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ABB IRC5 Compact, Product Manual

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ABB IRC5 Compact Product Manual Download Page 845

mechanical stop, 91
signal lamp, 138

safety fence, 18
safety risk

electric parts, 30
hot parts, 33
hydraulic system, 34
installation, 24
oil change, 37
operational disturbance, 24
pneumatic system, 34
service work, 24
voltage, 30

safety signals

in manual, 39

safety standards, 826
safety zones, 18
scales on robot, 799
schedule of maintenance, 101
screw joints, 829
securing

base plate, 69

securing the robot to foundation, attachment screws, 81
signal lamp, 96
signals

safety, 39

speed

adjusting, 98

stability, 55
standards, 826

ANSI, 827
CAN, 827
EN, 826
EN IEC, 826
EN ISO, 826

start of robot in cold environments, 98
steel

disposal, 819

storage conditions, 50
symbols

safety, 39

synchronization position, 801
sync marks, 799
system integrator requirements, 17

T

temperatures

operation, 51
storage, 50

testing

brakes, 35

three-position enabling device, 29
torques on foundation, 49

U

updating revolution counters, 801

V

validity and responsibility, 17
velocity

adjusting, 98

verifying calibration, 817

W

weight, 49

axis-1 motor, 570, 652, 657, 659, 667, 669
base plate, 68, 71
robot, 63, 74, 192, 196, 253, 263, 268, 271–272, 277, 
297, 310, 313, 352, 356, 361, 375, 378, 380, 382, 
384, 386, 388, 396, 399, 403, 424, 429, 436, 439, 
444, 458, 461, 463, 465, 467, 469, 471, 473–474, 
482, 485, 489, 510, 515, 519, 522, 525, 528, 535, 
540, 555, 557, 640, 642, 676, 832

working range

restricting axis 1, 91

X

xx

replacing, 432

Z

zero position

checking, 818

Product manual - IRB 8700

845

3HAC052853-001 Revision: F

© Copyright 2015-2018 ABB. All rights reserved.

Index

Summary of Contents for IRC5 Compact

Page 1: ...ROBOTICS Product manual IRB 8700 ...

Page 2: ...Trace back information Workspace R18 1 version a12 Checked in 2018 03 27 Skribenta version 5 2 025 ...

Page 3: ...Product manual IRB 8700 550 4 20 IRB 8700 800 3 50 IRC5 Document ID 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved ...

Page 4: ...BB 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 AB...

Page 5: ...ls 39 1 4 1 Safety signals in the manual 41 1 4 2 Safety symbols on product labels 47 2 Installation and commissioning 47 2 1 Introduction 48 2 2 Unpacking 48 2 2 1 Pre installation procedure 52 2 2 2 Working range 55 2 2 3 Risk of tipping stability 56 2 2 4 Main dimensions 57 2 3 On site installation 57 2 3 1 Lifting the robot with fork lift accessory set installed 65 2 3 2 Attaching the robot an...

Page 6: ... 3 gearbox 153 3 4 4 Changing oil axis 4 primary gearbox 159 3 4 5 Changing oil axis 4 secondary gearbox 164 3 4 6 Changing oil axis 5 gearbox 168 3 4 7 Changing oil axis 6 gearbox 173 3 4 8 Replacing the SMB battery 176 3 5 Lubrication activities 176 3 5 1 Lubricating the spherical roller bearings balancing device 178 3 5 2 Lubricating the cross roller bearing 180 3 6 Cleaning activities 180 3 6 ...

Page 7: ... methods 798 5 1 3 When to calibrate 799 5 2 Synchronization marks and axis movement directions 799 5 2 1 Synchronization marks and synchronization position for axes 800 5 2 2 Calibration movement directions for all axes 801 5 3 Updating revolution counters 805 5 4 Calibrating with Axis Calibration method 805 5 4 1 Description of Axis Calibration 807 5 4 2 Calibration tools for Axis Calibration 80...

Page 8: ...841 9 Circuit diagrams 841 9 1 Circuit diagrams 843 Index 8 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved Table of contents ...

Page 9: ...hrough before performing any installation or service work on robot Contains general safety aspects as well as more specific information on how to avoid personal injuries and damage to the product Safety Required information about lifting and installation of the robot Installation and commis sioning Step by step procedures that describe how to perform mainten ance of the robot Based on a maintenanc...

Page 10: ... warning regarding risk of pinching in Description of Axis Calibration on page 805 Added information about inspection of calibration tool prior to usage see Examining the calibration tool on page 807 Added information about the calibration procedure see Overview of the calibration procedure on the FlexPendant on page 811 Re starting an interrupted calibration procedure on page 813 Added informatio...

Page 11: ...ng the hub on page 630 Published in release R17 2 The following updates are made in this revi sion E Caution about removing metal residues added in sections about SMB boards Information about minimum resonance frequency added Base plate article number updated Is 3HAC053772 003 was 3HAC053772 002 Orange spare parts added Installation drawing updated Replacement methods for following spare parts are...

Page 12: ...is Calibration on page 807 Added sections in General procedures on page 184 Added reference manual for DressPack Safety restructured Updated spare parts number brake release board unit was BRK001 is DSQC1052 Note added to calibration chapter to emphasize the requirement of equally dressed robot when using previously created reference calibration values Information about myABB Business Portal added...

Page 13: ...erence information safety standards unit conversions screw joints lists of tools Spare parts list with corresponding figures or references to separate spare parts lists Circuit diagrams or 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 Ap...

Page 14: ...s The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters 14 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved Product documentation Continued ...

Page 15: ... include specific safety information when dangerous steps are to be performed Read more in the chapter Safety on page 17 Illustrations The product 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 product models can be illustrated with illustrations that show a different...

Page 16: ...This page is intentionally left blank ...

Page 17: ...arried 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 respo...

Page 18: ...eed 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 sl...

Page 19: ...al parts through welding riveting or drilling of new holes into the castings The strength could be affected CAUTION Ensure that a gripper is prevented from dropping a work piece if such is used Product manual IRB 8700 19 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 1 Safety 1 1 1 Limitation of liability Continued ...

Page 20: ...view The protective stops and emergency stops are described in the product manual for the controller 20 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 1 Safety 1 1 2 Protective stop and emergency stop ...

Page 21: ...uishing Note Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the manipulator or controller Product manual IRB 8700 21 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 1 Safety 1 2 1 Fire extinguishing ...

Page 22: ... 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 22 Product m...

Page 23: ...troller before proceeding work Note Switch off all main power switches in a MultiMove system Spot welding cabinet Wait for 5 minutes to let the capacitors discharge after the power has been switched off DANGER Even if the main switch is switched off the capacitors can cause electric shock if not given the time to discharge Product manual IRB 8700 23 3HAC052853 001 Revision F Copyright 2015 2018 AB...

Page 24: ...afety lock 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 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 pur...

Page 25: ...fications 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 we...

Page 26: ...y stop equipment is cor rectly installed and connected 1 How to use the hold to run function is de scribed in section How to use the hold to run function in the Operating manual IRC5 with FlexPendant Usually the hold to run function is active only in manual full speed mode To in crease safety it is also possible to activate hold to run for manual reduced speed with a system parameter 2 The hold to...

Page 27: ...fore it is powered up 2 Verify that any safety equipment installed to secure the position or restrict the robot motion during service activity is removed 3 Verify that the fixture and work piece are well secured if applicable 4 Install all safety equipment properly 5 Make sure all personnel are standing at a safe distance from the robot and is out of its reach behind safety fences or similar 6 If ...

Page 28: ...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...

Page 29: ...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 pr...

Page 30: ...lated 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...

Page 31: ...e live even if the robot system is in the OFF position Power supply cables which are in motion during the working process may be damaged Product manual IRB 8700 31 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 1 Safety 1 3 6 Risks associated with live electric parts Continued ...

Page 32: ...nics Safe handling Note Action Wrist straps must be tested frequently to ensure that they are not damaged and are operating cor rectly Product manual IRC5 Use a wrist strap The wrist strap button is located inside the control ler 1 The mat must be grounded through a current limit ing resistor Use an ESD protective floor mat 2 The mat should provide a controlled discharge of static voltages and mus...

Page 33: ... 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 Product manual IRB 8700 33 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 1 Safety 1 3 8 Ho...

Page 34: ...re 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 a...

Page 35: ...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 Product manual IRB 8700 35 3HAC052853 001 Revision F Cop...

Page 36: ...losion 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 ...

Page 37: ...ion Action Description Warning Make sure that protective gear like goggles and gloves are al ways worn during this activity Changing and draining gearbox oil or grease may require hand ling hot lubricant heated up to 90 C Hot oil or grease Make sure that protective gear like goggles and gloves are al ways worn When working with gearbox lub ricant there is a risk of an allergic reaction Allergic re...

Page 38: ... time to heat up the oil Warm oil drains quicker than cold oil Heat up the oil After filling verify that the level is correct The specified amount of oil or grease is based on the total volume of the gearbox When changing the lubricant the amount refilled may differ from the specified amount depending on how much has previously been drained from the gearbox Specified amount de pends on drained vol...

Page 39: ...ccur 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 WARNING xx0100000002 Warns for electrical hazards which could result in severe ...

Page 40: ...NOTE xx0100000004 Describes where to find additional information or how to do an operation in an easier way TIP xx0100000098 40 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 1 Safety 1 4 1 Safety signals in the manual Continued ...

Page 41: ...lish German and French Symbols on safety labels Description Symbol Warning xx0900000812 Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of c...

Page 42: ... Do not disassemble xx0900000815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the robot arm can fall down Continues on next page 42 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights re...

Page 43: ...ip over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page Product manual IRB 8700 43 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 44: ...1 1 06 xx1300001087 Moving robot 1 2 3 4 5 6 xx0900000819 The robot can move unexpectedly xx1000001141 1 2 3 4 xx1500002616 Continues on next page 44 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 45: ...0001242 Lifting of robot xx0900000822 Oil xx0900000823 Can be used in combination with prohibition if oil is not allowed Mechanical stop xx0900000824 Continues on next page Product manual IRB 8700 45 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 46: ...hat this part is pressurized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller Do not step xx1400002648 Warns that stepping on these parts can cause damage to the parts 46 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Contin...

Page 47: ...portant 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 page17 before performing any installation work Note If the IRB 8700 is connected to power always make sure that the robot is connected to protective...

Page 48: ...quired is suitable to handle the weight of the robot as specified in Weight robot on page 49 5 If the robot is not installed directly it must be stored as described in Storage condi tions robot on page 50 6 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 51 7 Before taking the robot to its installation...

Page 49: ... robots xy xy z z T F F T xx1100000521 Force in any direction in the XY plane Fxy Force in the Z plane Fz Bending torque in any direction in the XY plane Txy Bending torque in the Z plane Tz 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 ...

Page 50: ...a tion flexibility see Application manual Control ler software IRC5 section Motion Process Mode 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 interprete...

Page 51: ...ity i At low environmental temperature below 10 C a warm up phase is recommended to be run with the robot Otherwise there is a risk that the robot stops or runs with lower performance due to temperature dependent oil and grease viscosity Protection classes robot The table shows the available protection types of the robot with the corresponding protection class Protection class Protection type IP67...

Page 52: ...ns The default working range for axis 6 can be extended by changing parameter values in the software Option 610 1Independent axis can be used for resetting the revolu tion counter after the axis has been rotated no need for rewind ing the axis Working range axis 5 and axis 6 for LeanID option 780 4 Allowed working area for axis 6 related to axis 5 position is shown in the figure xx1300001587 Conti...

Page 53: ...hows the unrestricted working range of the robot 1197 5131 4157 R1174 xx1400002880 Continues on next page Product manual IRB 8700 53 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range Continued ...

Page 54: ...llustration shows the unrestricted working range of the robot 3487 4093 507 R928 xx1400002879 54 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range Continued ...

Page 55: ... robot position before securing it to the foundation Shipping and transportation position This figure shows the robot in its shipping position and transportation position xx1400002584 Move the robot to this position 90 Axis 1 65 Axis 2 2 Axis 3 90 Axis 4 90 Axis 5 0 Axis 6 WARNING The robot is likely to be mechanically unstable if not secured to the foundation Product manual IRB 8700 55 3HAC052853...

Page 56: ...5 600 IRB 8700 550 4 2 3106 1000 1580 310 149 R 340 515 R 955 257 328 G G 505 LeanID IRB 8700 800 3 5 1010 xx1400002868 56 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 2 4 Main dimensions ...

Page 57: ...t accessory set is only allowed if lifting is done using all four fork lift accessories Do not lift a robot with the Fork lift accessory set if any of the pockets or attachment screws are damaged or missing The operator of the fork lift truck must be fully trained and authorized to operate a fork lift truck The fork lift truck being used must have the lifting capacity to handle the weight 4 750 kg...

Page 58: ...ed with the fork lift accessory 3HAC055664 001 Directions for use Fork lift ac cessory for IRB 8700 Preparations before attaching the fork lift accessory set Note Action Note No extra load is permitted on the robot DressPack cable package can stay fitted as long as the tool has been removed Remove any tool attached on the turning disc Note No tool is permitted to be fitted on the robot when liftin...

Page 59: ...t before entering the robot working area 3 Attachment points for the fork lift accessory set Note Action xx1500002297 The attachment points for the fork lift accessory set can be found in the four corners of the base 1 Attaching the fork lift accessory set Note Action CAUTION Each fork lift accessory pocket weights 18 kg Use caution when handling them 1 Continues on next page Product manual IRB 87...

Page 60: ... 2 xx1500002295 Unscrew the two attachment screws with washers that secure the robot to the foundation situated closest to where the fork lift accessory pockets will be attached 3 xx1500002294 Remove the protection plugs 4 Continues on next page 60 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 3 1 Lifting the robot ...

Page 61: ...re the robot to the foundation will be removed after the fork lift truck has its forks inserted into the fork lift accessory pockets 7 Lifting with the fork lift accessory set Preparations before lifting Note Action Note No extra load is permitted on the robot DressPack cable package can stay fitted as long as the tool has been removed Make sure that any tool attached on the turning disc has been ...

Page 62: ...he fork lift accessory set is properly attached and secured before lifting 4 Lifting the robot Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1500002296 Release the torque on the remaining screws that secure the robot to the foundation DANGER DO NOT unscrew the attachment screws com pletely but only a few millimeters At th...

Page 63: ...rks into the fork lift accessory pockets without damaging anything on the robot or other equipment 5 Use caution and lift the forks of the truck up until they start touching the fork lift accessory set but not taking the weight of the robot CAUTION Do not lift up too much This will make it more difficult to remove the remaining attachment screws that secure the robot to the foundation 6 xx15000022...

Page 64: ...the robot with low speed to its new location 9 Note If the robot shall be stored or later be further transported make sure to follow appropriate safety measures 10 64 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 3 1 Lifting the robot with fork lift accessory set installed Continued ...

Page 65: ...ch the robot shall be placed is clean Make sure that all foreign objects has been removed prior to putting down the robot 1 Use caution and put down the robot in its new location 2 Molykote 1000 Lubricate the attachment screws used to secure the robot to the foundation 3 Attachment screws M24x100 one in each pocket Secure the robot to the foundation while the fork lift truck is still holding the r...

Page 66: ...x100 one in each pocket Secure the robot to the foundation with the remain ing attachment screws DANGER DO NOT power up the robot until it is secured to the foundation with all 12 attachment screws 7 Tightening torque Lubricated screws Molykote 1000 550 Nm Tightening torque not lightly lubric ated screws 600 750 Nm typical 650 Nm xx1500002295 Attach the protection plugs in the holes for the fork l...

Page 67: ...ent 1 pc Lifting eye M24 1 pc Lifting slings Length approx 2 m Hole configuration xx1400002587 Continues on next page Product manual IRB 8700 67 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 3 3 Lifting the base plate ...

Page 68: ...le of the base plate 2 Fit the roundsling to the lifting eye and lifting accessory Use caution and lift the base plate CAUTION Lift and move the base plate very slowly If the base plate starts to swing it is a risk for injuries or damage 3 68 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 3 3 Lifting the base plate C...

Page 69: ...10 465 320 240 4x11 4x 45 4 x 4 5 4 x 1 1 4 x 9 0 320 610 465 240 E 4x 4 3 12x M24 A A 3 2 0 2 A B C D 0 5 18 1 20 1 4x 12 H7 0 018 0 1 X 45 32 1 M5 B B 0 1 F xx1500000820 Common tolerance zone accuracy all over the base plate from one contact surface to the other A B C D Continues on next page Product manual IRB 8700 69 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Insta...

Page 70: ...ling bolts in the base plate A A A A B B B B xx1400002594 Orienting grooves 4 pcs A Levelling bolts attachment holes M20 through 4 pcs B Continues on next page 70 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 3 4 Securing the base plate Continued ...

Page 71: ... page 833 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Base plate This section details how to secure the base plate to the foundation Note Action Make sure the foundation is levelled 1 CAUTION The base plate weighs 760 kg All lifting ac cessories used m...

Page 72: ...he base plate and use the levelling bolts to level the base plate 6 If required fit strips of sheet metal underneath the base plate to fill any gaps 7 Secure the base plate to the foundation with screws and sleeves 8 Maximum allowed deviation all over the base plate from one contact surface to the other 0 3 mm Recheck the four contact surfaces on the base plate to make sure the base plate is level...

Page 73: ...o reach the length of 2 1 m use roundslings 2 5 m and shorten them to 2 1 m Tip Lifting chains with shorteners is an alternative Continues on next page Product manual IRB 8700 73 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 3 5 Lifting the robot with roundslings ...

Page 74: ... the robot into position Axis 1 90 optional Axis 2 65 Axis 3 2 Axis 4 90 Axis 5 90 Axis 6 0 WARNING The robot is mechanically unstable if not secured to the foundation 1 CAUTION The IRB 8700 robot weighs 4 750 kg All lifting accessories used must be sized accordingly 2 A xx1400002590 A Lifting eye M24 4 pcs Fit lifting eyes to the holes on frame and counter weight respectively 3 Continues on next ...

Page 75: ...es on the counter weight on the out side of the balancing devices CAUTION If the lifting eyes have sharp edges that might damage the roundslings lifting shackles must be used to attach the roundslings to the lifting eyes 4 Stretch the roundslings to take the weight of the robot 5 WARNING Personnel must not under any circum stances be present under the suspended load 6 Use caution and raise the ove...

Page 76: ...roperty of ABB It must therefore be returned within the specified time after the arrival of the robot system If the pallet is not returned it will be invoiced For more information and instructions see http new abb com Irb8700pallet 76 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 3 6 Returning of the ABB pallet ...

Page 77: ...unit on page 77 The internal brake release unit is equipped with buttons for controlling the axes brakes The buttons are numbered according to the numbers of the axes 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 78 1 Note The IRB 8700 has two R1 MP connectors R1 MP A and R1 MP B How...

Page 78: ...rder to enable the brake release buttons Note The IRB 8700 has two R1 MP connectors R1 MP A and R1 MP B See table how to supply power to the connectors Note Action DANGER Incorrect connections such as supplying power to the wrong pin may cause all brakes to be released simultaneously 1 MP A MP B 24V pin 11 MP B 0V pin 12 MP A xx1500001989 Valid for axes 1 2 and 3 Supply 0V on pin 12 R1 MP A Supply...

Page 79: ...n 12 R1 MP B Supply 24V on pin 11 R1 MP B Note Only R1 MP B contact is used when relas ing the brakes on axis 4 5 and 6 3 Product manual IRB 8700 79 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 3 7 Manually releasing the brakes Continued ...

Page 80: ... and securing the robot Note Seen from below R500 4x 45 8x 11 3 9 5 3 9 5 10 10 D D F F G G K K 1 2 x 5 6 12x 30 0 5 1 2 x 5 3 SECTION D D 3 2 0 3 D E H 2 X 45 2 0 24 5 SECTION K K 3 2 xx1700000972 Description Pos Holes for guide pins x2 Section K K Continues on next page 80 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioni...

Page 81: ... plate foundation M24 x 100 Suitable screws lightly lubricated 12 pcs Quantity 8 8 Quality 90 v 0 9 Screw tightening yield point utilization factor v according to VDI2230 4 mm flat washer Suitable washer 550 Nm screws lubricated with Molykote 1000 Tightening torque 600 725 Nm typical 650 Nm screws none or lightly lubricated Continues on next page Product manual IRB 8700 81 3HAC052853 001 Revision ...

Page 82: ...e robot 2 Move robot close to its installation location 3 Make sure the robot base is correctly fitted onto the guide sleeves Guide the robot gently using two M24 screws while lowering it into its mounting position 4 Specified in Attachment screws on page 81 Fit the bolts and washers in the base attachment holes Note Lightly lubricate screws before assembly 5 Tighten bolts in a crosswise pattern t...

Page 83: ... 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 Prod...

Page 84: ... arm load and robot payload Frame hip load Extra load can be fitted on the frame Description JH 200 kgm2 Permitted extra load on frame JH JH0 M4 x R2 Recommended position see the fol lowing figure where JH0 is the moment of inertia of the equipment R is the radius m from the center of axis 1 M4 is the total mass kg of the equipment including bracket and harness 500 kg R xx1400002873 Continues on n...

Page 85: ...00 mm from the center of gravity in the axis 3 extension a A M1 M1 xx1400002874 Mass center A 510 400 A xx1400002875 Center of gravity 50 kg A Continues on next page Product manual IRB 8700 85 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 3 10 Fitting equipment Continued ...

Page 86: ...15 4x M12 22 A 106 4xM12 A A 57 57 R152 5 4x M8 15 A A 38 B B C C xx1400002876 Holes located on both sides A Continues on next page 86 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 3 10 Fitting equipment Continued ...

Page 87: ...8 A 257 A D D E E xx1500000869 Measure from center axis 6 A Continues on next page Product manual IRB 8700 87 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 3 10 Fitting equipment Continued ...

Page 88: ... 18 400 160 390 80 65 400 4x M10 18 A A B B C L 2 C L 1 C L 2 C L 1 xx1400002877 Continues on next page 88 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 3 10 Fitting equipment Continued ...

Page 89: ... C D 0 2 DC B 160 H7 0 040 0 14 8 35 0 1 315 h8 0 0 081 1 X 45 290 13 12 8 SECTION B B 1 6 1 6 2 5 0 02 A C 3 0 3 5 M A X SECTION C C xx1400002878 Fastener quality Use suitable screws and tightening torque for your application Product manual IRB 8700 89 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 3 10 Fitting equipment Continued ...

Page 90: ... of the following axes may be restricted Axis 1 hardware mechanical stop 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 90 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All ri...

Page 91: ...standard without working range limitation 4 3 5x15 75 32 6x15 90 6x15 90 9 2 5x15 75 Min angle 17 positive direction Min angle 32 negative direction Max angle 73 negative direction Min angle 122 negative direction Max angle 43 positive direction Min angle 92 positive direction Max angle 118 positive direction Min angle 167 positive direction xx1400002593 Continues on next page Product manual IRB 8...

Page 92: ...chanical 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 Note Action 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 1 Continues on next page 92 Product manual IRB 8700 3HAC052853 00...

Page 93: ...g range limitations system parameter configuration to corres pond to the mechanical limitations 3 WARNING If the mechanical stop pin is deformed after a hard collision it must be replaced Deformed movable stops and or additional stops as well as deformed attachment screws must also be replaced after a hard collision 4 Product manual IRB 8700 93 3HAC052853 001 Revision F Copyright 2015 2018 ABB All...

Page 94: ...n with equipment fitted on the robot by the customer low voltage signals and high voltage power supply protective ground Customer cables option The customer cables also handle databus communication See the product manual for the controller see document number in References on page 10 Robot cables These cables are included in the standard delivery They are completely pre manufactured and ready to p...

Page 95: ...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 Connection point Art no Cable Distributing cable R1 FAN SW2 3 3HAC022723 001 Harness cooling 7 m Inside cabinet A43 X10 and A43 ...

Page 96: ...mbly 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 96 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 6 1 Signal lamp option ...

Page 97: ...n All required installation information is enclosed with the fan packages sent from ABB Service Product manual IRB 8700 97 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 6 2 Installing the motor cooling fans ...

Page 98: ...regulated with the RAPID instruction VelSet Start the robot with its normal program but with reduced speed 1 Adjusting the speed and acceleration during warm up Depending on how cold the environment is and what program is being used the speed might need to be ramped up until reached maximum The table shows examples of how to adjust the speed Speed velocity AccSet Work cycles v100 100 mm s 20 20 3 ...

Page 99: ... 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 17 before performing any service work Note If ...

Page 100: ...rs More frequent running means more frequent maintenance activities 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 Custo...

Page 101: ...in axis 1 gearbox on page 104 x Inspecting the oil level in axis 1 gearbox Inspecting the oil level in axis 2 and 3 gearboxes on page107 x Inspecting the oil level in axis 2 gearbox Inspecting the oil level in axis 2 and 3 gearboxes on page107 x Inspecting the oil level in axis 3 gearbox Inspecting the oil level in axis 4 primary gearbox on page110 x Inspecting the oil level in axis 4 primary gear...

Page 102: ...box Replacing the SMB battery on page 173 x iii Replacing the SMB battery pack Lubrication activities Lubricating the spherical roller bearings balancing device on page 176 x iv Lubricating the balancing device bearings Lubricating the cross roller bearing on page 178 x Lubricating the cross roller bearing Overhaul Contact your local ABB Cus tomer Service office www abb com robotics xv Overhaul of...

Page 103: ...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...

Page 104: ...n page 833 Standard toolkit Required consumable Note Article number Consumable Information about the oil is found in Technical reference manu al Lubrication in gearboxes Lubrication oil Required documents Note Document number Document 3HAC042927 001 Technical reference manual Lub rication in gearboxes Continues on next page 104 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ...

Page 105: ...ssure 3 xx1500001993 Open the ventilation plug Note The ventilation plug shall be opened prior to the inspection plug in order to release possible pressure inside 4 xx1500001992 Open the inspection plug 5 Inspect the oil level 6 Required oil level is a few millimeters below the lower edge of the inspection hole 7 Type of oil and total amount is de tailed in Technical reference manual Lubrication i...

Page 106: ...et when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 27 10 106 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 3 1 Inspecting the oil level in axis 1 gearbox Continued ...

Page 107: ...andard toolkit Required consumable Note Article number Consumable Information about the oil is found in Technical reference manu al Lubrication in gearboxes Lubrication oil Required documents Note Document number Document 3HAC042927 001 Technical reference manual Lub rication in gearboxes Continues on next page Product manual IRB 8700 107 3HAC052853 001 Revision F Copyright 2015 2018 ABB All right...

Page 108: ...on page 37 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous Use caution when the oil plug is opened in order to let out the excess pressure 3 xx1500001994 Open the ventilation plug Note The ventilation plug shall be opened prior to the inspection plug in order to release possible pressure inside 4 xx1500001995 Open the inspection plug 5 Inspect the oil level 6 Required...

Page 109: ...2 and ax is 3 gearbox on page 147 Tightening torque 24 Nm Refit the oil plugs 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 27 10 Product manual IRB 8700 109 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 3 2 Inspecting the oil l...

Page 110: ...andard toolkit Required consumable Note Article number Consumable Information about the oil is found in Technical reference manu al Lubrication in gearboxes Lubrication oil Required documents Note Document number Document 3HAC042927 001 Technical reference manual Lub rication in gearboxes Continues on next page 110 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All right...

Page 111: ...ain an excess of pressure that can be hazardous Use caution when the oil plug is opened in order to let out the excess pressure 3 xx1500001999 Open the ventilation plug Note The ventilation plug shall be opened prior to the inspection plug in order to release possible pressure inside 4 xx1500001998 Open the inspection plug 5 Inspect the oil level 6 Required oil level is a few millimeters below the...

Page 112: ...4 primary gearbox on page 153 Tightening torque 24 Nm Refit the oil plugs 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 27 10 112 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 3 3 Inspecting the oil level...

Page 113: ...on about the oil is found in Technical reference manu al Lubrication in gearboxes Lubrication oil Required documents Note Document number Document 3HAC042927 001 Technical reference manual Lub rication in gearboxes Inspecting the oil level in axis 4 secondary gearbox Note Action Jog axis 2 to 60 position approximately 1 Jog axis 3 to 10 position approximately 2 Continues on next page Product manua...

Page 114: ...xis 3 very slowly to approximately 3 5 position until oil starts to spill out 7 Required oil level is when oil starts to spill out with axis 3 in 3 5 position 8 Type of oil and total amount is de tailed in Technical reference manual Lubrication in gearboxes Add or drain oil if required 9 Further information about how to drain or fill with oil is found in sec tion Changing oil axis 4 secondary gear...

Page 115: ...andard toolkit Required consumable Note Article number Consumable Information about the oil is found in Technical reference manu al Lubrication in gearboxes Lubrication oil Required documents Note Document number Document 3HAC042927 001 Technical reference manual Lub rication in gearboxes Continues on next page Product manual IRB 8700 115 3HAC052853 001 Revision F Copyright 2015 2018 ABB All right...

Page 116: ...ion and ventilation plug Note Open the plug with caution There may be some pressure inside that will be released when the plug is opened 4 Jog axis 4 very slowly until oil is visible in the in spection hole approximately 54 position 5 Inspect the oil level 6 Required oil level is when the oil level is visible just below the lower edge of the inspection hole with axis 4 approximately in 54 position...

Page 117: ...first test run These are further detailed in the section First test run may cause injury or damage on page 27 10 Product manual IRB 8700 117 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 3 5 Inspecting the oil level in axis 5 gearbox Continued ...

Page 118: ...andard toolkit Required consumable Note Article number Consumable Information about the oil is found in Technical reference manu al Lubrication in gearboxes Lubrication oil Required documents Note Document number Document 3HAC042927 001 Technical reference manual Lub rication in gearboxes Continues on next page 118 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All right...

Page 119: ... oil involves several safety risks Before proceeding please read the safety inform ation in the section Safety risks during work with gearbox lubricants oil or grease on page 37 3 xx1700001288 Jog axis 5 approximately 75 4 CAUTION The gearbox can contain an excess of pressure that can be hazardous Use caution when the oil plug is opened in order to let out the excess pressure 5 xx1700001289 Open t...

Page 120: ...reference manual Lubrication in gearboxes Add or drain oil if required 9 Further information about how to drain or fill with oil is found in sec tion Changing oil axis 6 gearbox on page 168 Tightening torque 24 Nm Refit the oil plug 10 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 dam...

Page 121: ...spection no tools are required Inspecting the transparent oil plugs The gearboxes are equipped with transparent plugs through which oil leakage from the hubs can be detected If an oil leakage is detected remove the hub and replace the defective part radial sealing or o ring Note If only a few drops of oil are detected is not necessarily a sign of an oil leakage A few drops of oil inside can normal...

Page 122: ... main lip Tip Add an extra 2 mm shim between the hub and the radial sealing to eliminate the problem Tip In a clean environment the transparent oil plugs can be removed Do not remove the transparent oil plugs in other than clean environments 122 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 3 7 Inspecting the transparent plugs Continu...

Page 123: ... Inspection points balancing devices The balancing devices are located on either side of the lower arm as shown in the figure The figure also shows the inspection points further described in the instructions xx1500002076 Required tools Visual inspection no tools are required Continues on next page Product manual IRB 8700 123 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 M...

Page 124: ... such as scratches general wear uneven surfaces or incorrect positions Action Inspection points If damage is detected perform maintenance according to given instructions in the maintenance set Check for damage on the part of the piston rod that is visible on the balancing device 1 Inspection for leakage The upper and lower ears of the balancing devices are lubricated with grease Leaks at V rings e...

Page 125: ...ic power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Keep the areas around the balancing devices clean and free from objects such as service tools etc 2 Product manual IRB 8700 125 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 3 8 Inspecting the balancing devices Continued ...

Page 126: ...re supply air pressure supply to the robot before entering the robot working area 1 Pay special attention to the areas of axis 2 and axis 3 movement Make sure the cabling is not dam aged in any way between the cable brackets in these areas Perform an overall inspection of the cable harness in order to detect wear and damage 2 Continues on next page 126 Product manual IRB 8700 3HAC052853 001 Revisi...

Page 127: ...ect the cable harness running through the protection tube in the frame to detect possible cable chafing Use a hand inside the tube to feel the cables Ensure that the cables are undam aged 6 Remove any objects that may cause possible cable chafing Replace the cable harness if wear cracks or other damage is detected 7 Product manual IRB 8700 127 3HAC052853 001 Revision F Copyright 2015 2018 ABB All ...

Page 128: ...he symbols are described in section Safety symbols on product labels on page 41 Illustration 1 A A SECTION A A A Q Q L M D H H H H H C N C C G C J K xx1700000986 Continues on next page 128 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 3 10 Inspecting the information labels ...

Page 129: ...lustration Description Calibration label A 3HAC 4517 1 03 xx1700000980 Warning label Risk of crush injuries B Oil specification label C Continues on next page Product manual IRB 8700 129 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 3 10 Inspecting the information labels Continued ...

Page 130: ...ut off with handle See user documentation Moving robot Brake release buttons E Complete oil specification F 4 xx1700000981 Warning label Tip risk when loosening bolts G Grease specification label H 29454489 16 xx1700000984 Instruction plate Heat J Continues on next page 130 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 3 10 Inspecting...

Page 131: ...no tools are required Inspecting labels Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Inspect the labels located as shown in the figures 2 Article numbers for the labels and plate set is specified in Spare parts on page 839 Replace any missing or damaged labels 3 Product manual IRB 8700 131 ...

Page 132: ...ing mechanical stop pin Use this procedure to inspect the axis 1 mechanical stop pin Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Continues on next page 132 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 3 11 Inspecting the axis...

Page 133: ... damaged it must be replaced Note The expected life of gearboxes can be reduced after collision with the mechanical stop Product manual IRB 8700 133 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 3 11 Inspecting the axis 1 mechanical stop pin Continued ...

Page 134: ...nical stop pin axis 1 C Required equipment Note Article number Equipment etc Includes Mechanical stop 2 pcs Attachment screw and washer 4 4 pcs Document for mechanical stop pin 3HAC053706 001 Movable mechanical stop axis 1 Content is defined in section Standard toolkit on page 833 Standard toolkit Continues on next page 134 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB ...

Page 135: ... stops are damaged 2 Make sure the stops are properly attached 3 Correct tightening torque additional mechanical stops Axis 1 300 Nm Article number is specified in Required equipment on page134 If any damage is detected the mechanical stops must be replaced Correct attachment screws M16x90 quality 12 9 Gleitmo 603 2 pcs per additional mechanical stop 4 Product manual IRB 8700 135 3HAC052853 001 Re...

Page 136: ...ed to the robot as shown in the figure A B C xx1400002588 CE label A Fork lift pocket 4 pcs B Attachment screws MC6S 20x60 8 8 2x4 pcs C Continues on next page 136 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 3 13 Inspecting the fork lift accessories ...

Page 137: ...rk lift accessory pockets for damage 2 Inspect the attachment screws for deformation and other type of damage 3 Tightening torque 300 Nm Make sure the fork lift pockets are properly attached 4 pcs 4 Article number is specified in Required equipment on page134 If any damage is detected the fork lift pockets and attachment screws must be replaced 5 Attachment screws M20x60 quality steel 8 8 A3F Prod...

Page 138: ... that signal lamp is lit when motors are put in operation MOTORS ON 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Article number is specified in Re quired tools and equipment on page 138 If the lamp is not lit trace the fault by inspecting whether the signal lamp is broken If so replace it inspecting ...

Page 139: ...e supply air pressure supply to the robot before entering the robot working area 1 Inspect all dampers for damage cracks or existing impressions larger than 1 mm 2 Inspect the attachment screws for deformation 3 Damper lower and parallel arms 3HAC12991 1 7 pcs If any damage is detected the damper and or screws must be replaced with new ones 4 Attachment screws M6x20 1x7 pcs Damper wrist 3HAC050601...

Page 140: ...nce 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 ...

Page 141: ...tended for use of a oil dispenser when filling or draining oil Left Required consumable Note Material Information about the oil is found in Technical refer ence manual Lubrication in gearboxes Lubricating oil See Type and amount of oil in gearboxes on page140 Required tools and equipment Note Article number Equipment etc The capacity of the vessel must be sufficient to take the complete amount of ...

Page 142: ...roceeding read the safety information in the section Safety risks during work with gearbox lubricants oil or grease on page 37 2 CAUTION The gearbox may contain an excessive pressure that can be hazardous Open the oil plug carefully to let the excess pressure out 3 xx1500001993 Open the ventilation plug WARNING If the ventilation hole is closed when the oil dispenser is in use there is a risk of d...

Page 143: ...d oil is hazardous material and must be disposed of in a safe way See section Decommissioning on page819 for more in formation 8 Remove the oil dispenser 9 xx1600001405 Remove the oil filling nipple put the protect ive cap on and put the oil filling hose into the connection box 10 Continues on next page Product manual IRB 8700 143 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserv...

Page 144: ...essure supply air pressure supply to the robot before entering the robot working area 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 lub ricants oil or grease on page 37 2 Continues on next page 144 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rig...

Page 145: ...manual Lubrication in gearboxes Refill the gearbox with oil by using the oil dispenser Note The amount of oil to be filled depends on the amount previously being drained 6 See Type and amount of oil in gearboxes on page 140 xx1500001992 Inspect the oil level 7 Required oil level 58 mm 5 mm below the sealing surface of the oil plug Remove the oil dispenser 8 Continues on next page Product manual IR...

Page 146: ...rk in volving oil always wipe the robot clean from all surplus oil The robot color may otherwise discolor 11 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 27 12 146 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenan...

Page 147: ...gearboxes Lubricating oil See Type and amount of oil in gearboxes on page140 Required tools and equipment Note Article number Equipment etc The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel One example of oil dispenser can be found in section Type of lubrication in gearboxes on page 140 Oil dispenser Content is defined in section Standard toolki...

Page 148: ... the section Safety risks during work with gearbox lub ricants oil or grease on page 37 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 3 xx1500001994 Remove the plug from the ventilation hole WARNING If the ventilation hole is not open when the oil dispenser is working there is a risk of damaging vi...

Page 149: ...G Used oil is hazardous material and must be disposed of in a safe way See section Decommissioning on page819 for more in formation 7 xx1500002014 Remove the oil dispenser and refit the protection cap to the nipple of the oil draining plug 8 Continues on next page Product manual IRB 8700 149 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 4 3 Changing oil in a...

Page 150: ... area 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 lub ricants oil or grease on page 37 2 xx1500001994 Remove the ventilation plug Note The ventilation plug is opened to let out air during the filling process 3 Continues on next page 150 Product manual IRB 8700 3HAC052853 001 R...

Page 151: ...be filled depends on the amount previously being drained 6 See Type of lubrication in gearboxes on page 140 Required oil level is Inspect the oil level at the oil inspection plug 7 A few millimeters below the lower edge of the inspection hole More information is found in Inspecting the oil level in axis 2 and 3 gearboxes on page 107 xx1500001995 Continues on next page Product manual IRB 8700 151 3...

Page 152: ...e 24 Nm xx1500001994 Refit the ventilation plug 10 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 27 11 152 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 4 3 Changing oil in axis 2 and axis 3 gearbox Continu...

Page 153: ...gearboxes Lubricating oil See Type and amount of oil in gearboxes on page140 Required tools and equipment Note Article number Equipment etc The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel One example of oil dispenser can be found in section Type of lubrication in gearboxes on page 140 Oil dispenser Content is defined in section Standard toolki...

Page 154: ...uring work with gearbox lub ricants oil or grease on page 37 3 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 4 xx1500002017 Remove the plug from the ventilation hole WARNING If the ventilation hole is not open when the oil dispenser is working there is a risk of damaging vital parts in the gear 5 Con...

Page 155: ...al and must be disposed of in a safe way See section Decommissioning on page819 for more in formation 8 xx1500002016 Remove the oil dispenser and refit the protection cap to the nipple of the oil draining plug 9 Tightening torque 24 Nm xx1500002017 Refit the ventilation plug 10 Continues on next page Product manual IRB 8700 155 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved ...

Page 156: ...the section Safety risks during work with gearbox lub ricants oil or grease on page 37 3 xx1500002017 Open the ventilation plug Note The ventilation plug is opened to let out air during the filling process WARNING If the ventilation hole is not open when the oil dispenser is working there is a risk of damaging vital parts in the gear 4 xx1500002018 Open the inspection plug 5 Continues on next page...

Page 157: ...previously being drained 7 See Type and amount of oil in gearboxes on page 140 Required oil level is 0 10 mm below the oil plug hole Inspect the oil level 8 See Inspecting the oil level in axis 4 primary gearbox on page 110 xx1500002018 xx1500002016 Remove the oil dispenser and refit the protection cap to the nipple of the oil filling plug 9 Continues on next page Product manual IRB 8700 157 3HAC0...

Page 158: ... 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 27 12 158 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 4 4 Changing oil axis 4 primary gearbox Continued ...

Page 159: ...g oil See Type and amount of oil in gearboxes on page140 Required tools and equipment Note Article number Equipment etc The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel Content is defined in section Standard toolkit on page 833 Standard toolkit Required documents Note Document number Document name 3HAC042927 001 Technical reference manu al Lubr...

Page 160: ...rking area 2 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section Safety risks during work with gearbox lub ricants oil or grease on page 37 3 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 4 Place the oil collecting vessel unde...

Page 161: ... the robot is secured to the founda tion Ax2 comfortable working position Ax3 3 5 Ax4 0 Ax5 0 Ax6 No significance 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section Safety risks du...

Page 162: ...in the gearbox after draining 6 See Type and amount of oil in gearboxes on page 140 The level is measured at the fill hole xx1500002022 Inspect the oil level 7 Required oil level is 0 10 mm below the oil plug hole See Inspecting the oil level in axis 4 sec ondary gearbox on page 113 Tightening torque 24 Nm Refit the oil plugs 8 Continues on next page 162 Product manual IRB 8700 3HAC052853 001 Revi...

Page 163: ...he first test run These are further detailed in the section First test run may cause injury or damage on page 27 9 Product manual IRB 8700 163 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 4 5 Changing oil axis 4 secondary gearbox Continued ...

Page 164: ...und in Technical refer ence manual Lubrication in gearboxes Lubricating oil See Type and amount of oil in gearboxes on page140 Required tools and equipment Note Article number Equipment etc The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel Content is defined in section Standard toolkit on page 833 Standard toolkit Continues on next page 164 Prod...

Page 165: ...e supply to the robot before entering the robot working area 2 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section Safety risks during work with gearbox lub ricants oil or grease on page 37 3 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex ce...

Page 166: ...re WARNING Used oil is hazardous material and must be disposed of in a safe way See section Decommissioning on page819 for more in formation 9 Tightening torque 24 Nm Refit the oil plugs 10 Filling oil into the axis 5 gearbox Note Action Jog the robot to the specified position Axis 1 no significance as long as the robot is secured to the founda tion Axis 2 as far forward as possible Axis 3 0 Axis ...

Page 167: ...ication in gearboxes Refill the gearbox with oil Note The amount of oil to be filled depends on the amount previously being drained 5 See Type and amount of oil in gearboxes on page 140 See Inspecting the oil level in axis 5 gear box on page 115 Inspect the oil level at the combined oil filling inspection ventilation hole 6 Tightening torque 24 Nm Refit the oil plugs 7 DANGER Make sure all safety ...

Page 168: ...ols and equipment Note Article number Equipment etc The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel Content is defined in section Standard toolkit on page 833 Standard toolkit Required documents Note Document number Document name 3HAC042927 001 Technical reference manu al Lubrication in gearboxes Draining the axis 6 gearbox Note Action Jog the...

Page 169: ...fore proceeding please read the safety information in the section Safety risks during work with gearbox lub ricants oil or grease on page 37 4 Place the oil collecting vessel underneath the oil draining plug 5 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 6 xx1500002034 Remove the oil plug from the c...

Page 170: ... to the axis 6 gearbox 1 The figure shows axis 5 in position 0 if also axis 2 and axis 3 are standing in 0 The upcoming figures in this procedure are based on this starting position xx1700001291 Jog axis 5 so that the tilt house is horizont al turning disk points straight forward 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering ...

Page 171: ... in gearboxes Refill the gearbox with oil Note The amount of oil to be filled depends on the amount previously being drained 6 See Type and amount of oil in gearboxes on page 140 xx1700001288 Jog axis 5 approximately 75 7 xx1700001290 Inspect the oil level by slowly jogging the axis 5 further 7 to approximately 82 totally CAUTION Excessive oil can be spilled 8 Continues on next page Product manual...

Page 172: ...equired 10 Further information about how to drain or fill with oil is found in section Changing oil axis 6 gearbox on page 168 Tightening torque 24 Nm Refit the oil plug 11 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 27 12 172 Product manual IRB 8700 3HAC052853 001 Re...

Page 173: ...t 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 Required tools Note Article number Equipment etc Content is defined in section Standard toolkit on page 833 Standard toolkit Continues on next page Product manual IRB 8700 173 3HAC05285...

Page 174: ...andling the unit please read the safety information in the sec tion The unit is sensitive to ESD on page 32 3 xx1500002052 Remove the SMB battery cover CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures 4 Pull out the battery and disconnect the battery cable 5 Remove the SMB battery Note Battery includes pro...

Page 175: ... page 32 2 xx1500002052 Reconnect the battery cable and install the battery pack into the SMB battery recess 3 Secure the SMB battery cover with its attachment screws 4 See Updating revolution counters on page 801 Update the revolution counters 5 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 in...

Page 176: ...ower ends of the balancing devices xx1500002056 Consumable Note Article number Equipment etc Tribol GR 100 0 PD 50 ml 3HAC042534 001 Grease Used for lubrication of the spherical roller bearing Continues on next page 176 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 5 1 Lubricating the spherical roller bearings balancing device ...

Page 177: ... 3HAC042534 001 xx1500002055 Unscrew both screws on either side of the bearing and fill grease from one of the holes until grease appears in the other hole 2 Refit the two screws 3 Wipe clean from residual grease 4 Note Inspect the bearings after a few days run ning Some of the refilled grease may have emerged from the bearing Wipe clean from residual grease 5 Product manual IRB 8700 177 3HAC05285...

Page 178: ...ross roller bearing Lubricating the cross roller bearing Use this procedure to lubricate the cross roller bearing Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Continues on next page 178 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenan...

Page 179: ... Refit the two screws 3 Wipe clean from residual grease 4 Note Inspect the cross roller bearing after a few days running Some of the refilled grease may have emerged from the bearing Wipe clean from residual grease 5 Product manual IRB 8700 179 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 5 2 Lubricating the cross roller bearing Continued ...

Page 180: ...on page 104 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 Oil spills discolors painted surfaces Oil spills on painted surfaces of the robot can result in discoloration Note After all repair and maintenance work involving oil always wipe the robot clean from all surplus oil Special cleaning considerations...

Page 181: ...ter water cleaner 1 The following list defines the prerequisites Maximum water pressure at the nozzle 700 kN m2 7 bar I Fan jet nozzle should be used min 45 spread Minimum distance from nozzle to encapsulation 0 4 meters Maximum flow 20 liters minI I Typical tap water pressure and flow Instructions for steam or high pressure water cleaning ABB robots with protection types Foundry Plus Wash or Foun...

Page 182: ...ooling fans Inspect the air supply inlet of the the motor cooling fans Clean to remove any contamination that could hinder the air supply 182 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 6 1 Cleaning the IRB 8700 Continued ...

Page 183: ...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 825 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 sur...

Page 184: ...he pressure must under no circumstance be higher than 0 25 bar 20 25 kPa Also during the time when the pressure is raised 3 0 2 0 25 bar 20 25 kPa Disconnect the compressed air supply 4 If the compressed air is signific antly colder or warmer than the gearbox to be tested a slight pressure increase or decrease may occur This is quite normal Wait for approximately 8 10 minutes and make sure that no...

Page 185: ...o any stresses during the assembly work 3 Assembly of tapered bearings Follow the preceding instructions for the assembly of the bearings when mounting a tapered bearing on the robot In addition to those instructions the following procedure must be carried out to enable the roller elements to adjust to the correct position against the race flange Note Action Tension the bearing gradually until the...

Page 186: ...arted 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 186 Product manual IRB 8...

Page 187: ...s of the correct type provided with cutting edge There is no damage to the sealing edge feel with a fingernail 1 Inspect the sealing surface before mounting If scratches or damage are found the seal must be replaced since it may result in future leakage 2 Article number is specified in Equipment on page187 Lubricate the seal with grease just before fitting Not too early there is a risk of dirt and...

Page 188: ...nly when fastening the flange joint 4 O rings The following procedure describes how to fit o rings Note Action Ensure that the correct o ring size is used 1 Defective o rings including damaged or deformed o rings may not be used Check the o ring for surface defects burrs shape accuracy or deformation 2 Defective o rings may not be used Check the o ring grooves 3 The grooves must be geometrically c...

Page 189: ...52 001 Touch up paint Standard Foundry Plus ABB Orange Removing Description Action xx0900000121 Cut the paint with a knife in the joint between the part that will be removed and the struc ture to avoid that the paint cracks 1 Carefully grind the paint edge that is left on the structure to a smooth surface 2 Product manual IRB 8700 189 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights re...

Page 190: ...e to the robot Elimination To eliminate the danger after service work has been performed inside the SMB recess follow the procedure below Action Make sure the power is turned off 1 Remove the push button guard if necessary 2 Verify that the push buttons of the brake release unit are working by pressing them down one by one 3 Make sure none of the buttons are jammed in the tube If a button gets jam...

Page 191: ...r Equipment etc Lifting capacity 2 000 kg Roundsling 2 5 m Lifting capacity 2 000 kg Roundsling 3 m M12 3HAC16131 1 Lifting eye Outer diameter minimum 26 mm hole diameter 13 mm thickness 3 mm Fender washer Continues on next page Product manual IRB 8700 191 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 3 1 Attaching lifting accessories to the upper arm ...

Page 192: ...er supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Attaching lifting accessories to the upper arm complete Note Action CAUTION The complete upper arm weighs 900 kg All lifting accessories used must be sized accordingly 1 Mobile platform ladder If needed use a Mobile platform ladder or similar to attach the lifting accessories DANGER Never ...

Page 193: ...mm Roundsling 2 5 m Lifting capacity 2 000 kg xx1500002713 Attach a roundsling looped to the Lifting eye and to an overhead crane or similar xx1400002599 5 Roundsling 3 m Lifting capacity 2 000 kg xx1500002714 Attach a roundsling looped to the wrist and to an overhead crane or similar 6 Continues on next page Product manual IRB 8700 193 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights ...

Page 194: ...ies to take the weight of the upper arm 7 Adjust the lifting accessories if needed 8 194 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 3 1 Attaching lifting accessories to the upper arm Continued ...

Page 195: ...RB 6700 but the principle is the same Required tools and equipment Note Article number Equipment etc Lifting capacity 2 000 kg Roundsling 2 5 m Continues on next page Product manual IRB 8700 195 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 3 2 Attaching lifting accessories to the wrist ...

Page 196: ...6 no significance 1 Attaching lifting accessories to the wrist Note Action CAUTION The complete wrist weighs 500 kg All lifting accessories used must be sized accordingly 1 Mobile platform ladder xx1500001985 Use a Mobile platform ladder or similar to attach the lifting accessories DANGER Never use the robot as ladder 2 Continues on next page 196 Product manual IRB 8700 3HAC052853 001 Revision F C...

Page 197: ...rhead crane or similar xx1400000730 3 Stretch the lifting accessories to take the weight of the wrist 4 Adjust the lifting accessories if needed 5 Product manual IRB 8700 197 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 3 2 Attaching lifting accessories to the wrist Continued ...

Page 198: ...ee the latest revision of Product manual spare parts IRB 8700 on ABB Library Note Article number Spare part 3HAC050792 001 Cable harness Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 833 Standard toolkit ESD bag Continues on next page 198 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights rese...

Page 199: ... axis 5 as close as possible to 90 2 Jog the robot to the specified position Axis 1 0 Axis 2 comfortable working position Axis 3 comfortable working position Axis 4 0 Axis 5 90 Axis 6 Depending on which tool is used if still fitted 3 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 4 Retrieving access to the...

Page 200: ... Cut the cable tie that secures the axis 6 motor cable 3 Disconnecting the axis 6 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 200 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 201: ...Unscrew the attachment screws and re move the motor cover Note Do not damage the gasket Replace if damaged 3 xx1300000488 Disconnect the motor cables 4 xx1300000484 Unscrew the attachment screws holding the cable bracket 5 Continues on next page Product manual IRB 8700 201 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 202: ...tion and pull out the axis 6 motor cables by holding the cables at the motor with one hand and the other one at the carrier 8 Disconnecting the axis 5 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 202 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights res...

Page 203: ... 2 xx1200001070 Note Make sure the o ring is present when re moving the cover 3 xx1200001066 Disconnect the motor cables 4 Continues on next page Product manual IRB 8700 203 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 204: ...es 6 Disconnecting the axis 1 axis 2 axis 3 and axis 4 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws with washers and remove the motor cover 2 Continues on next page 204 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Rep...

Page 205: ...s facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Removing the cable harness in the upper arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 8700 205 3HAC052853 001 Revision F Copyright 2015 2018 ...

Page 206: ...xis 3 bracket 3 xx1500002719 Remove the protection cover Make sure not to damage the surface exposed 4 xx1500002720 Unscrew the nut holding the bracket inside the upper arm Note The nut is reached from the outside 5 Continues on next page 206 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 207: ... remove the cable harness out of the upper arm 9 Disconnecting the cable harness in the base Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 8700 207 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 208: ...wrench xx1500003084 Disconnect R1 SMB Tip Use a Sparkplug wrench or similar xx1200000888 4 xx1500003085 Remove the two earth cables 5 Continues on next page 208 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 209: ...R Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Axis 2 motor cable xx1500003091 Cut the cable ties that secure the axis 2 and axis 3 motor cables to the cable fixing brackets 2 Axis 3 motor cable xx1500003090 Continues on next page Product manual IRB 8700 209 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 4 1...

Page 210: ...le harness in the lower arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1500002695 If not already done unscrew the screws that hold the two cable brackets inside the lower arm Note The screws are reached from the outside 2 Continues on next page 210 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 A...

Page 211: ... pressure supply to the robot before entering the robot working area 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 32 2 xx1300000829 Open the small battery cover on the SMB cover dis connect the battery cable and remove the battery 3 Continues on next page Product manual IRB...

Page 212: ...re are turned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 32 2 xx1300000670 If needed disconnect the brake release unit connect ors X8 X9 and X10 3 xx1300000730 Remove the screws with washers that hold bracket with the SMB unit 4 Continues on next page 212 Product manu...

Page 213: ... unit 6 ESD bag Keep the SMB unit in an ESD bag until it shall be re fitted 7 Removing the SMB BU cables Note Action DANGER Make sure that all supplies for electrical power hy draulic pressure and air pressure are turned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 32 2...

Page 214: ...500003089 Use caution and pull out the cable harness from the SMB recess 4 Concluding procedure Note Action Use caution and remove the cable harness from the robot 1 214 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 215: ...al spare parts IRB 8700 on ABB Library Note Article number Spare part 3HAC050792 001 Cable harness Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 833 Standard toolkit Used to remove and refit the R1 SMB in the base Sparkplug wrench Continues on next page Product manual IRB 8700 215 3HAC052853 001 Revision F Copyright 2015 2018 ...

Page 216: ...ower hydraulic pressure and air pressure are turned off 1 Attachment screws M6x16 stainless steel A2 70 4 pcs Refit the connection plate in the base if it has been removed 2 Tightening torque 6 Nm xx1500003088 Use caution and run the cable harness through the hole in the frame and out to the base plate 3 Continues on next page 216 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 20...

Page 217: ... twisted or tangled Do not fasten the axis 1 bracket yet 4 A B xx1600000078 A Bar code B Hole for pin 1 Before refitting the R1 MP A and R1 MP B contacts make sure that the hole for pin 1 as well as the bar code will be on the left side See figure 5 xx1500003083 Refit the R1 MP A and R1 MP B contacts Note Run the cables on top of each other through the base without being twisted 6 Screws M6x20 sta...

Page 218: ... the two earth cables 9 Refitting the cable harness in the lower arm Note Action Run the cable harness up through the lower arm 1 Note Make sure the cable harness is rotated one revolution between the upper and lower bracket inside the lower arm when refitted 2 Continues on next page 218 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 4 2 Re...

Page 219: ...ews are reached from the outside 3 xx1600000075 Refit upper and lower cable guides 4 The figure show the positions of the cable guides Continues on next page Product manual IRB 8700 219 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 220: ...n the cables for SMB and brake release units into the SMB recess 5 Attachment screws M6x16 4 pcs xx1500003086 Use caution and refit the SMB BU cover in its hole from inside the SMB recess without damaging the o ring Note Do not tighten the screws fully It must still be possible to adjust the position of the cable harness by rotating the SMB BU cover in its hole a little 6 Continues on next page 22...

Page 221: ...e cables must be placed so that they don t rub against any part of the robot 7 xx1500003086 Secure the SMB BU cover from inside the SMB recess 8 Refitting the SMB unit Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 8700 221 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights...

Page 222: ...tors to the SMB board R1 SMB1 3 R1 SMB4 6 and R2 SMB 4 xx1300000730 Carefully push the SMB unit into position and refit the bracket 5 X9 X8 X10 xx1700000978 If disconnected reconnect the connectors X8 X9 and X10 to the brake release board Be careful not to damage the sockets or pins Make sure the connector and its locking arms are snapped down properly 6 Continues on next page 222 Product manual I...

Page 223: ...6 Nm 9 Refitting the SMB battery Note Action ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 32 1 Get a hold of the battery cable in the recess for the battery and reconnect 2 xx1300000829 Place the battery in the recess 3 Continues on next page Product manual IRB 8700 223 3HAC0...

Page 224: ...ints down through the hole in the frame to the base plate to the axis 1 motor to the axis 2 motor to the axis 3 motor to the SMB BU recess Adjust the cables if needed The different cables must not be twisted or tangled Do not fasten the axis 1 bracket yet 1 xx1600000080 Run the cables to axis 1 and axis 3 motors through the hole on the right side of the frame 2 xx1600000079 Run the cables to axis ...

Page 225: ...s 2 and axis 3 motor cables with cable ties 6 xx1500003090 Connecting the axis 1 axis 2 axis 3 and axis 4 motor cables Note Action xx1300000738 Push the motor cables in through the cable gland opening 1 Continues on next page Product manual IRB 8700 225 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 226: ...n o ring and o ring groove 4 xx1200001070 Inspect the o ring Note Replace if damaged 5 O ring 3HAC054692 002 Refit the o ring 6 CAUTION When refitting the motor cover make sure none of the cables inside will be damaged 7 Continues on next page 226 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 227: ...ly sealed 9 Refitting the cable harness in the upper arm Note Action Carefully push the cable harness in through the upper arm and out off the wrist 1 Nut M6 xx1500002720 Refit the cable clamp inside the upper arm Note The nut is attached from the outside 2 Attachment screw M8 xx1500002719 Refit the protection cover 3 Continues on next page Product manual IRB 8700 227 3HAC052853 001 Revision F Cop...

Page 228: ...094 Make sure that the gasket on the cover is correctly fitted Note Replace if damaged The gasket is covered with adhesive on the side facing the upper arm cover The three washers are pressed into the holes in the gasket Make sure all three washers are fitted 7 Continues on next page 228 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 4 2 Re...

Page 229: ...les in through the cable gland opening 1 Attachment screws M5x16 2 pcs xx1200001016 Refit the cable gland cover Note Replace the gasket if damaged 2 Continues on next page Product manual IRB 8700 229 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 230: ...les inside will be dam aged 5 Attachment screws M5x12 8 8 7 pcs xx1200001013 Refit the motor cover Note Do not reuse the self threading attachment screws Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is properly fitted and undamaged 6 Continues on next page 230 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights re...

Page 231: ...result will be damage to the cable harness 1 xx1300001113 Use caution and push the carrier into posi tion 2 Attachment screws M4x10 xx1300000485 Secure the carrier with the M4 screw Note The screw is located at the bottom of the carrier Tip The screw that secure the carrier may be difficult to fit Make sure the carrier is level and completely pressed against the bottom 3 Continues on next page Pro...

Page 232: ...cable underneath the motor cable 5 xx1500003095 Make sure the gasket on the motor cover is undamaged Note Replace if damaged 6 CAUTION Make sure not to damage the cables inside the motor when refitting the motor cover 7 Continues on next page 232 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 233: ... sealant and other contamination from the contact sur faces of the wrist cover 10 xx1600000046 Make sure the contact surface of the wrist cover is undamaged 11 Loctite 574 Apply flange sealant on the wrist cover flange 12 Place the cable harness so it will not be damaged when fitting the cover 13 Continues on next page Product manual IRB 8700 233 3HAC052853 001 Revision F Copyright 2015 2018 ABB A...

Page 234: ... procedure Note Action See Updating revolution counters on page 801 Update the revolution counters 1 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 27 2 234 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 4 2 Refit...

Page 235: ...of Product manual spare parts IRB 8700 on ABB Library Note Article number Spare part RMU102 3HAC043904 001 SMB Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 833 Standard toolkit ESD bag Continues on next page Product manual IRB 8700 235 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 4 3 Replac...

Page 236: ...ve to ESD on page 32 2 xx1300000829 Open the small battery cover on the SMB cover dis connect the battery cable and remove the battery 3 xx1300000669 Remove the SMB cover CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures 4 Disconnecting and removing the SMB unit Note Action DANGER Make sure that all supplie...

Page 237: ...that hold bracket with the SMB unit 4 xx1300000728 Carefully pull the SMB unit out a little and disconnect the connectors from the SMB board R1 SMB1 3 R1 SMB4 6 and R2 SMB Battery cable connector R2 G Disconnect the battery cable by pressing down the upper lip of the R2 G connector to release the lock while pulling the connector upwards 5 xx1700000993 Continues on next page Product manual IRB 8700...

Page 238: ...ulic pressure and air pressure are turned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 32 2 xx1300000729 Connect the battery cable to the SMB unit Make sure the lock snaps into place during refit ting 3 Continues on next page 238 Product manual IRB 8700 3HAC052853 001 R...

Page 239: ...tors X8 X9 and X10 to the brake release board Be careful not to damage the sockets or pins Make sure the connector and its locking arms are snapped down properly 6 xx1300000834 Take a hold of the SMB cover and pull the battery cable out through the recess for the battery 7 Continues on next page Product manual IRB 8700 239 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Rep...

Page 240: ...ty information in the section The unit is sensitive to ESD on page 32 1 Get a hold of the battery cable in the recess for the battery and reconnect 2 xx1300000829 Place the battery in the recess 3 Attachment screws M6x16 8 8 2 pcs Refit the battery cover 4 Tightening torque 6 Nm Concluding procedure Note Action See Updating revolution counters on page 801 Update the revolution counter 1 Continues ...

Page 241: ...performing the first test run These are further detailed in the section First test run may cause injury or damage on page 27 2 Product manual IRB 8700 241 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 4 3 Replacing the SMB Continued ...

Page 242: ...oduct manual spare parts IRB 8700 on ABB Library Note Article number Spare part Brake release unit DSQC1052 and harness 3HAC065021 001 Brake release unit Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 833 Standard toolkit Continues on next page 242 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All ri...

Page 243: ...tion The unit is sensitive to ESD on page 32 2 xx1300000743 Remove the push button guard from the SMB cover The push button guard must be removed to ensure a correct refitting of the brake release unit 3 xx1300000742 Remove the SMB cover 4 The battery can stay connected to avoid needing to synchronize the robot CAUTION Carefully put the SMB cover down to avoid damaging the battery cable connectors...

Page 244: ...d to the brake release board 3 xx1300000670 Use caution and remove the connectors X8 X9 and X10 from the brake release board 4 Removing the brake release unit Note Action DANGER Make sure that all supplies for electrical power hy draulic pressure and air pressure are turned off 1 Unscrew the attachment screws securing the brake release unit bracket 2 xx1300000744 Remove the bracket with the brake ...

Page 245: ...to the bracket 2 xx1300000744 Refit the bracket with the brake release unit fitted Make sure the unit is placed as straight as possible on the bracket The push buttons can otherwise get jammed when the SMB cover is refitted 3 X9 X8 X10 xx1700000978 Reconnect the connectors X8 X9 and X10 to the brake release unit Be careful not to damage the sockets or pins Make sure the connector and its locking a...

Page 246: ...hment screws M6x16 8 8 6 pcs xx1300000742 Refit the SMB cover with its attachment screws Note Do not refit the push button guard at this point 6 WARNING Before continuing any service work follow the safety procedure in section The brake release buttons may be jammed after service work on page 190 7 Attachment screws M5x16 8 8 6 pcs xx1300000743 Refit the push button guard to the SMB cover 8 Contin...

Page 247: ...n counters must be updated if the battery has been disconnected 10 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 27 11 Product manual IRB 8700 247 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 4 4 Replacing the brake release unit Conti...

Page 248: ...pare part numbers that are listed in the table can be out of date See the latest revision of Product manual spare parts IRB 8700 on ABB Library Note Article number Spare part 3HAC048079 006 Upper arm excluding wrist Continues on next page 248 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm ...

Page 249: ...949 001 Press plate Used to disassemble and assemble the parallel rod Round plate To be used with the press tool 3HAC11731 1 Hydraulic cylinder To be used with the hydraulic cylinder 3HAC13086 1 Hydraulic pump 80 MPa Velcro strap Set of tools Instruction 3HAC056526 002 enclosed 3HAC056095 002 Assembly tool Set of tools Instruction 3HAC056526 002 enclosed 3HAC056095 003 Removal tool Used to replace...

Page 250: ...alues If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page...

Page 251: ...evices Use this procedure to unload both balancing devices Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Mobile platform ladder xx1500001985 Use a Mobile platform ladder or similar to reach the upper end of the balancing device DANGER Do not use the robot as ladder 2 Continues on next page Product manual IRB 8700 251 3HAC05...

Page 252: ...rews reaches the piston Then alternately little by little attach the screws at least another five mil limeters The pressure is now unloaded 5 Screw M16x80 2 pcs In a procedure where both balancing devices shall be removed unload the pressure of the other in the same way 6 Removing the balancing devices Use this procedure to remove both balancing devices Note Action DANGER Make sure that all suppli...

Page 253: ...ling 1 m Lifting capacity 1 000 kg xx1500001983 Attach a roundsling to the lifting hole on top of the balancing device and to an overhead crane or similar 4 Stretch the lifting accessories to take the weight of the balancing device 5 xx1500001973 Remove upper and lower KM nuts V rings and support rings 6 Continues on next page Product manual IRB 8700 253 3HAC052853 001 Revision F Copyright 2015 20...

Page 254: ...esent on the shaft No need to remove 8 Pallet Put the balancing device down Tip Turn a pallet upside down and place the balancing device in the opening for the trucks forks This will prevent the balancing device from starting to move unexpectedly 9 If both balancing devices shall be removed remove the other in the same way 10 Continues on next page 254 Product manual IRB 8700 3HAC052853 001 Revisi...

Page 255: ...air pressure supply to the robot before entering the robot working area 2 Retrieving access to the wrist cabling Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1500003100 Remove the wrist cover Note Do not damage the sealing Replace if damaged Note The position of axis 4 depends on the on going procedure 2 xx1500002330 Con...

Page 256: ...ydraulic pressure and air pressure are turned off 1 Make sure that the axis 5 is as close to 90 or 90 position as possible depend ing on what repair work is being done Note Not needed if only replacing the axis 6 unit 2 Continues on next page 256 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 257: ...sket Replace if damaged 3 xx1300000488 Disconnect the motor cables 4 xx1300000484 Unscrew the attachment screws holding the cable bracket 5 Continues on next page Product manual IRB 8700 257 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 258: ...aution and pull out the axis 6 motor cables by holding the cables at the motor with one hand and the other one at the carrier 8 Disconnecting the axis 5 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 258 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights r...

Page 259: ...er 2 xx1200001070 Note Make sure the o ring is present when re moving the cover 3 xx1200001066 Disconnect the motor cables 4 Continues on next page Product manual IRB 8700 259 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 260: ...the motor cables 6 Disconnecting the axis 4 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 Continues on next page 260 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 1 Re...

Page 261: ...otor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Removing the cable harness in the upper arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 8700 261 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights re...

Page 262: ...axis 3 bracket 3 xx1500002719 Remove the protection cover Make sure not to damage the surface exposed 4 xx1500002720 Unscrew the nut holding the bracket inside the upper arm Note The nut is reached from the outside 5 Continues on next page 262 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 263: ...ries to the upper arm complete Note Action CAUTION The complete upper arm weighs 900 kg All lifting accessories used must be sized accordingly 1 Mobile platform ladder If needed use a Mobile platform ladder or similar to attach the lifting accessories DANGER Never use the robot as ladder 2 Continues on next page Product manual IRB 8700 263 3HAC052853 001 Revision F Copyright 2015 2018 ABB All righ...

Page 264: ...thickness 3 mm Roundsling 2 5 m Lifting capacity 2 000 kg xx1500002713 Attach a roundsling looped to the Lifting eye and to an overhead crane or similar xx1400002599 5 Roundsling 3 m Lifting capacity 2 000 kg xx1500002714 Attach a roundsling looped to the wrist and to an overhead crane or similar 6 Continues on next page 264 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB...

Page 265: ...ece of wood or similar between parallel arm and parallel rod used as pro tection to prevent the rod from moving un expectedly during the continued procedure 1 xx1400002600 Remove the attachment screw with washer that secure the rod shaft 2 Continues on next page Product manual IRB 8700 265 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm ...

Page 266: ...s in the holes and adjust the screws against the parallel rod from both sides 4 Attachment screws M10x80 4 pcs xx1500002300 xx1500001967 Remove the protection plug Note Keep the protection plug It shall be refitted when the work is done 5 Assembly tool 3HAC051000 001 Apply the press tool parts Assembly tool Press plate and Round plate 6 Press plate 3HAC050949 001 Round plate Continues on next page...

Page 267: ...ely 5 mm on one side of the parallel rod Leave the screws on the other side 8 xx1500001964 Right side Left side Cover washer Thrust washer Remove the thrust washer and cover washer on either side of the bearing Tip Make a note on which side the respective washer is fitted for a correct assembly later 9 Continues on next page Product manual IRB 8700 267 3HAC052853 001 Revision F Copyright 2015 2018...

Page 268: ...that the up per arm is secured in the lifting accessories and overhead crane Stretch the lifting accessories to take the weight of the upper arm CAUTION The upper arm including the wrist weighs approximately 900 kg All lifting accessor ies must be sized accordingly 1 In order to release the brakes connect the 24 VDC power supply 2 Connect connector R2 MP2 pin 2 24V pin 5 0V Continues on next page ...

Page 269: ...AC038174 067 xx1500002726 Use a Sleeve KM nut to release the torque on one of the KM nuts Note Do not remove this KM nut at this point Only release the torque 6 xx1500002727 Use the Sleeve KM nut open and remove the KM nut on the other side Note Make sure not to lose gamma sealing and sealing ring 7 Note Continue the removal on the same side until the shaft is removed completely Leave the other sh...

Page 270: ... clean 10 Glycerine adapter xx1600000081 Attach the Glycerine adapter Note Tighten the adapter very hard in order to avoid leakage 11 xx1500002729 Remove the small VK cover 12 Continues on next page 270 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 271: ...shaft including the removal tool weighs approximately 25 kg 15 Secure the shaft and the removal tool to the upper arm using lifting eyes and a short roundsling This is done as a safety precau tion Tip How to secure removal tool and shaft is described in the instruction 3HAC056526 002 delivered with the tool 16 xx1600000077 CAUTION Do not stand close to the robot on any side when the shaft is being...

Page 272: ... pressure are turned off 1 Make sure that the roundslings are stretched and so that they will carry the weight of the upper arm 2 xx1500002732 Use caution and lift the upper arm complete off 3 Pallet 2 pcs Put the upper arm complete down on two pallets 4 Refitting the upper arm Use these procedures to refit the upper arm Attaching lifting accessories to the upper arm complete Note Action CAUTION T...

Page 273: ... arm housing with a Fender washer underneath xx1400002196 4 Lifting eye M12 Fender washer Outer diameter minimum 26 mm hole diameter 13 mm thickness 3 mm Roundsling 2 5 m Lifting capacity 2 000 kg xx1500002713 Attach a roundsling looped to the Lifting eye and to an overhead crane or similar xx1400002599 5 Continues on next page Product manual IRB 8700 273 3HAC052853 001 Revision F Copyright 2015 2...

Page 274: ...s if needed 8 Preparations before refitting the upper arm shafts Make the preparations on both sides of the robot and on both upper arm shafts Note Action xx1500002731 Remove residues of Loctite and other contamination from the shafts and in the holes where the shafts will be refitted 1 Continues on next page 274 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights ...

Page 275: ...n with Isopropanol Note Do not touch the cleaned cone surface of the shaft with anything after cleaning 3 Scotch brite abrasive cleaning hand pad xx1500002750 Use a Scotch brite abrasive cleaning hand pad and rub the contact surfaces in the holes for the shafts outer ring of bearings and sealing rings 4 Continues on next page Product manual IRB 8700 275 3HAC052853 001 Revision F Copyright 2015 201...

Page 276: ...ged 6 Isopropanol xx1500002748 Wipe the sealing rings clean with Isopro panol 7 Attach the sealing rings onto the shafts 8 Refitting the upper arm and the upper arm shafts Note Start the refitting of the shafts on the axis 2 side Note Action Tribol GR 100 2 PD Fill the bearing with grease 1 Continues on next page 276 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rig...

Page 277: ... on the shaft is turned downwards 4 CAUTION The shaft weighs 19 kg 5 xx1500002731 Use caution and lift the shaft into mounting position Note Do not touch the surfaces cleaned with Isopropanol 6 Glycerine adapter Wipe the Glycerine adapter connection meticulously clean 7 Continues on next page Product manual IRB 8700 277 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair...

Page 278: ...y tool 3HAC056095 002 Set of tools Instruction 3HAC056526 002 en closed Attach the assembly tool Tip How to use the assembly tool is described in the instruction 3HAC056526 002 de livered with the tool 11 Put the hydraulic pump onto the pull bar 12 Manually tighten the adjustment nut against the hydraulic cylinder 13 Tightening torque 20 Nm Tighten the adjustment nut 14 Dial gauge Attach a Dial ga...

Page 279: ...glycerine tools 22 xx1500003125 Refit the magnetic plug 23 Refit the other shaft by repeating the pro cedure Note Leave the horseshoe shim fitted on the axis 2 side also when fitting the axis 3 shaft Do not move the shim or attach an other one on the axis 3 side 24 Refitting the KM nut axis 3 side Note Start refitting KM nut on the axis 3 side Continues on next page Product manual IRB 8700 279 3HA...

Page 280: ...ect sealing ring 2 xx1600000084 Refit sealing ring 3 xx1600000193 Wipe clean the KM nut 4 Wipe clean the o ring in the KM nut 5 Continues on next page 280 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 281: ...HAC038174 067 Secure the KM nut with the Sleeve KM nut 8 Tightening torque 300 Nm xx1600000187 Wipe the shaft clean 9 Dial gauge value 0 38 mm xx1700000970 Attach the attachment of the dial gauge in the holes on the axis 3 side with the dial gauge against the axis 2 side 10 Continues on next page Product manual IRB 8700 281 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Re...

Page 282: ... side Do not remove or add another shim 1 xx1600000083 Inspect the pre mounted gamma sealing on the KM nut 2 xx1600000084 Inspect sealing ring 3 xx1600000084 Refit sealing ring 4 Continues on next page 282 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 283: ... xx1600000192 Apply locking liquid on the threads and refit the KM nut 8 xx1700000970 Make sure that the dial gauge attachment is fitted 9 Sleeve KM nut D 152 L 220 3HAC038174 067 Secure the axis 2 KM nut with the Sleeve KM nut until the dial gauge shows 0 38 mm 10 Continues on next page Product manual IRB 8700 283 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 ...

Page 284: ...01965 Take a firm grip of the parallel rod and lift it up into mounting position 2 xx1500001963 Put a piece of wood or similar between parallel arm and parallel rod used as pro tection to prevent the rod from moving un expectedly during the procedure 3 Continues on next page 284 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing t...

Page 285: ...he parallel rod without problems and to be able to find the correct position of the parallel rod 5 Attachment screws M10x50 4 pcs xx1500002300 Place the parallel rod into position and reattach the two M10x50 screws against the parallel rod Note This is done to prevent the arm housing from being deformed when pressing the shaft and thereby making it more difficult to press the shaft in or out 6 App...

Page 286: ...locking liquid on the attachment screw and secure shaft 10 Loctite 243 xx1400002600 xx1500001961 Remove the four M10x50 screws and refit the protection plugs 4 4 pcs 11 Continues on next page 286 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 287: ...is attached from the outside 2 Attachment screw M8 xx1500002719 Refit the protection cover 3 xx1500002718 Refit the cable clamp on the axis 3 bracket 4 xx1500003092 Refit the cable clamp on the axis 3 bracket between axis 4 motor and arm housing 5 Continues on next page Product manual IRB 8700 287 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the up...

Page 288: ...gasket is covered with adhesive on the side facing the upper arm cover The three washers are pressed into the holes in the gasket Make sure all three washers are fitted 7 xx1500002722 Refit the cover 8 Continues on next page 288 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 289: ...efit the cable gland cover Note Replace the gasket if damaged 2 xx1200001066 Connect the motor cables Connect in accordance with the markings on the connectors 3 Continues on next page Product manual IRB 8700 289 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 290: ...make sure that none of the cables inside will be dam aged 7 Attachment screws M5x12 8 8 7 pcs xx1200001135 Refit the motor cover with its attachment screws Note Do not reuse the self threading attachment screws Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Continues ...

Page 291: ...cable gland opening 1 Attachment screws M5x16 2 pcs xx1200001016 Refit the cable gland cover Note Replace the gasket if damaged 2 Continues on next page Product manual IRB 8700 291 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 292: ...ables inside will be dam aged 5 Attachment screws M5x12 8 8 7 pcs xx1200001013 Refit the motor cover Note Do not reuse the self threading attachment screws Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is properly fitted and undamaged 6 Continues on next page 292 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights ...

Page 293: ...ing else of the axis 6 mo tor cables at this point The remaining refit ting must wait until the axis 5 has been moved into 90 position Axis 5 must be in 90 position when the carrier and cable bracket are refitted If not the spiral of the cable harness will be in the wrong position and it will be damaged when axis 5 is moving 3 Robot position when refitting the axis 6 motor cables Note Action Turn ...

Page 294: ...UTION Make sure that the cable spiral is not twis ted an extra revolution The result will be damage to the cable harness xx1300001113 Use caution and push the carrier into posi tion 2 Attachment screw M4x10 xx1300000485 Secure the carrier with the M4 screw Note The screw is located at the bottom of the carrier Tip The attachment screw that secure the car rier may be difficult to fit Make sure the ...

Page 295: ...6 motor and make sure they are connected Note The resolver cable shall be placed under neath the motor cable 5 Gasket 3HAC033489 001 xx1200001095 Inspect the gasket Note Replace if damaged 6 Continues on next page Product manual IRB 8700 295 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 296: ...n replacing the balancing device Note Action xx1500002310 Jog the robot to calibration position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Continues on next page 296 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm ...

Page 297: ...ty 1 000 kg xx1500001983 Attach a roundsling to the lifting hole on top of the balancing device and to an overhead crane or similar 3 Use caution and lift the balancing device up an let it hang in the lifting accessories 4 Wipe clean the contact surfaces 5 Grease xx1500002304 Apply some grease on shafts and in bear ing holes Note Do not apply any grease on the threads for the KM nut 6 Continues on...

Page 298: ... DANGER Do not use the robot as ladder 1 xx1500002735 Use caution and raise the balancing device into mounting position 2 xx1500002306 Note Make sure the bearings are axially centered in the balancing device ears before putting them on the shafts 3 Continues on next page 298 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the u...

Page 299: ...and put the balancing device onto upper and lower shafts 5 Locking liquid Loctite 243 xx1500002307 Apply locking liquid on the threads of the lock nuts 6 Inspect that the bearings are axially centered in the balancing device ears 7 Continues on next page Product manual IRB 8700 299 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continue...

Page 300: ... with 30 gram of bearing grease 10 Wipe away surplus grease and refit the M6x10 screws 11 If both balancing devices shall be refitted refit the other in the same way 12 Restoring the pressure of the balancing device Note Action Mobile platform ladder xx1500001985 Use a Mobile platform ladder or similar to reach the upper end of the balancing device DANGER Do not use the robot as ladder 1 Continues...

Page 301: ...M16x35 screws in the holes on top of the balancing device 4 Concluding procedure Note Action Clean the wrist cover from residues of sealant and other contamination 1 xx1600000046 Make sure the contact surface on the wrist cover is undamaged 2 Continues on next page Product manual IRB 8700 301 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper a...

Page 302: ...cedure 5 Tightening torque 24 Nm xx1500003100 xx1500002330 Axis Calibration is described in Calibrating with Axis Calibration method on page 805 Recalibrate the robot 6 General calibration information is included in section Calibration on page 795 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 i...

Page 303: ... in the table can be out of date See the latest revision of Product manual spare parts IRB 8700 on ABB Library Note Article number Color Spare part 3HAC048653 006 Graphite White Wrist 3HAC048653 004 ABB Orange Wrist Continues on next page Product manual IRB 8700 303 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist ...

Page 304: ... the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in...

Page 305: ... Mobile platform ladder xx1500001985 Use a Mobile platform ladder or similar to reach the wrist DANGER Do not use the robot as ladder 4 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 5 Retrieving access to the wrist cabling Note Action DANGER Make sure that all supplies for electrical power hydraulic press...

Page 306: ...2331 Cut the cable tie that secures the axis 6 motor cable 3 Disconnecting the axis 6 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 306 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 307: ...80 Unscrew the attachment screws and re move the motor cover Note Do not damage the gasket Replace if damaged 3 xx1300000488 Disconnect the motor cables 4 xx1300000484 Unscrew the attachment screws holding the cable bracket 5 Continues on next page Product manual IRB 8700 307 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 308: ... caution and pull out the axis 6 motor cables by holding the cables at the motor with one hand and the other one at the carrier 8 Disconnecting the axis 5 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 308 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights...

Page 309: ...over 2 xx1200001070 Note Make sure the o ring is present when re moving the cover 3 xx1200001066 Disconnect the motor cables 4 Continues on next page Product manual IRB 8700 309 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 310: ...capacity 1 000 kg xx1300000673 The figure show the IRB 6700 but the prin ciple is the same Attach a roundsling choked as shown in the figure CAUTION It is very important that the roundsling is placed as shown in the figure in order to keep the wrist balanced when it is removed Placed at a different position there is a risk of sudden change in the balance which may cause damage or injury WARNING Do...

Page 311: ...essure are turned off 1 xx1500003103 Remove two attachment screws in opposite holes and replace them with guide pins Tip Lubricate the guide pins with some grease to make the wrist slide better 2 xx1500003104 Remove the remaining attachment screws 3 Continues on next page Product manual IRB 8700 311 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the ...

Page 312: ...5 xx1500003107 CAUTION When the wrist is hanging free the front end will tend to lean slightly downwards 6 Put down the wrist on a pallet or similar 7 Refitting the wrist Use these procedures to refit the wrist Preparations before refitting the wrist Note Action Clean the contact surfaces on wrist and arm tube flange 1 Continues on next page 312 Product manual IRB 8700 3HAC052853 001 Revision F Co...

Page 313: ...n in the figure CAUTION It is very important that the roundsling is placed as shown in the figure in order to keep the wrist balanced when it is removed Placed at a different position there is a risk of sudden change in the balance which can cause damage or injury CAUTION Make sure the roundsling is fitted as tightly as possible in order not to risk that the wrist starts moving out of position 2 N...

Page 314: ...and arm tube flange 2 xx1500003107 CAUTION When the wrist is hanging free the front end will tend to lean slightly downwards 3 Run the cable harness into the wrist carefully 4 Use caution and slide the wrist into fitting position against the arm tube flange CAUTION Make sure not to damage any parts of the cable harness 5 Continues on next page 314 Product manual IRB 8700 3HAC052853 001 Revision F ...

Page 315: ...ning screws 7 Tightening torque 120 Nm Secure the wrist 8 Remove the lifting accessories 9 Connecting the axis 5 motor cables Note Action xx1500002717 Push the motor cables in through the cable gland opening 1 Continues on next page Product manual IRB 8700 315 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 316: ...ith the markings on the connectors 3 O ring 3HAC054692 002 xx1200001070 Inspect the o ring Note Replace if damaged 4 CAUTION When refitting the motor cover make sure that none of the cables inside will be dam aged 5 Continues on next page 316 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 317: ...otor cables Note Action Make sure that the axis 5 is in 90 position before continuing If not the cable spiral will be attached in the wrong position and cause damage to the cable harness CAUTION Make sure that the cable spiral is not turned an extra revolution The result will be damage to the cable harness 1 xx1300001113 Use caution and push the carrier into posi tion 2 Continues on next page Prod...

Page 318: ...level and completely pressed against the bottom 3 Attachment screws M6x16 2 pcs xx1300000484 Secure the cable bracket with its attach ment screws 4 xx1300000488 Reconnect the connectors to the axis 6 motor Note Place the resolver cable underneath the motor cable 5 Continues on next page 318 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 2...

Page 319: ...ke sure not to damage the cables inside the motor when refitting the motor cover 7 Attachment screws M5x20 5 pcs xx1200001080 Refit the motor cover 8 Continues on next page Product manual IRB 8700 319 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 320: ...ion from the contact sur faces of the wrist cover 10 xx1600000046 Make sure the contact surface of the wrist cover is undamaged 11 Loctite 574 Apply flange sealant on the wrist cover flange 12 Place the cable harness so it will not be damaged when fitting the cover 13 Continues on next page 320 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4...

Page 321: ... in Calibrating with Axis Calibration method on page 805 Re calibrate the robot 1 General calibration information is included in section Calibration on page 795 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 27 2 Product manual IRB 8700 321 3HAC052853 001 Revision F Copy...

Page 322: ...ate See the latest revision of Product manual spare parts IRB 8700 on ABB Library Note Article number Spare part 3HAC048651 006 Axis 6 Unit Required tools and equipment Note Article number Equipment etc Used to release the motor brakes 24 VDC power supply Continues on next page 322 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 3 Replacin...

Page 323: ... refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference c...

Page 324: ... robot before entering the robot working area 4 Retrieving access to the wrist cabling Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1500003100 Remove the wrist cover Note Do not damage the sealing Replace if damaged Note The position of axis 4 depends on the on going procedure 2 xx1500002330 Continues on next page 324 Pr...

Page 325: ...draulic pressure and air pressure are turned off 1 Make sure that the axis 5 is as close to 90 or 90 position as possible depend ing on what repair work is being done Note Not needed if only replacing the axis 6 unit 2 Continues on next page Product manual IRB 8700 325 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 3 Replacing the axis 6 unit Continued ...

Page 326: ...ket Replace if damaged 3 xx1300000488 Disconnect the motor cables 4 xx1300000484 Unscrew the attachment screws holding the cable bracket 5 Continues on next page 326 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 3 Replacing the axis 6 unit Continued ...

Page 327: ...tion and pull out the axis 6 motor cables by holding the cables at the motor with one hand and the other one at the carrier 8 Removing the axis 6 motor Note Action 24 VDC power supply To release the brakes connect the 24 VDC power supply 1 Connect to R2 MP6 connector pin 2 24V pin 5 0V Continues on next page Product manual IRB 8700 327 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights r...

Page 328: ...ON The motor weighs 14 kg 5 xx1500003098 Remove the motor by lifting it straight up from the gear Make sure the motor pinion is not dam aged 6 Disconnect the 24 VDC power supply 7 Attaching lifting accessories to the axis 6 unit Note Action CAUTION The axis 6 unit weighs 165 kg All lifting accessories must be sized accordingly 1 Continues on next page 328 Product manual IRB 8700 3HAC052853 001 Rev...

Page 329: ...l VK covers on the axis 5 gearbox cover Always replace VK covers with a new one Note Do not remove any other VK cover 1 Note Before removing the attachment screws on the axis 5 side plan in advance in which order the screws are removed When the last three of the 21 screws is removed the turning disc on the axis 6 unit shall be fa cing upwards 2 xx1600000195 Slowly rotate the axis 6 unit upwards un...

Page 330: ...he axis 6 unit weight the unit will start to rotate uncontrolled Make sure that the axis 6 unit is securely attached to the lifting accessory before the last screw is removed 6 Removing the axis 6 unit Note Action Make sure the lifting accessories still are attached securely and takes the weight of the axis 6 unit 1 This is done to be able to reach the attach ment screws that secure the axis 6 uni...

Page 331: ...imilar on the floor to be used for putting the axis 6 unit on 6 Lower the axis 6 unit towards the pallet Grab the roundslings by hand to be able to force the axis 6 unit to lay on the side on the pallet CAUTION Be very careful not to damage the motor if still fitted The axis 6 must never rest on the motor 7 Continues on next page Product manual IRB 8700 331 3HAC052853 001 Revision F Copyright 2015...

Page 332: ... or similar 3 Use caution and raise the axis 6 unit up and let it hang in the lifting accessories 4 Refitting the support shaft side Note Action Wipe clean all contact surfaces including the o ring grooves 1 xx1600000200 Use caution and move the axis 6 unit to its mounting position 2 Wipe clean and inspect the o rings Re place damaged o rings 3 Refit the o rings in the grooves Tip Lubricate the o ...

Page 333: ...ing 7 Tightening torque 24 Nm xx1600000197 Refitting the axis 5 gearbox side Note Action Refitting of the axis 6 unit must start with the turning disc facing upwards When the last screws are attached the axis 5 shall be as close as possible to 90 position 1 Continues on next page Product manual IRB 8700 333 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 3 Replac...

Page 334: ...ws M16x80 Attach and secure these three screws 5 Tightening torque 300 Nm Continue to lower the axis 6 unit in steps until all 21 screws are attached and se cured in the same way 6 Note Make sure that all 21 screws are attached and secured before removing the lifting accessories and continuing the procedure 7 Continues on next page 334 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 20...

Page 335: ...f 10 Remove old paint residues and other contamina tion from the contact surfaces on both motor and gearbox 11 Wipe clean the contact surfaces from any remain ing contamination 12 Also wipe clean the o ring groove O ring 3HAB3772 107 xx1200001019 Make sure the o ring is undamaged Replace if damaged 13 Continues on next page Product manual IRB 8700 335 3HAC052853 001 Revision F Copyright 2015 2018 ...

Page 336: ...a new spare part remove the motor cover 16 Securing the axis 6 motor Note Action To release the brakes connect the 24 VDC power supply 1 Connect to connector R2 MP6 pin 2 24V pin 5 0V CAUTION Parting mating motor pinion and hub may damage the splines if excessive force is used 2 Continues on next page 336 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved...

Page 337: ...h its attachment screws 5 Screw dimension M8x25 quality 12 9 Gleitmo 4 pcs xx1200001090 Make sure that the gasket is fitted correctly Disconnect the 24 V DC power supply 6 Continues on next page Product manual IRB 8700 337 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 3 Replacing the axis 6 unit Continued ...

Page 338: ...h the carrier into posi tion 2 Attachment screws M4x10 xx1300000485 Secure the carrier with the M4 screw Note The screw is located at the bottom of the carrier Tip The screw that secure the carrier may be difficult to fit Make sure the carrier is level and completely pressed against the bottom 3 Attachment screws M6x16 2 pcs xx1300000484 Secure the cable bracket with its attach ment screws 4 Conti...

Page 339: ... cover is undamaged Note Replace if damaged 6 CAUTION Make sure not to damage the cables inside the motor when refitting the motor cover 7 Attachment screws M5x20 5 pcs xx1200001080 Refit the motor cover 8 Continues on next page Product manual IRB 8700 339 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 3 Replacing the axis 6 unit Continued ...

Page 340: ... from the contact sur faces of the wrist cover 10 xx1600000046 Make sure the contact surface of the wrist cover is undamaged 11 Loctite 574 Apply flange sealant on the wrist cover flange 12 Place the cable harness so it will not be damaged when fitting the cover 13 Continues on next page 340 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 ...

Page 341: ...n Calibrating with Axis Calibration method on page 805 Recalibrate the robot 1 General calibration information is included in section Calibration on page 795 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 27 2 Product manual IRB 8700 341 3HAC052853 001 Revision F Copyrig...

Page 342: ... latest revision of Product manual spare parts IRB 8700 on ABB Library Note Article number Spare part 3HAC048445 003 Turning disc Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 833 Standard toolkit Continues on next page 342 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4...

Page 343: ...fore entering the robot working area 2 Remove any tools or other equipment fitted to the turning disk 3 Removing the turning disk Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1500002318 Unscrew the 27 M12x40 screws and washers that secure the turning disk 2 Continues on next page Product manual IRB 8700 343 3HAC052853 00...

Page 344: ...ng disk Refitting the turning disk Note Action xx1500002319 Wipe clean the contact surfaces 1 xx1500002984 Make sure the sealing ring is fitted 2 Continues on next page 344 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 4 Replacing the turning disc Continued ...

Page 345: ...ed with the calibration tools Recalibrate the robot 1 General calibration information is included in section Calibration on page 795 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 27 2 Product manual IRB 8700 345 3HAC052853 001 Revision F Copyright 2015 2018 ABB All righ...

Page 346: ...in section Standard toolkit on page 833 Standard toolkit Removing the process turning disc Use these procedures to remove the process turning disc Preparations before removing the process turning disk Note Action Jog the robot to a comfortable position for removing the process turning disk 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before...

Page 347: ...ing the process turning disc Use these procedures to refit the process turning disk Refitting the process turning disk Note Action CAUTION The process turning disc weigh 50 kg All lifting accessories must be sized accord ingly 1 Roundsling 1 m Lifting capacity 1 000 kg Attach a roundsling to the process turning disk and to an overhead crane or similar 2 Wipe clean the contact surfaces 3 Make sure ...

Page 348: ...is included in section Calibration on page 795 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 27 2 348 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 5 Replacing the process turning disc Continued ...

Page 349: ...are parts Note The spare part numbers that are listed in the table can be out of date See the latest revision of Product manual spare parts IRB 8700on ABB Library Note Article number Spare part 3HAC048081 005 Graphite White 3HAC048081 006 ABB Orange Lower arm Continues on next page Product manual IRB 8700 349 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Repl...

Page 350: ...and assemble the parallel rod 3HAC051000 001 Assembly tool Used to disassemble and assemble the parallel rod 3HAC050949 001 Press plate Used to disassemble and assemble the parallel rod Round plate To be used with the press tool 3HAC11731 1 Hydraulic cylinder To be used with the hydraulic cylinder 3HAC13086 1 Hydraulic pump 80 MPa Velcro strap Set of tools Instruction 3HAC056526 002 enclosed 3HAC0...

Page 351: ...create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibrati...

Page 352: ...supply air pressure supply to the robot before entering the robot working area 2 Removing the counterweight Note Action CAUTION The counterweight weighs 1200 kg All lifting accessories used must be sized accordingly 1 xx1500001980 If used remove the plastic plugs covering the holes for the lifting eyes Note Keep the plastic plugs They shall be refit ted 2 Continues on next page 352 Product manual ...

Page 353: ...g accessory to take the weight of the counterweight 5 Attachment screws M16x70 10 pcs xx1500001981 Unscrew the attachment screws with washers that hold the counterweight 6 xx1500001982 Use caution lift the counterweight off 7 Continues on next page Product manual IRB 8700 353 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Conti...

Page 354: ...pply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Unloading the pressure of the balancing devices Use this procedure to unload both balancing devices Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 354 Product manual IRB 8700 3HAC052853 001 Revision...

Page 355: ...1500002303 Apply some Molykote on threads and at the bottom end of two fully threaded screws 4 Screws M16x80 fully threaded xx1500002309 Unload the pressure of the balancing device by inserting the screws Attach the screws until the screws reaches the piston Then alternately little by little attach the screws at least another five mil limeters The pressure is now unloaded 5 Screw M16x80 2 pcs Cont...

Page 356: ...h the upper end of the balancing device DANGER Do not use the robot as a ladder 2 CAUTION The balancing device weights 200 kg All lifting accessories used must be sized accordingly 3 Roundsling 1 m Lifting capacity 1 000 kg xx1500001983 Attach a roundsling to the lifting hole on top of the balancing device and to an overhead crane or similar 4 Stretch the lifting accessories to take the weight of ...

Page 357: ...xx1500001975 Verify that the support ring V ring and spacer ring are present on the shaft No need to remove 8 Pallet Put the balancing device down Tip Turn a pallet upside down and place the balancing device in the opening for the trucks forks This will prevent the balancing device from starting to move unexpectedly 9 Continues on next page Product manual IRB 8700 357 3HAC052853 001 Revision F Cop...

Page 358: ...ctric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Removing the attachment screws in the first area Remove attachment screws in the first of the three areas of screws Remove screws that secure the axis 2 gearbox to the lower arm as well as the ones that secure the axis 3 gearbox to the parallel arm Note Action Unscrew and remove s...

Page 359: ...r the position of the robot is changed Note The screws are reached from the outside 1 xx1500002695 Robot position when removing the upper arm Note Action xx1700001306 Turn on the power and jog the robot to the specified position Axis 1 no significance as long as the robot is fitted to the foundation Axis 2 65 Axis 3 65 horizontal to the foundation Axis 4 90 Axis 5 90 Axis 6 no significance 1 Conti...

Page 360: ...all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1500003100 Remove the wrist cover Note Do not damage the sealing Replace if damaged Note The position of axis 4 depends on the on going procedure 2 xx1500002330 Continues on next page 360 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the ...

Page 361: ...900 kg All lifting accessories used must be sized accordingly 1 Mobile platform ladder If needed use a Mobile platform ladder or similar to attach the lifting accessories DANGER Never use the robot as ladder 2 Continues on next page Product manual IRB 8700 361 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 362: ...ness 3 mm Roundsling 2 5 m Lifting capacity 2 000 kg xx1500002713 Attach a roundsling looped to the Lifting eye and to an overhead crane or similar xx1400002599 5 Roundsling 3 m Lifting capacity 2 000 kg xx1500002714 Attach a roundsling looped to the wrist and to an overhead crane or similar 6 Continues on next page 362 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All ...

Page 363: ...f wood or similar between parallel arm and parallel rod used as pro tection to prevent the rod from moving un expectedly during the continued procedure 1 xx1400002600 Remove the attachment screw with washer that secure the rod shaft 2 Continues on next page Product manual IRB 8700 363 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower ...

Page 364: ...the holes and adjust the screws against the parallel rod from both sides 4 Attachment screws M10x80 4 pcs xx1500002300 xx1500001967 Remove the protection plug Note Keep the protection plug It shall be refitted when the work is done 5 Assembly tool 3HAC051000 001 Apply the press tool parts Assembly tool Press plate and Round plate 6 Press plate 3HAC050949 001 Round plate Continues on next page 364 ...

Page 365: ...5 mm on one side of the parallel rod Leave the screws on the other side 8 xx1500001964 Right side Left side Cover washer Thrust washer Remove the thrust washer and cover washer on either side of the bearing Tip Make a note on which side the respective washer is fitted for a correct assembly later 9 Continues on next page Product manual IRB 8700 365 3HAC052853 001 Revision F Copyright 2015 2018 ABB...

Page 366: ...s 6 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Make sure that the axis 5 is as close to 90 or 90 position as possible depend ing on what repair work is being done Note Not needed if only replacing the axis 6 unit 2 Continues on next page 366 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 20...

Page 367: ... Replace if damaged 3 xx1300000488 Disconnect the motor cables 4 xx1300000484 Unscrew the attachment screws holding the cable bracket 5 Continues on next page Product manual IRB 8700 367 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 368: ...n and pull out the axis 6 motor cables by holding the cables at the motor with one hand and the other one at the carrier 8 Disconnecting the axis 5 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 368 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserv...

Page 369: ...xx1200001070 Note Make sure the o ring is present when re moving the cover 3 xx1200001066 Disconnect the motor cables 4 Continues on next page Product manual IRB 8700 369 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 370: ...motor cables 6 Disconnecting the axis 4 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 Continues on next page 370 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replac...

Page 371: ... will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Removing the cable harness in the upper arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 8700 371 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserv...

Page 372: ... 3 bracket 3 xx1500002719 Remove the protection cover Make sure not to damage the surface exposed 4 xx1500002720 Unscrew the nut holding the bracket inside the upper arm Note The nut is reached from the outside 5 Continues on next page 372 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 373: ...move the cable harness out of the upper arm 9 Removing the cable harness in the lower arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 8700 373 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 374: ... outside 2 xx1600000075 Remove the upper and lower cable guides 3 The figure show the positions of the cable guides Use caution and remove the cable harness from the lower arm 4 Continues on next page 374 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 375: ...e 24 VDC power supply 2 Connect connector R2 MP2 pin 2 24V pin 5 0V Release the brakes on axis 2 to allow the lower arm to position according to the lift ing force applied from the overhead crane This eliminates any strain in the upper arm shafts 3 Remove the brake release from R2 MP2 4 xx1500002725 Remove grease and other contamination from the axis 2 and axis 3 shaft ends and around the KM nuts ...

Page 376: ...remove the KM nut on the other side Note Make sure not to lose gamma sealing and sealing ring 7 Note Continue the removal on the same side until the shaft is removed completely Leave the other shaft fitted for now 8 xx1500002728 Remove gamma sealing and sealing ring 9 Continues on next page 376 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4...

Page 377: ...600000081 Attach the Glycerine adapter Note Tighten the adapter very hard in order to avoid leakage 11 xx1500002729 Remove the small VK cover 12 Continues on next page Product manual IRB 8700 377 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 378: ... including the removal tool weighs approximately 25 kg 15 Secure the shaft and the removal tool to the upper arm using lifting eyes and a short roundsling This is done as a safety precau tion Tip How to secure removal tool and shaft is described in the instruction 3HAC056526 002 delivered with the tool 16 xx1600000077 CAUTION Do not stand close to the robot on any side when the shaft is being remo...

Page 379: ...or electrical power hydraulic pressure and air pressure are turned off 1 Make sure that the roundslings are stretched and so that they will carry the weight of the upper arm 2 xx1500002732 Use caution and lift the upper arm complete off 3 Pallet 2 pcs Put the upper arm complete down on two pallets 4 Removing the parallel rod lower end Note If the parallel rod shall be removed from the robot always...

Page 380: ...taking the weight of the parallel rod 3 xx1500001966 Remove the attachment screw with washer that secure the rod shaft 4 xx1500001968 Remove the protection plug Note Keep the protection plug It shall be refitted when the work is done 5 Apply the press tool parts Assembly tool Press plate and Round plate 6 Continues on next page 380 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2...

Page 381: ...her on either side of the bearing are present Tip Make a note on which side the respective washer is fitted for a correct assembly later 8 xx1500002745 Use caution and lift the parallel rod off 9 Continues on next page Product manual IRB 8700 381 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 382: ...The lower arm complete weighs 600 kg All lifting accessories used must be sized accordingly 1 Roundsling 2 m Lifting capacity 2 000 kg xx1500002708 Attach a roundsling to the lower arm and to an overhead crane or similar with the robot in the current position 2 Continues on next page 382 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Re...

Page 383: ... as possible to calibration position 5 Remove the 24 VDC power supply 6 Unscrewing the axis 1 bracket Note Action xx1500002372 Remove the axis 1 cable bracket to protect the lower end of the cable harness Leave the cables attached Note There is no need to disconnect the motor cables to axis 1 2 and 3 motors or to the SMB unit 1 Continues on next page Product manual IRB 8700 383 3HAC052853 001 Revi...

Page 384: ... similar 1 CAUTION The parallel arm weighs 255 kg All lifting accessories used must be sized accordingly 2 Stretch the lifting accessories to take the weight of the parallel arm 3 To release the brakes on axis 3 connect the 24 VDC power supply 4 Connect to connector R2 MP3 pin 2 24V pin 5 0V Continues on next page 384 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All ri...

Page 385: ...het lashing belt 6 With the brakes still released on axis 3 use the ratchet belt and manually move the parallel arm the last bit against the lower arm 7 Secure with the ratchet belt Remove the 24 VDC power supply 8 Remove the lifting accessory from the par allel arm 9 Continues on next page Product manual IRB 8700 385 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4...

Page 386: ...ccordingly 1 Roundsling 2 m Lifting capacity 2 000 kg xx1500002733 Attach a roundsling to the lower arm as sembly and to an overhead crane or simil ar Attach the roundsling through the holes in the upper end of the lower arm 2 Continues on next page 386 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Cont...

Page 387: ...aining attachment screws that secure the lower arm to the axis 2 gearbox and the parallel arm to the axis 3 gearbox 4 Crowbar small Use a Crowbar small or similar and press the lower arm and parallel arm togeth er as much as possible 5 xx1500002700 Use caution and lift the lower arm complete off 6 Continues on next page Product manual IRB 8700 387 3HAC052853 001 Revision F Copyright 2015 2018 ABB ...

Page 388: ...he parallel arm Note Action CAUTION The lower arm complete weighs 600 kg All lifting accessories used must be sized accordingly 1 Endless ratchet lashing belt DANGER Make sure that the parallel arm is secured to the lower arm with an Endless ratchet lashing belt to prevent the parallel arm from falling down uncontrolled when the lower arm complete is lifted up 2 Roundsling 2 m Lifting capacity 2 0...

Page 389: ...tical position 4 xx1500002700 Move the lower arm assembly into mount ing position 5 Continues on next page Product manual IRB 8700 389 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 390: ...le pattern between lower arm and axis 2 gearbox Tip Use caution and rotate the small gear on the axis 2 gearbox 2 xx1500002740 Attach as many screws as possible with the robot in this position Tip Begin by fitting screws in the outer holes in the outer ring of holes to make sure the hole pattern will match If needed carefully turn the small gear in the gearbox to find the hole pattern 3 Tightening...

Page 391: ...tting screws in the most outer holes in the outer ring of holes to make sure the hole pattern will be matching If needed use caution and turn the small gear in the gearbox to find the hole pattern 6 Tightening torque 300 Nm Secure the attached screws that secure the parallel arm to the axis 3 gearbox 7 Continues on next page Product manual IRB 8700 391 3HAC052853 001 Revision F Copyright 2015 2018...

Page 392: ... to the parallel arm 1 xx1500002743 Remove the Endless ratchet lashing belt 2 Stretch the roundsling to take the weight of the parallel arm 3 Continues on next page 392 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 393: ... Action Roundsling 2 m Lifting capacity 2 000 kg xx1500002747 Attach a roundsling to the lower arm 1 Stretch the roundsling to take the weight of the parallel arm 2 Continues on next page Product manual IRB 8700 393 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 394: ...ximately 30 mm 3 Remove the 24 VDC power supply 4 Remove the lifting accessories 5 Refitting the axis 1 bracket Note Action xx1500002372 Refit the axis 1 cable bracket with the screws 1 Continues on next page 394 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 395: ...her and cover washer and wipe them clean Note Make a note on which side the covers are placed 2 Wipe the shafts and the holes for the shafts clean 3 Mercasol xx1500002100 Apply corrosion protection on both sides of the bearings and on all machined sur faces on the parallel rod 4 Continues on next page Product manual IRB 8700 395 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved...

Page 396: ...llel rod has been removed from the robot always start refitting at the lower end 1 CAUTION The parallel rod weighs 55 kg 2 Roundsling 1 m Lifting capacity 1 000 kg Attach a roundsling to the parallel rod and to an overhead crane or similar 3 Continues on next page 396 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete...

Page 397: ...d plate 5 xx1500002098 Thrust washer Left side Cover washer Right side Make sure that the thrust washer and cover washer on either side of the bearing are in position Note Make sure that the washers are on the correct sides of the bearing 6 Continues on next page Product manual IRB 8700 397 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete ...

Page 398: ...ion and press the shaft in 8 xx1500001968 Refit the protection plug 9 Attachment screw M10x16 8 8 Apply locking liquid on the screw and se cure the shaft 10 Loctite 243 xx1500001966 Continues on next page 398 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 399: ...the back hole of the arm housing 3 Attach a Lifting eye to the hole in the arm housing with a Fender washer underneath xx1400002196 4 Lifting eye M12 Fender washer Outer diameter minimum 26 mm hole diameter 13 mm thickness 3 mm Roundsling 2 5 m Lifting capacity 2 000 kg xx1500002713 Attach a roundsling looped to the Lifting eye and to an overhead crane or similar xx1400002599 5 Continues on next p...

Page 400: ... needed 8 Preparations before refitting the upper arm shafts Make the preparations on both sides of the robot and on both upper arm shafts Note Action xx1500002731 Remove residues of Loctite and other contamination from the shafts and in the holes where the shafts will be refitted 1 Continues on next page 400 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights rese...

Page 401: ...th Isopropanol Note Do not touch the cleaned cone surface of the shaft with anything after cleaning 3 Scotch brite abrasive cleaning hand pad xx1500002750 Use a Scotch brite abrasive cleaning hand pad and rub the contact surfaces in the holes for the shafts outer ring of bearings and sealing rings 4 Continues on next page Product manual IRB 8700 401 3HAC052853 001 Revision F Copyright 2015 2018 AB...

Page 402: ... Isopropanol xx1500002748 Wipe the sealing rings clean with Isopro panol 7 Attach the sealing rings onto the shafts 8 Refitting the upper arm and the upper arm shafts Note Start the refitting of the shafts on the axis 2 side Note Action Tribol GR 100 2 PD Fill the bearing with grease 1 Continues on next page 402 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights r...

Page 403: ...he shaft is turned downwards 4 CAUTION The shaft weighs 19 kg 5 xx1500002731 Use caution and lift the shaft into mounting position Note Do not touch the surfaces cleaned with Isopropanol 6 Glycerine adapter Wipe the Glycerine adapter connection meticulously clean 7 Continues on next page Product manual IRB 8700 403 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 ...

Page 404: ...l 3HAC056095 002 Set of tools Instruction 3HAC056526 002 en closed Attach the assembly tool Tip How to use the assembly tool is described in the instruction 3HAC056526 002 de livered with the tool 11 Put the hydraulic pump onto the pull bar 12 Manually tighten the adjustment nut against the hydraulic cylinder 13 Tightening torque 20 Nm Tighten the adjustment nut 14 Dial gauge Attach a Dial gauge a...

Page 405: ...rine tools 22 xx1500003125 Refit the magnetic plug 23 Refit the other shaft by repeating the pro cedure Note Leave the horseshoe shim fitted on the axis 2 side also when fitting the axis 3 shaft Do not move the shim or attach an other one on the axis 3 side 24 Refitting the KM nut axis 3 side Note Start refitting KM nut on the axis 3 side Continues on next page Product manual IRB 8700 405 3HAC0528...

Page 406: ...sealing ring 2 xx1600000084 Refit sealing ring 3 xx1600000193 Wipe clean the KM nut 4 Wipe clean the o ring in the KM nut 5 Continues on next page 406 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 407: ...38174 067 Secure the KM nut with the Sleeve KM nut 8 Tightening torque 300 Nm xx1600000187 Wipe the shaft clean 9 Dial gauge value 0 38 mm xx1700000970 Attach the attachment of the dial gauge in the holes on the axis 3 side with the dial gauge against the axis 2 side 10 Continues on next page Product manual IRB 8700 407 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair...

Page 408: ... Do not remove or add another shim 1 xx1600000083 Inspect the pre mounted gamma sealing on the KM nut 2 xx1600000084 Inspect sealing ring 3 xx1600000084 Refit sealing ring 4 Continues on next page 408 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 409: ...00000192 Apply locking liquid on the threads and refit the KM nut 8 xx1700000970 Make sure that the dial gauge attachment is fitted 9 Sleeve KM nut D 152 L 220 3HAC038174 067 Secure the axis 2 KM nut with the Sleeve KM nut until the dial gauge shows 0 38 mm 10 Continues on next page Product manual IRB 8700 409 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Rep...

Page 410: ...lower bracket inside the lower arm when refitted 2 Screws M6x16 4 pcs xx1500002695 Refit the two cable brackets inside the lower arm Note The screws are reached from the outside 3 xx1600000075 Refit upper and lower cable guides 4 The figure show the positions of the cable guides Continues on next page 410 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved...

Page 411: ...tached from the outside 2 Attachment screw M8 xx1500002719 Refit the protection cover 3 xx1500002718 Refit the cable clamp on the axis 3 bracket 4 xx1500003092 Refit the cable clamp on the axis 3 bracket between axis 4 motor and arm housing 5 Continues on next page Product manual IRB 8700 411 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complet...

Page 412: ...t is covered with adhesive on the side facing the upper arm cover The three washers are pressed into the holes in the gasket Make sure all three washers are fitted 7 xx1500002722 Refit the cover 8 Continues on next page 412 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 413: ... the cable gland cover Note Replace the gasket if damaged 2 xx1200001066 Connect the motor cables Connect in accordance with the markings on the connectors 3 Continues on next page Product manual IRB 8700 413 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 414: ...sure that none of the cables inside will be dam aged 7 Attachment screws M5x12 8 8 7 pcs xx1200001135 Refit the motor cover with its attachment screws Note Do not reuse the self threading attachment screws Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Continues on ne...

Page 415: ... gland opening 1 Attachment screws M5x16 2 pcs xx1200001016 Refit the cable gland cover Note Replace the gasket if damaged 2 Continues on next page Product manual IRB 8700 415 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 416: ... inside will be dam aged 5 Attachment screws M5x12 8 8 7 pcs xx1200001013 Refit the motor cover Note Do not reuse the self threading attachment screws Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is properly fitted and undamaged 6 Continues on next page 416 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reser...

Page 417: ...else of the axis 6 mo tor cables at this point The remaining refit ting must wait until the axis 5 has been moved into 90 position Axis 5 must be in 90 position when the carrier and cable bracket are refitted If not the spiral of the cable harness will be in the wrong position and it will be damaged when axis 5 is moving 3 Robot position when refitting the axis 6 motor cables Note Action Turn on t...

Page 418: ...N Make sure that the cable spiral is not twis ted an extra revolution The result will be damage to the cable harness xx1300001113 Use caution and push the carrier into posi tion 2 Attachment screw M4x10 xx1300000485 Secure the carrier with the M4 screw Note The screw is located at the bottom of the carrier Tip The attachment screw that secure the car rier may be difficult to fit Make sure the carr...

Page 419: ...or and make sure they are connected Note The resolver cable shall be placed under neath the motor cable 5 Gasket 3HAC033489 001 xx1200001095 Inspect the gasket Note Replace if damaged 6 Continues on next page Product manual IRB 8700 419 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 420: ...bot to the spe cified position Axis 2 No significance as long as the ro bot is secured to the foundation Axis 2 20 Axis 3 0 Axis 4 0 Axis 5 0 Axis 6 No significance 1 Refit the remaining screws that secure the lower arm and parallel arm to the axis 2 and axis 3 gearboxes 2 Attachment screws M16x70 12 9 Gleitmo Secure the attachment screws 3 Tightening torque 300 Nm Continues on next page 420 Produ...

Page 421: ...used as pro tection to prevent the rod from moving un expectedly during the procedure 3 xx1500001964 Right side Left side Cover washer Thrust washer Place the thrust washer and cover washer on either side of the bearing and make sure that they are correctly fitted Note Make sure that the washers are on the correct sides of the bearing 4 Continues on next page Product manual IRB 8700 421 3HAC052853...

Page 422: ...tion and reattach the two M10x50 screws against the parallel rod Note This is done to prevent the arm housing from being deformed when pressing the shaft and thereby making it more difficult to press the shaft in or out 6 Apply the press tool parts Assembly tool Press plate and Round plate 7 xx1700001307 Use caution and press the shaft in 8 xx1500001967 Refit the protection plug 9 Continues on nex...

Page 423: ...tion when replacing the balancing device Note Action xx1500002310 Jog the robot to calibration position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Continues on next page Product manual IRB 8700 423 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the co...

Page 424: ...000 kg xx1500001983 Attach a roundsling to the lifting hole on top of the balancing device and to an overhead crane or similar 3 Use caution and lift the balancing device up an let it hang in the lifting accessories 4 Wipe clean the contact surfaces 5 Grease xx1500002304 Apply some grease on shafts and in bear ing holes Note Do not apply any grease on the threads for the KM nut 6 Continues on next...

Page 425: ...GER Do not use the robot as ladder 1 xx1500002735 Use caution and raise the balancing device into mounting position 2 xx1500002306 Note Make sure the bearings are axially centered in the balancing device ears before putting them on the shafts 3 Continues on next page Product manual IRB 8700 425 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the compl...

Page 426: ...put the balancing device onto upper and lower shafts 5 Locking liquid Loctite 243 xx1500002307 Apply locking liquid on the threads of the lock nuts 6 Inspect that the bearings are axially centered in the balancing device ears 7 Continues on next page 426 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Con...

Page 427: ...h 30 gram of bearing grease 10 Wipe away surplus grease and refit the M6x10 screws 11 If both balancing devices shall be refitted refit the other in the same way 12 Restoring the pressure of the balancing device Note Action Mobile platform ladder xx1500001985 Use a Mobile platform ladder or similar to reach the upper end of the balancing device DANGER Do not use the robot as ladder 1 Continues on ...

Page 428: ...of the balancing device 4 Robot position when refitting the counterweight Note Action xx1500002096 If not already in this position turn on the power and jog to a position where the area the counterweight is fitted to the parallel arm is horizontal to the foundation 1 Continues on next page 428 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 ...

Page 429: ...s if not already done 2 Lifting accessory chain with four chains Attach the lifting accessory chain with four chains to the lifting eyes 3 Stretch the lifting accessory to take the weight of the counterweight 4 Flange sealant Loctite 574 xx1600000049 Apply flange sealant Loctite 574 on the contact surface between parallel arm and counterweight 5 Continues on next page Product manual IRB 8700 429 3...

Page 430: ... the lifting eyes 8 xx1500001980 If used refit the plastic plugs in the holes for the lifting eyes 9 Concluding procedure Note Action Axis Calibration is described in Calibrating with Axis Calibration method on page 805 Recalibrate the robot 1 General calibration information is included in section Calibration on page 795 Continues on next page 430 Product manual IRB 8700 3HAC052853 001 Revision F ...

Page 431: ...ing the first test run These are further detailed in the section First test run may cause injury or damage on page 27 2 Product manual IRB 8700 431 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 432: ...re listed in the table can be out of date See the latest revision of Product manual spare parts IRB 8700 on ABB Library Note Article number Spare part 3HAC049074 003 Graphite White 3HAC049074 004 ABB Orange Parallel arm Continues on next page 432 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parallel arm ...

Page 433: ...sed to disassemble and assemble the parallel rod 3HAC051000 001 Assembly tool Used to disassemble and assemble the parallel rod 3HAC050949 001 Press plate Used to disassemble and assemble the parallel rod Round plate Used on parallel arm for assembly of bearings lower arm and parallel arm 3HAC051101 001 Assembly tool press plate Used on parallel arm for assembly of bearings lower arm and parallel ...

Page 434: ...propanol Glycerine Mercasol 3110 Waxcoat Recom mended drying time is 24h 3HAC034903 001 Rust preventive Tribol GR 100 0 PD 3HAA1001 294 Grease Loctite 243 3HAB7116 1 Locking liquid Cable ties 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 ...

Page 435: ...bration Remove all external cable packages DressPack and tools from the robot Removing the parallel arm Use these procedures to remove the parallel arm Preparations before removing the parallel arm Note Action Decide which calibration routine to use and take actions accordingly prior to begin ning the repair procedure 1 Remove any tool or other equipment fitted to the robot 2 Robot position when r...

Page 436: ...4 pcs xx1500002087 Attach lifting eyes 3 Lifting accessory four chains Attach the lifting accessory chain with four chains to the lifting eyes 4 Stretch the lifting accessory to take the weight of the counterweight 5 Attachment screws M16x70 10 pcs xx1500001981 Unscrew the attachment screws with washers that hold the counterweight 6 Continues on next page 436 Product manual IRB 8700 3HAC052853 001...

Page 437: ...ding the pressure of balancing device Note Action xx1500002310 Jog the robot to calibration position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Continues on next page Product manual IRB 8700 437 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the paral...

Page 438: ...evice DANGER Do not use the robot as ladder 2 xx1500001971 Remove the screws fitted in the screw holes on top of the balancing device Note Keep the screws They shall be refitted after the work is done 3 M16x35 Apply Molykote on colored areas xx1500002303 Apply some Molykote on threads and at the bottom end of two fully threaded screws 4 Screws M16x80 fully threaded Continues on next page 438 Produ...

Page 439: ...ncing devices Use this procedure to remove both balancing devices Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Mobile platform ladder xx1500001985 Use a Mobile platform ladder to reach the upper end of the balancing device DANGER Do not use the robot as a ladder 2 CAUTION The balancing device weights 200 kg All lifting acc...

Page 440: ...x1500001973 Remove upper and lower KM nuts V rings and support rings 6 Crowbar small xx1500002735 Use caution and lift the balancing device off Tip If needed use a Crowbar small to care fully help pressing the balancing device out A suitable bearing puller is another al ternative 7 Continues on next page 440 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reser...

Page 441: ... this position it is possible to reach the screws in the first of the three areas of screws that secure the axis 2 gearbox to the lower arm and the axis 3 gearbox to the parallel arm Note Action Jog the robot to the specified position Axis 1 no significance as long as the robot is fitted to the foundation Axis 2 30 Axis 3 20 Axis 4 0 Axis 5 0 Axis 6 No significance 1 DANGER Turn off all electric p...

Page 442: ... reach 2 Unscrewing the brackets that secure cable harness in lower arm Note Action xx1500002694 Unscrew the screws of the two brackets that secure the cable harness inside the lower arm In order to be able to remove the cable harness later on it is necessary to unscrew the two brackets inside the lower arm at this stage It will be very difficult to reach the bracket screws after the position of t...

Page 443: ...r pressure supply to the robot before entering the robot working area 2 Retrieving access to the wrist cabling Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1500003100 Remove the wrist cover Note Do not damage the sealing Replace if damaged Note The position of axis 4 depends on the on going procedure 2 xx1500002330 Conti...

Page 444: ...hs 900 kg All lifting accessories used must be sized accordingly 1 Mobile platform ladder If needed use a Mobile platform ladder or similar to attach the lifting accessories DANGER Never use the robot as ladder 2 Continues on next page 444 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parallel arm Continued ...

Page 445: ...ickness 3 mm Roundsling 2 5 m Lifting capacity 2 000 kg xx1500002713 Attach a roundsling looped to the Lifting eye and to an overhead crane or similar xx1400002599 5 Roundsling 3 m Lifting capacity 2 000 kg xx1500002714 Attach a roundsling looped to the wrist and to an overhead crane or similar 6 Continues on next page Product manual IRB 8700 445 3HAC052853 001 Revision F Copyright 2015 2018 ABB A...

Page 446: ...e of wood or similar between parallel arm and parallel rod used as pro tection to prevent the rod from moving un expectedly during the continued procedure 1 xx1400002600 Remove the attachment screw with washer that secure the rod shaft 2 Continues on next page 446 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parallel arm...

Page 447: ...in the holes and adjust the screws against the parallel rod from both sides 4 Attachment screws M10x80 4 pcs xx1500002300 xx1500001967 Remove the protection plug Note Keep the protection plug It shall be refitted when the work is done 5 Assembly tool 3HAC051000 001 Apply the press tool parts Assembly tool Press plate and Round plate 6 Press plate 3HAC050949 001 Round plate Continues on next page P...

Page 448: ...ly 5 mm on one side of the parallel rod Leave the screws on the other side 8 xx1500001964 Right side Left side Cover washer Thrust washer Remove the thrust washer and cover washer on either side of the bearing Tip Make a note on which side the respective washer is fitted for a correct assembly later 9 Continues on next page 448 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ...

Page 449: ...axis 6 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Make sure that the axis 5 is as close to 90 or 90 position as possible depend ing on what repair work is being done Note Not needed if only replacing the axis 6 unit 2 Continues on next page Product manual IRB 8700 449 3HAC052853 001 Revision F Copyright 2015...

Page 450: ...ket Replace if damaged 3 xx1300000488 Disconnect the motor cables 4 xx1300000484 Unscrew the attachment screws holding the cable bracket 5 Continues on next page 450 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parallel arm Continued ...

Page 451: ...tion and pull out the axis 6 motor cables by holding the cables at the motor with one hand and the other one at the carrier 8 Disconnecting the axis 5 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 8700 451 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights res...

Page 452: ... 2 xx1200001070 Note Make sure the o ring is present when re moving the cover 3 xx1200001066 Disconnect the motor cables 4 Continues on next page 452 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parallel arm Continued ...

Page 453: ...he motor cables 6 Disconnecting the axis 4 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 Continues on next page Product manual IRB 8700 453 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Rep...

Page 454: ...tor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Removing the cable harness in the upper arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 454 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights res...

Page 455: ...xis 3 bracket 3 xx1500002719 Remove the protection cover Make sure not to damage the surface exposed 4 xx1500002720 Unscrew the nut holding the bracket inside the upper arm Note The nut is reached from the outside 5 Continues on next page Product manual IRB 8700 455 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parallel arm Continued ...

Page 456: ... remove the cable harness out of the upper arm 9 Removing the cable harness in the lower arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 456 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parallel arm Continued ...

Page 457: ...the outside 2 xx1600000075 Remove the upper and lower cable guides 3 The figure show the positions of the cable guides Use caution and remove the cable harness from the lower arm 4 Continues on next page Product manual IRB 8700 457 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parallel arm Continued ...

Page 458: ... the 24 VDC power supply 2 Connect connector R2 MP2 pin 2 24V pin 5 0V Release the brakes on axis 2 to allow the lower arm to position according to the lift ing force applied from the overhead crane This eliminates any strain in the upper arm shafts 3 Remove the brake release from R2 MP2 4 xx1500002725 Remove grease and other contamination from the axis 2 and axis 3 shaft ends and around the KM nu...

Page 459: ...nd remove the KM nut on the other side Note Make sure not to lose gamma sealing and sealing ring 7 Note Continue the removal on the same side until the shaft is removed completely Leave the other shaft fitted for now 8 xx1500002728 Remove gamma sealing and sealing ring 9 Continues on next page Product manual IRB 8700 459 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repai...

Page 460: ...xx1600000081 Attach the Glycerine adapter Note Tighten the adapter very hard in order to avoid leakage 11 xx1500002729 Remove the small VK cover 12 Continues on next page 460 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parallel arm Continued ...

Page 461: ...aft including the removal tool weighs approximately 25 kg 15 Secure the shaft and the removal tool to the upper arm using lifting eyes and a short roundsling This is done as a safety precau tion Tip How to secure removal tool and shaft is described in the instruction 3HAC056526 002 delivered with the tool 16 xx1600000077 CAUTION Do not stand close to the robot on any side when the shaft is being r...

Page 462: ...s for electrical power hydraulic pressure and air pressure are turned off 1 Make sure that the roundslings are stretched and so that they will carry the weight of the upper arm 2 xx1500002732 Use caution and lift the upper arm complete off 3 Pallet 2 pcs Put the upper arm complete down on two pallets 4 Removing the parallel rod lower end Note If the parallel rod shall be removed from the robot alw...

Page 463: ...rt taking the weight of the parallel rod 3 xx1500001966 Remove the attachment screw with washer that secure the rod shaft 4 xx1500001968 Remove the protection plug Note Keep the protection plug It shall be refitted when the work is done 5 Apply the press tool parts Assembly tool Press plate and Round plate 6 Continues on next page Product manual IRB 8700 463 3HAC052853 001 Revision F Copyright 201...

Page 464: ...washer on either side of the bearing are present Tip Make a note on which side the respective washer is fitted for a correct assembly later 8 xx1500002745 Use caution and lift the parallel rod off 9 Continues on next page 464 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parallel arm Continued ...

Page 465: ...ON The lower arm complete weighs 600 kg All lifting accessories used must be sized accordingly 1 Roundsling 2 m Lifting capacity 2 000 kg xx1500002708 Attach a roundsling to the lower arm and to an overhead crane or similar with the robot in the current position 2 Continues on next page Product manual IRB 8700 465 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7...

Page 466: ...ose as possible to calibration position 5 Remove the 24 VDC power supply 6 Unscrewing the axis 1 bracket Note Action xx1500002372 Remove the axis 1 cable bracket to protect the lower end of the cable harness Leave the cables attached Note There is no need to disconnect the motor cables to axis 1 2 and 3 motors or to the SMB unit 1 Continues on next page 466 Product manual IRB 8700 3HAC052853 001 R...

Page 467: ... or similar 1 CAUTION The parallel arm weighs 255 kg All lifting accessories used must be sized accordingly 2 Stretch the lifting accessories to take the weight of the parallel arm 3 To release the brakes on axis 3 connect the 24 VDC power supply 4 Connect to connector R2 MP3 pin 2 24V pin 5 0V Continues on next page Product manual IRB 8700 467 3HAC052853 001 Revision F Copyright 2015 2018 ABB All...

Page 468: ...atchet lashing belt 6 With the brakes still released on axis 3 use the ratchet belt and manually move the parallel arm the last bit against the lower arm 7 Secure with the ratchet belt Remove the 24 VDC power supply 8 Remove the lifting accessory from the par allel arm 9 Continues on next page 468 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repai...

Page 469: ...d accordingly 1 Roundsling 2 m Lifting capacity 2 000 kg xx1500002733 Attach a roundsling to the lower arm as sembly and to an overhead crane or simil ar Attach the roundsling through the holes in the upper end of the lower arm 2 Continues on next page Product manual IRB 8700 469 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parallel arm Continu...

Page 470: ...remaining attachment screws that secure the lower arm to the axis 2 gearbox and the parallel arm to the axis 3 gearbox 4 Crowbar small Use a Crowbar small or similar and press the lower arm and parallel arm togeth er as much as possible 5 xx1500002700 Use caution and lift the lower arm complete off 6 Continues on next page 470 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 A...

Page 471: ...tchet lashing belt 1 CAUTION The parallel arm weighs 255 kg All lifting accessories used must be sized accordingly 2 Roundsling 2 m Lifting capacity 2 000 kg xx1500002734 Attach a roundsling to the parallel arm and lift it to vertical position 3 Press tool Use the press tool and disassemble the parallel arm from the lower arm 4 Continues on next page Product manual IRB 8700 471 3HAC052853 001 Revi...

Page 472: ...y corrosion protection on the outer surface of the bearings 4 Mercasol Apply corrosion protection in the holes 5 Replacing the bearings Note Action Remove the bearing 1 Remove the washer and remove all residues of old corrosion protection and other contamination from the washer 2 Remove residues of old corrosion protec tion and other contamination on the parallel arm shafts 3 Wipe clean all contac...

Page 473: ...ccessories used must be sized accordingly 1 Roundsling 2 m Roundsling 2 m Attach the roundsling to the parallel arm and to an overhead crane or similar and lift it up to vertical position 2 xx1500002703 Use caution and move the parallel arm into mounting position 3 Press tool Use the press tool and assemble the paral lel arm and lower arm 4 Continues on next page Product manual IRB 8700 473 3HAC05...

Page 474: ... arm and the parallel arm Note Action CAUTION The lower arm complete weighs 600 kg All lifting accessories used must be sized accordingly 1 Endless ratchet lashing belt DANGER Make sure that the parallel arm is secured to the lower arm with an Endless ratchet lashing belt to prevent the parallel arm from falling down uncontrolled when the lower arm complete is lifted up 2 Continues on next page 47...

Page 475: ...ng through the hole in the upper end of the lower arm xx1500002739 Lift the lower arm assembly to a vertical position 4 xx1500002700 Move the lower arm assembly into mount ing position 5 Continues on next page Product manual IRB 8700 475 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parallel arm Continued ...

Page 476: ... hole pattern between lower arm and axis 2 gearbox Tip Use caution and rotate the small gear on the axis 2 gearbox 2 xx1500002740 Attach as many screws as possible with the robot in this position Tip Begin by fitting screws in the outer holes in the outer ring of holes to make sure the hole pattern will match If needed carefully turn the small gear in the gearbox to find the hole pattern 3 Tighten...

Page 477: ... fitting screws in the most outer holes in the outer ring of holes to make sure the hole pattern will be matching If needed use caution and turn the small gear in the gearbox to find the hole pattern 6 Tightening torque 300 Nm Secure the attached screws that secure the parallel arm to the axis 3 gearbox 7 Continues on next page Product manual IRB 8700 477 3HAC052853 001 Revision F Copyright 2015 2...

Page 478: ...ing to the parallel arm 1 xx1500002743 Remove the Endless ratchet lashing belt 2 Stretch the roundsling to take the weight of the parallel arm 3 Continues on next page 478 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parallel arm Continued ...

Page 479: ...ote Action Roundsling 2 m Lifting capacity 2 000 kg xx1500002747 Attach a roundsling to the lower arm 1 Stretch the roundsling to take the weight of the parallel arm 2 Continues on next page Product manual IRB 8700 479 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parallel arm Continued ...

Page 480: ...proximately 30 mm 3 Remove the 24 VDC power supply 4 Remove the lifting accessories 5 Refitting the axis 1 bracket Note Action xx1500002372 Refit the axis 1 cable bracket with the screws 1 Continues on next page 480 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parallel arm Continued ...

Page 481: ...washer and cover washer and wipe them clean Note Make a note on which side the covers are placed 2 Wipe the shafts and the holes for the shafts clean 3 Mercasol xx1500002100 Apply corrosion protection on both sides of the bearings and on all machined sur faces on the parallel rod 4 Continues on next page Product manual IRB 8700 481 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reser...

Page 482: ...arallel rod has been removed from the robot always start refitting at the lower end 1 CAUTION The parallel rod weighs 55 kg 2 Roundsling 1 m Lifting capacity 1 000 kg Attach a roundsling to the parallel rod and to an overhead crane or similar 3 Continues on next page 482 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the paral...

Page 483: ...ound plate 5 xx1500002098 Thrust washer Left side Cover washer Right side Make sure that the thrust washer and cover washer on either side of the bearing are in position Note Make sure that the washers are on the correct sides of the bearing 6 Continues on next page Product manual IRB 8700 483 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parall...

Page 484: ...aution and press the shaft in 8 xx1500001968 Refit the protection plug 9 Attachment screw M10x16 8 8 Apply locking liquid on the screw and se cure the shaft 10 Loctite 243 xx1500001966 Continues on next page 484 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parallel arm Continued ...

Page 485: ...om the back hole of the arm housing 3 Attach a Lifting eye to the hole in the arm housing with a Fender washer underneath xx1400002196 4 Lifting eye M12 Fender washer Outer diameter minimum 26 mm hole diameter 13 mm thickness 3 mm Roundsling 2 5 m Lifting capacity 2 000 kg xx1500002713 Attach a roundsling looped to the Lifting eye and to an overhead crane or similar xx1400002599 5 Continues on nex...

Page 486: ... if needed 8 Preparations before refitting the upper arm shafts Make the preparations on both sides of the robot and on both upper arm shafts Note Action xx1500002731 Remove residues of Loctite and other contamination from the shafts and in the holes where the shafts will be refitted 1 Continues on next page 486 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights r...

Page 487: ... with Isopropanol Note Do not touch the cleaned cone surface of the shaft with anything after cleaning 3 Scotch brite abrasive cleaning hand pad xx1500002750 Use a Scotch brite abrasive cleaning hand pad and rub the contact surfaces in the holes for the shafts outer ring of bearings and sealing rings 4 Continues on next page Product manual IRB 8700 487 3HAC052853 001 Revision F Copyright 2015 2018...

Page 488: ...d 6 Isopropanol xx1500002748 Wipe the sealing rings clean with Isopro panol 7 Attach the sealing rings onto the shafts 8 Refitting the upper arm and the upper arm shafts Note Start the refitting of the shafts on the axis 2 side Note Action Tribol GR 100 2 PD Fill the bearing with grease 1 Continues on next page 488 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All right...

Page 489: ...n the shaft is turned downwards 4 CAUTION The shaft weighs 19 kg 5 xx1500002731 Use caution and lift the shaft into mounting position Note Do not touch the surfaces cleaned with Isopropanol 6 Glycerine adapter Wipe the Glycerine adapter connection meticulously clean 7 Continues on next page Product manual IRB 8700 489 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4...

Page 490: ...tool 3HAC056095 002 Set of tools Instruction 3HAC056526 002 en closed Attach the assembly tool Tip How to use the assembly tool is described in the instruction 3HAC056526 002 de livered with the tool 11 Put the hydraulic pump onto the pull bar 12 Manually tighten the adjustment nut against the hydraulic cylinder 13 Tightening torque 20 Nm Tighten the adjustment nut 14 Dial gauge Attach a Dial gaug...

Page 491: ...ycerine tools 22 xx1500003125 Refit the magnetic plug 23 Refit the other shaft by repeating the pro cedure Note Leave the horseshoe shim fitted on the axis 2 side also when fitting the axis 3 shaft Do not move the shim or attach an other one on the axis 3 side 24 Refitting the KM nut axis 3 side Note Start refitting KM nut on the axis 3 side Continues on next page Product manual IRB 8700 491 3HAC0...

Page 492: ...ct sealing ring 2 xx1600000084 Refit sealing ring 3 xx1600000193 Wipe clean the KM nut 4 Wipe clean the o ring in the KM nut 5 Continues on next page 492 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parallel arm Continued ...

Page 493: ...AC038174 067 Secure the KM nut with the Sleeve KM nut 8 Tightening torque 300 Nm xx1600000187 Wipe the shaft clean 9 Dial gauge value 0 38 mm xx1700000970 Attach the attachment of the dial gauge in the holes on the axis 3 side with the dial gauge against the axis 2 side 10 Continues on next page Product manual IRB 8700 493 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Rep...

Page 494: ...ide Do not remove or add another shim 1 xx1600000083 Inspect the pre mounted gamma sealing on the KM nut 2 xx1600000084 Inspect sealing ring 3 xx1600000084 Refit sealing ring 4 Continues on next page 494 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parallel arm Continued ...

Page 495: ...x1600000192 Apply locking liquid on the threads and refit the KM nut 8 xx1700000970 Make sure that the dial gauge attachment is fitted 9 Sleeve KM nut D 152 L 220 3HAC038174 067 Secure the axis 2 KM nut with the Sleeve KM nut until the dial gauge shows 0 38 mm 10 Continues on next page Product manual IRB 8700 495 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 ...

Page 496: ...nd lower bracket inside the lower arm when refitted 2 Screws M6x16 4 pcs xx1500002695 Refit the two cable brackets inside the lower arm Note The screws are reached from the outside 3 xx1600000075 Refit upper and lower cable guides 4 The figure show the positions of the cable guides Continues on next page 496 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reser...

Page 497: ... attached from the outside 2 Attachment screw M8 xx1500002719 Refit the protection cover 3 xx1500002718 Refit the cable clamp on the axis 3 bracket 4 xx1500003092 Refit the cable clamp on the axis 3 bracket between axis 4 motor and arm housing 5 Continues on next page Product manual IRB 8700 497 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the para...

Page 498: ...sket is covered with adhesive on the side facing the upper arm cover The three washers are pressed into the holes in the gasket Make sure all three washers are fitted 7 xx1500002722 Refit the cover 8 Continues on next page 498 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parallel arm Continued ...

Page 499: ...fit the cable gland cover Note Replace the gasket if damaged 2 xx1200001066 Connect the motor cables Connect in accordance with the markings on the connectors 3 Continues on next page Product manual IRB 8700 499 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parallel arm Continued ...

Page 500: ...ke sure that none of the cables inside will be dam aged 7 Attachment screws M5x12 8 8 7 pcs xx1200001135 Refit the motor cover with its attachment screws Note Do not reuse the self threading attachment screws Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Continues on...

Page 501: ...ble gland opening 1 Attachment screws M5x16 2 pcs xx1200001016 Refit the cable gland cover Note Replace the gasket if damaged 2 Continues on next page Product manual IRB 8700 501 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parallel arm Continued ...

Page 502: ...les inside will be dam aged 5 Attachment screws M5x12 8 8 7 pcs xx1200001013 Refit the motor cover Note Do not reuse the self threading attachment screws Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is properly fitted and undamaged 6 Continues on next page 502 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights re...

Page 503: ...ng else of the axis 6 mo tor cables at this point The remaining refit ting must wait until the axis 5 has been moved into 90 position Axis 5 must be in 90 position when the carrier and cable bracket are refitted If not the spiral of the cable harness will be in the wrong position and it will be damaged when axis 5 is moving 3 Robot position when refitting the axis 6 motor cables Note Action Turn o...

Page 504: ...TION Make sure that the cable spiral is not twis ted an extra revolution The result will be damage to the cable harness xx1300001113 Use caution and push the carrier into posi tion 2 Attachment screw M4x10 xx1300000485 Secure the carrier with the M4 screw Note The screw is located at the bottom of the carrier Tip The attachment screw that secure the car rier may be difficult to fit Make sure the c...

Page 505: ...motor and make sure they are connected Note The resolver cable shall be placed under neath the motor cable 5 Gasket 3HAC033489 001 xx1200001095 Inspect the gasket Note Replace if damaged 6 Continues on next page Product manual IRB 8700 505 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parallel arm Continued ...

Page 506: ...tion Turn on the power and jog the robot to the specified position Axis 2 No significance as long as the robot is secured to the founda tion Axis 2 20 Axis 3 0 Axis 4 0 Axis 5 0 Axis 6 No significance 1 Refit the remaining screws that secure the lower arm and parallel arm to the axis 2 and axis 3 gearboxes 2 Tightening torque 300 Nm Secure the attachment screws 3 Continues on next page 506 Product...

Page 507: ...od used as pro tection to prevent the rod from moving un expectedly during the procedure 3 xx1500001964 Right side Left side Cover washer Thrust washer Place the thrust washer and cover washer on either side of the bearing and make sure that they are correctly fitted Note Make sure that the washers are on the correct sides of the bearing 4 Continues on next page Product manual IRB 8700 507 3HAC052...

Page 508: ...osition and reattach the two M10x50 screws against the parallel rod Note This is done to prevent the arm housing from being deformed when pressing the shaft and thereby making it more difficult to press the shaft in or out 6 Apply the press tool parts Assembly tool Press plate and Round plate 7 xx1700001307 Use caution and press the shaft in 8 xx1500001967 Refit the protection plug 9 Continues on ...

Page 509: ...osition when replacing the balancing device Note Action xx1500002310 Jog the robot to calibration position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Continues on next page Product manual IRB 8700 509 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the...

Page 510: ... 1 000 kg xx1500001983 Attach a roundsling to the lifting hole on top of the balancing device and to an overhead crane or similar 3 Use caution and lift the balancing device up an let it hang in the lifting accessories 4 Wipe clean the contact surfaces 5 Grease xx1500002304 Apply some grease on shafts and in bear ing holes Note Do not apply any grease on the threads for the KM nut 6 Continues on n...

Page 511: ...t as ladder 1 xx1500002735 Use caution and raise the balancing device into mounting position 2 xx1500002306 Note Make sure the bearings are axially centered in the balancing device ears before putting them on the shafts 3 Continues on next page Product manual IRB 8700 511 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parallel arm Continued ...

Page 512: ...nd put the balancing device onto upper and lower shafts 5 Locking liquid Loctite 243 xx1500002307 Apply locking liquid on the threads of the lock nuts 6 Inspect that the bearings are axially centered in the balancing device ears 7 Continues on next page 512 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parallel arm Contin...

Page 513: ...with 30 gram of bearing grease 10 Wipe away surplus grease and refit the M6x10 screws 11 If both balancing devices shall be refitted refit the other in the same way 12 Restoring the pressure of the balancing device Note Action Mobile platform ladder xx1500001985 Use a Mobile platform ladder or similar to reach the upper end of the balancing device DANGER Do not use the robot as ladder 1 Continues ...

Page 514: ...op of the balancing device 4 Robot position when refitting the counterweight Note Action xx1500002096 If not already in this position turn on the power and jog to a position where the area the counterweight is fitted to the parallel arm is horizontal to the foundation 1 Continues on next page 514 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair...

Page 515: ...eyes if not already done 2 Lifting accessory chain with four chains Attach the lifting accessory chain with four chains to the lifting eyes 3 Stretch the lifting accessory to take the weight of the counterweight 4 Flange sealant Loctite 574 xx1600000049 Apply flange sealant Loctite 574 on the contact surface between parallel arm and counterweight 5 Continues on next page Product manual IRB 8700 51...

Page 516: ...and the lifting eyes 8 xx1500001980 If used refit the plastic plugs in the holes for the lifting eyes 9 Concluding procedure Note Action Axis Calibration is described in Calibrating with Axis Calibration method on page 805 Recalibrate the robot 1 General calibration information is included in section Calibration on page 795 Continues on next page 516 Product manual IRB 8700 3HAC052853 001 Revision...

Page 517: ...orming the first test run These are further detailed in the section First test run may cause injury or damage on page 27 2 Product manual IRB 8700 517 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 5 7 Replacing the parallel arm Continued ...

Page 518: ...e The spare part numbers that are listed in the table can be out of date See the latest revision of Product manual spare parts IRB 8700 on ABB Library Note Article number Spare part 3HAC048154 004 Counterweight Continues on next page 518 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 6 1 Replacing the counterweight ...

Page 519: ...emoving the counterweight Note Action xx1500002096 Jog the robot to a position so that the area where the counterweight is fitted to the parallel arm is horizontal to the foundation 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Removing the counterweight Note Action CAUTION The counterweight weighs 12...

Page 520: ... chains Attach the lifting accessory chain with four chains to the lifting eyes 4 Stretch the lifting accessory to take the weight of the counterweight 5 Attachment screws M16x70 10 pcs xx1500001981 Unscrew the attachment screws with washers that hold the counterweight 6 Continues on next page 520 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repai...

Page 521: ...to refit the counterweight Robot position when refitting the counterweight Note Action xx1500002096 If not already in this position turn on the power and jog to a position where the area the counterweight is fitted to the parallel arm is horizontal to the foundation 1 Continues on next page Product manual IRB 8700 521 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4...

Page 522: ...yes if not already done 2 Lifting accessory chain with four chains Attach the lifting accessory chain with four chains to the lifting eyes 3 Stretch the lifting accessory to take the weight of the counterweight 4 Flange sealant Loctite 574 xx1600000049 Apply flange sealant Loctite 574 on the contact surface between parallel arm and counterweight 5 Continues on next page 522 Product manual IRB 8700...

Page 523: ...e the counterweight to the parallel arm 7 Tightening torque 300 Nm xx1500001981 Remove lifting accessories lifting chains and the lifting eyes 8 xx1500001980 If used refit the plastic plugs in the holes for the lifting eyes 9 Product manual IRB 8700 523 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 6 1 Replacing the counterweight Continued ...

Page 524: ...t revision of Product manual spare parts IRB 8700 on ABB Library Note Article number Spare part 3HAC048180 001 Mechanical stop pin Required tools and equipment Note Article number Equipment etc Used when replacing the parallel rod and mechanical stop pin as a safety measure Piece of wood Continues on next page 524 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights...

Page 525: ...bot position when replacing the mechanical stop pin Note Action xx1500002093 Jog axis 1 to the position where it is pos sible to replace the mechanical stop pin 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Removing the mechanical stop pin Note Action CAUTION The mechanical stop pin weighs 13 kg 1 Con...

Page 526: ...on the stop pin with one hand 3 xx1500002090 Unscrew the set screw with the other hand 4 xx1500002299 Hold the stop pin with one hand and re move the piece of wood or similar with the other hand 5 Continues on next page 526 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 6 2 Replacing the mechanical stop pin Continued ...

Page 527: ...op pin Note Action xx1500002093 Make sure that axis 1 is in the position where it will be possible to replace the mechanical stop pin If not turn on the power use caution and jog axis 1 to that position 1 Clean the stop pin as well as the hole for it 2 Continues on next page Product manual IRB 8700 527 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 6 2 Replacing t...

Page 528: ...002091 Put a piece of wood or similar underneath the stop pin to prevent it from falling down uncontrolled when the set screw is refitted 5 Locking liquid Loctite 243 xx1500002090 Apply locking liquid Loctite 243 on the set screw 6 Continues on next page 528 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 6 2 Replacing the mechanical stop pi...

Page 529: ...ecure the stop pin in the groove 7 Tightening torque 35 Nm Secure the mechanical stop pin with the set screw 8 Concluding procedure Note Action 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 27 1 Product manual IRB 8700 529 3HAC052853 001 Revision F Copyright 2015 2018 A...

Page 530: ... in the table can be out of date See the latest revision of Product manual spare parts IRB 8700 on ABB Library Note Article number Color Spare part 3HAC048077 003 Graphite White Parallel bar 3HAC048077 004 ABB Orange Parallel bar Continues on next page 530 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 6 3 Replacing the parallel rod ...

Page 531: ...inder 3HAC13086 1 Hydraulic pump 80 MPa Velcro strap Lifting capacity 1 000 kg Roundsling 1 m Content is defined in section Standard toolkit on page 833 Standard toolkit Required consumables Note Article number Consumable Grease Mercasol 3110 Waxcoat Recom mended drying time is 24h 3HAC034903 001 Rust preventive Loctite 243 3HAB7116 1 Locking liquid Removing the parallel rod Use these procedures t...

Page 532: ... 90 only needed if the cable harness shall be removed later in the procedure Axis 6 No significance 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Removing the parallel rod upper end Note Action xx1500001963 Put a piece of wood or similar between parallel arm and parallel rod used as pro tection to pre...

Page 533: ...en pressing the shaft and thereby making it more difficult to press the shaft in or out Fit 2 2 M10x80 screws in the holes and adjust the screws against the parallel rod from both sides 4 Attachment screws M10x80 4 pcs xx1500002300 xx1500001967 Remove the protection plug Note Keep the protection plug It shall be refitted when the work is done 5 Continues on next page Product manual IRB 8700 533 3H...

Page 534: ...fitting it xx1500002710 Unscrew two of the M10x50 screws approx imately 5 mm on one side of the parallel rod Leave the screws on the other side 8 xx1500001964 Right side Left side Cover washer Thrust washer Remove the thrust washer and cover washer on either side of the bearing Tip Make a note on which side the respective washer is fitted for a correct assembly later 9 Continues on next page 534 P...

Page 535: ...out of its position 11 Removing the parallel rod lower end Note If the parallel rod shall be removed from the robot always disassemble the upper end shaft first Note Action CAUTION The parallel rod weighs 55 kg All lifting accessories used must be sized accordingly 1 Continues on next page Product manual IRB 8700 535 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 ...

Page 536: ...0001966 Remove the attachment screw with washer that secure the rod shaft 4 xx1500001968 Remove the protection plug Note Keep the protection plug It shall be refitted when the work is done 5 Apply the press tool parts Assembly tool Press plate and Round plate 6 Continues on next page 536 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 6 3 Re...

Page 537: ...washer on either side of the bearing are present Tip Make a note on which side the respective washer is fitted for a correct assembly later 8 xx1500002745 Use caution and lift the parallel rod off 9 Continues on next page Product manual IRB 8700 537 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 6 3 Replacing the parallel rod Continued ...

Page 538: ... in both upper and lower ends of the parallel rod shall be refitted start refitting in the lower end Preparations before refitting the parallel rod lower end Note Action xx1500002744 Remove the strap which was used to keep bearing thrust washer and cover washer in position 1 Continues on next page 538 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 R...

Page 539: ...lean 3 Mercasol xx1500002100 Apply corrosion protection on both sides of the bearings and on all machined sur faces on the parallel rod 4 xx1500002098 Right side Left side Cover washer Thrust washer Put back the thrust washer left side and cover washer right side 5 Continues on next page Product manual IRB 8700 539 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 6 ...

Page 540: ...undsling to the parallel rod and to an overhead crane or similar 3 xx1500002745 Use caution stretch the roundsling and lift the parallel rod into mounting position 4 Place the lower end at mounting position and apply the press tool parts Assembly tool Press plate and Round plate 5 Continues on next page 540 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserv...

Page 541: ...ashers are on the correct sides of the bearing 6 xx1500002301 Apply some grease on the shafts and in the holes on both sides of parallel arm as well as in the bearing hole 7 xx1500001969 Use caution and press the shaft in 8 Continues on next page Product manual IRB 8700 541 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 6 3 Replacing the parallel rod Continued ...

Page 542: ...500001966 Preparations before refitting the parallel rod upper end Note Action xx1500002097 Remove the strap which was used to keep bearing thrust washer and cover washer in position 1 Continues on next page 542 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 6 3 Replacing the parallel rod Continued ...

Page 543: ...sol xx1500002100 Apply corrosion protection Mercasol on both sides of the bearings and on all ma chined surfaces on the parallel arm 4 xx1500002293 Apply some grease on shafts and in holes of both sides of parallel rod 5 Continues on next page Product manual IRB 8700 543 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 6 3 Replacing the parallel rod Continued ...

Page 544: ...od used as pro tection to prevent the rod from moving un expectedly during the procedure 3 xx1500001964 Right side Left side Cover washer Thrust washer Place the thrust washer and cover washer on either side of the bearing and make sure that they are correctly fitted Note Make sure that the washers are on the correct sides of the bearing 4 Continues on next page 544 Product manual IRB 8700 3HAC052...

Page 545: ...osition and reattach the two M10x50 screws against the parallel rod Note This is done to prevent the arm housing from being deformed when pressing the shaft and thereby making it more difficult to press the shaft in or out 6 Apply the press tool parts Assembly tool Press plate and Round plate 7 xx1700001307 Use caution and press the shaft in 8 xx1500001967 Refit the protection plug 9 Continues on ...

Page 546: ...calib ration manual enclosed with the calibration tools Recalibrate the robot 1 General calibration information is included in section Calibration on page 795 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 27 2 546 Product manual IRB 8700 3HAC052853 001 Revision F Copyri...

Page 547: ... be out of date See the latest revision of Product manual spare parts IRB 8700 on ABB Library Note Article number Color Spare part 3HAC048239 003 Graphite White Balancing device 3HAC048239 004 ABB Orange Balancing device Required tools and equipment Note Article number Equipment etc Mobile platform ladder Continues on next page Product manual IRB 8700 547 3HAC052853 001 Revision F Copyright 2015 2...

Page 548: ...g device Note Action xx1500002310 Jog the robot to calibration position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Unloading the pressure of the balancing device Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on nex...

Page 549: ...2303 Apply some Molykote on threads and at the bottom end of two fully threaded screws 4 Screws M16x80 fully threaded xx1500002309 Unload the pressure of the balancing device by inserting the screws Attach the screws until the screws reaches the piston Then alternately little by little attach the screws at least another five mil limeters The pressure is now unloaded 5 Screw M16x80 2 pcs Continues ...

Page 550: ...m ladder or similar to reach the upper end of the balancing device DANGER Do not use the robot as ladder 1 xx1500002308 Restore the pressure of the balancing device by unscrewing the two M16x80 screws alternately little by little 2 Remove the screws 3 Attachment screws M16x35 2 pcs xx1500001971 Refit the M16x35 screws in the holes on top of the balancing device 4 Continues on next page 550 Product...

Page 551: ...forming the first test run These are further detailed in the section First test run may cause injury or damage on page 27 1 Product manual IRB 8700 551 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 6 4 Unloading and restoring the balancing device Continued ...

Page 552: ...n be out of date See the latest revision of Product manual spare parts IRB 8700 on ABB Library Note Article number Color Spare part 3HAC048239 003 Graphite White Balancing device 3HAC048239 004 ABB Orange Balancing device Required tools and equipment Note Article number Equipment etc Mobile platform ladder Continues on next page 552 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 ...

Page 553: ...116 1 Locking liquid Molykote 1000 Removing the balancing device Use these procedures to remove the balancing device Robot position when replacing the balancing device Note Action xx1500002310 Jog the robot to calibration position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Continues on next page Pr...

Page 554: ...obot as ladder 2 xx1500001971 Remove the screws fitted in the screw holes on top of the balancing device Note Keep the screws They shall be refitted after the work is done 3 M16x35 Apply Molykote on colored areas xx1500002303 Apply some Molykote on threads and at the bottom end of two fully threaded screws 4 Screws M16x80 fully threaded Continues on next page 554 Product manual IRB 8700 3HAC052853...

Page 555: ... way 6 Removing the balancing device Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Mobile platform ladder xx1500001985 Use a Mobile platform ladder to reach the upper end of the balancing device DANGER Do not use the robot as a ladder 2 CAUTION The balancing device weights 200 kg All lifting accessories used must be sized a...

Page 556: ...00001973 Remove upper and lower KM nuts V rings and support rings 6 Crowbar small xx1500002735 Use caution and lift the balancing device off Tip If needed use a Crowbar small to care fully help pressing the balancing device out A suitable bearing puller is another al ternative 7 Continues on next page 556 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved...

Page 557: ...e same way 10 Refitting the balancing device Use these procedures to refit the balancing device Preparations before refitting the balancing device Note Action CAUTION The balancing device weighs 200 kg All lifting accessories used must be sized accordingly 1 Mobile platform ladder xx1500001985 Use a Mobile platform ladder or similar to reach the upper end of the balancing device DANGER Do not use ...

Page 558: ...xx1500002304 Apply some grease on shafts and in bear ing holes Note Do not apply any grease on the threads for the KM nut 6 Refitting the balancing device Note Action Mobile platform ladder xx1500001985 Use a Mobile platform ladder or similar to reach the upper end of the balancing device DANGER Do not use the robot as ladder 1 Continues on next page 558 Product manual IRB 8700 3HAC052853 001 Revi...

Page 559: ...ears before putting them on the shafts 3 xx1500001975 Make sure that the spacer ring with V ring and the support ring are placed correctly on the shafts before the balancing device is put on the shafts 4 Continues on next page Product manual IRB 8700 559 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 6 5 Replacing the balancing devices Continued ...

Page 560: ...re axially centered in the balancing device ears 7 Tightening torque 120 Nm xx1500001973 Secure the balancing device with the two lock nuts Note Make sure that the V ring and support ring is fitted correctly 8 Remove the lifting accessories 9 Continues on next page 560 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 6 5 Replacing the balanci...

Page 561: ...toring the pressure of the balancing device Note Action Mobile platform ladder xx1500001985 Use a Mobile platform ladder or similar to reach the upper end of the balancing device DANGER Do not use the robot as ladder 1 xx1500002308 Restore the pressure of the balancing device by unscrewing the two M16x80 screws alternately little by little 2 Remove the screws 3 Continues on next page Product manua...

Page 562: ...on tools Recalibrate the robot 1 General calibration information is included in section Calibration on page 795 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 27 2 562 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair ...

Page 563: ... be out of date See the latest revision of Product manual spare parts IRB 8700 on ABB Library Note Article number Color Spare part 3HAC058949 003 Graphite White Rotating AC motor including pinion 3HAC058949 004 ABB Orange Rotating AC motor including pinion Continues on next page Product manual IRB 8700 563 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 1 Replaci...

Page 564: ...ration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer e...

Page 565: ... supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 Disconnecting the motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws with washers and remove the motor cover 2 Continues on next page Product manual IRB 8700 565 3HAC...

Page 566: ...ng if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Removing the axis 1 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 566 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved ...

Page 567: ...ew the attachment screws and washers Use a bits extender to reach the screws 5 Guide pin M10x150 3HAC15521 2 Fit guide pins in opposite holes 6 Always use guide pins in pairs CAUTION Whenever parting mating motor pinion and hub the splines may be damaged if excess ive force is used 7 Removal tool M12 3HAC14631 1 If needed use removal tools to help re move the motor 8 Always use removal tools in pa...

Page 568: ... axis 1 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Remove old paint residues and other contamina tion from the contact surfaces on both motor and gearbox 2 Wipe clean the contact surfaces from any remain ing contamination 3 Also wipe clean the o ring groove Continues on next page 568 Product manual IRB 8700 3HAC052...

Page 569: ... groove Tip Lubricate the o ring with some grease for a better fitting in the groove 5 Flange sealant Loctite 574 xx1500002357 Apply flange sealant on the motor flange 6 Continues on next page Product manual IRB 8700 569 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 motor Continued ...

Page 570: ...cessory 3 Rotation tool 3HAC7887 1 Fit the rotation tool 4 Grease Castrol Molub Alloy 777 1 NG xx1500002346 Make sure that there is enough grease on the splines before fitting If not apply 1 gram of grease 5 Connect the 24 VDC power supply to re lease the brakes 6 To release the brakes connect the 24 VDC power supply as described in the list Connect to R2 MP1 connector pin 2 pin 5 Continues on nex...

Page 571: ...he correct way 8 Lifting accessory motor 3HAC14459 1 xx1500002084 Bits extender 3HAC12342 1 Secure the motor with its attachment screws and washers 9 Tightening torque 50 Nm Use a bits extender to reach the screws Screws M10x40 quality 12 9 Gleitmo 4 pcs xx1500002083 See Performing a leak down test on page 184 Perform a leak down test if not already done 10 Disconnect the 24 VDC power supply 11 Co...

Page 572: ...t the cable gland cover Note Replace the gasket if damaged 2 xx1200001066 Connect the motor cables Connect in accordance with the markings on the connectors 3 Continues on next page 572 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 motor Continued ...

Page 573: ...hment screws Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Concluding procedure Note Action Axis Calibration is described in Calibrating with Axis Calibration method on page 805 Recalibrate the robot 1 General calibration information is included in section Calibratio...

Page 574: ...rming the first test run These are further described in the section First test run may cause injury or damage on page 27 2 574 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 motor Continued ...

Page 575: ...ble can be out of date See the latest revision of Product manual spare parts IRB 8700 on ABB Library Note Article number Color Spare part 3HAC058949 003 Graphite White Rotating AC motor including pinion 3HAC058949 004 ABB Orange Rotating AC motor including pinion Continues on next page Product manual IRB 8700 575 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 2 ...

Page 576: ...outine is chosen action might be required prior to beginning the repair work of the robot see the table Note Action Decide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions g...

Page 577: ... the plug is accessible 2 Lock screw quality 12 9 M20x150 Valid for replacement of the axis 2 motor 3 Tightening torque 100 Nm xx1500002322 Insert the lock screw through the frame and into the hole in the lower arm to secure the weight of the lower arm If needed adjust the position of axis 2 to make it possible to insert the lock screw Note Tighten the lock screw manually No tools needed DANGER Fa...

Page 578: ... to secure the weight of the parallel arm If needed adjust the position of axis 3 to make it possible to insert the lock screw Note Tighten the lock screw manually No tools needed DANGER Failure to secure the weight of the parallel arm will cause the parallel arm to fall when the brakes of the axis 3 motor are released xx1500002085 Jog the robot to the calibration position 6 Continues on next page...

Page 579: ...motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 xx1200001070 Make sure the o ring is present 3 Continues on next page Product manual IRB 8700 579 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 2...

Page 580: ... Action DANGER When releasing the holding brakes of the motor the lower arm and or the parallel arm will move and may fall down Before continuing make sure the lower arm and or parallel arm are secured with lock screws 1 To release the brake connect the 24 VDC power supply to the motor in question 2 Connect to connector R2 MP2 axis 2 mo tor or R2 MP3 axis 3 motor pin 2 24V pin 5 0V Continues on ne...

Page 581: ...the motor out of position by using the removal tool in opposite holes of the motor 6 CAUTION The motor weighs 27 kg All lifting accessories used must be sized accordingly 7 Lifting accessory motor 3HAC15534 1 Attach the lifting accessory 8 xx1500002325 Use caution and lift the motor out on the guide pins in order to get the pinion away from the hub Let the motor rest on the guide pins 9 Disconnect...

Page 582: ...pressure are turned off 1 Remove old paint residues and other contamina tion from the contact surfaces on both motor and gearbox 2 Wipe clean the contact surfaces from any remain ing contamination 3 Also wipe clean the o ring groove O ring 3HAB3772 107 xx1200001019 Inspect the o ring Note Replace if damaged 4 Continues on next page 582 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 20...

Page 583: ... the motor is a new spare part remove the cover 7 Securing the motor Note Action Guide pin M10x150 3HAC15521 2 Fit guide pins in opposite holes 1 Always use guide pins in pairs CAUTION The motor weighs 27 kg All lifting accessories used must be sized accordingly 2 Continues on next page Product manual IRB 8700 583 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 2...

Page 584: ...ve the lifting accessory and allow the motor to rest on the guide pins 7 Rotation tool 3HAC7887 1 Apply the rotation tool and use it to rotate the pinion when mating it into the gear 8 Valid for the axis 2 motor 9 To release the brakes connect the 24 VDC power supply Connect to connector R2 MP2 axis 2 mo tor pin 2 24V pin 5 0V Valid for the axis 3 motor 10 To release the brakes connect the 24 VDC ...

Page 585: ...he cable exit is facing the correct way 12 Screw dimension M10x40 quality 12 9 Gleitmo 4 pcs Fit two of the attachment screws 13 Remove the guide pins and replace with the remaining attachment screws 14 Bits extender 3HAC12342 1 Secure the motor with its attachment screws and washers 15 Tightening torque 50 Nm Use a bits extender in order to reach the screws Screw dimension M10x40 quality 12 9 Gle...

Page 586: ...it the cable gland cover Note Replace the gasket if damaged 2 xx1200001066 Connect the motor cables Connect in accordance with the markings on the connectors 3 Continues on next page 586 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 2 Replacing the axis 2 and axis 3 motors Continued ...

Page 587: ...e that none of the cables inside will be dam aged 7 Attachment screws M5x12 8 8 7 pcs xx1200001135 Refit the motor cover with its attachment screws Note Do not reuse the self threading attachment screws Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Continues on next ...

Page 588: ...tic plug in lower arm 2 xx1500002321 Valid for replacement of the axis 3 motor Use caution and jog axis 3 until it is pos sible to remove the lock screw 3 xx1500002365 Valid for replacement of the axis 3 motor Refit the plastic plug in parallel arm 4 Continues on next page 588 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 2 Replacing the...

Page 589: ...ction Calibration on page 795 DANGER Make sure all safety requirements are met when performing the first test run These are further described in the section First test run may cause injury or damage on page 27 6 Product manual IRB 8700 589 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 2 Replacing the axis 2 and axis 3 motors Continued ...

Page 590: ...n the table can be out of date See the latest revision of Product manual spare parts IRB 8700 on ABB Library Note Article number Spare part 3HAC058950 003 Graphite White 3HAC049837 003 ABB Orange Rotating AC motor including pinion Continues on next page 590 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 3 Replacing the axis 4 motor ...

Page 591: ...ecide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibr...

Page 592: ...c power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 Disconnecting the axis 4 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 Continues on next page 592 Product manual ...

Page 593: ... hole is facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Removing the axis 4 motor Note Action CAUTION Use caution when releasing the brakes Axis 4 can move unexpectedly 1 Continues on next page Product manual IRB 8700 593 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 3 Repl...

Page 594: ... gear box the gears may be damaged if excess ive force is used 5 Removal tool M12 3HAC14631 1 Press the motor out of position by fitting the removal tool in the remaining attach ment holes for the motor 6 Always use removal tools in pairs CAUTION The motor weighs 27 kg All lifting accessories used must be sized accordingly 7 Lifting accessory motor 3HAC15534 1 Attach the lifting accessory 8 Discon...

Page 595: ...c pressure and air pressure are turned off 1 Remove old paint residues and other contamina tion from the contact surfaces on both motor and gearbox 2 Wipe clean the contact surfaces from any remain ing contamination 3 Also wipe clean the o ring groove O ring 3HAB3772 107 xx1200001019 Make sure the o ring is undamaged Note Replace if damaged 4 Continues on next page Product manual IRB 8700 595 3HAC...

Page 596: ... spare part remove the cover 7 Securing the axis 4 motor Note Action Guide pin M10x150 3HAC15521 2 Apply two guide pins in opposite holes 1 Always use guide pins in pairs Lifting accessory motor 3HAC15534 1 CAUTION The motor weighs 27 kg All lifting accessories used must be sized accordingly 2 Continues on next page 596 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All ...

Page 597: ...nect the 24 VDC power supply 8 Connect to connector R2 MP2 pin 2 24V pin 5 0V CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 9 Push the motor carefully in position while at the same time the motor pinion is slightly rotated Make sure that the motor pinion is properly mated into the hub Make sure that the motor pinion does not get damaged Mak...

Page 598: ...s xx1600000064 Disconnect the 24 VDC power supply 13 Connecting the axis 4 motor cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 xx1200001067 Refit the cable gland cover Note Replace the gasket if damaged 2 Continues on next page 598 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 3 Replacing the axi...

Page 599: ... ring axis 4 3HAC054692 002 xx1200001070 Wipe clean o ring and o ring groove 5 Refit the o ring Tip Lubricate the o ring with some grease for a better fitting in the groove 6 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 7 Continues on next page Product manual IRB 8700 599 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repai...

Page 600: ...luding procedure Note Action Axis Calibration is described in Calibrating with Axis Calibration method on page 805 Recalibrate the robot 1 General calibration information is included in section Calibration on page 795 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 27 2 6...

Page 601: ...8949 003 Graphite White Rotating AC motor including pinion 3HAC058949 004 ABB Orange Rotating AC motor including pinion Required tools and equipment Note Article number Equipment etc 3HAC14459 1 Lifting accessory Axis 1 mo tor Used to release the motor brakes 24 VDC power supply 300 mm bits 1 2 3HAC12342 1 Bits extender Always use guide pins in pairs 3HAC15521 2 Guide pin M10x150 Continues on next...

Page 602: ...instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Re...

Page 603: ... the robot before entering the robot working area 3 Retrieving access to the wrist cabling Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1500003100 Remove the wrist cover Note Do not damage the sealing Replace if damaged Note The position of axis 4 depends on the on going procedure 2 xx1500002330 Continues on next page Pr...

Page 604: ...that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws with washers and remove the motor cover 2 Continues on next page 604 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 4 Replacing the axis 5 motor Continued ...

Page 605: ...ver Tip Make a note in which direction the cable exit hole is facing if the motor shall be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Continues on next page Product manual IRB 8700 605 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 4 Replacing the axis 5 motor Continued ...

Page 606: ...e the motor using a bits extender 3 CAUTION Whenever parting mating motor pinion and hub the splines may be damaged if excess ive force is used 4 Removal tool M12 If needed fit removal tools in opposite holes 5 CAUTION The motor weighs 27 kg All lifting accessories used must be sized accordingly 6 Lifting accessory motor 3HAC14459 1 Attach the lifting accessory to the motor 7 Continues on next pag...

Page 607: ...ions before refitting the axis 5 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 8700 607 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 4 Replacing the axis 5 motor Continued ...

Page 608: ...07 Make sure the o ring is undamaged Note Replace if damaged 3 Lubricate the o ring with some grease 4 xx1200001020 Make sure the o ring is seated in the groove 5 Continues on next page 608 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 4 Replacing the axis 5 motor Continued ...

Page 609: ...AC7887 1 Attach the rotation tool and use it to rotate the pinion when mating it into the gear 2 24 VDC power supply To release the brakes connect the 24 VDC power supply 3 Connect to connector R2 MP5 pin 2 24V pin 5 0V CAUTION The motor weighs 27 kg All lifting accessories used must be sized accordingly 4 Attach the lifting accessory and lift the motor up 5 Continues on next page Product manual I...

Page 610: ... posi tion on the guide pins while at the same time rotating the motor pinion slightly Make sure that the motor pinion is properly mated into the hub the motor pinion does not get dam aged the direction of the cable exit is fa cing the correct way 7 xx1200001018 Remove the guide pins 8 Continues on next page 610 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights r...

Page 611: ...uality 12 9 Gleitmo 4 pcs xx1200001017 Disconnect the 24 VDC power supply 10 Connecting the axis 5 motor cables Note Action xx1500002717 Push the motor cables in through the cable gland opening 1 Continues on next page Product manual IRB 8700 611 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 4 Replacing the axis 5 motor Continued ...

Page 612: ...the markings on the connectors 3 O ring 3HAC054692 002 xx1200001070 Inspect the o ring Note Replace if damaged 4 CAUTION When refitting the motor cover make sure that none of the cables inside will be dam aged 5 Continues on next page 612 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 4 Replacing the axis 5 motor Continued ...

Page 613: ... cover is tightly sealed 7 Concluding procedure Note Action xx1600000046 Make sure the contact surface on the wrist cover is undamaged 1 Loctite 574 xx1600000048 Apply flange sealant Loctite 574 on the wrist cover flange 2 Place the cable harness in a way so it will not be damaged when the wrist cover is fitted 3 Continues on next page Product manual IRB 8700 613 3HAC052853 001 Revision F Copyrigh...

Page 614: ...ge 805 Recalibrate the robot 5 General calibration information is included in section Calibration on page 795 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 27 6 614 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 ...

Page 615: ...ber Spare part 3HAC058951 003 Graphite White 3HAC049875 004 ABB Orange Rotating AC motor including pinion Required tools and equipment Note Article number Equipment etc Used to release the motor brakes 24 VDC power supply Used to push out the motor if neces sary Removal tool M10 Content is defined in section Standard toolkit on page 833 Standard toolkit Continues on next page Product manual IRB 87...

Page 616: ...he robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 806 If no...

Page 617: ...obot before entering the robot working area 3 Retrieving access to the wrist cabling Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1500003100 Remove the wrist cover Note Do not damage the sealing Replace if damaged Note The position of axis 4 depends on the on going procedure 2 xx1500002330 Continues on next page Product ...

Page 618: ...draulic pressure and air pressure are turned off 1 Make sure that the axis 5 is as close to 90 or 90 position as possible depend ing on what repair work is being done Note Not needed if only replacing the axis 6 unit 2 Continues on next page 618 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis 6 motor Continued ...

Page 619: ...ket Replace if damaged 3 xx1300000488 Disconnect the motor cables 4 xx1300000484 Unscrew the attachment screws holding the cable bracket 5 Continues on next page Product manual IRB 8700 619 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis 6 motor Continued ...

Page 620: ...ion and pull out the axis 6 motor cables by holding the cables at the motor with one hand and the other one at the carrier 8 Removing the axis 6 motor Note Action 24 VDC power supply To release the brakes connect the 24 VDC power supply 1 Connect to R2 MP6 connector pin 2 24V pin 5 0V Continues on next page 620 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights re...

Page 621: ...n by fitting the removal tool to the attach ment holes of the motor 4 CAUTION The motor weighs 14 kg 5 xx1500003098 Remove the motor by lifting it straight up from the gear Make sure the motor pinion is not dam aged 6 Disconnect the 24 VDC power supply 7 Continues on next page Product manual IRB 8700 621 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 5 Replacing...

Page 622: ...r and gearbox 11 Wipe clean the contact surfaces from any remain ing contamination 12 Also wipe clean the o ring groove O ring 3HAB3772 107 xx1200001019 Make sure the o ring is undamaged Replace if damaged 13 xx1200001020 Make sure the o ring is seated in the groove Tip Lubricate the o ring with some grease for a better fitting in the groove 14 Continues on next page 622 Product manual IRB 8700 3H...

Page 623: ... 90 or as close as possible for a correct installation of the cable harness spiral in the wrist If not connect the 24 VDC power supply release the brakes and move axis 5 manu ally to 90 1 xx1500003099 Use caution and push the cable harness in through the wrist recess 2 Continues on next page Product manual IRB 8700 623 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair ...

Page 624: ... Note The M4 screw is located at the bottom of the carrier Tip The M4 screw may be difficult to fit Make sure the carrier is level and completely pressed against the bottom 4 Attachment screws M6x12 2 pcs xx1300000484 Secure the cable bracket 5 Continues on next page 624 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis ...

Page 625: ... R2 MP6 pin 2 24V pin 5 0V Grease Castrol Molub Alloy 777 1 NG xx1500002346 Make sure that there is enough grease on the splines before fitting If not apply 1 gram of grease 3 CAUTION Whenever parting mating motor pinion and hub the splines may be damaged if excess ive force is used 4 Continues on next page Product manual IRB 8700 625 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights re...

Page 626: ... into its mounting position while at the same time pushing the motor cables in through the cable gland recess Make sure the motor pinion is properly mated into the hub Make sure the motor pinion is not dam aged 7 Continues on next page 626 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis 6 motor Continued ...

Page 627: ...axis 6 motor cables step 2 Note Action xx1300000488 Reconnect the the axis 6 motor connectors Note Place the resolver cable underneath the motor cable 1 xx1500003095 Make sure the gasket on the motor cover is undamaged Note Replace if damaged 2 Continues on next page Product manual IRB 8700 627 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis ...

Page 628: ...ket with a cable tie Note The position of axis 4 depends on the on going procedure 5 xx1500002331 Remove all residues of old sealant and other contamination from the wrist cover contact surfaces 6 Flange sealant Loctite 574 Apply flange sealant Loctite 574 on the wrist cover flange 7 Continues on next page 628 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights res...

Page 629: ...ibed in Calibrating with Axis Calibration method on page 805 Recalibrate the robot 1 General calibration information is included in section Calibration on page 795 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 27 2 Product manual IRB 8700 629 3HAC052853 001 Revision F C...

Page 630: ...e listed in the table can be out of date See the latest revision of Product manual spare parts IRB 8700 on ABB Library Note Article number Spare part 3HAC049795 003 Hub with pinion Required tools and equipment Note Article number Equipment etc 2 pcs Fully threaded Used as removal tools when removing the hub 2 pcs Screw M6x110 Content is defined in section Standard toolkit on page 833 2 pcs Standar...

Page 631: ...xes Axis 6 Axis 5 Axis 4 Axis 3 Axis 2 Axis 1 4 pcs 6 pcs 4 pcs 8 pcs 8 pcs 6 pcs Pinion on the hub There are three different pinions on the hub Pinion axis 5 Pinion axis 4 and axis 6 Pinion axis 1 axis 2 and ax is 3 xx1500002978 xx1500002977 xx1500002976 Removing the hub Use these procedures to remove the hub Preparations before removing the hub Note Action DANGER Turn off all electric power supp...

Page 632: ...estion 3 Removing the hub Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1500002038 Unscrew the M6x30 hex socket head cap screws that secure the hub Note Do not remove the M6x16 torx pan head screws 2 CAUTION Whenever parting mating the hub pinion and gearbox the gears may be damaged if excessive force is used 3 Continues ...

Page 633: ...ully 5 Refitting the hub Use these procedures to refit the hub Preparations before refitting the hub Note Action Wipe the hub clean 1 Inspect the hole where the hub shall be refitted Wipe clean if needed 2 Continues on next page Product manual IRB 8700 633 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 1 Replacing the hub Continued ...

Page 634: ...amine the pinion and the splines in the hub for damages 5 Grease Castrol Molub Alloy 777 1 NG xx1500002346 Make sure that there is enough grease on the splines before fitting If not apply 1 gram of grease 6 Continues on next page 634 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 1 Replacing the hub Continued ...

Page 635: ...chment screws M6x30 12 9 Remove the two M6x110 and fit the attach ment screws for the hub 4 Loctite 243 Apply locking liquid Loctite 243 on the screws Note The number of attachment screws differ depending on gearbox Quantity Axis 1 6 pcs Axis 2 8 pcs Axis 3 8 pcs Axis 4 4 pcs Axis 5 6 pcs Axis 6 4 pcs Tightening torque 14 Nm Secure the hub 5 Continues on next page Product manual IRB 8700 635 3HAC0...

Page 636: ...libration is described in Calibrating with Axis Calibration method on page 805 Re calibrate the robot 4 General calibration information is included in section Calibration on page 795 DANGER Make sure all safety requirements are met when performing the first test run These are further described in First test run may cause injury or damage on page 27 5 636 Product manual IRB 8700 3HAC052853 001 Revi...

Page 637: ...rt numbers that are listed in the table can be out of date See the latest revision of Product manual spare parts IRB 8700 on ABB Library Note Article number Spare part 3HAC048963 002 Reduction gear RV 700CS Continues on next page Product manual IRB 8700 637 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox ...

Page 638: ...15521 2 Guide pin M10x150 Used to push out the motor if neces sary Always use removal tools in pairs 3HAC14631 1 Removal tool M12 2 pcs Fully threaded Used as removal tools when removing the hub Screw M6x110 Always use guide pins in pairs 3HAC Guide pin M16x300 M16 3HAC14457 4 Lifting eye Nova Torque Torque Multiplier Always use guide pins in pairs 3HAC13120 3 Guide pin M16x200 Always use guide pi...

Page 639: ...ues These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 806 If no previous reference values exist and no new reference values can be created then reference calibration is not possible If the ro...

Page 640: ...he robot working area 2 Removing the mechanical stop pin Note Action CAUTION The mechanical stop pin weighs 13 kg 1 xx1500002091 Put a piece of wood or similar underneath the stop pin to prevent it from falling down uncontrolled when the set screw is re moved 2 Take a firm grip on the stop pin with one hand 3 Continues on next page 640 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 20...

Page 641: ...the piece of wood or similar with the other hand 5 xx1500002089 Remove the stop pin by sliding it down out off its hole and moving it slightly forwards 6 Continues on next page Product manual IRB 8700 641 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Continued ...

Page 642: ... accessories used must be sized accordingly 2 A xx1400002590 A Lifting eye M24 4 pcs Fit two lifting eyes to the holes in the frame and two lifting eyes to the holes in the counter weight DANGER Never use the robot as ladder Use a Mobile platform ladder or similar to reach 3 Continues on next page 642 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 R...

Page 643: ... eyes have sharp edges that might damage the roundslings lifting shackles must be used to attach the roundslings to the lifting eyes Make sure the roundslings do not rub against any sharp edges xx1700000969 A Lifting chains with shortener 2 pcs B Roundsling 2 m Lifting capacity 2 000 kg 2 pcs C Lifting eye M24 3HAC038295 003 4 pcs Stretch the lifting accessories to take the weight of the robot 5 C...

Page 644: ...ent screws 4 Tightening torque 325 Nm Use caution and lower the robot slowly down onto the supporting pillars making sure the holes in robot base will match the holes in the pillars 5 Follow user instructions enclosed with the pillars Secure the base to the supporting pillars with the robot attachment screws 6 Tightening torque 325 Nm xx1700000928 Disconnecting the cable harness in the base Note A...

Page 645: ...rench xx1500003084 Disconnect R1 SMB Tip Use a Sparkplug wrench or similar xx1200000888 4 xx1500003085 Remove the two earth cables 5 Continues on next page Product manual IRB 8700 645 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Continued ...

Page 646: ...xis 1 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws with washers and remove the motor cover 2 Continues on next page 646 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Continued ...

Page 647: ...t hole is facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Removing the axis 1 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 8700 647 3HAC052853 001 Revision F Copyright 2015 2018 ABB All ri...

Page 648: ...w the attachment screws and washers Use a bits extender to reach the screws 5 Guide pin M10x150 3HAC15521 2 Fit guide pins in opposite holes 6 Always use guide pins in pairs CAUTION Whenever parting mating motor pinion and hub the splines may be damaged if excess ive force is used 7 Removal tool M12 3HAC14631 1 If needed use removal tools to help re move the motor 8 Always use removal tools in pai...

Page 649: ... electrical power hydraulic pressure and air pressure are turned off 1 xx1500002038 Unscrew the M6x30 hex socket head cap screws that secure the hub Note Do not remove the M6x16 torx pan head screws 2 CAUTION Whenever parting mating the hub pinion and gearbox the gears may be damaged if excessive force is used 3 Continues on next page Product manual IRB 8700 649 3HAC052853 001 Revision F Copyright...

Page 650: ...2326 Lift out the hub carefully 5 Separating base including gearbox from the arm system Note Action xx1500003118 Remove the plastic plugs covering the M16x110 screws 1 Continues on next page 650 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Continued ...

Page 651: ...n place and making sure the bit is correctly fitted Person two working beside the ro bot working with the torque wrench 3 Make sure that all screws have been re moved and that the lifting accessories are fastened correctly 4 Lifting the complete arm system off Note Action xx1700000930 Prepare an area where to put down the arm system after removal Use for example two wooden planks on which the flan...

Page 652: ...ing is still fitted to the frame and the axis 1 gearbox is still fitted to the base xx1500003121 Use caution and lift the complete arm sys tem up Note Lifting height needed for the complete arm system to go free from the axis 1 gearbox 4 m 4 Remove the guide pins before the arm system is put down 5 Continues on next page 652 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB...

Page 653: ...he lifting ac cessories are removed 7 Removing the axis 1 gearbox Note Action Lifting eye M16 3HAC14457 4 2 pcs Fit lifting eyes in opposite holes Note Do not tighten the lifting eyes completely against the gearbox Leave a 5 mm gap or the sealing surface on the gearbox will be damaged 1 CAUTION The gearbox weighs 150 kg All lifting accessories used must be sized accordingly 2 Attach the lifting ac...

Page 654: ... and the torque wrench to facilitate the re moval 5 xx1500003123 Use caution and lift the gearbox off 6 xx1500003124 Make sure not to loose the small o ring between base and gearbox 7 Continues on next page 654 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Continued ...

Page 655: ...ting accessory chain to the axis 1 gearbox 3 Stretch the lifting chain and lift the axis 1 gearbox up 4 Remove old residues of sealant and other contamination from the axis 1 gearbox and base DANGER Let only one hand stay underneath the hanging gearbox while cleaning 5 Clean the contact surfaces between gear box and base DANGER Let only one hand stay underneath the hanging gearbox while cleaning 6...

Page 656: ... guide pins 6 Attachment screws M20x60 12 9 Gleitmo xx1500003122 Attach the 16 of the 18 attachment screws that will secure the gearbox to the base Tip This procedure is best done with two per sons working together Person one working under the base holding the torque wrench in place making sure the bit is correctly fitted Person two working beside the ro bot working with the torque wrench 7 Remove...

Page 657: ...Tightening torque step 2 450 Nm Torque Multiplier xx1500003127 Attaching lifting accessories complete arm system If the lifting accessories have been removed from the arm system refit them accordingly Note Action CAUTION The complete armsystem weighs 4 300 kg All lifting accessories used must be sized accordingly 1 Continues on next page Product manual IRB 8700 657 3HAC052853 001 Revision F Copyri...

Page 658: ...ave sharp edges that might damage the roundslings lifting shackles must be used to attach the roundslings to the lifting eyes Make sure the roundslings do not rub against any sharp edges xx1700000969 A Lifting chains with shortener 2 pcs B Roundsling 2 m Lifting capacity 2 000 kg 2 pcs C Lifting eye M24 3HAC038295 003 4 pcs Stretch the lifting accessories and adjust if needed to make the lift leve...

Page 659: ...ed must be sized accordingly 3 Use caution and lift the complete arm sys tem up 4 Clean contact surfaces between base in cluding gearbox cross roller bearing and frame DANGER Let only one hand stay underneath the hanging gearbox while cleaning 5 Flange sealant Loctite 574 xx1600000045 Apply flange sealant Loctite 574 on the sealing surface for the cross roller bearing on the base 6 Continues on ne...

Page 660: ...er bearing One of the guide pins shall be matched against the hole closest to the small dowel pin in the bas 7 xx1700000933 Continues on next page 660 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Continued ...

Page 661: ...e guide pins 9 Securing the complete arm system to base and axis 1 gearbox Note Action Attachment screws M16x70 12 9 Gleitmo 18 pcs xx1500003120 Attach the screws that hold the cross roller bearing to the frame Do not tighten yet Tip This procedure is best done with two per sons working together Person one working under the base holding the torque wrench in place making sure the bit is correctly f...

Page 662: ...be very difficult to reach Using a magnet will probably be the only way to get hold of the lost screw 3 Attachment screws M16x110 12 9 Gleitmo 18 pcs xx1500003119 Fit the attachment screws that hold the gearbox to the frame Do not tighten yet Tip This procedure is best done with two per sons working together Person one working under the base holding the torque wrench in place making sure the bit i...

Page 663: ...ng of the screws 6 Tightening torque step 2 300 Nm xx1600000040 xx1500003118 Refit the plastic plugs 7 xx1700000934 Refit the cable bracket inside the frame 8 Preparations before refitting the hub Note Action Wipe the hub clean 1 Inspect the hole where the hub shall be refitted Wipe clean if needed 2 Continues on next page Product manual IRB 8700 663 3HAC052853 001 Revision F Copyright 2015 2018 A...

Page 664: ...the pinion and the splines in the hub for damages 5 Grease Castrol Molub Alloy 777 1 NG xx1500002346 Make sure that there is enough grease on the splines before fitting If not apply 1 gram of grease 6 Continues on next page 664 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Continued ...

Page 665: ...t screws M6x30 12 9 Remove the two M6x110 and fit the attach ment screws for the hub 4 Loctite 243 Apply locking liquid Loctite 243 on the screws Note The number of attachment screws differ depending on gearbox Quantity Axis 1 6 pcs Axis 2 8 pcs Axis 3 8 pcs Axis 4 4 pcs Axis 5 6 pcs Axis 6 4 pcs Tightening torque 14 Nm Secure the hub 5 Continues on next page Product manual IRB 8700 665 3HAC052853...

Page 666: ...e contact surfaces on both motor and gearbox 2 Wipe clean the contact surfaces from any remain ing contamination 3 Also wipe clean the o ring groove O ring 3HAB3772 107 xx1200001019 Inspect the o ring Note Replace if damaged 4 xx1200001020 Make sure the o ring is seated in the groove Tip Lubricate the o ring with some grease for a better fitting in the groove 5 Continues on next page 666 Product m...

Page 667: ...de pins in opposite holes 1 Always use guide pins in pairs CAUTION The motor weighs 27 kg All lifting accessories used must be sized accordingly 2 Lifting accessory motor 3HAC14459 1 Apply the lifting accessory 3 Rotation tool 3HAC7887 1 Fit the rotation tool 4 Continues on next page Product manual IRB 8700 667 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 2 Re...

Page 668: ...ng motor pinion and hub the splines may be damaged if excess ive force is used 7 Lifting accessory chain 3HAC15556 1 Lower the motor into position Make sure that the motor pinion is properly mated into the hub Make sure that the motor pinion does not get damaged Make sure that the direction of the cable gland exit is facing the correct way 8 Lifting accessory motor 3HAC14459 1 xx1500002084 Continu...

Page 669: ...if not already done 10 Disconnect the 24 VDC power supply 11 Attaching lifting accessories complete robot If the lifting accessories have been removed from the arm system refit them accordingly Note Action CAUTION The complete armsystem weighs 4 300 kg All lifting accessories used must be sized accordingly 1 Continues on next page Product manual IRB 8700 669 3HAC052853 001 Revision F Copyright 201...

Page 670: ...ead crane CAUTION If the lifting eyes have sharp edges that might damage the roundslings lifting shackles must be used to attach the roundslings to the lifting eyes Make sure the roundslings do not rub against any sharp edges xx1700000969 A Lifting chains with shortener 2 pcs B Roundsling 2 m Lifting capacity 2 000 kg 2 pcs C Lifting eye M24 3HAC038295 003 4 pcs Continues on next page 670 Product ...

Page 671: ...lars 2 Unscrew the attachment screws that secure the supporting pillars to the foundation 3 Remove the supporting pillars 4 Screws M24 x 100 12 pcs 8 8 Lower the robot onto the foundation and secure 5 Washers 4 mm flat washer Tightening torque 550 Nm screws lubricated with Molykote 1000 600 725 Nm typical 650 Nm screws none or lightly lubricated Refitting the cable harness in the base Note Action ...

Page 672: ...s from the axis 1 bracket runs untangled to all connection points down through the hole in the frame to the base plate to the axis 1 motor to the axis 2 motor to the axis 3 motor to the SMB BU recess Adjust the cables if needed The different cables must not be twisted or tangled Do not fasten the axis 1 bracket yet 4 A B xx1600000078 A Bar code B Hole for pin 1 Before refitting the R1 MP A and R1 ...

Page 673: ... R1 MP cables through the base 7 Sparkplug wrench xx1500003084 Refit the R1 SMB cable with the large re cess pointing upwards to the right Tip Use a Sparkplug wrench or similar xx1200000888 8 Attachment screw M6x16 stainless steel A2 70 xx1500003085 Refit the two earth cables 9 Continues on next page Product manual IRB 8700 673 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved ...

Page 674: ...he cable gland cover Note Replace the gasket if damaged 2 xx1200001066 Connect the motor cables Connect in accordance with the markings on the connectors 3 Continues on next page 674 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Continued ...

Page 675: ...5 Refit the motor cover with its attachment screws Note Do not reuse the self threading attachment screws Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Continues on next page Product manual IRB 8700 675 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights res...

Page 676: ...osition 1 Clean the stop pin as well as the hole for it 2 Corrosion protection Mercasol xx1500002094 Apply corrosion protection on the marked area on the stop pin and on the matching area in the hole 3 CAUTION The mechanical stop pin weighs 13 kg 4 Continues on next page 676 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing the a...

Page 677: ...anical stop pin Tip Use caution and move the stop pin a little up and down while at the same time care fully fitting the set screw making sure that the screw will secure the stop pin in the groove 7 Tightening torque 35 Nm Secure the mechanical stop pin with the set screw 8 Concluding procedure Note Action See Changing oil axis 1 gearbox on page 141 Refill oil in the gearbox 1 Continues on next pa...

Page 678: ...mation is included in section Calibration on page 795 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 27 4 678 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Continued ...

Page 679: ...isted in the table can be out of date See the latest revision of Product manual spare parts IRB 8700 on ABB Library Note Article number Spare part 3HAC048392 003 Reduction gear RV 900N incl input gear 3HAC052423 001 Sealing ring Continues on next page Product manual IRB 8700 679 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox ...

Page 680: ...e axis 2 or axis 3 gear box in out 3HAC059801 001 Mounting set gear axis 2 and 3 Mobile platform ladder Lifting capacity 2 000 kg Roundsling 2 m Lifting capacity 2 000 kg Roundsling 2 5 m M16 3HAC14457 4 Lifting eye M24 3HAC038295 003 Lifting eye Used to rotate the motor pinion 3HAC7887 1 Rotation tool Content is defined in section Standard toolkit on page 833 Standard toolkit Required consumables...

Page 681: ...n page 806 If no previous reference values exist and no new reference values can be created then reference calibration is not possible If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the gearbox Use these procedures to remove the axis 2 gearbox DANGER Never remove both the axis 2 and axis 3 gearboxes at the same ...

Page 682: ...ox to the lower arm is reversed area 3 then area 2 and last area 1 Robot position when removing screws in area 1 With the robot in this position it is possible to reach the screws in area 1 of screws that secure the axis 2 gearbox to the lower arm Note Action Jog the robot to the specified position Axis 1 no significance as long as the robot is secured to the founda tion Axis 2 0 Axis 3 66 Axis 4 ...

Page 683: ...me One side must always be attached when the gearbox on the other side is removed If not there is a potential risk that a severe accident will happen 1 1 2 3 1 2 3 xx1500002975 Find area 1 Note Do not remove screws in area 2 or area 3 at this point 2 xx1500003110 Remove the screws in area 1 3 Preparations before jogging the robot into calibration position Note Action Turn the power to the robot on...

Page 684: ...ock screw hole Note Keep the plastic plugs It shall be refitted after the work is done 3 xx1500002335 xx1500002367 Jog axis 3 to the area shown in the figure 4 Continues on next page 684 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Continued ...

Page 685: ...o axis 2 and axis 3 Note Action xx1500002310 Jog the robot to calibration position 1 Tightening torque 100 Nm Secure the axis 2 with a lock screw 2 Lock screw quality 12 9 M20x150 xx1500002322 Continues on next page Product manual IRB 8700 685 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Continued ...

Page 686: ... 24 VDC power supply Release the brakes on axis 3 using the brake release button and let the axis rest on the lock screw 5 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 6 Continues on next page 686 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 3...

Page 687: ...GER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Mobile platform ladder xx1500001985 Use a Mobile platform ladder or similar to reach the upper end of the balancing device DANGER Do not use the robot as ladder 2 Continues on next page Product manual IRB 8700 687 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4...

Page 688: ... screws until the screws reaches the piston Then alternately little by little attach the screws at least another five mil limeters The pressure is now unloaded 5 Screw M16x80 2 pcs In a procedure where both balancing devices shall be removed unload the pressure of the other in the same way 6 Disconnecting the axis 2 motor cables Note Action DANGER Make sure that all supplies for electrical power h...

Page 689: ...he motor cover 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page Product manual IRB 8700 689 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Continued ...

Page 690: ...ing make sure the lower arm and or parallel arm are secured with lock screws 1 To release the brake connect the 24 VDC power supply to the motor in question 2 Connect to connector R2 MP2 axis 2 mo tor or R2 MP3 axis 3 motor pin 2 24V pin 5 0V Bits extender 3HAC12342 1 xx1500002323 Remove the attachment screws that secure the motor Tip Use a bits extender in order to reach the screws 3 Guide pin M1...

Page 691: ...accessory 8 xx1500002325 Use caution and lift the motor out on the guide pins in order to get the pinion away from the hub Let the motor rest on the guide pins 9 Disconnect the 24 VDC power supply 10 xx1500002324 Use caution and remove the motor by slid ing it out on the guide pins 11 Removing the hub Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pr...

Page 692: ...arbox the gears may be damaged if excessive force is used 3 Attachment screws M6x110 2 pcs xx1500002081 Fit two screws in opposite holes of the hub and use them as removal tools 4 xx1500002326 Lift out the hub carefully 5 Continues on next page 692 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Continued ...

Page 693: ...te hole below the present ones 1 Always use guide pins in pairs xx1500002336 1 2 3 1 2 3 xx1500002975 Find area 2 2 xx1500003111 Remove the attachment screws in area 2 3 Continues on next page Product manual IRB 8700 693 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Continued ...

Page 694: ...ide pins in pairs xx1700000935 Removing the axis 2 gearbox from the lower arm step 3 screws in area 3 Note Action 1 2 3 1 2 3 xx1500002975 Find area 3 1 xx1500003112 Remove the attachment screws that secure the gearbox to the lower arm in area 3 2 Continues on next page 694 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 3 Replacing the ax...

Page 695: ...nt screws 22 pcs and the six hole washers 4 pcs 3 Note There will be some oil spill when the motor flange is removed Put some paper or similar to absorb the surplus oil 4 xx1500002314 Use caution and move the motor flange out over the guide pins 5 Continues on next page Product manual IRB 8700 695 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 3 Replacing the ax...

Page 696: ...HAC059801 001 xx1600001553 Insert the guide pins in four of the screw holes Fasten the set collars 1 xx1500002337 Attach three screws in a triangle and use them as removal tools 2 Continues on next page 696 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Continued ...

Page 697: ...1600001554 Attach the lifting accessories 4 Attaching lifting accessories and removal of gearbox Note Action CAUTION The gearbox weighs 160 kg All lifting accessories used must be sized accordingly 1 Continues on next page Product manual IRB 8700 697 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Continued ...

Page 698: ...ity 2 000 kg Connect another roundsling to the first one with a shackle 4 Shackle SA 10 8 NA1 xx1400000729 Attach the roundslings to an overhead crane or similar and raise to take the weight of the gearbox 5 Remove the set collars 6 Lift the gearbox off 7 Continues on next page 698 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 3 Replacin...

Page 699: ...ews with the robot in only one position Removal and refitting must be performed with the robot in two different positions described in the procedures Robot position Note Action xx1500002085 Make sure that the position of the robot has not been changed Correct position is cal ibration position 1 Preparations before refitting the gearbox Note Action xx1500002342 Use caution and lift the gearbox up a...

Page 700: ...me 3 Grease xx1500002340 Apply some grease on the thin chamfer on the lower arm 4 Grease xx1500002341 Apply some grease on the thin chamfer on the gearbox 5 Continues on next page 700 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Continued ...

Page 701: ...tting 8 Attaching lifting accessories to the gearbox Note Action CAUTION The gearbox weighs 160 kg All lifting accessories used must be sized accordingly 1 Lifting accessory gearbox 3HAC054404 001 Attach the lifting accessory to the gearbox 2 Roundsling 2 m Lifting capacity 2 000 kg 2 pcs Attach a roundsling to the lifting accessory 3 Continues on next page Product manual IRB 8700 701 3HAC052853 0...

Page 702: ...ply Mercasol 40 mm from the lower arm side on the contact surface 1 Note Area where to apply Mercasol 40 mm wide from the lower arm side Mercasol xx1500002350 Apply Mercasol on the surface of the sealing ring and attach it on the gearbox Note Make sure that the sealing ring is attached cor rectly on the gearbox 2 Continues on next page 702 Product manual IRB 8700 3HAC052853 001 Revision F Copyrigh...

Page 703: ...he figure be attached to the frame The other side of the gearbox shall be attached to the lower arm 5 Tightening torque 100 Nm Attach three M16x130 screws with six hole washers underneath in a triangle and use them alternately to press the gearbox into position Note The six hole washers are needed for protection of the gearbox surface when the screws are at tached 6 Screws M16x130 3 pcs xx15000023...

Page 704: ... turn the small gear in the gearbox to find the hole pattern 2 Attachment screws M16x70 12 9 Gleitmo xx1500003112 Attach the screws with washers in area 3 Note Do not torque the screws at this point 3 Attaching the axis 2 gearbox to lower arm screws in area 2 Note Action 1 2 3 1 2 3 xx1500002975 Find area 2 1 Continues on next page 704 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 20...

Page 705: ...M16x70 12 9 Gleitmo xx1500003111 Attach the screws with washers in area 2 Note Do not torque the screws at this point 4 Refitting the motor flange Note Action xx1500002347 Remove the three M16x130 screws and six hole washers previously attached in a triangle 1 Clean the contact surfaces on gearbox and motor flange 2 Continues on next page Product manual IRB 8700 705 3HAC052853 001 Revision F Copyr...

Page 706: ...e guide pins make sure the oil inspection glass is facing at six o clock 8 xx1500002314 Lift the motor flange onto the guide pins 9 Make sure the o rings are in position and slide the motor flange into position 10 xx1600000068 Note Make sure that the three holes in the gearbox are covered when the four six hole washers are fitted 11 Continues on next page 706 Product manual IRB 8700 3HAC052853 001...

Page 707: ... Nm xx1500002373 Secure motor flange together with the gearbox to the frame 1 Securing the axis 2 gearbox to lower arm screws in areas 2 and 3 Note Action Tightening torque 300 Nm xx1500002339 Secure the gearbox to the lower arm with the at tachment screws now possible to reach Start with area 3 finish with area 2 1 Continues on next page Product manual IRB 8700 707 3HAC052853 001 Revision F Copyr...

Page 708: ...grease on the o ring for a bet ter fitting 4 xx1500002082 Examine the pinion and the splines in the hub for damages 5 Grease Castrol Molub Alloy 777 1 NG xx1500002346 Make sure that there is enough grease on the splines before fitting If not apply 1 gram of grease 6 Continues on next page 708 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8...

Page 709: ...t screws M6x30 12 9 Remove the two M6x110 and fit the attach ment screws for the hub 4 Loctite 243 Apply locking liquid Loctite 243 on the screws Note The number of attachment screws differ depending on gearbox Quantity Axis 1 6 pcs Axis 2 8 pcs Axis 3 8 pcs Axis 4 4 pcs Axis 5 6 pcs Axis 6 4 pcs Tightening torque 14 Nm Secure the hub 5 Continues on next page Product manual IRB 8700 709 3HAC052853...

Page 710: ...ontact surfaces on both motor and gearbox 2 Wipe clean the contact surfaces from any remain ing contamination 3 Also wipe clean the o ring groove O ring 3HAB3772 107 xx1200001019 Inspect the o ring Note Replace if damaged 4 xx1200001020 Make sure the o ring is seated in the groove Tip Lubricate the o ring with some grease for a better fitting in the groove 5 Continues on next page 710 Product manu...

Page 711: ...osite holes 1 Always use guide pins in pairs CAUTION The motor weighs 27 kg All lifting accessories used must be sized accordingly 2 Lifting accessory motor 3HAC15534 1 Attach the lifting accessory 3 xx1200001120 Note Make sure the cable exit hole is turned the correct way 4 Continues on next page Product manual IRB 8700 711 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 R...

Page 712: ...e rotating the motor pinion slightly using the rotation tool Make sure that the motor pinion is properly mated into the hub Make sure that the motor pinion does not get damaged Make sure that the direction of the cable exit is facing the correct way 10 Screw dimension M10x40 quality 12 9 Gleitmo 4 pcs Fit two of the attachment screws 11 Remove the guide pins and replace with the remaining attachme...

Page 713: ...the cable gland cover Note Replace the gasket if damaged 2 xx1200001066 Connect the motor cables Connect in accordance with the markings on the connectors 3 Continues on next page Product manual IRB 8700 713 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Continued ...

Page 714: ...e sure that none of the cables inside will be dam aged 7 Attachment screws M5x12 8 8 7 pcs xx1200001135 Refit the motor cover with its attachment screws Note Do not reuse the self threading attachment screws Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Continues on ...

Page 715: ...re of the balancing device by unscrewing the two M16x80 screws alternately little by little 2 Remove the screws 3 Attachment screws M16x35 2 pcs xx1500001971 Refit the M16x35 screws in the holes on top of the balancing device 4 Removing lock screws Note Action Turn on the power 1 Continues on next page Product manual IRB 8700 715 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserve...

Page 716: ...2335 Jog axis 2 to be able to attach the plastic plug 4 xx1500002366 Jog axis 3 to be able to attach the plastic plug 5 Refitting the axis 2 gearbox to the lower arm screws in area 1 Note Action Jog the robot to the specified position Axis 1 No significance as long as the ro bot is secured to the foundation Axis 2 0 Axis 3 66 Axis 4 0 Axis 5 0 Axis 6 No significance 1 Continues on next page 716 Pr...

Page 717: ...done 1 See Changing oil in axis 2 and axis 3 gearbox on page 147 Refill the gearbox with oil 2 Axis Calibration is described in Calibrating with Axis Calibration method on page 805 Recalibrate the robot 3 General calibration information is included in section Calibration on page 795 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in th...

Page 718: ...sted in the table can be out of date See the latest revision of Product manual spare parts IRB 8700 on ABB Library Note Article number Spare part 3HAC048392 003 Reduction gear RV 900N incl in put gear 3HAC052423 001 Sealing ring Continues on next page 718 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox ...

Page 719: ...ed to slide the axis 2 or axis 3 gear box in out 3HAC059801 001 Mounting set gear axis 2 and 3 Mobile platform ladder Lifting capacity 2 000 kg Roundsling 2 m Lifting capacity 2 000 kg Roundsling 2 5 m M16 3HAC14457 4 Lifting eye M24 3HAC038295 003 Lifting eye Used to rotate the motor pinion 3HAC7887 1 Rotation tool Content is defined in section Standard toolkit on page 833 Standard toolkit Requir...

Page 720: ...806 If no previous reference values exist and no new reference values can be created then reference calibration is not possible If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the gearbox Use these procedures to remove the axis 3 gearbox DANGER Never remove both the axis 2 and axis 3 gearboxes at the same time On...

Page 721: ...e axis 3 gearbox to the parallel arm is reversed area 3 area 2 and then area 1 Robot position when removing axis 3 from parallel arm screws in area 1 With the robot in this position it is possible to reach the screws in the first of the three areas of screws that secure the axis 3 gearbox to the parallel arm Note Action Jog the robot to the specified position Axis 1 no significance as long as the ...

Page 722: ... same position This procedure describes how to reach the screws in the first area Only remove the screws in this area at this point Use this procedure to remove the screws that secure the axis 3 gearbox to the parallel arm in area 1 Note Action DANGER Never remove the screws on both axis 2 and axis 3 at the same time One side must always be attached when the gearbox on the other side is removed If...

Page 723: ...ly air pressure supply to the robot before entering the robot working area 2 Removing the axis 3 gearbox from parallel arm step 2 screws in area 2 Use this procedure to remove the screws that secure the axis 3 gearbox to the parallel arm in area 2 Note Action DANGER Never remove the screws on both axis 2 and axis 3 at the same time One side must always be attached when the gearbox on the other sid...

Page 724: ...w Preparations before jogging the robot into calibration position Note Action Turn the power to the robot on 1 xx1500002334 Jog axis 2 to within the area shown in the figure 2 Continues on next page 724 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox Continued ...

Page 725: ...stic plug It shall be refitted after the work is done 3 xx1500002335 xx1500002367 Jog axis 3 to the area shown in the figure 4 Continues on next page Product manual IRB 8700 725 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox Continued ...

Page 726: ...o axis 2 and axis 3 Note Action xx1500002310 Jog the robot to calibration position 1 Tightening torque 100 Nm Secure the axis 2 with a lock screw 2 Lock screw quality 12 9 M20x150 xx1500002322 Continues on next page 726 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox Continued ...

Page 727: ... 24 VDC power supply Release the brakes on axis 3 using the brake release button and let the axis rest on the lock screw 5 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 6 Continues on next page Product manual IRB 8700 727 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 4...

Page 728: ...GER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Mobile platform ladder xx1500001985 Use a Mobile platform ladder or similar to reach the upper end of the balancing device DANGER Do not use the robot as ladder 2 Continues on next page 728 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4...

Page 729: ... screws until the screws reaches the piston Then alternately little by little attach the screws at least another five mil limeters The pressure is now unloaded 5 Screw M16x80 2 pcs In a procedure where both balancing devices shall be removed unload the pressure of the other in the same way 6 Disconnecting the axis 3 motor cables Note Action DANGER Make sure that all supplies for electrical power h...

Page 730: ...he motor cover 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page 730 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox Continued ...

Page 731: ...may fall down Before continuing the lower arm and parallel arm must be secured 1 24 VDC power supply In order to release the brakes connect the 24 VDC power supply 2 Connect connector R2 MP3 pin 2 24V pin 5 0V Bits extender 3HAC12342 1 xx1600000069 Remove the attachment screws that secure the motor Tip Use a bits extender in order to reach the screws 3 Guide pin M10x150 3HAC15512 1 Fit guide pins ...

Page 732: ...sized accordingly 7 Lifting accessory motor 3HAC15534 1 Attach the lifting accessory 8 xx1600000070 Lift the motor out on the guide pins in or der to get the pinion away from the hub Let the motor rest on the guide pins 9 Disconnect the 24 VDC power supply 10 xx1600000071 Remove the motor by sliding it out on the guide pins and then lifting it away 11 Continues on next page 732 Product manual IRB ...

Page 733: ...e M6x16 torx pan head screws 2 CAUTION Whenever parting mating the hub pinion and gearbox the gears may be damaged if excessive force is used 3 Attachment screws M6x110 2 pcs xx1500002081 Fit two screws in opposite holes of the hub and use them as removal tools 4 Continues on next page Product manual IRB 8700 733 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 4 ...

Page 734: ... step 3 screws area 3 Note Action 1 2 3 1 2 3 xx1500002974 Find area 3 1 xx1500003116 Remove the attachment screws in area 3 2 Continues on next page 734 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox Continued ...

Page 735: ...tor flange Note Action xx1500002358 Remove two attachment screws in opposite holes 1 Mounting set gear axis 2 and 3 3HAC059801 001 Fit guide pins in the holes 2 xx1500002359 Remove the remaining attachment screws and the six hole washers 4 pcs 3 Continues on next page Product manual IRB 8700 735 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis...

Page 736: ...1500002317 Make sure the o rings are present 6 Removing the axis 3 gearbox from parallel arm Note Action Mounting set gear axis 2 and 3 3HAC059801 001 xx1600001553 Attach two additional guide pins in opposite holes below the present ones 1 Continues on next page 736 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gea...

Page 737: ... the four guide pins just enough to be able to attach the lifting accessories 3 Lifting accessory gearbox 3HAC054404 001 xx1600001554 Attach the lifting accessories 4 Continues on next page Product manual IRB 8700 737 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox Continued ...

Page 738: ...s 3 gearboxes at the same time One of the gearboxes must stay fitted when the other is replaced If not the complete arm system will not have any secure connection to the frame and thereby be a great security risk A serious accident will most probably happen Note The attachment screws that secure the gearboxes to the lower arm or to the parallel arm are arranged in three areas with 15 screws in eac...

Page 739: ...on and lift the gearbox up and let it rest on its side CAUTION Make sure the gearbox is resting in a stable position 1 Sealing ring 3HAC052423 001 xx1600000067 Fit a new sealing ring 2 Clean the contact surfaces between gear box and frame 3 Continues on next page Product manual IRB 8700 739 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 ge...

Page 740: ...x1500002341 Apply some grease on the thin chamfer on the gearbox 5 Mounting set gear axis 2 and 3 3HAC059801 001 xx1500002361 Fit guide pins as shown in the figure 6 Continues on next page 740 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox Continued ...

Page 741: ...ssories used must be sized accordingly 1 Lifting accessory gearbox 3HAC054404 001 xx1600001554 Attach the lifting accessories to the gear box 2 Roundsling 2 m Lifting capacity 2 000 kg 2 pcs Attach a roundsling to the lifting accessor ies 3 Attach the roundslings to an overhead crane or similar and raise to take the weight of the gearbox 4 Continues on next page Product manual IRB 8700 741 3HAC052...

Page 742: ...e Make sure that the sealing ring is attached cor rectly on the gearbox 2 xx1500002344 Orient the gearbox to match the hole patterns before lifting the gearbox onto the guide pins If the hole pattern does not match carefully turn the small gear in the gearbox very slowly in order to find the hole pattern xx1500002345 3 Continues on next page 742 Product manual IRB 8700 3HAC052853 001 Revision F Co...

Page 743: ...ath in a triangle and use them alternately to press the gearbox into position Note The six hole washers are needed for protection of the gearbox surface when screws are attached 6 Attachment screws M16x130 12 9 Gleitmo xx1500002368 Attaching the axis 3 gearbox to parallel arm screws in area 3 Note Action 1 2 3 1 2 3 xx1500002974 Find area 3 1 Continues on next page Product manual IRB 8700 743 3HAC...

Page 744: ...e outer ring of holes 3 Attachment screws M16x70 12 9 Gleitmo xx1500003116 Attach the remaining attachment screws with washers in area 3 Note Do not torque the screws at this point 4 Lower arm is hidden in this figure to get a better view Continues on next page 744 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gear...

Page 745: ...e Apply some grease on the o rings 5 Attach the smaller o ring in the gearbox groove 6 Attach the larger o ring on the motor flange 7 xx1500002354 Before lifting the motor flange onto the guide pins make sure the oil inspection glass is facing at six o clock See figure 8 xx1500002314 Lift the motor flange onto the guide pins 9 Continues on next page Product manual IRB 8700 745 3HAC052853 001 Revis...

Page 746: ...with the four six hole washers 12 xx1500002356 Remove the guide pins and attach the remaining screws 13 Attaching the axis 3 gearbox to frame step 2 Use this procedure to secure the axis 3 gearbox together with the motor flange to the frame Note Action Tightening torque 300 Nm xx1500002373 Secure motor flange together with the gearbox to the frame 1 Continues on next page 746 Product manual IRB 87...

Page 747: ...ne that all screws in this area now has been torqued 4 Preparations before refitting the hub Note Action Wipe the hub clean 1 Inspect the hole where the hub shall be refitted Wipe clean if needed 2 xx1500002039 Make sure the o ring on the hub is undam aged Note Replace if damaged 3 Apply some grease on the o ring for a bet ter fitting 4 Continues on next page Product manual IRB 8700 747 3HAC052853...

Page 748: ...ing the hub Note Action Attachment screws M6x110 2 pcs xx1500002081 Attach two screws in opposite holes of the hub and use them as tools to fit the hub 1 CAUTION Whenever parting mating the hub pinion and gearbox the gears may be damaged if excessive force is used 2 Continues on next page 748 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8...

Page 749: ...e Action See Performing a leak down test on page 184 Perform a leak dowm test 1 Preparations before refitting the motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Remove old paint residues and other contamina tion from the contact surfaces on both motor and gearbox 2 Wipe clean the contact surfaces from any remain ing co...

Page 750: ...groove Tip Lubricate the o ring with some grease for a better fitting in the groove 5 Flange sealant Loctite 574 xx1500002357 Apply flange sealant on the motor flange 6 Continues on next page 750 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox Continued ...

Page 751: ...d the correct way 4 Lift the motor and put it on the guide pins as close as possible to its final position without pushing the motor pinion into the gear 5 Remove the lifting accessory and allow the motor to rest on the guide pins 6 Rotation tool 3HAC7887 1 Apply the rotation tool and use it to rotate the pinion when mating it into the gear 7 To release the brakes connect the 24 VDC power supply 8...

Page 752: ...ew dimension M10x40 quality 12 9 Gleitmo 4 pcs Fit two of the attachment screws 11 Remove the guide pins and replace with the remaining attachment screws 12 Bits extender 3HAC12342 1 Secure the motor with its attachment screws and washers 13 Screw dimension M10x40 quality 12 9 Gleitmo 4 pcs Use a bits extender in order to reach the screws Tightening torque 50 Nm xx1200001117 Performing a leak down...

Page 753: ...it the cable gland cover Note Replace the gasket if damaged 2 xx1200001066 Connect the motor cables Connect in accordance with the markings on the connectors 3 Continues on next page Product manual IRB 8700 753 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox Continued ...

Page 754: ...e sure that none of the cables inside will be dam aged 7 Attachment screws M5x12 8 8 7 pcs xx1200001135 Refit the motor cover with its attachment screws Note Do not reuse the self threading attachment screws Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Continues on ...

Page 755: ...re of the balancing device by unscrewing the two M16x80 screws alternately little by little 2 Remove the screws 3 Attachment screws M16x35 2 pcs xx1500001971 Refit the M16x35 screws in the holes on top of the balancing device 4 Removing lock screws Note Action Turn on the power 1 Continues on next page Product manual IRB 8700 755 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserve...

Page 756: ...position where it is possible to attach the plastic plug and attach the plug 4 xx1500002366 Jog axis 3 to the position where it is possible to attach the plastic plug and attach the plug 5 Robot position when attaching the screws in area 2 Note Action Jog the robot to the specified position Axis 1 no significance as long as the robot is fitted to the foundation Axis 2 65 Axis 3 0 Axis 4 0 Axis 5 0...

Page 757: ... Gleitmo Attach and secure the screws in area 2 2 Tightening torque 300 Nm xx1500003115 Lower arm is hidden in this figure to get a better view Tip To make sure that all screws in this area are torqued use a marker pen and mark each screw after it has been torqued 3 Examine that all screws in this area has been torqued 4 Continues on next page Product manual IRB 8700 757 3HAC052853 001 Revision F ...

Page 758: ...upply to the robot before entering the robot working area 2 Refitting the axis 3 gearbox to parallel arm screws in area 1 Note Action 1 2 3 1 2 3 xx1500002974 Find area 1 1 Attachment screws M16x70 12 9 Gleitmo Attach and secure the screws in area 1 2 Tightening torque 300 Nm xx1500003114 Lower arm is hidden in this figure to get a better view Continues on next page 758 Product manual IRB 8700 3HA...

Page 759: ...x on page 147 Refill the gearbox with oil 2 Axis Calibration is described in Calibrating with Axis Calibration method on page 805 Recalibrate the robot 3 General calibration information is included in section Calibration on page 795 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...

Page 760: ... are listed in the table can be out of date See the latest revision of Product manual spare parts IRB 8700 on ABB Library Note Article number Spare part 3HAC043073 003 Graphite White 3HAC048293 001 ABB Orange Reduction Gear RV 500N 236 36 Continues on next page 760 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 5 Replacing the axis 4 prim...

Page 761: ...bles Note Article number Consumable Castrol Molub Alloy 777 1 NG 5 ml To be used on hub splines to prevent from fretting corrosion 3HAC063069 001 Grease Loctite 243 3HAB7116 1 Locking liquid Loctite 574 12340011 116 Flange sealant 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 requi...

Page 762: ...s from the robot Removing the axis 4 primary gearbox Use these procedures to remove the gearbox Preparations before removing the gearbox Note Action Decide which calibration routine to use and take actions accordingly prior to begin ning the repair procedure 1 Jog the robot to the most comfortable pos ition for removing the axis 4 primary gear box 2 DANGER Turn off all electric power supply hydrau...

Page 763: ...otor cover 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page Product manual IRB 8700 763 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 5 Replacing the axis 4 primary gearbox Continued ...

Page 764: ...ending on the position of axis 5 1 To release the brakes connect the 24 VDC power supply 2 Connect to connector R2 MP4 pin 2 24V pin 5 0V xx1600000064 Unscrew the attachment screws with washers that secure the motor 3 Guide pin M10x150 3HAC15521 2 Attach two guide pins in opposite holes 4 Always use guide pins in pairs CAUTION Whenever parting mating motor and gear box the gears may be damaged if ...

Page 765: ...d remove the motor by lifting it straight out Make sure the pinion is not damaged 9 Disconnect the 24 VDC power supply 10 Removing the hub Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1500002038 Unscrew the M6x30 hex socket head cap screws that secure the hub Note Do not remove the M6x16 torx pan head screws 2 Continues ...

Page 766: ...l tools 4 xx1500002326 Lift out the hub carefully 5 Removing the gear Z3 Note Action xx1500002985 Make a note of the position of the revolu tion indicator on axis 4 Tip Use a marker pen to indicate the position of axis 4 before the indicator is removed 1 Continues on next page 766 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 5 Replacing...

Page 767: ...pins 3HAC13056 3 M12x200 2 pcs xx1500002988 Unscrew two M12 screws in opposite holes and replace them with guide pins Tip Put some grease on the guide pins for a better fitting 4 M12 and M16 xx1500002989 Unscrew the attachment screws holding the gear 5 Continues on next page Product manual IRB 8700 767 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 5 Replacing t...

Page 768: ...ear weighs 11 kg All lifting accessories used must be sized accordingly 8 Use caution and lift the gear off 9 xx1500002991 Note Do not remove the washers shown in the figure Underneath is a sealing which pre vents oil from leaking through the screw holes that secure the axis 4 primary gear box from the other side 10 Continues on next page 768 Product manual IRB 8700 3HAC052853 001 Revision F Copyr...

Page 769: ...C13056 2 M12x150 mm Attach guide pins in the holes Tip Apply some grease on the guide pins for a better fitting 3 Guide pins 3HAC13056 3 M12x200 mm xx1500002994 Remove the remaining attachment screws and the six hole washers 4 pcs 4 Continues on next page Product manual IRB 8700 769 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 5 Replacing the axis 4 primary ge...

Page 770: ...x16 3 pcs xx1500002996 Unscrew the screws that hold the axis 3 bracket and let it hang free 1 Lifting accessory axis 4 primary gearbox Attach the lifting accessories to the primary gearbox 2 If needed use removal tools to press out the gearbox 3 xx1500002997 Lift the gearbox off 4 Continues on next page 770 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserv...

Page 771: ...act surfaces on the axis 4 primary gearbox 3 Guide pins 3HAC13056 2 M12x150 Attach guide pins in opposite holes Tip Put some grease on the guide pins for a better fitting 4 Guide pins 3HAC13056 3 M12x200 mm xx1500002998 xx1500003000 Clean the o rings and o ring grooves on the gearbox 5 xx1500002999 Inspect the o rings Note Replace if damaged 6 Continues on next page Product manual IRB 8700 771 3HA...

Page 772: ...ase on the o ring for a better fitting 3 CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 4 Loctite 574 xx1600000073 Apply flange sealant 5 xx1500003072 Make sure that one of the M8 holes in the gearbox will be at twelve o clock when lifting the gearbox onto the guide pins 6 Continues on next page 772 Product manual IRB 8700 3HAC052853 001 Rev...

Page 773: ...ove the lifting accessories 9 Refitting the motor flange Note Action Clean the contact surfaces on gearbox and motor flange 1 xx1500003074 Clean o ring and o ring groove on motor flange 2 Inspect the o ring Note Replace if damaged 3 Put some grease on the o ring and fit it into its groove 4 Continues on next page Product manual IRB 8700 773 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rig...

Page 774: ...nge into position 7 xx1600000068 Note When the four six hole washers are fitted make sure that the three holes in the gearbox are covered 8 Attachment screws M12x110 12 9 Gleitmo 603 32 pcs xx1500002994 Attach 30 of the 32 attachment screws with the four six hole washers 9 Continues on next page 774 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Rep...

Page 775: ... primary gearbox 1 Preparations before refitting the hub Note Action Wipe the hub clean 1 Inspect the hole where the hub shall be refitted Wipe clean if needed 2 xx1500002039 Make sure the o ring on the hub is undam aged Note Replace if damaged 3 Apply some grease on the o ring for a bet ter fitting 4 Continues on next page Product manual IRB 8700 775 3HAC052853 001 Revision F Copyright 2015 2018 ...

Page 776: ...the hub Note Action Attachment screws M6x110 2 pcs xx1500002081 Attach two screws in opposite holes of the hub and use them as tools to fit the hub 1 CAUTION Whenever parting mating the hub pinion and gearbox the gears may be damaged if excessive force is used 2 Continues on next page 776 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 5 R...

Page 777: ... Axis 4 4 pcs Axis 5 6 pcs Axis 6 4 pcs Tightening torque 14 Nm Secure the hub 5 Refitting the gear Z3 step 1 Note Action Wipe clean the contact surfaces 1 Guide pins 3HAC13056 2 M12x150 Attach guide pins in opposite holes Tip Put some grease on the guide pins for a better fitting 2 Guide pins 3HAC13056 3 M12x200 xx1500003076 Continues on next page Product manual IRB 8700 777 3HAC052853 001 Revisi...

Page 778: ...de pins 4 Attachment screws M16x50 12 9 Gleitmo 603 Secure the gear and shims with three of the nine M16x50 screws Attach screws in a triangle 5 Tightening torque 300 Nm xx1500003079 Remove the guide pins 6 Continues on next page 778 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 5 Replacing the axis 4 primary gearbox Continued ...

Page 779: ...l with a micromet er that the value is correct 4 Tightening torque 300 Nm Secure the gear with three of the M16x50 screws attached in a triangle 5 Measure the play again If the measured result deviates too much the gear must be disassembled and the number of shims be adjusted 6 Refitting the axis 4 gear Z3 Step 2 Note Action Attachment screws M16x50 12 9 Gleitmo 603 9 pcs When the play is measured...

Page 780: ...age 184 Perform a leak down test 7 Preparations before refitting the axis 4 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Remove old paint residues and other contamina tion from the contact surfaces on both motor and gearbox 2 Wipe clean the contact surfaces from any remain ing contamination 3 Also wipe clean the o ri...

Page 781: ... 5 xx1200001135 If the motor is a new spare part remove the cover 6 Securing the axis 4 motor Note Action Guide pin M10x150 3HAC15521 2 Apply two guide pins in opposite holes 1 Always use guide pins in pairs Put the motor onto the guide pins 2 Continues on next page Product manual IRB 8700 781 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 5 Replacing the axis 4...

Page 782: ...ting mating motor and gear box the gears may be damaged if excess ive force is used 7 xx1600000065 Use caution and push the motor in position while at the same time the motor pinion is slightly rotated Make sure that the motor pinion is properly mated to the gear of the gearbox Make sure that the motor pinion does not get damaged Make sure that the direction of the cable exit is facing the correct...

Page 783: ...wn test on page 184 Perform a leak down test 11 Disconnect the 24 VDC power supply 12 Connecting the axis 4 motor cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 Continues on next page Product manual IRB 8700 783 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 5 Replacing the axis 4 primary gearbox Continued ...

Page 784: ...054692 002 xx1200001070 Inspect the o ring Note Replace if damaged 4 Wipe clean o ring and o ring groove 5 Refit the o ring 6 CAUTION When fitting the motor cover make sure that none of the cables inside are damaged 7 Continues on next page 784 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 5 Replacing the axis 4 primary gearbox Continued...

Page 785: ... 4 primary gearbox 1 See Changing oil axis 4 secondary gear box on page 159 Refill oil in the axis 4 secondary gearbox 2 Axis Calibration is described in Calibrating with Axis Calibration method on page 805 Recalibrate the robot 3 General calibration information is included in section Calibration on page 795 DANGER Make sure all safety requirements are met when performing the first test run These ...

Page 786: ...le can be out of date See the latest revision of Product manual spare parts IRB 8700 on ABB Library Note Article number Spare part 3HAC043073 003 Graphite White 3HAC048293 001 ABB Orange Reduction Gear RV 500N 236 36 3HAC052423 002 Sealing ring Continues on next page 786 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 6 Replacing the axis ...

Page 787: ...ation routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axi...

Page 788: ...d other equipment fitted to the turning disc 4 See Changing oil axis 6 gearbox on page 168 Drain the axis 6 gearbox 5 Removing the turning disc Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1500002318 Unscrew the 27 M12x40 screws and washers that secure the turning disc 2 Continues on next page 788 Product manual IRB 8700...

Page 789: ...ydraulic pressure and air pressure are turned off 1 CAUTION The process turning disc weighs 50 kg All lifting accessories must be sized accord ingly 2 Roundsling 1 m Lifting capacity 1 000 kg Attach a roundsling to the process turning disc and to an overhead crane or similar 3 Stretch the roundsling to take the weight of the process turning diss 4 Unscrew the 22 attachment screws and washers that ...

Page 790: ...5 0V xx1500002981 Remove the calibration pin holder by un screwing the two M12x110 screws Note Use caution not to damage the guiding pins 3 xx1500002982 Unscrew the attachment screws that secure the axis 6 gearbox 4 CAUTION Whenever parting mating hub and gearbox the splines may be damaged if excessive force is used 5 Continues on next page 790 Product manual IRB 8700 3HAC052853 001 Revision F Cop...

Page 791: ...ns before refitting the axis 6 gearbox Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Wipe clean all contact surfaces 2 Sealing ring 3HAC052423 001 xx1600000067 Fit a new sealing ring 3 Continues on next page Product manual IRB 8700 791 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 6 Repl...

Page 792: ...nect to connector R2 MP6 pin 2 24V pin 5 0V xx1500002983 Use caution and refit the gearbox 4 Attachment screws M12x80 12 9 Gleitmo 29 pcs Secure the gearbox with its attachment screws and washers Note Do not refit any of the M12x80 screws where the pin holder will be refitted with the M12x110 screws 5 Tightening torque 120 Nm xx1500002982 Continues on next page 792 Product manual IRB 8700 3HAC0528...

Page 793: ... page 184 Perform a leak down test 7 Refitting the turning disc Note Action xx1500002319 Wipe clean the contact surfaces and refit the axis 6 gearbox 1 xx1500002984 Make sure the sealing ring is fitted on the gearbox 2 Continues on next page Product manual IRB 8700 793 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 6 Replacing the axis 6 gearbox Continued ...

Page 794: ...s Secure the process turning disc with its attachment screws and washers 5 Tightening torque 120 Nm Concluding procedure Note Action See Changing oil axis 6 gearbox on page 168 Refill the gearbox with oil 1 Axis Calibration is described in Calibrating with Axis Calibration method on page 805 Recalibrate the robot 2 General calibration information is included in section Calibration on page 795 DANG...

Page 795: ...eneric term for all calibration methods that aim to move the robot to calibration position Standard calibration A calibration routine that generates a new zero posi tion of the robot Fine calibration A calibration routine that in the first step generates a reference to current zero position of the robot The same calibration routine can later on be used to re calibrate the robot back to the same po...

Page 796: ...ing accuracy in the Cartesian coordinate system for the robot Absolute accuracy calibration option al 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 moto...

Page 797: ...e 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 case...

Page 798: ...unter memory is lost If the revolution counter memory is lost the counters must be updated See Updating revolution counters on page 801 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 co...

Page 799: ...tion marks and the synchronization position for each axis Synchronization marks IRB 8700 Axis 2 xx1500000946 Axis 1 xx1500000945 Axis 4 xx1500000948 Axis 3 xx1500000947 Axis 6 xx1500000950 Axis 5 xx1500000949 Product manual IRB 8700 799 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchronization position for axes ...

Page 800: ...nes 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 800 Product manual IRB 8700 3HAC052853 001 Rev...

Page 801: ...sulting 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 befor...

Page 802: ...ABB menu tap Calibration xx1500000942 1 All mechanical units connected to the system are shown with their calibration status 2 Tap the mechanical unit in question xx1500000943 Continues on next page 802 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 5 Calibration 5 3 Updating revolution counters Continued ...

Page 803: ... calibration method used during last field calibration Tap Manual Method Advanced xx1500000944 A screen is displayed tap Rev Counters en0400000771 4 Continues on next page Product manual IRB 8700 803 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 5 Calibration 5 3 Updating revolution counters Continued ...

Page 804: ...e updating operation cannot be undone Tap Update to proceed with updating the revolution counters Tap Cancel to cancel updating the revolution counters Tapping Update updates the selected revolution counters and removes the tick from the list of axes 7 CAUTION If a revolution counter is incorrectly updated it will cause incorrect manipulator posi tioning which in turn may cause damage or injury Ch...

Page 805: ...vable 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 inse...

Page 806: ... 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 m...

Page 807: ...g other pins in the calibration bushings may cause severe damage to the robot and or personnel Note Article number Equipment etc Delivered as a set of calibration tools 3HAC055412 001 Calibration tool box Axis Calibration Examining the calibration tool Check prior to usage Before using the calibration tool make sure that the tube insert the plastic protection and the steel spring ring are present ...

Page 808: ...solution Note Action It is possible to use any RFID solution with the correct dimensions ABB has verifed function on some suppliers fulfilling the requirements of NFC compatible devices 13 56 Mhz according to ISO 14443 or ISO 15693 Note The maximum dimensions on the RFID chip must not exceed Ø7 9 mm x 8 0 mm Ø5 9 mm x 8 0 mm or Ø3 9 mm x 8 0 mm depending on calibra tion tool size 1 There is a cavi...

Page 809: ...n fixed calibration pins and or bushings The figure does not show installed calibration tools A fixed calibration pin and a bushing for the movable calibration tool are located on each axis as follows xx1500000786 Continues on next page Product manual IRB 8700 809 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 5 Calibration 5 4 3 Installation locations for the calibration to...

Page 810: ...ealing in the bushing Replace damaged parts with new if needed Note Article number Spare part Contains replacement calibration pin covers and protective plugs for the bushing 3HAC056806 001 Protection cover and plug set 810 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 5 Calibration 5 4 3 Installation locations for the calibration tools Continued ...

Page 811: ...on procedure and what to do at each step is given on the FlexPendant You will be guided through the calibration procedure step by step Use the following list to learn about the calibration procedure before running the RobotWare program on the FlexPendant It gives you a brief overview of the calibration procedure sequence After the calibration method has been called for on the FlexPendant the follo...

Page 812: ...ER 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 1 Use a clean cloth Wipe the calibration tool clean Note The calibration method is exact Dust dirt or color flakes will affect the calibration value 2 Starting the calibration procedure Use this procedure to call for the Axis Cal...

Page 813: ...n the FlexPendant is given in Overview of the calibra tion procedure on the FlexPendant on page 811 Follow the instructions given on the FlexPendant 4 Restarting an interrupted calibration procedure If the Axis Calibration procedure is interrupted before the calibration is finished the RobotWare program needs to be started again Use this procedure to take required action Action Situation Press and...

Page 814: ...alibration 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 Note Action SafeMove generates the message Safety control ler not sync...

Page 815: ... Unsynchronized time limit expired SafeMove message anytime during Axis Calibration routine Note Action SafeMove generates the message Unsynchron ized time limit expired anytime xx1500002482 1 Press OK to continue Axis Calibration procedure 2 Restart Axis Calibration procedure by pressing Play 3 Continues on next page Product manual IRB 8700 815 3HAC052853 001 Revision F Copyright 2015 2018 ABB Al...

Page 816: ...ection cover and plug set 3HAC056806 001 xx1500000952 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 3 Protection cover and plug set 3HAC056806 001 816 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 20...

Page 817: ...change the position of the robot axes after running the program 1 This is detailed in section Synchronization marks and synchronization position for axes on page 799 Adjust the synchronization marks when the calibration is done if necessary 2 Write down the values on a new label and stick it on top of the calibration label 3 The label is located on the lower arm Remove any calibration equipment fr...

Page 818: ... page 799 and Updating revolution counters on page 801 Check that the synchronization marks for the axes align correctly If they do not update the revolu tion counters 6 Using the jogging window Use this procedure to jog the robot to the synchronization position of all axes Note Action On the ABB menu tap Jogging 1 Tap Motion mode to select group of axes to jog 2 Tap to select the axis to jog axis...

Page 819: ...s Copper Base lower arm upper arm Cast iron nodular iron Gears screws base frame and so on Steel Brakes motors Neodymium Cables connectors drive belts and so on Plastic rubber Gearboxes Oil grease Covers synchronization brackets Aluminium Turning disc foundry Nickel Oil and grease Where possible arrange for oil and grease to be recycled Dispose of via an authorized person contractor in accordance ...

Page 820: ...o organisms Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination 820 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 6 Decommissioning 6 1 Environmental information Continued ...

Page 821: ...attery is exposed to heat for example from a blow torch it will explode Always remove all oil grease in gearboxes If exposed to heat for example from a blow torch the oil grease will catch fire When motors are removed from the robot the robot will collapse if it is not properly supported before the motor is removed Product manual IRB 8700 821 3HAC052853 001 Revision F Copyright 2015 2018 ABB All r...

Page 822: ...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...

Page 823: ...amp the device at the working location Place the device at ground level so that the hole and spring coils are cut from a safe distance and somewhat from above 2 DANGER The hole must be cut as specified in the figure Pieces of the spring can be thrown out from the cylinder at high speed if the hole is cut larger than specified 3 Use a cutting torch with a long shaft Cut a hole in the housing as sho...

Page 824: ...This page is intentionally left blank ...

Page 825: ...pter includes general information complementing the more specific information in the different procedures in the manual Product manual IRB 8700 825 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 7 Reference information 7 1 Introduction ...

Page 826: ...015i Ergonomics of the thermal environment Part 1 EN ISO 13732 1 2008 EMC Generic emission EN 61000 6 4 2007 A1 2011 IEC 61000 6 4 2006 A1 2010 option 129 1 EMC Generic immunity EN 61000 6 2 2005 IEC 61000 6 2 2005 Arc welding equipment Part 1 Welding power sources EN IEC 60974 1 2012ii Arc welding equipment Part 10 EMC requirements EN IEC 60974 10 2014ii Safety of machinery Electrical equipment o...

Page 827: ...R15 06 Safety standard for robots and robotic equipment ANSI UL 1740 Industrial robots and robot Systems General safety require ments CAN CSA Z 434 14 Product manual IRB 8700 827 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 7 Reference information 7 2 Applicable standards Continued ...

Page 828: ...39 37 in 3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume 828 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 7 Reference information 7 3 Unit conversion ...

Page 829: ...uld be used Screws lubricated in other ways Screws lubricated with Molycote 1000 should only be used when specified in the repair maintenance or installation procedure descriptions In such cases proceed as follows 1 Apply lubricant to the screw thread 2 Apply lubricant between the plain washer and screw head 3 Screw dimensions of M8 or larger must be tightened with a torque wrench Screw dimensions...

Page 830: ...pair maintenance or installation procedure overrides the standard torque Tightening torque Nm Class 12 9 oil lubric ated Tightening torque Nm Class 10 9 oil lubric ated Tightening torque Nm Class 8 8 oil lubricated Dimension 6 M5 10 M6 40 34 24 M8 80 67 47 M10 140 115 82 M12 340 290 200 M16 670 560 400 M20 1150 960 680 M24 Lubricated screws Molycote Gleitmo or equivalent with allen head screws The...

Page 831: ...ning torque for water and air connectors when one or both connectors are made of brass Note A special torque specified in the repair maintenance or installation procedure overrides the standard torque Tightening torque Nm Max Tightening torque Nm Min Tightening torque Nm Nominal Dimension 15 8 12 1 8 20 10 15 1 4 25 15 20 3 8 50 30 40 1 2 90 55 70 3 4 Product manual IRB 8700 831 3HAC052853 001 Rev...

Page 832: ...ory when handling components with a weight exceeding 22 kg A wide range of lifting accessories and devices are available for each manipulator model Example Following is an example of a weight specification in a procedure Note Action CAUTION The robot weighs 4 750 kg All lifting accessories used must be sized accord ingly 832 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB...

Page 833: ...it Comment Tool Qty Ring open end spanner 8 19 mm 1 Socket head cap 2 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 1 Hexagon headed screw M10x100 2 Hexagon headed screw M16x90 1 Hex bit socket head cap no 14 socket 40 mm L 100 mm 1 To be shortened to 12 mm Hex bit socket head cap no 14 socket 40 mm L 20 mm...

Page 834: ... page 833 and of special tools listed directly in the instructions and also gathered in this section Special tools Note The list of special tools in this revision is not updated A complete and updated list will be presented in the next revision Continues on next page 834 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 7 Reference information 7 7 Specia...

Page 835: ... Guide pin M16x150 3HAC13120 2 x x x Guide pin M16x200 3HAC13120 3 Lifting accessories x x x x x x xx1200001241 Lifting accessory chain 3HAC15556 1 x x Lifting accessory motor 3HAC14459 1 x x x Lifting accessory motor 3HAC15534 1 x Lifting accessory gearbox 3HAC054404 001 x Lifting accessory gearbox 3HAC046128 001 2 2 2 2 2 xx1200001242 Lifting eye M12 3HAC16131 1 x 2 xx1200001242 Lifting eye M16 ...

Page 836: ... x Hydraulic pump 80 MPa 3HAC13086 1 x x x x Threaded bar M16x340 3HAC9909 15 Removal tools Removal tool M10 x x Removal tool M12 3HAC14631 1 x x x x x Removal tool M14 3HAC047108 001 Other tools x x x x x x x x x x x x x 24 VDC power supply x x x Long Allen Key Socket IN19L 6 140 x x x x x Bits extender 3HAC12342 1 x x x x x x x x x x x x x x Calibration Pendulum toolkit 3HAC15716 1 x x x x x x x...

Page 837: ...ting accessories is not detailed in the activity procedure but in the instruction delivered with each piece of lifting accessories This implies that the instructions delivered with the lifting accessories should be stored for later reference Product manual IRB 8700 837 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 7 Reference information 7 8 Lifting accessories and lifting ...

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Page 839: ...ews are not included in the manual but delivered as a separate document for registered users on myABB Business Portal www mypo rtal abb com Product manual IRB 8700 839 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 8 Spare parts 8 1 Spare part lists and illustrations ...

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Page 841: ...B 140 type C 3HAC025611 001 Circuit diagram IRB 260 3HAC028647 009 Circuit diagram IRB 360 3HAC036446 005 Circuit diagram IRB 460 3HAC025691 001 Circuit diagram IRB 660 3HAC025691 001 Circuit diagram IRB 760 3HAC046307 003 Circuit diagram IRB 1200 3HAC2800 3 Circuit diagram IRB 1410 3HAC021351 003 Circuit diagram IRB 1600 1660 3HAC039498 007 Circuit diagram IRB 1520 3HAC6670 3 Circuit diagram IRB ...

Page 842: ...m IRB 6650S 3HAC025744 001 3HAC025744 001 Circuit diagram IRB 6660 3HAC029940 001 3HAC043446 005 Circuit diagram IRB 6700 3HAC13347 1 Circuit diagram IRB 7600 3HAC025744 001 3HAC050778 003 Circuit diagram IRB 14000 3HAC056159 002 Circuit diagram IRB 910SC 842 Product manual IRB 8700 3HAC052853 001 Revision F Copyright 2015 2018 ABB All rights reserved 9 Circuit diagrams 9 1 Circuit diagrams Contin...

Page 843: ...ugh 801 standard type 796 verification 817 when to calibrate 798 calibration Absolute Accuracy 797 calibration manuals 797 calibration marks 799 calibration position jogging to 818 scales 799 calibration scales 799 CalibWare 796 carbon dioxide extinguisher 21 cast iron disposal 819 cleaning 180 climbing on robot 24 Cold environments 98 connecting the robot and controller cabling 94 connection exte...

Page 844: ...osal 819 positive directions axes 800 product standards 826 protection classes 51 protection type 51 protective equipment 25 protective wear 25 R refitting cable harness 215 region specific regulations 17 release brakes 22 removing cable harness 198 replacing axis 6 gearbox 786 axis 6 motor 615 axis 6 unit 322 axis 5 motor 601 axis 4 motor 590 axis 2 and axis 3 motors 575 axis 1 gearbox 637 axis 1...

Page 845: ...tions 50 symbols safety 39 synchronization position 801 sync marks 799 system integrator requirements 17 T temperatures operation 51 storage 50 testing brakes 35 three position enabling device 29 torques on foundation 49 U updating revolution counters 801 V validity and responsibility 17 velocity adjusting 98 verifying calibration 817 W weight 49 axis 1 motor 570 652 657 659 667 669 base plate 68 ...

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Page 848: ...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 3HAC052853 001 Rev F en Copyright 2015 2018 ABB All rights reserved ...

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