, provid-
ing they are lubricated as detailed in
section Screw joints on page 377 be-
fore fitting.
13 Reconnect all connectors beneath the motor Connect in accordance with markings
cover. on connectors.
14 Refit the cable gland cover at the cable exit with
its two attachment screws.
Note
Use a new gasket!

4 Repair
Continued
Action Note
15 Refit the motor cover with its attachment screws
and washers.
Note
xx1000001102
16 Remove the lock screw from the hole for lock

screw.
xx1000001101
17 Perform a leak-down test of the axis 2 (or 3)

gearbox.
18 Refill the gearbox with oil. Detailed in Filling, axes 2 and 3 on
page 151.
lum, enclosed with the calibration
tools.
page 352.
page 341.

4 Repair
Continued
Action Note
20
DANGER


4 Repair
4.6.3 Replacement of motor, axis 4
Location of motor
The motor axis 4 is located on the left-hand side of the upper arm as shown in the
figure below.
xx0700000061
A Motor, axis 4
B Attachment screws M8X25 quality 8.8 (4 pcs)
Required equipment

Motor including pinion See spare part number Includes:
in Spare part lists on • motor
• o-ring 21522012-430
O-ring 21522012-430 Must be replaced when reas-
sembling motor!
Lifting tool, motor ax 1, 4, 5 3HAC14459-1
Grease 3HAB3537-1 Used to lubricate the o-ring.
Removal tool. motor M10x 3HAC14972-1 Always use the removal tools in
pairs!
Guide pins M8 x 100 3HAC15520-1 For guiding the motor.
Rotation tool 3HAC17105-1 Used to rotate the motor pinion
when mating it to the gear when
brakes are released with 24 VDC
power supply.
Power supply - 24 VDC, max. 1,5 A

4 Repair
Continued

Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes
operating manual.
Required if Calibration Pendulum
is the valid calibration method for
the robot.
Calibration tool box, Axis Calibra- 3HAC055412-001 Delivered as a set of calibration
tion tools.
Required if Axis Calibration is the
valid calibration method for the
robot.
Circuit diagram 3HAC025744-001 See chapter Circuit diagram on
page 389.

Action Note
calibration:
Removal, motor axis 4

The procedure below details how to remove the motor, axis 4.
Action Note

4 Repair
Continued
Action Note
2 Move the robot to a position where the upper Draining of oil is described in section
arm is pointed straight up. Draining, oil on page 154.
This position enables the motor to be re-
placed without draining the gear oil, which
in turn saves time.
Any other position of the upper arm requires
a draining of oil from the gearbox for axis 4.
3
DANGER
Turn off all:

4 Remove the cable gland cover at the cable Shown in the figure Location of motor on
exit of the motor by unscrewing its two at- page 292.
tachment screws. Make sure the gasket is not damaged!
5 Remove the cover on top of the motor by
unscrewing its four attachment screws.
cover.
7 In order to release the brake, connect the Connect to connector R2.MP4
24 VDC power supply. • +: pin 2
• -: pin 5
8 Unscrew the motors four attachment screws Shown in the figure Location of motor on
and plain washers. page 292.
9 Fit the two guide pins in two of the motor
attachment screw holes.
10 If required, press the motor out of position Art. no. is specified in Required equipment
by fitting removal tool, motor to the motor on page 292.
attachment screw holes. Always use the removal tools in pairs!
11 Lift the motor to get the pinion away from
the gear and disconnect the brake release
voltage.
12 Remove the motor by gently lifting it straight Make sure the motor pinion is not dam-
out. aged!
13 Foundry Plus:
Remove old Loctite 574 flange sealant
residues and other contamination from the
contact surfaces on both motor and gearbox.
xx1400000989

4 Repair
Continued
Refitting, motor axis 4

The procedure below details how to refit motor, axis 4.
Action Note
1
DANGER
Turn off all:

2 Make sure the o-ring on the circumference Art. no. is specified in Required equip-
of the motor is seated properly. Lightly lub- ment on page 292.
ricate the o-ring with grease.
3 In order to release the brakes, connect the Connect to connector R2.MP4:
24 VDC power supply. • +: pin 2
• -: pin 5
4 Foundry Plus:
Apply Loctite 574 flange sealant on the
contact surface.
xx1400000990
5 Fit the two guide pins in two of the motor Art. no. is specified in Required equip-
attachment holes. ment on page 292.
Shown in the figure Location of motor on
page 292.
6 Fit the motor with guidance of the pins, Make sure the motor pinion does not get
making sure the motor pinion is properly damaged!
mated to the gear of gearbox 4.

4 Repair
Continued
Action Note
7 Use the rotation tool in order to rotate the Art. no. is specified in Required equip-
motor pinion when mating it to the gear! ment on page 292.
Fit the motor, making sure the motor pinion Make sure the motor pinion does not get
is properly mated to the gear, axis 4. damaged!
Make sure the motor is turned the right
direction, that is the cables facing for-
wards.
xx0200000165
The rotation tool is used beneath the mo-

tor cover, directly on the motor shaft as
shown in figure above.
• A: Rotation tool.
9 Secure the motor with four attachment 4 pcs: M8 x 25, tightening torque: 24 Nm.
screws and plain washers.
cover.
12 Refit the cover on top of the motor with its Make sure the cover is tightly sealed!
four attachment screws.
13 Refit the cable gland cover at the cable exit Shown in the figure Location of motor on
with its two attachment screws. page 292.
14 Perform a leak-down test if the gearbox has Detailed in the section Performing a leak-
been drained. down test on page 174.
15 Refill the gearbox with oil if drained.
16 Recalibrate the robot! Pendulum Calibration is described in Op-
page 352.
17
DANGER


4 Repair
Location of motor
The motor axis 5 is located inside the upper arm tube, but attached to the wrist
unit, as shown in the figure below.
lists on page 387.
xx0700000062
A Robot variant IRB 6660 - 100/3.3, IRB 6660 - 130/3.1

B Robot variant IRB 6660 - 205/1.9
C Wrist unit
D Motor, axis 5 (Inside upper arm tube)
E Upper arm tube
Required equipment

Motor For spare part number,
page 387.
Set of shim, motor 3HAC7941-28 Used to obtain the correct distance
between motor flange and outer sur-
face of motor pinion.
O-ring 21522012-430 Must be replaced when reassembling
motor!
Isopropanol 11771012-208 For cleaning motor pinion and motor
pinion hole.
Mineral oil CS 320 For lubrication of pinion shaft and
pinion hole.

4 Repair
Continued

Removal tool, motor M10x 3HAC14972-1 Always use the removal tools in pairs!
Measuring tool 6896134-GN
Other tools and procedures These procedures include references
may be required. See refer- to the tools required.
tions below.
page 389.

Action Note
calibration:

4 Repair
Continued
Removal, motor, axis 5

The procedure below details how to remove motor, axis 5.
Action Note
procedure.
2
DANGER
Turn off all:

3 Drain the oil from gearbox axis 5. Detailed in the section Changing oil,
axis-5 gearbox on page 156.
4 Remove the wrist unit. Detailed in the section Removal,
wrist unit on page 223.
xx1400002580
5 Place the wrist unit safely on a workbench, in a

fixture or similar.
6 Remove the cover on top of the motor by unscrew-
ing its four attachment screws.
7 Remove the cable gland cover at the cable exit
by unscrewing its two attachment screws.
cover and remove the cable of the axis-5 motor.
9 In order to release the brake, connect the 24 VDC Connect to either:
power supply. - connector R4.MP5 (in the motor):
• + : pin 2
• -: pin 5
- connector R3.MP5 (on the separate
cable, if not removed):
• +: pin C
• -: pin D
10 Remove the motor by unscrewing its four attach-
ment screws and plain washers.

4 Repair
Continued
Action Note
11 Fit the two guide pins in two of the motor attach- Art. no. is specified in Required
ment screw holes. equipment on page 297.
12 If required, press the motor out of position by fit- Art. no. is specified in Required
ting removal tool, motor, M10 to the motor attach- equipment on page 297.
ment screw holes. Always use the removal tools in
pairs and diagonally!
13 Lift the motor to get the pinion away from the Make sure the motor pinion is not
gear and disconnect the brake release voltage. damaged!
14 Remove the motor by gently lifting it straight out. Keep track of the shims between the
motor flange and the wrist housing.
15 Foundry Plus:
xx1400000991
Refitting, motor, axis 5

Action Note
1
DANGER
Turn off all:

2 Make sure the o-ring on the circumference of Art. no. is specified in Required equip-
the motor is seated properly. Lightly lubricate ment on page 297.
3 In order to release the brake, connect the 24 Connect to either:
VDC power supply. - connector R4.MP5 (in the motor):
• +: pin 2
• -: pin 5
- connector R3.MP5 (on the separate
cable, if not removed):
• +: pin C
• -: pin D

4 Repair
Continued
Action Note
4 Foundry Plus:
surface.
xx1400000991
5 Fit the two guide pins in two of the motor attach- Art. no. is specified in Required equip-
ment holes. ment on page 297.
6 Fit the motor, with guidance from the pins, Make sure the motor pinion does not
making sure the motor pinion is properly mated get damaged!
to the gear of axis 5.
7 Secure the motor with four attachment screws 4 pcs: M8 x 25; tightening torque: 24
and plain washers. Nm.
9 Refit the cable of the axis-5 motor and recon-
nect all connectors beneath the motor cover.
10 Refit the cable gland cover at the cable exit
with its two attachment screws.
11 Refit the cover on top of the motor with its four Make sure the cover is tightly sealed!
attachment screws.
12 Perform a leak-down test. Detailed in the section Performing a
leak-down test on page 174.
13 Refit the wrist unit.
14 Foundry Plus
Make sure that the gasket is undamaged. Also
the small gasket fitted in the cover recess.
Replace if damaged.
xx1400002579

4 Repair
Continued
Action Note
15 Foundry Plus
Make sure the washers are fitted in the gasket
holes. Refit the cover, wrist unit Foundry Plus.
xx1400002580
16 Refill the gear with oil. Detailed in the section Changing oil,
17 Re-calibrate the robot. Pendulum Calibration is described in
page 352.
page 341.
18
DANGER

further detailed in the section First test run may
cause injury or damage on page 28.

4 Repair
Location of motor
The motor axis 6 is located in the center of the wrist unit as shown in the figure
below.
xx0700000068
A Axis-6 motor. Figure shows a motor with cooling elements. (There are no cooling
elements on the motor on variant IRB 6660 - 205/1.9.)
B Axis-6 gearbox
C Attachment screws and washers gearbox (18 pcs)
D Attachment screws, turning disk (12 pcs)
Required equipment
Equipment, etc. Spare part no. Art. no. Note

Motor, axis 6 See spare part Includes:
number in Spare • motor
part lists on • pinion
page 387.
• o-ring
O-ring 21522012-430 Must be replaced when reas-
sembling motor!
Gasket 3HAC048560-001 Must be replaced when repla-
cing motor
Gasket, cover 3HAC033489-001 Must be replaced when
opening cover.
Removal tool, motor 3HAC14972-1 Always use the removal tools
M10x in pairs!

4 Repair
Continued
Equipment, etc. Spare part no. Art. no. Note

Loctite 574, Flange 12340011-116 Option Foundry Plus
sealant
Calibration Pendulum 3HAC15716-1 Complete kit that also in-
toolkit cludes operating manual.
Required if Calibration Pendu-
lum is the valid calibration
method for the robot.
Calibration tool box, 3HAC055412- Delivered as a set of calibra-
Axis Calibration 001 tion tools.
Required if Axis Calibration
is the valid calibration meth-
od for the robot.
Other tools and proced- These procedures include
ures may be required. references to the tools re-
See references to these quired.
procedures in the step-
by-step instructions be-
low.
Circuit diagram 3HAC025744- See chapter Circuit diagram
001 on page 389.

Action Note

4 Repair
Continued
Action Note
calibration:
Removal, motor
The procedure below details how to remove the motor, axis 6.
Note
Robots with protection type Foundry Plus or Foundry Prime require special repair
routines to maintain the tightness level, in addition to the procedure below,
described in Replacement of the motor axis 6 (Foundry Plus) on page 308.
Action Note
procedure.
2 Move the robot to a position where the motor in
axis 6 is pointed straight up. This position enables
the motor to be replaced without draining the gear
oil, which in turn saves time.
3
DANGER
Turn off all:

4 Remove the rear motor cover by unscrewing the

five attachment screws.
5 Disconnect all connectors beneath the cover.
6 In order to release the brake, connect the 24 VDC Connect to connector R3.MP6
power supply. • +: pin 2
• -: pin 5

4 Repair
Continued
Action Note
7 (Not applicable to robot variant IRB 6660 - 205/1.9
!)
If needed, loosen the strap securing the cooling
elements in order to reach the attachment screws
securing motor axis 6.
xx0700000164
• A: Strap
• B: Cooling element.
8 Remove the motor by unscrewing its four attach-
ment screws and plain washers.
9 If required, press the motor out of position by fitting Art. no. is specified in Required
removal tool, motor to the motor attachment screw equipment on page 303.
holes. Always use the removal tools in
pairs!
10 Lift the motor carefully to get the pinion away from Make sure the motor pinion is not
the gear and disconnect the brake release voltage. damaged!
11 Remove the motor by gently lifting it straight out.
Refitting, motor
Note
Robots with protection type Foundry Plus or Foundry Prime require special repair
routines to maintain the tightness level, in addition to the procedure below,
described in Replacement of the motor axis 6 (Foundry Plus) on page 308.
Action Note
1 Make sure the o-ring on the circumference of Art. no. is specified in Required
the motor is seated properly. Lightly lubricate equipment on page 303.
VDC power supply. • +: pin 2
• -: pin 5
3 Fit the two guide pins in two of the motor attach- Art. no. is specified in Required
ment holes. equipment on page 303.
4 Fit the motor, with guidance from the pins, Make sure the pinion on the motor
making sure the motor pinion is properly mated shaft is not damaged!
to the gear of gearbox, axis 6.
6 Secure the motor with its four attachment screws 4 pcs: M8 x 25, tightening torque: 24
and plain washers. Nm.

4 Repair
Continued
Action Note
7 (Not applicable to robot variant IRB 6660 -
205/1.9!)
Refit the strap securing the cooling elements.
xx0700000164
• A: Strap
• B: Cooling elements
cover.
10 Refit the cover on top of the motor with its five Make sure the cover is tightly sealed!
attachment screws.
11 Re-calibrate the robot. Pendulum Calibration is described in
Operating manual - Calibration Pen-
dulum, enclosed with the calibration
tools.
rating with Axis Calibration method
on page 352.
page 341.
12
DANGER


4 Repair
Continued
Replacement of the motor axis 6 (Foundry Plus)

Robots with protection type Foundry Plus require special repair routines to maintain
the tightness level.
The repair must be done according to the previous repair procedure with the
following additions.
Action Note
1
DANGER
Turn off all:

2 Remove the rear motor cover by unscrewing

the five attachment screws.
xx1500002524
• A: Motor unit
• B: Connection box
• C: Attachment screw (5 pcs)
• D: Rear motor cover
• E: Gasket
3 Continue to remove the motor unit, according
to step 6 and forwards in Removal, motor on
page 305.
4
Note
Keep the old rear motor cover with the air

nipple.

4 Repair
Continued
Action Note
5 Remove old Loctite 574 flange sealant residues
xx1400000992
6 Remove the protection strip on the gasket and

mount it on the motor.
xx1500002425
• A: Attachment screw (4pcs)

Mercasol 3106
• B: Motor unit
• C: O-ring
• D: Sikaflex in screw recesses
• E: Tilt house
• F: Washer
• G: Rear motor cover
• H: Sealing
• J: Loctite 574
7 Apply Mercasol 3106 on the motor end cover.

4 Repair
Continued
Action Note
8 Apply Loctite 574 flange sealant on the contact
surface.
xx1400000992
9 Apply grease on the o-ring on the motor.

10 Continue to refit the new motor according to
section, Refitting, motor on page 306.

4 Repair
4.7.1 Replacing the axis 1 gearbox
4.7 Gearboxes
Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure.
xx0700000074
A Gearbox, axis 1
B Frame
C Base
D Attachment screws gearbox axis 1, M12x70 quality 12.9 UNBRAKO (24 pcs)
E Attachment screws gearbox axis 1, M16x90 quality 12.9 UNBRAKO (18 pcs)
Required equipment

Gearbox For spare part no. Includes:
see: • gearbox
• Spare part • all o-rings and seal-
lists on ing rings
page 387.
O-ring 3HAB3772-54 Replace if damaged!
O-ring 3HAB3772-55 Replace if damaged!
Sealing ring 3HAC11581-4 Replace if damaged!
Grease 3HAB3537-1 For lubricating the o-rings.

4 Repair
Continued

Support, base and 3HAC15535-1
gear 1
Lifting accessory, 3HAC15560-1
base
Lifting accessory 3HAC15556-1
(chain)
Guide pins 2 pcs, M16x150.
Used for guiding the gear-
box into place in the base.
Always use guide pins in
pairs!
Calibration Pendulum 3HAC15716-1 Complete kit that also in-
toolkit cludes operating manual.
Required if Calibration
Pendulum is the valid calib-
ration method for the robot.
Calibration tool box, 3HAC055412-001 Delivered as a set of calib-
Axis Calibration ration tools.
Required if Axis Calibration
is the valid calibration
method for the robot.
page 381.
Other tools and pro- These procedures include
cedures may be re- references to the tools re-
quired. See refer- quired.
ences to these pro-
cedures in the step-
by-step instructions
below.

Action Note

4 Repair
Continued
Action Note
calibration:
Removal, gearbox axis 1

Use this procedure to remove gearbox, axis 1.
Action Note

4 Repair
Continued
Action Note
2 Move the robot to its most stable position, IRB 6660 - 130/3.1, IRB 6660 - 100/3.3
shown in the figure to the right.
xx0700000137
IRB 6660 - 205/1.9
42°
xx0700000518
3
DANGER
Turn off all:

working area.
4 Drain the axis 1 gearbox. See Changing oil, axis-1 gearbox on

page 146.
5 Remove the complete arm system. Detailed in section Removal, arm system
on page 209.
6 Unfasten the robot base from the foundation
by removing the base attachment screws.

4 Repair
Continued
Action Note
7 Attach the lifting accessory, base and gear
1 and the lifting tool (chain) to the gearbox
and base.
xx1000001395
Specified in Required equipment on

page 311.
8
CAUTION
The base and axis 1 gearbox weighs 310

kg + 200 kg.
accordingly!
9 Lift the robot base including the axis 1 Art. no. is specified in Required equip-
gearbox to allow the base and gear 1 sup- ment on page 311.
port be fitted on each sides of the base.
10 Secure the support to the base and to the
foundation.
Make sure the base remains in a stable
position before performing any work under-
neath the base!
xx1000000364
A Support base (4 pcs)

4 Repair
Continued
Action Note
11 Remove the bottom plate from underneath
the base in order to get access to the attach-
ment screws.
It may be necessary to also remove the rear
connector plate.
xx1000001385
xx0300000612
A Bottom plate
B Rear connector plate
C Attachment screw
D Groove
12 Unscrew the attachment screws and re-
move the washers.
xx0200000227
A view from below:

• A: Oil drain hose
• B: Attachment screws, gearbox
axis 1, 18 pcs
• C: Washers, 3 pcs

4 Repair
Continued
Action Note
13 Remove the cable guide in the center of
gearbox 1 by unscrewing its attachment
screws.
xx1000001387
14
CAUTION
The gearbox weighs 200 kg.

accordingly!
15 Lift the gearbox away with the already

mounted lifting tools.
16 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

4 Repair
Continued
Refitting, gearbox axis 1

Use this procedure to refit gearbox, axis 1.
Action Note
1 Fit the support, base and gear 1 to the base. Mounting of the support, base and gear
1 is detailed in section Removal, gear-
box axis 1 on page 313.
xx1000000364
A Support base (4 pcs)

2 Make sure the two o-rings on the circumfer- Art no. is specified in Required equip-
ence of the gearbox are seated properly in ment on page 311.
their respective groove. Lubricate them with
grease.
xx0200000055
• A: Guide pin
• C: O-ring 3HAB 3772-54
• D: O-ring 3HAB 3772-55
• E: Sealing ring 3HAC 11581-4

4 Repair
Continued
Action Note
3 Make sure the small o-ring around the oil hole
is fitted properly!
xx1000001392
4 Attach the lifting accessory, base and gear 1 Specified in Required equipment on
and the lifting tool (chain) to the gearbox. page 311.
xx1000001395
5 Fit two guide pins in two of the attachment Specified in Required equipment on
holes in the gearbox, parallel to each other. page 311.
6
CAUTION

cordingly!

4 Repair
Continued
Action Note
7 Lift the gearbox.
Make sure the guide pin in the bottom face of
the gearbox is properly aligned with the base.
xx1000001389
xx1000001391
8 Lift gearbox axis 1 onto the guide pins and Always use guide pins in pairs!
lower it carefully to its mounting position.

4 Repair
Continued
Action Note
9 Secure the gearbox with its attachment 18 pcs, M16 x 90, 12.9 quality UN-
screws and washers. BRAKO.
Tightening torque: 300 Nm
ting.
xx0200000227
A view from below:

• A: Oil drain hose
• B: Attachment screws, gearbox
axis 1, 18 pcs
• C: Washers, 3 pcs
10 Refit the cable guide in the center of gearbox
1 with its attachment screws.
xx1000001393

4 Repair
Continued
Action Note
11 Refit the bottom plate underneath the robot 1 screw: M6 x 8.
base by pushing it into the groove and fitting
the attachment screw.
If removed, also refit the rear connector plate.
Note
Direct the bends on the bottom plate down-

wards!
xx0300000612
• A: Bottom plate
• B: Rear connector plate
• C: Attachment screw
• D: Groove
12
CAUTION
The base and axis 1 gearbox weighs 310 kg

+ 200 kg.
cordingly!
13 Lift the robot base and gearbox 1 and remove

the base and gear support.
14 Secure the base to the mounting site. See Orienting and securing the robot
on page 81.
15 Refit the complete arm system. Detailed in section Refitting, arm sys-
tem on page 213.
CAUTION
This is a complex task to be performed with

utmost care in order to avoid injury or dam-
age!
16 Perform a leak-down test. See section Performing a leak-down

test on page 174.
17 Refill the gearbox with oil. See Changing oil, axis-1 gearbox on
page 146.
page 352.
page 341.

4 Repair
Continued
Action Note
19
DANGER


4 Repair
4.7.2 Replacing the gearbox, axes 2- 3
Location of gearbox, axes 2-3

The axis-2 and axis-3 gearboxes are located on either side of the frame as shown
in the figure.
The figure shows robot variant IRB 6660 - 130/3.1. The location of the gearboxes
is the same on all variants.
xx0700000063
A Gearbox, axis 2
B Gearbox, axis 3
C Hole for lockscrew
Required equipment
Equipment, etc. Art.no Note

Gearbox, axes 2-3 For spare part no. see:
page 387.
Sealing axes 2-3 3HAC022379-001 Always replace.
O-ring 3HAB3772-127 Replace if damaged.
Lock screw M16x55 - Use to lock the lower arm.
Screw M12x50 - 2 pcs. Use to unload the balancing
device.
Screw M12x100 - 2 pcs, must have full thread. Use to
press the gearbox free from the
frame.
Guide pins M12 - Use guide pins in pairs.
Lifting accessory - Roundsling and a rotating lifting
point.
Lifting capacity: 100 kg. Used to lift
the gearbox.
Guide sleeves 3HAC14628-1/2 Use to keep the sealing in place.

4 Repair
Continued
Equipment, etc. Art.no Note

Grease Use to lubricate surfaces on the
gearbox for easier assembly.
Bearing grease 3HAB3537-1 Shell Alvania W R2
Option Foundry Plus
Standard toolkit Content is defined in section Stand-
tions below.

Action Note
calibration:
Removal, axis-2 / axis-3 gearbox

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!

4 Repair
Continued
Action Note
2 When removing axis 2 gearbox: Run the
axis 2 to -42° and all other axes to 0° (cal-
ibration position).
When removing axis 3 gearbox: Run the
axis 2 to -40°, axis 3 to +15° and all other
axes to 0°.
3 When removing axis 2 gearbox: Remove Axis 2:
all screws in the lower screw area on the
inside of the lower arm (7 pcs M12, 2 pcs
M16). See figure.
When removing axis 3 gearbox: Remove
all screws in the upper front screw area and
three screws in the upper back area.
xx1100000623
Axis 3:
xx1100000624
4 Run axis 2 to 0°.

4 Repair
Continued
Action Note
5 Fit the lock screw in the lower arm to secure
axis 2.
CAUTION
Tighten by hand!
xx1000001101
6 Secure the weight of the upper arm with

roundslings in an overhead crane.
7 Raise the lifting equipment to take the
weight of the upper arm.
8 Release the brakes of axis 2 to rest the
weight of the axis against the lock screw.
9 Release the brakes of axis 3 to rest the
weight of the axis by the roundslings and
overhead crane.
10 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

4 Repair
Continued
Action Note
11 Insert two screws, M12x50 in the holes to See the previous figure!
neutralize the spring force. Screw in the
screws until they have proper contact with
the cylinder inside.
The length of the cylinder is now locked
and the balancing device is unloaded. It
should now be possible to easily rotate the
balancing device.
12
DANGER
Turn off all:

working area.
13 Drain the gearbox. Detailed in section Draining, axes 2 and 3

on page 151.
Note
Time-consuming activity!
14 Remove the motor cables of axis-2 or axis-

3 motor, depending on which gearbox is
being removed. Protect the cables from
getting damaged and from oil spill.
15 Remove one gearbox at a time!
16 Remove the axis-2 or axis-3 motor, depend- Detailed in section Replacing motors, axes
ing on which gearbox is being removed. 2 and 3 on page 281
17 Remove all remaining attachment screws
that secure the gearbox to the lower arm
system.
Axis 2: M16 and M12.
Axis 3: M12.
xx1000001405

4 Repair
Continued
Action Note
18 Remove the gearbox cover by removing its
attachment screws.
xx1200000628
19 Remove two opposite screws of the attach-

ment screws that hold the gearbox and re- Note
place them with two guide pins.
Always use guide pins in pairs!
20 Remove the remaining attachment screws.

21 Fit the lifting accessory to the gearbox. Art. no. is specified in Required equipment
on page 324.
22
CAUTION

accordingly!
23 If required, apply two screws, M12x100 to

the holes in the gearbox, in order to press
it free. (The screws need to have a full
thread.)
24
CAUTION
When the gearbox comes free from the

frame and comes off the guide pins it will
tilt and there is a risk of damage to the
gearbox surfaces! Be aware of this and re-
move the gearbox carefully!

4 Repair
Continued
Action Note
25 Remove the gearbox axis 2-3 using an
overhead crane or similar, with guidance
from the fitted guide pins.
xx1200000629
26 Remove the sealing from the lower arm and

clean it.
Note
The sealing can hang onto the gearbox,

sticking to the oil.
xx1200000630

4 Repair
Continued
Refitting, axis-2 / axis-3 gearbox

Use this procedure to refit the axes-2 or axis-3 gearbox.
Action Note
1 Make sure that the o-ring is fitted to the
gearbox. Lightly lubricate it with grease.
xx1000001404
Specified in Required equipment on

page 324.
2 Fit two guide pins in the frame.
Use two of the attachment holes for the
screws that hold the gearbox.
3
CAUTION
The gearbox weighs 69 kg! All lifting

equipment used must be sized accordingly!
4 Fit the lifting accessory to the gearbox and Specified in Required equipment on
lift it with an overhead crane. page 324.

4 Repair
Continued
Action Note
5 Fit a new sealing to the gearbox and secure Art. no. is specified in Required equipment
it to the gearbox by using two guide on page 324.
sleeves. Axis 2:
When refitting axis 2 gearbox:Insert the
guide sleeves in the two middle holes of
the upper screw areas.
When refitting axis 3 gearbox: Insert one
guide sleeve in the middle screw hole in
the upper back area and one guide sleeve
in the middle screw hole in the the lower
area.
xx1100000621
Axis 3:
xx1100000622
6 Foundry Plus:
Apply bearing grease on the highlighted
areas on both sides of the sealing.
Note
Do not apply grease closer than 20 mm

from the edge of the holes in the sealing.
xx1400000993

4 Repair
Continued
Action Note
Foundry Plus:
Apply rust preventive on the highlighted
area.
xx1400001132
7 Lubricate necessary surfaces of the gear- Specified in Required equipment on

box with grease in order to make it easier page 324.
to insert the gearbox into the frame.
8 Put the gearbox onto the guide pins and
slide it carefully into place in the frame.
Note
Check that the sealing is in place during

the procedure.
xx1000001406
9 Use a crank to move the gears in order to

find the holes for the attachment screws.
10 Secure the gearbox to the lower arm with Axis 2
the attachment screws and washers in two M12x60 quality 12.9 Gleitmo (6+6 pcs)
of the screw areas (the third is not reach- • Tightening torque: 120 Nm.
able at this point). Do not remove the guide
sleeves yet. M16x90 quality 12.9 Gleitmo (2+2 pcs)
• Tightening torque: 300 Nm.
Axis 3
M12x60 quality 12.9 Gleitmo
11 Remove the two guide sleeves and replace M12x60 quality 12.9 Gleitmo (1+1 pc)
them with the two remaining M12 screws. • Tightening torque: 120 Nm.
12 Secure the gearbox to the frame. M12, quality 8.8-A2F

4 Repair
Continued
Action Note
13 Clean the gearbox of residual grease.
14 Apply locking liquid in the attachment holes Loctite 243.
for the gearbox cover.
15 Fit the o-ring in the cover.
xx1000001407
16 Refit the cover with its attachment screws M8x35 quality 8.8-A2F (12 pcs)
and washers. Tightening torque: 24 Nm
Note
Fit the cover so that the arrow on the cover

points upwards!
xx1000001408
17 Refit the motors axes 2-3. See Replacing motors, axes 2 and 3 on
page 281
18 Perform a leakdown test. See Performing a leak-down test on
page 174.

4 Repair
Continued
Action Note
19 Refill the gearbox axes 2-3 with oil. See Filling, axes 2 and 3 on page 151
20 Remove the screws that unload the balan-
cing device and put back the plastic
screws.
xx1000001111
21 Remove the lock screw from the lower arm.

22 Run the axes 2 and 3 to a position where Axis 2
the remaining screws in the lower arm can M12x60 quality 12.9 Gleitmo (6 pcs)
be fitted. • Tightening torque: 120 Nm.
M16x90 quality 12.9 Gleitmo (2 pcs)
Axis 3
M12x60 quality 12.9 Gleitmo
24
DANGER

run may cause injury or damage on
page 28.

4 Repair
4.7.3 Replacement of gearbox, axis 6
Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure
below.
The figure shows the motor for robot variant IRB 6660 - 130/3.1 (with cooling
elements).
xx0700000165
A Strap
B Gearbox, axis 6
C Attachment screws and washers, gearbox (18 pcs)
D Attachment screws and washers, turning disk (12 pcs)
E Oil plug, draining
F Oil plug, filling
G Cooling elements
Required equipment

Gearbox For spare part number, Includes o-ring
page 387.
Washers 3HAA1001-172 Not included in gearbox!
Replace when damaged.
O-ring 3HAB3772-57 164.7x3.53
Must be replaced when reas-
sembling gearbox.
O-ring 3HAB3772-64 150.0x2.0
sembling gearbox.
O-ring 3HAB3772-61 12 pcs, 13.1x1.6
sembling gearbox.

4 Repair
Continued

Flange sealant 12340011-116 Loctite 574
Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes op-
erating manual.
Required if Calibration Pendulum
is the valid calibration method for
the robot.
Calibration tool box, Axis 3HAC055412-001 Delivered as a set of calibration
Calibration tools.
Required if Axis Calibration is the
valid calibration method for the ro-
bot.
tions below.

Action Note
calibration:

4 Repair
Continued
Removal, gearbox
The procedure below details how to remove gearbox, axis 6.
Action Note
repair procedure.
2
DANGER
Turn off all:

3 Drain the oil from gearbox, axis 6. Detailed in the section Changing oil,
4 Remove the turning disc. Detailed in the section Removing,
turning disk on page 218.
5 Remove the gearbox by unscrewing its attach- Shown in the figure Location of gearbox
ment screws. on page 336.
6 If required, apply M8 screws to the holes
shown in the figure beside to press the gearbox
out.
xx0200000220
• A: M8 holes for pressing out the

gearbox
Foundry Plus:
faces.
xx1400001123

4 Repair
Continued
Action Note
7 Remove the gearbox axis 6 by lifting it out Be careful not to damage the motor
carefully. pinion!
Refitting, gearbox
The procedure below details how to refit gearbox, axis 6.
Action Note
1
DANGER
Turn off all:

• hydraulic pressure supply to the ro-
bot
2 Make sure the o-ring is fitted to the rear of Article number is specified in Required
the gearbox. Lubricate the o-ring with equipment on page 336.
grease.
xx0200000221
• A: O-ring, gearbox axis 6

3 Release the holding brake of motor axis 6. Detailed in the section Manually releasing
the brakes on page 73.
4 Foundry Plus:
Apply Loctite 574 flange sealant on the
contact surface.
xx1400001122

4 Repair
Continued
Action Note
5 Insert the gearbox, axis 6 into the wrist Article number is specified in Required
unit. equipment on page 336.
Shown in the figure Location of gearbox on
page 336.
Make sure the gears of the gearbox mate
with the gears of the motor!
6 Secure the gearbox with the attachment Shown in the figure Location of gearbox on
screws and washers. page 336.
8 pcs or 18 pcs (depending on wrist ver-
sion): M8 x 40, 12.9 quality Gleitmo, Tight-
ening torque: 30 Nm.
they are lubricated as detailed in section
Screw joints on page 377 before fitting.
7 Refit the turning disc. Detailed in the section Refitting, turning
disk on page 219.
8 Perform a leak-down test. Detailed in the section Performing a leak-
down test on page 174.
9 Refill the gearbox with oil. Detailed in the section Changing oil, axis-
6 gearbox on page 159.
10 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
11
DANGER

run may cause injury or damage on
page 28.

5 Calibration
5.1.1 Introduction and calibration terminology
5 Calibration
5.1 Introduction to calibration
5.1.1 Introduction and calibration terminology
Calibration information
This chapter includes general information about the recommended calibration
methods and also the detailed procedures for updating the revolution counters,
checking the calibration position etc.
Detailed instructions of how to perform Axis Calibration are given on the
FlexPendant during the calibration procedure. To prepare calibration with Axis
Calibration method, see Calibrating with Axis Calibration method on page 352.
Detailed instructions of how to perform Pendulum Calibration are given in the
documentation enclosed with the calibration tools.
Calibration terminology
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.
Calibration position Known position of the complete robot that is used
for calibration of the robot.
Standard calibration A generic term for all calibration methods that aim
to move the robot to calibration position.
Fine calibration A calibration routine that generates a new zero posi-
tion of the robot.
Reference calibration A calibration routine that in the first step generates
a reference to current zero position of the robot. The
same calibration routine can later on be used to re-
calibrate the robot back to the same position as when
the reference was stored.
This routine is more flexible compared to fine calib-
ration and is used when tools and process equipment
are installed.
Requires that a reference is created before being
used for recalibrating the robot.
Requires that the robot is dressed with the same
tools and process equipment during calibration as
during creation of the reference values.
Update revolution counter A calibration routine to make a rough calibration of
each manipulator axis.
Synchronization mark Visual marks on the robot axes. When marks are
aligned, the robot is in synchronization position.

5 Calibration
5.1.2 Calibration methods
Overview
This section specifies the different types of calibration and the calibration methods
that are supplied by ABB.
Types of calibration
Type of calibration Description Calibration method

Standard calibration The calibrated robot is positioned at calibration Axis Calibration or Cal-
position. ibration Pendulum i
Standard calibration data is found on the SMB
(serial measurement board) or EIB in the robot.
For robots with RobotWare 5.04 or older, the
calibration data is delivered in a file, calib.cfg,
supplied with the robot at delivery. The file
identifies the correct resolver/motor position
corresponding to the robot home position.
Absolute accuracy Based on standard calibration, and besides CalibWare
calibration (option- positioning the robot at synchronization posi-
al) tion, the Absolute accuracy calibration also
compensates for:
• Mechanical tolerances in the robot
structure
• Deflection due to load
Absolute accuracy calibration focuses on pos-
itioning accuracy in the Cartesian coordinate
system for the robot.
Absolute accuracy calibration data is found
on the SMB (serial measurement board) in the
robot.
For robots with RobotWare 5.05 or older, the
absolute accuracy calibration data is delivered
in a file, absacc.cfg, supplied with the robot at
delivery. The file replaces the calib.cfg file and
identifies motor positions as well as absolute
accuracy compensation parameters.
A robot calibrated with absolute accuracy has
a sticker next to the identification plate of the
robot.
To regain 100% absolute accuracy perform-
ance, the robot must be recalibrated for abso-
lute accuracy!
xx0400001197
i The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory. Always use
the same calibration method as used at the factory.
Information about valid calibration method is found on the calibration label or in the calibration
menu on the FlexPendant.
If no data is found related to standard calibration, Calibration Pendulum is used as default.

5 Calibration
Continued
Brief description of calibration methods

Calibration Pendulum method
Calibration Pendulum is a standard calibration method for calibration of all ABB
robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S).
Two different routines are available for the Calibration Pendulum method:
• Calibration Pendulum II
• Reference calibration
The calibration equipment for Calibration Pendulum is delivered as a complete
toolkit, including the Operating manual - Calibration Pendulum, which describes
the method and the different routines further.
Axis Calibration method

Axis Calibration is a standard calibration method for calibration of IRB 6660 and
is the most accurate method for the standard calibration. It is the recommended
method in order to achieve proper performance.
The following routines are available for the Axis Calibration method:
• Fine calibration
• Update revolution counters
• Reference calibration
The calibration equipment for Axis Calibration is delivered as a toolkit.
An introduction to the calibration method is given in this manual, see Calibrating
The actual instructions of how to perform the calibration procedure and what to
do at each step is given on the FlexPendant. You will be guided through the
calibration procedure, step by step.
CalibWare - Absolute Accuracy calibration

To achieve a good positioning in the Cartesian coordinate system, Absolute
Accuracy calibration is used as a TCP calibration. The CalibWare tool guides
through the calibration process and calculates new compensation parameters.
This is further detailed in the Application manual - CalibWare Field 5.0.
If a service operation is done to a robot with the option Absolute Accuracy, a new
absolute accuracy calibration is required in order to establish full performance.
For most cases after motor and transmission replacements that do not include
taking apart the robot structure, standard calibration is sufficient. Standard
calibration also supports wrist exchange.
References
Article numbers for the calibration tools are listed in the section Special tools on
page 382.
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.

5 Calibration
5.1.3 When to calibrate
5.1.3 When to calibrate
When to calibrate
The system must be calibrated if any of the following situations occur.
The resolver values are changed

If resolver values are changed, the robot must be recalibrated using the calibration
methods supplied by ABB. Calibrate the robot carefully with standard calibration,
according to information in this manual.
If the robot has absolute accuracy calibration, it is also recommended, but not
always necessary to calibrate for new absolute accuracy.
The resolver values will change when parts affecting the calibration position are
replaced on the robot, for example motors or parts of the transmission.
The revolution counter memory is lost

If the revolution counter memory is lost, the counters must be updated. See
Updating revolution counters on page 348. This will occur when:
• The battery is discharged
• A resolver error occurs
• The signal between a resolver and measurement board is interrupted
• A robot axis is moved with the control system disconnected
The revolution counters must also be updated after the robot and controller are
connected at the first installation.
The robot is rebuilt

If the robot is rebuilt, for example, after a crash or when the reach ability of a robot
is changed, it needs to be recalibrated for new resolver values.
If the robot has absolute accuracy calibration, it needs to be calibrated for new
absolute accuracy.

5 Calibration
5.2.1 Synchronization marks and synchronization position for axes
5.2 Synchronization marks and axis movement directions
Introduction
This section shows the position of the synchronization marks and the
synchronization position for each axis.
Synchronization marks, IRB 6660

The figure shows robot variant IRB 6660 - 130/3.1 but the position of the marks
are the same on all IRB 6660 robot variants.
xx0700000148
A Synchronization plate, axis 1

B Synchronization tab on robot

5 Calibration
Continued
C Synchronization mark, axis 2

D Synchronization mark, axis 3
E Synchronization mark, axis 4
F Synchronization mark, axis 5
G Synchronization mark, axis 6

5 Calibration
5.2.2 Calibration movement directions for all axes
5.2.2 Calibration movement directions for all axes
Overview
When calibrating, the axis must consistently be run towards the calibration position
in the same direction in order to avoid position errors caused by backlash in gears
and so on. Positive directions are shown in the graphic below.
Calibration service routines will handle the calibration movements automatically
and these might be different from the positive directions shown below.
Manual movement directions, 6 axes

Note! The graphic shows an IRB 7600. The positive direction is the same for all
6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in the
opposite direction!
xx0200000089

5 Calibration
5.3 Updating revolution counters
Introduction
This section describes how to do a rough calibration of each manipulator axis by
updating the revolution counter for each axis, using the FlexPendant.
Step 1 - Manually running the manipulator to the synchronization position

Use this procedure to manually run the manipulator to the synchronization position.
Action Note
1 Select axis-by-axis motion mode.
2 Jog the manipulator to align the synchron- See Synchronization marks and synchron-
ization marks. ization position for axes on page 345.
3 When all axes are positioned, update the Step 2 - Updating the revolution counter
revolution counter. with the FlexPendant on page 349.
Correct calibration position of axis 4 and 6

When jogging the manipulator to synchronization position, it is extremely important
to make sure that axes 4 and 6 of the following mentioned manipulators are
positioned correctly. The axes can be calibrated at the wrong turn, resulting in an
incorrect manipulator calibration.
Make sure the axes are positioned according to the correct calibration values, not
only according to the synchronization marks. The correct values are found on a
label, located either on the lower arm, underneath the flange plate on the base or
on the frame.
At delivery the manipulator is in the correct position, do NOT rotate axis 4 or 6 at
power up before the revolution counters are updated.
If one of the following mentioned axes are rotated one or more turns from its
calibration position before updating the revolution counter, the correct calibration
position will be lost due to non-integer gear ratio. This affects the following
manipulators:
Manipulator variant Axis 4 Axis 6
IRB 6660 Yes Yes
If the synchronization marks seem to be wrong (even if the motor calibration data
is correct), try to rotate the axis one turn, update the revolution counter and check
the synchronization marks again (try both directions, if needed).

5 Calibration
Continued
Step 2 - Updating the revolution counter with the FlexPendant

Use this procedure to update the revolution counter with the FlexPendant (IRC5).
Action
1 On the ABB menu, tap Calibration.
xx1500000942
2 All mechanical units connected to the system are shown with their calibration status.
Tap the mechanical unit in question.
xx1500000943

5 Calibration
Continued
Action
3 This step is valid for RobotWare 6.02 and later.
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
4 A screen is displayed, tap Rev. Counters.
en0400000771

5 Calibration
Continued
Action
5 Tap Update Revolution Counters....
A dialog box is displayed, warning that updating the revolution counters may change
programmed robot positions:
• Tap Yes to update the revolution counters.
• Tap No to cancel updating the revolution counters.
Tapping Yes displays the axis selection window.
6 Select the axis to have its revolution counter updated by:
• Ticking in the box to the left
• Tapping Select all to update all axes.
Then tap Update.
7 A dialog box is displayed, warning that the updating operation cannot be undone:
• Tap Update to proceed with updating the revolution counters.
• Tap Cancel to cancel updating the revolution counters.
Tapping Update updates the selected revolution counters and removes the tick from
the list of axes.
8
CAUTION
If a revolution counter is incorrectly updated, it will cause incorrect manipulator posi-

tioning, which in turn may cause damage or injury!
Check the synchronization position very carefully after each update. See Checking
the synchronization position on page 365.

5 Calibration
5.4.1 Description of Axis Calibration
5.4 Calibrating with Axis Calibration method
Instructions for Axis Calibration procedure given on the FlexPendant

This manual contains a brief description of the method, additional information to
the information given on the FlexPendant, article number for the tools and images
of where to fit the calibration tools on the robot.
Overview of the Axis Calibration procedure

The Axis Calibration procedure applies to all axes, and is performed on one axis
at the time. The robot axes are both manually and automatically moved into position,
as instructed on the FlexPendant.
A fixed calibration pin/bushing is installed on each robot axis at delivery.
The Axis Calibration procedure described roughly:
• A removable calibration tool is inserted by the operator into a calibration
bushing on the axis chosen for calibration, according to instructions on the
FlexPendant.
WARNING
Calibrating the robot with Axis Calibration requires special calibration tools
from ABB. Using other pins in the calibration bushings may cause severe
damage to the robot and/or personnel.
WARNING
The calibration tool must be fully inserted into the calibration bushing, until
the steel spring ring snaps into place.
• During the calibration procedure, RobotWare moves the robot axis chosen
for calibration so that the calibration tools get into contact. RobotWare records
values of the axis position and repeats the coming-in-contact procedure
several times to get an exact value of the axis position.
WARNING
Risk of pinching! The contact force for large robots can be up to 150 kg.
Keep a safe distance to the robot.
• The axis position is stored in RobotWare with an active choice from the
operator.

5 Calibration
Continued
Routines in the calibration procedure

The following routines are available in the Axis Calibration procedure, given at the
beginning of the procedure on the FlexPendant.
Fine calibration routine

Choose this routine to calibrate the robot when there are no tools, process cabling
or equipment fitted to the robot.
Reference calibration routine

Choose this routine to create reference values and to calibrate the robot when the
robot is dressed with tools, process cabling or other equipment.
If calibrating the robot with reference calibration there must be reference values
created before repair is made to the robot, if values are not already available.
Creating new values requires possibility to move the robot. The reference values
contain positions of all axes, torque of axes and technical data about the tool
installed. 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.
Follow the instructions given in the reference calibration routine on the FlexPendant
to create reference values.
When reference calibration is performed, the robot is restored to the status given
by the reference values.
Note
When calibrating the robot with the reference calibration routine, the robot must
be dressed with the same tools, process cabling and any other equipment as
when the reference values were created.
Update revolution counters

Choose this routine to make a rough calibration of each manipulator axis by
updating the revolution counter for each axis, using the FlexPendant.
Validation
In the mentioned routines, it is also possible to validate the calibration data.
Position of robot axes

The axis chosen for calibration is automatically run by the calibration program to
its calibration position during the calibration procedure.
In order for the axis to be able to be moved to calibration position, or in order for
getting proper access to the calibration bushing, other axes might need to be
jogged to positions different from 0 degrees. Information about which axes are
allowed to be jogged will be given on the FlexPendant. These axes are marked
with Unrestricted in the FlexPendant window.

5 Calibration
5.4.2 Calibration tools for Axis Calibration
Calibration tool set

The calibration tools used for Axis Calibration are designed to meet requirements
for calibration performance, durability and safety in case of accidental damage.
The calibration tool will eventually break from fatigue after longer period of use
and then needs to be replaced. 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.

Calibration tool box, 3HAC055412-001 Delivered as a set of calibration tools.
Axis Calibration Required if Axis Calibration is the valid calib-
ration method for the robot.
Examining the calibration tool

Check prior to usage
Before using the calibration tool, make sure that the tube insert, the plastic
protection and the steel spring ring are present.
WARNING
If any part is missing or damaged, the tool must be replaced immediately.
xx1500001914
A Tube insert
B Plastic protection
C Steel spring ring

5 Calibration
Continued
Periodic check of the calibration tool

If including the calibration tool in a local periodic check system, the following
measures should be checked.
• Outer diameter within Ø12g4 mm, Ø8g4 mm or Ø6g5 mm (depending on
calibration tool size).
• Straightness within 0.005 mm.
xx1500000951
A Outer diameter
Identifying the calibrating tools

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
1 It is possible to use any RFID solution, with the
correct dimensions. ABB has verifed function on
some suppliers fulfilling the requirements of NFC
compatible devices (13.56 Mhz) according to ISO
14443 or ISO 15693.
Note
The maximum dimensions on the RFID chip must

not exceed Ø7.9 mm x 8.0 mm, Ø5.9 mm x 8.0
mm or Ø3.9 mm x 8.0 mm (depending on calibra-
tion tool size).
2 There is a cavity on one end of the calibration tool

in which the RFID chip can be installed.
Install the RFID chip according to supplier instruc-
tions.
Install the chip in flush with the tool end.

5 Calibration
5.4.3 Installation locations for the calibration tools
5.4.3 Installation locations for the calibration tools
Location of fixed calibration items

This section shows how the robot is equipped with items for installation of
calibration tools for Axis Calibration (fixed calibration pins and/or bushings).
Installed calibration tools are not shown.
A fixed calibration pin and a bushing for the movable calibration tool are located
on each axis as follows.
xx1500003256
The fixed calibration pin for axis 1 is installed on a removable tower. The tower will
need to be removed if electronic position switches are fitted to the robot. Keep the
tower in a safe location for future recalibration needs and mark it with robot serial
number to ensure that the correct one is refitted.
Spare parts
When calibration is not being performed, a protective cover and an o-ring should
always be installed on the fixed calibration pin as well as a protective plug, included
a sealing, in the bushing. Replace damaged parts with new, if needed.
Spare part Article number Note
Protection cover and plug set 3HAC056806-001 Contains replacement calibration
pin covers and protective plugs
for the bushing.

5 Calibration
5.4.4 Axis Calibration - Running the calibration procedure
Required tools
The calibration tools used for Axis Calibration are designed to meet requirements
for calibration performance, durability and safety in case of accidental damage.
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.

Calibration tool box, Axis 3HAC055412-001 Delivered as a set of calibration tools.
Calibration Required if Axis Calibration is the valid
calibration method for the robot.
Required consumables
Consumable Article number Note
Clean cloth -
Spare parts
Spare part Article number Note

Protection cover and plug set 3HAC056806-001 Contains replacement calibration
pin covers and protective plugs
for the bushing.
Overview of the calibration procedure on the FlexPendant

Use the following list to learn about the calibration procedure before running the
RobotWare program on the FlexPendant. It gives you a brief overview of the
calibration procedure sequence.
After the calibration method has been called for on the FlexPendant, the following
sequence will be run.
1 Choose calibration routine. The routines are described in Routines in the
calibration procedure on page 353.
2 Choose which axis/axes to calibrate.
3 The robot moves to synchronization position.
4 Validate the synchronization marks.
5 The robot moves to preparation position.
6 Remove the protective cover from the fixed pin and the protection plug from
the bushing, if any, and install the calibration tool.

5 Calibration
Continued
7 The robot performs a measurement sequence by rotating the axis back and
forth.
8 Remove the calibration tool and reinstall the protective cover on the fixed
pin and the protection plug in the bushing, if any.
9 The robot moves to verify that the calibration tool is removed.
10 Choose whether to save the calibration data or not.
Calibration of the robot is not finished until the calibration data is saved, as last
step of the calibration procedure.
Preparation prior to calibration

The calibration procedure is described in the FlexPendant while conducting it.
Action Note
1
DANGER
While conducting the calibration, the robot needs

to be connected to power.
Make sure that the robots working area is empty,
as the robot can make unpredictable movements.
2 Wipe the calibration tool clean. Use a clean cloth.
Note
The calibration method is exact. Dust, dirt or color

flakes will affect the calibration value.
Starting the calibration procedure

Use this procedure to call for the Axis Calibration method on the FlexPendant.
Action Note
1 On the ABB menu, tap Calibration.
xx1500000942

5 Calibration
Continued
Action Note
2 All mechanical units connected to the system are
shown with their calibration status.
Tap the mechanical unit in question.
xx1500000943
3 Calibration method used at factory for each axis The FlexPendant will give all inform-
is shown, as well as calibration method used for ation needed to proceed with Axis
the robot during last field calibration. Calibration.
Tap Run Calibration Method. The software will
automatically call for the procedure for the valid
calibration method.
xx1500000944
4 Follow the instructions given on the FlexPendant. A brief overview of the sequence
that will be run on the FlexPendant
is given in Overview of the calibra-
tion procedure on the FlexPendant
on page 357.
Restarting an interrupted calibration procedure

If the Axis Calibration procedure is interrupted before the calibration is finished,
the RobotWare program needs to be started again. Use this procedure to take
required action.
Situation Action
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.

5 Calibration
Continued
Situation Action
The RobotWare program is terminated with Remove the calibration tool, if it is installed,
PP to Main. and restart the calibration procedure from
the beginning. See Starting the calibration
procedure on page 358.
If the calibration tool is in contact the robot
axis needs to be jogged in order to release
the calibration tool. Jogging the axis in wrong
direction will cause the calibration tool to
break. Directions of axis movement is shown
in Calibration movement directions for all
axes on page 347
Axis Calibration with SafeMove option

To be able to run Axis Calibration SafeMove needs to be unsynchronized. The Axis
Calibration routine recognizes if the robot is equipped with SafeMove and will force
SafeMove to unsynchronize automatically.
However, SafeMove may generate other warning messages anytime during the
Axis Calibration routine.
Safety controller not synchronized - SafeMove message
Action Note
1 SafeMove generates the message "Safety control-
ler not synchronized".
xx1500002480
2 Confirm unsynchronized state by pressing Ac-

knowledge to continue Axis Calibration proced-
ure.
3 Restart Axis Calibration procedure by pressing
Play.

5 Calibration
Continued
Unsynchronized speed exceeded - SafeMove message while saving robot data
Action Note
1 SafeMove generates the message "Unsynchron-
ized speed exceeded" while saving robot data.
xx1500002481
2 Press Acknowledge to continue Axis Calibration

procedure.
Play.
Unsynchronized time limit expired - SafeMove message anytime during Axis Calibration routine
Action Note
1 SafeMove generates the message "Unsynchron-
ized time limit expired" (anytime).
xx1500002482
2 Press OK to continue Axis Calibration procedure.

Play.

5 Calibration
Continued
After calibration
Action Note
1 Check the o-ring on the fixed calibration pin.
Replace if damaged or missing.
2 Reinstall the protective cover on the fixed calibra-
tion pin on each axis, directly after the axis has
been calibrated.
Replace the cover with new spare part, if missing
or damaged.
xx1600002102
Protection cover and plug set:

3HAC056806-001.
3 Reinstall the protective plug and sealing in the
bushing on each axis, directly after the axis has
been calibrated. Ensure that the sealing is not
damaged.
Replace the plug and the sealing with new spare
part, if missing or damaged.
xx1500000952
Protection cover and plug set:

3HAC056806-001.

5 Calibration
5.5 Calibrating with Calibration Pendulum method
5.5 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.

5 Calibration
5.6 Verifying the calibration
5.6 Verifying the calibration
Introduction
Always verify the results after calibrating any robot axis to verify that all calibration
positions are correct.
Verifying the calibration

Use this procedure to verify the calibration result.
Action Note
1 Run the calibration home position program twice. See Checking the synchron-
Do not change the position of the robot axes after running ization position on page 365.
the program!
2 Adjust the synchronization marks when the calibration is This is detailed in section
done, if necessary. Synchronization marks and
synchronization position for
axes on page 345.
3 Write down the values on a new label and stick it on top
of the calibration label.
xx
4 Remove any calibration equipment from the robot.

5 Calibration
5.7 Checking the synchronization position
5.7 Checking the synchronization position
Introduction
Check the synchronization position of the robot before beginning any programming
of the robot system. This may be done:
• Using a MoveAbsJ instruction with argument zero on all axes.
• Using the Jogging window on the FlexPendant.
Using a MoveAbsJ instruction

Use this procedure to create a program that runs all the robot axes to their
synchronization position.
Action Note
1 On ABB menu tap Program editor.
2 Create a new program.
3 Use MoveAbsJ in the Motion&Proc menu.
4 Create the following program:
MoveAbsJ [[0,0,0,0,0,0],
[9E9,9E9,9E9,9E9,9E9,9E9]]
\NoEOffs, v1000, fine, tool0
5 Run the program in manual mode.

6 Check that the synchronization marks for the axes See Synchronization marks and
align correctly. If they do not, update the revolu- synchronization position for axes on
tion counters. page 345 and Updating revolution
counters on page 348.
Using the jogging window

Use this procedure to jog the robot to the synchronization position of all axes.
Action Note
1 On the ABB menu, tap Jogging.
2 Tap Motion mode to select group of axes
to jog.
3 Tap to select the axis to jog, axis 1, 2, or
3.
4 Manually run the robots axes to a position
where the axis position value read on the
FlexPendant, is equal to zero.
5 Check that the synchronization marks for See Synchronization marks and synchron-
the axes align correctly. If they do not, up- ization position for axes on page 345 and
date the revolution counters. Updating revolution counters on page 348.

6 Decommissioning
6.1 Introduction
6 Decommissioning
6.1 Introduction
Introduction
This section contains information to consider when taking a product, robot or
controller, out of operation.
It deals with how to handle potentially dangerous components and potentially
hazardous materials.
General
All used grease/oils and dead batteries must be disposed of in accordance with
the current legislation of the country in which the robot and the control unit are
installed.
If the robot or the control unit is partially or completely disposed of, the various
parts must be grouped together according to their nature (which is all iron together
and all plastic together), and disposed of accordingly. These parts must also be
disposed of in accordance with the current legislation of the country in which the
robot and control unit are installed.

6 Decommissioning
6.2 Environmental information
6.2 Environmental information
Symbol
The following symbol indicates that the product must not be disposed of as common
garbage. Handle each product according to local regulations for the respective
content (see table below).
xx1800000058
Hazardous material
The table specifies some of the materials in the product and their respective use
throughout the product.
Dispose components properly according to local regulations to prevent health or
environmental hazards.
Material Example application
Batteries, NiCad or Lithium Serial measurement board
Copper Cables, motors
Cast iron/nodular iron Base, lower arm, upper arm
Steel Gears, screws, base frame, and so on.
Neodymium Brakes, motors
Plastic/rubber Cables, connectors, drive belts, and so on.
Oil, grease Gearboxes
Aluminium Covers, synchronization brackets
Oil and grease

Where possible, arrange for oil and grease to be recycled. Dispose of via an
authorized person/contractor in accordance with local regulations. Do not dispose
of oil and grease near lakes, ponds, ditches, down drains, or onto soil. Incineration
must be carried out under controlled conditions in accordance with local regulations.
Also note that:
• 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.

6 Decommissioning
6.3 Scrapping of robot
6.3 Scrapping of robot
Important when scrapping the robot
DANGER
When a robot is disassembled while being scrapped, it is very important to

remember the following before disassembling starts, in order to prevent injuries:
• Always remove all batteries. If a battery is exposed to heat, for example
from a blow torch, it will explode.
• Always remove all oil/grease in gearboxes. If exposed to heat, for example
from a blow torch, the oil/grease will catch fire.
• When motors are removed from the robot, the robot will collapse if it is not
properly supported before the motor is removed.

6 Decommissioning
6.4 Decommissioning of balancing device
Note
This section is not applicable to robot variant IRB 6660 - 205/1.9.
General
There is much energy stored in the balancing device. Therefore a special procedure
is required to dismantle it. The coil springs inside the balancing device exert a
potentially lethal force unless dismantled properly.
The device must be dismantled by a decommissioning company.
Required equipment

tools on page 381.
Protective clothing that also covers - Must protect against spatter of sparks
face and hands and flames.
Cutting torch with a long shaft - For opening housing and cutting coils.
The long shaft is a safety requirement.
Other tools and procedures may be These procedures include references
required. See references to these to the tools required.
procedures in the step-by-step in-
structions below.
DANGER
Do not under any circumstances, deal with the balancing device in any other
way than that detailed in the product documentation! For example, attempting
to open the balancing device is potentially lethal!
Action on field, decommissioning

The procedure below details the actions to perform on field, when the balancing
device is to be decommissioned.
Action Note
1 Remove the balancing device from the robot. Detailed in section Replacing the balan-
cing device on page 266.
2 Send the device to a decommissioning Make sure the decommissioning com-
company. pany is well informed about the stored
energy built up by high tensioned com-
pression springs and that the device
contains some grease.
The following procedure contains useful
information about decommissioning.

6 Decommissioning
Continued
Decommissioning at decommissioning company, balancing device

The instruction below details how to decommission the balancing device. Contact
ABB Robotics for further consultation.
Action Note
1
DANGER
There is stored energy built up by high

tensioned compression springs inside the
balancing device! When a coil is cut the
released tension creates a spatter of
sparks and flames.
The working area must be free of flam-
mable materials. Position the balancing
device so that the spatter will be directed
away from personnel.
2 Clamp the device at the working location.

Place the device at ground level so that
the hole and spring coils are cut from a
more safe distance.
3
DANGER
The hole must be cut as specified in the

figure. Pieces can be ejected from the cyl-
inder at high speed if the hole is cut larger
than specified!
4 Cut a hole in the housing as shown in the Use a cutting torch with a long shaft.
figure. The measurements shown below are maxim-
um values!
xx0700000155

6 Decommissioning
Continued
Action Note
5
DANGER
There is stored energy built up by high

tensioned compression springs inside the
balancing device! When a coil is cut the
released tension creates a spatter of
sparks and flames.
The working area must be free of flam-
mable materials. Position the balancing
device so that the spatter will be directed
away from personnel.
6 Cut the coils of the springs inside the Use a cutting torch with a long shaft.
housing as specified below:
• Outer spring: cut at least five coils!
• Middle spring: cut at least four coils!
• Inner spring: cut at least four coils!
7 Double-check the number of coils cut and
make sure all the tension in the springs
are removed.

7 Reference information
7.1 Introduction
7.1 Introduction
General
This chapter includes general information, complementing the more specific
information in the different procedures in the manual.

7.2 Applicable standards
Note
The listed standards are valid at the time of the release of this document. Phased
out or replaced standards are removed from the list when needed.
Standards, EN ISO
The product is designed in accordance with the requirements of:
Standard Description
EN ISO 12100:2010 Safety of machinery - General principles for design - Risk as-
sessment and risk reduction
EN ISO 13849-1:2015 Safety of machinery, safety related parts of control systems -
Part 1: General principles for design
EN ISO 13850:2015 Safety of machinery - Emergency stop - Principles for design
EN ISO 10218-1:2011 Robots for industrial environments - Safety requirements -Part
1 Robot
ISO 9787:2013 Robots and robotic devices -- Coordinate systems and motion
nomenclatures
ISO 9283:1998 Manipulating industrial robots, performance criteria, and related
test methods
EN ISO 14644-1:2015 i Classification of air cleanliness
EN ISO 13732-1:2008 Ergonomics of the thermal environment - Part 1
EN 61000-6-4:2007 + EMC, Generic emission
A1:2011
IEC 61000-6-4:2006 +
A1:2010
(option 129-1)
EN 61000-6-2:2005 EMC, Generic immunity
IEC 61000-6-2:2005
EN IEC 60974-1:2012 ii Arc welding equipment - Part 1: Welding power sources
EN IEC 60974-10:2014 ii Arc welding equipment - Part 10: EMC requirements
EN IEC 60204-1:2006 Safety of machinery - Electrical equipment of machines - Part
1 General requirements
IEC 60529:1989 + A2:2013 Degrees of protection provided by enclosures (IP code)
i Only robots with protection Clean Room.
ii Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.
European standards
EN 614-1:2006 + A1:2009 Safety of machinery - Ergonomic design principles - Part 1:
Terminology and general principles
EN 574:1996 + A1:2008 Safety of machinery - Two-hand control devices - Functional
aspects - Principles for design

Continued
Other standards
ANSI/RIA R15.06 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

7.3 Unit conversion
7.3 Unit conversion
Converter table
Use the following table to convert units used in this manual.
Quantity Units
Length 1m 3.28 ft. 39.37 in
Weight 1 kg 2.21 lb.
Weight 1g 0.035 ounces
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.225 lbf
Moment 1 Nm 0.738 lbf-ft
Volume 1L 0.264 US gal

7.4 Screw joints
7.4 Screw joints
General
This section describes how to tighten the various types of screw joints on the IRB
6660.
The instructions and torque values are valid for screw joints comprised of metallic
materials and do not apply to soft or brittle materials.
UNBRAKO screws
UNBRAKO is a special type of screw recommended by ABB for certain screw joints.
It features special surface treatment (Gleitmo as described below) and is extremely
resistant to fatigue.
Whenever used, this is specified in the instructions, and in such cases, no other
type of replacement screw is allowed. Using other types of screws will void any
warranty and may potentially cause serious damage or injury.
Gleitmo treated screws

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

Screws lubricated with Molycote 1000 should only be used when specified in the
repair, maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1 Apply lubricant to the screw thread.
2 Apply lubricant between the plain washer and screw head.
3 Screw dimensions of M8 or larger must be tightened with a torque wrench.
Screw dimensions of M6 or smaller may be tightened without a torque wrench
if this is done by trained and qualified personnel.
Lubricant Article number
Molycote 1000 (molybdenum disulphide grease) 3HAC042472-001
Tightening torque
Before tightening any screw, note the following:
• Determine whether a standard tightening torque or special torque is to be
applied. The standard torques are specified in the following tables. Any
special torques are specified in the repair, maintenance or installation
procedure descriptions. Any special torque specified overrides the standard
torque!
• Use the correct tightening torque for each type of screw joint.
• Only use correctly calibrated torque keys.

7.4 Screw joints
Continued
• Always tighten the joint by hand, and never use pneumatic tools.
• Use the correct tightening technique, that is do not jerk. Tighten the screw
in a slow, flowing motion.
• Maximum allowed total deviation from the specified value is 10%!
Oil-lubricated screws with slotted or cross-recess head screws

The following table specifies the recommended standard tightening torque for
oil-lubricated screws with slotted or cross-recess head screws.
Note
A special torque specified in the repair, maintenance or installation procedure

overrides the standard torque.
Oil-lubricated screws with allen head screws

oil-lubricated screws with allen head screws.
Note

Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm)
Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric-
ated ated
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340
M20 400 560 670
M24 680 960 1150
Lubricated screws (Molycote, Gleitmo or equivalent) with allen head screws

screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head
screws.
Note

Dimension Tightening torque (Nm) Tightening torque (Nm)

Class 10.9, lubricated i Class 12.9, lubricated i
M8 28 35

7.4 Screw joints
Continued
Dimension Tightening torque (Nm) Tightening torque (Nm)

Class 10.9, lubricated i Class 12.9, lubricated i
M10 55 70
M12 96 120
M16 235 280
M20 460 550
M24 790 950
i Lubricated with Molycote 1000, Gleitmo 603 or equivalent
Water and air connectors

water and air connectors when one or both connectors are made of brass.
Note

Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm -

Nominal Min. Max.
1/8 12 8 15
1/4 15 10 20
3/8 20 15 25
1/2 40 30 50
3/4 70 55 90

7.5 Weight specifications
7.5 Weight specifications
Definition
In installation, repair, and maintenance procedures, weights of the components
handled are sometimes specified. 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.
Example
Following is an example of a weight specification in a procedure:
Action Note
CAUTION
The robot weighs 1950 kg.

ingly.

7.6 Standard tools
7.6 Standard tools
General
All service (repairs, maintenance, and installation) procedures contains lists of
tools required to perform the specified activity.
All special tools required are listed directly in the procedures while all the tools
that are considered standard are gathered in the standard toolkit and defined in
the following table.
This way, the tools required are the sum of the standard toolkit and any tools listed
in the instruction.
Contents, standard toolkit
Qty Tool Rem.

1 Ring-open-end spanner 8-19 mm
1 Socket head cap 5-17 mm
1 Torx socket no: 20-60
1 Box spanner set
1 Torque wrench 10-100 Nm
1 Torque wrench 75-400 Nm
1 Ratchet head for torque wrench 1/2
2 Hexagon-headed screw M10x100
1 Hex bit socket head cap no. 14 socket 40 mm L=100 mm
1 Hex bit socket head cap no. 14 socket 40 mm L=20 mm To be shortened to 12 mm
1 Hex bit socket head cap no. 6 socket 40 mm L=145 mm
1 Hex bit socket head cap no. 6 socket 40mm bit L=220 mm

7.7 Special tools
7.7 Special tools
General
All service instructions contain lists of tools required to perform the specified
activity. The required tools are a sum of standard tools, defined in the section
Standard tools on page 381, and of special tools, listed directly in the instructions
and also gathered in this section.
Calibration equipment, Calibration Pendulum

The following table specifies the calibration equipment needed when calibrating
the robot with the Calibration Pendulum method.
The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory.
Always use the same calibration method as used at the factory.
Information about valid calibration method is found on the calibration label or in
the calibration menu on the FlexPendant.
If no data is found related to standard calibration, Calibration Pendulum is used
as default.
Description Art. no. Note
Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes operating
manual.
Calibration equipment, Axis Calibration

The following table specifies the calibration equipment needed when calibrating
the robot with the Axis Calibration method.
The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory.
Always use the same calibration method as used at the factory.
Information about valid calibration method is found on the calibration label or in
the calibration menu on the FlexPendant.
If no data is found related to standard calibration, Calibration Pendulum is used
as default.
Calibration tool box, Axis Cal- 3HAC055412- Delivered as a set of calibration tools.
ibration 001 Required if Axis Calibration is the valid
calibration method for the robot.

7.7 Special tools
Continued
Oil exchange equipment

The following table specifies the recommended equipment for oil exchange.
Oil exchange equipment 3HAC021745-001 Includes:
• Vacuum pump with regulator,
hose and coupling
• Couplings and adapters
• Pump (manual) with hose and
coupling
• Graduated measuring glass
• Oil gun
• User instructions.
Basic tools
The following table specifies the tools in the basic toolkit that are used for the
current robot model. This toolkit is necessary primarily when removing and refitting
the motors.
The tools are also listed directly in the instructions.
Description Qty Art. no.
Extension 300mm for bits 1/2" 1 3HAC12342-1
Guide pins M8 x 100 2 3HAC15520-1
Lifting tool, motor ax 1 1 3HAC14459-1
Lifting tool, motor ax 2, 3 1 3HAC15534-1
Removal tool, motor M10x 2 3HAC14972-1
Fits motors, axes 6.
Removal tool, motor M12x Fits motors axes 1, 2 and 3.
Rotation tool 1 3HAC17105-1
Standard toolkit (content described in sec- 1 -
tion Standard tools on page 381)
Lifting tools
The following table specifies the lifting tools required during several of the service
procedures. The tools may be ordered separately and are also specified directly
in concerned instructions.
Description Qty Article no.
Hoisting block 1
Lifting chain (used together with the hoisting 1
block)
Support, base and gearbox axis 1 1 3HAC15535-1
Lifting tool, gearbox axis 1 1 3HAC15556-1

7.7 Special tools
Continued

Lifting eye (used together with lifting tool 3HAC025333-005
3HAC15556-1)
Lifting tool, motor 1 3HAC14586-1
Lifting tool, gearbox axes 2-3 1 3HAC023240-001
Lifting tool, frame 1 3HAC023308-001
Lifting tool. complete robot 1 3HAC15607-1
(User instruction 3HAC15971-1)
Lifting tool, parallel arm 1 3HAC023098-001
Lifting tool, wrist unit 1 3HAC13605-1
Lifting tool, base 1 3HAC14868-1
Standard toolkit (content described in sec- 1 -
tion Standard tools on page 381)
Special tools
The following table specifies the special tools required during several of the service
procedures. The tools may be ordered separately and are also specified directly
in concerned instructions.
KM8 socket Standard
KM10 socket Standard
Pinion crank 3HAC023132-001
Pressing, lower arm/balancing weight 3HAC023092-001
Pressing, upper arm 3HAC023084-001
Pressing, tie rod 3HAC5021-1
Auxiliary shaft, long 3HAC5275-1
Auxiliary shaft, short 3HAC5276-1
Support shaft/bearing race 3HAC5281-1
Tool for lubrication 3HAC5222-1
Adapter for shaft axis 3 3HAC023916-001
Guide sleeves 3HAC14446-1

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

8 Spare part lists
8.1 Spare part lists and illustrations
8 Spare part lists

8.1 Spare part lists and illustrations
Location
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.

9 Circuit diagram
9.1 Circuit diagrams
9 Circuit diagram
Overview
The circuit diagrams are not included in this manual, but are available for registered
users on myABB Business Portal, www.myportal.abb.com.
See the article numbers in the tables below.
Controllers
Product Article numbers for circuit diagrams

Circuit diagram - IRC5 3HAC024480-011
Circuit diagram - IRC5 Compact 3HAC049406-003
Circuit diagram - IRC5 Panel Mounted Con- 3HAC026871-020
troller
Circuit diagram - Euromap 3HAC024120-004
Circuit diagram - Spot welding cabinet 3HAC057185-001
Robots

Circuit diagram - IRB 120 3HAC031408-003
Circuit diagram - IRB 140 type C 3HAC6816-3
Circuit diagram - IRB 1600/1660 3HAC021351-003
Circuit diagram - IRB 4400/4450S 3HAC9821-1
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

9 Circuit diagram
Continued

Circuit diagram - IRB 6620 / IRB 6620LX 3HAC025090-001
Circuit diagram - IRB 6650S 3HAC13347-1
3HAC025744-001
3HAC029940-001
3HAC025744-001
Circuit diagram - Product.ProductName 3HAC050778-003
Circuit diagram - IRB 910SC 3HAC056159-002

Index
Index calibration manuals, 343

calibration marks, 345
calibration position
A jogging to, 365
Absolute Accuracy, calibration, 343
scales, 345
additional mechanical stop location, 138
calibration scales, 345
aluminum
CalibWare, 342
disposal, 368
carbon dioxide extinguisher, 22
ambient humidity
cast iron
operation, 53
disposal, 368
storage, 53
changing oil
ambient temperature
axis 1, 146
operation, 53
axis 2, 149
storage, 53
axis 3, 149
assembly instructions, 49
cleaning, 169
assessment of hazards and risks, 20
climbing on robot, 25
Axis Calibration, 352
Cold environments, 107
calibration tool
complete arm system, replacement, 207
article number, 354, 357
connecting the robot and controller, cabling, 104
examining, 354
connection
installation position, 356
external safety devices, 26
overview of method, 352
copper
procedure on FlexPendant, 357
disposal, 368
protective cover and protection plug, 356–357
D
B damage to additional mechanical stop, 138
balancing device
damage to mechanical stop, 136
inspecting bearing, 126
danger levels, 40
inspecting piston rod guide ring, 126
dimensions
lubricating bearing, 166
frame, 86
lubricating piston rod, 166
turning disk, 87
base plate
upper arm, 84
guide pins, 76
direction of axes, 347
securing, 76
batteries E
disposal, 368 enabling device, 30
handling, 37 environmental information, 368
battery EPS, 103
replacing, 162, 259 equipment on robot, 84
battery pack ESD
replacing, interval, 112 damage elimination, 33
battery shutdown sensitive equipment, 33
service routine, 162, 259 expected life, 113
bearing,balancing device, 126 extended working range, axis 1, 103
bearing, balancing device, 166 external safety devices, 26
brake release, 73 extra equipment
brake release board, replacement, 262 fastener quality, 87
brakes frame, 86
testing function, 36 robot, 84
buttons for brake release, 73 turning disk, 87
upper arm, 84
C
cabinet lock, 25, 31 F
cabling, robot, 104 fastener quality for extra equipment, 87
cabling axis 5, replacement, 204 fire extinguishing, 22
cabling between robot and controller, 104 fitting equipment on robot, 84
calibrating FlexPendant
robot, 352 jogging to calibration position, 365
roughly, 348 MoveAbsJ instruction, 365
calibrating robot, 352 updating revolution counters, 349
calibration fork lift, 60
Absolute Accuracy type, 342 foundation
rough, 348 requirements, 52
standard type, 342 frame
verification, 364 dimensions, 86
when to calibrate, 344
calibration, Absolute Accuracy, 343

Index
G M
gearbox maintenance schedule, 111
oil change axis 1, 146 manually releasing brakes, 73
oil change axis 2, 149 mechanical stop
oil change axis 3, 149 axis 1, 101
gearbox axis 1, replacement, 311 mechanical stop location, 136
gearbox axis 6, replacement, 336 motion of axes, 57
gearboxes motor axis 4, replacement, 292
location of, 144 motor axis 5, replacement, 297
grease motor axis 6, replacement, 303
disposal, 368 MoveAbsJ instruction, 365
guide pins, base plate, 76
guide ring, piston rod, 126 N
nation specific regulations, 19
H negative directions, axes, 347
hanging neodymium
installed hanging, 25 disposal, 368
hazardous material, 368 NiCad
height disposal, 368
installed at a height, 25 nodular iron
hold-to-run, 30 disposal, 368
HRA, 20
humidity O
operation, 53 oil
storage, 53 amount in gearboxes, 144
disposal, 368
I type of oil, 144
information labels location, 134 oil change
inspecting axis 1, 146
additional mechanical stop, 138 axis 2, 149
balancing device bearing, 126 axis 3, 149
balancing device piston rod guide ring, 126 safety risks, 38
information labels, 134 oil level
mechanical stop, 136 gearbox axes 2-3, 116
inspecting oil levels gearbox axis-6, 123
axes 2-3, 116 gearbox axis-5, 121
axis-6, 123 gearbox axis-4, 119
axis-5, 121 gearbox axis-1, 114
axis-4, 119 operating conditions, 53
axis-1, 114
installation P
mechanical stop axis 1, 101 pedestal
installing equipment on robot, 84 installed on pedestal, 25
instructions for assembly, 49 piston rod, balancing device, 166
integrator responsibility, 19 piston rod guide ring inspectiong, 126
intervals for maintenance, 111 plastic
disposal, 368
L positive directions, axes, 347
labels product standards, 374
robot, 42 protection classes, 53
leak-down test, 174 protection type, 53
lifting accessory, 380 protective equipment, 26
lifting robot protective wear, 26
with fork lift, 60
with lifting slings, 69 R
with roundslings, 66 range of movement, 57
lifting slings, robot, 69 region specific regulations, 19
limitation of liability, 19 release brakes, 23
Lithium replacement
disposal, 368 brake release board, 262
loads on foundation, 51 cabling axis 5, 204
lubricating complete arm system, 207
balancing device bearing, 166 gearbox axis 1, 311
balancing device piston rod, 166 gearbox axis 6, 336
lubrication motor axis 4, 292
amount in gearboxes, 144 motor axis 5, 297
type of lubrication, 144 motor axis 6, 303

Index
turning disk, 217 special tools, 382

wrist unit, 221 speed
requirements on foundation, 52 adjusting, 107
responsibility and validity, 19 stability, 58
restricting standards, 374
working range axis 1, 101, 103 ANSI, 375
revolution counters CAN, 375
storing on FlexPendant, 349 EN, 374
updating, 348 EN IEC, 374
risk of tipping, 58 EN ISO, 374
robot start of robot in cold environments, 107
labels, 42 steel
protection class, 53 disposal, 368
protection types, 53 storage conditions, 53
symbols, 42 symbols
rubber safety, 40
disposal, 368 synchronization position, 348
sync marks, 345
S system integrator requirements, 19
safety
brake testing, 36 T
ESD, 33 temperatures
fire extinguishing, 22 operation, 53
moving robots, 27 storage, 53
release robot axes, 23 testing
signal lamp, 99 brakes, 36
signals, 40 three-position enabling device, 30
signals in manual, 40 tools
symbols, 40 Axis Calibration, 382
symbols on robot, 42 Calibration Pendulum, 382
test run, 28 for service, 382
working range, 29 oil exchange equipment, 383
safety equipment torques on foundation, 51
mechanical stop, 101 troubleshooting
signal lamp, 142 oil spills, 169
safety fence, 20 turning disk dimensions, 87
safety risk turning disk replacement, 217
electric parts, 31 type of motion, 57
hot parts, 34
hydraulic system, 35 U
installation, 25 updating revolution counters, 348
oil change, 38 upper arm
operational disturbance, 25 dimensions, 84
pneumatic system, 35
service work, 25 V
voltage, 31 validity and responsibility, 19
safety signals velocity
in manual, 40 adjusting, 107
safety standards, 374 verifying calibration, 364
safety zones, 20
scales on robot, 345 W
schedule for maintenance, 111 weight, 50
screw joints, 377 base plate, 75, 80
securing gearbox, 331
base plate, 76 motor, 277–278
securing, robot, 81 robot, 65–66, 72, 241, 246–249, 255, 257, 269, 271,
securing the robot to foundation, attachment screws, 81 315, 317, 319, 322, 329, 380
signal lamp, 99 upper arm, 233–234
signals wrist unit, 224–225
safety, 40 working range, 54
SMB restricting axis 1, 101
replacing, 259 wrist unit, replacement, 221
SMB battery Z
extension of lifetime, 162, 259 zero position
replacing, 162, 259 checking, 365

ABB AB, Robotics
Robotics and Motion
S-721 68 VÄSTERÅS, Sweden
Telephone +46 (0) 21 344 400
ABB AS, Robotics

Robotics and Motion
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000
ABB Engineering (Shanghai) Ltd.

Robotics and Motion
No. 4528 Kangxin Highway
PuDong District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666
ABB Inc.
Robotics and Motion
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000
abb.com/robotics
3HAC028197-001, Rev S, en


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Document ID: 3HAC028197-001

© Copyright 2007-2018 ABB. All rights reserved.

© Copyright 2007-2018 ABB. All rights reserved.

2 Installation and commissioning 49

Product manual - IRB 6660 5

6 Product manual - IRB 6660

4.6 Motors ............................................................................................................ 274

7 Reference information 373

8 Spare part lists 387

9 Circuit diagram 389

Product manual - IRB 6660 7

Overview of this manual

Who should read this manual?

Product manual scope

Continues on next page

Continues on next page

Continues on next page

Continues on next page

14 Product manual - IRB 6660

Technical reference manuals

Continues on next page

16 Product manual - IRB 6660

How to read the product manual

References to required equipment

Product manual - IRB 6660 17

1.1.1 Limitation of liability

Nation/region specific regulations

To be observed by the supplier of the complete system

Continues on next page

The integrator of the final application is required to perform an assessment of the

The integrator is responsible for the safety of the final application.

20 Product manual - IRB 6660

1.1.2 Protective stop and emergency stop

Product manual - IRB 6660 21

1.2 Safety actions

1.2.1 Fire extinguishing

Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the

22 Product manual - IRB 6660

1.2.2 Emergency release of the robot axes

Product manual - IRB 6660 23

Switch off all main power switches in a MultiMove system.

24 Product manual - IRB 6660

1.3 Safety risks

1.3.1 Safety risks during installation and service work on robots

General risks during installation and service

Safety risks during operational disturbances

Continues on next page

Spare parts and special equipment

Connection of external safety devices

Personal protective equipment

26 Product manual - IRB 6660

1.3.2 Moving robots are potentially lethal

Product manual - IRB 6660 27

1.3.3 First test run may cause injury or damage

28 Product manual - IRB 6660

1.3.4 Work inside the working range of the robot

Product manual - IRB 6660 29

1.3.5 Enabling device and hold-to-run functionality

Three-position enabling device