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1.3.9 Safety risks related to pneumatic/hydraulic systems

General

Special safety regulations apply to pneumatic and hydraulic systems.

Note

All components that remain pressurized after separating the machine from the
power supply must be provided with clearly visible drain facilities and a warning
sign that indicates the need for pressure relief before adjustments or performing
any maintenance on the robot system.

Residual energy

Residual energy can be present in these systems. After shutdown, particular care
must be taken.

The pressure must be released in the complete pneumatic or hydraulic systems
before starting to repair them.

Work on hydraulic equipment may only be performed by persons with special
knowledge and experience of hydraulics.

All pipes, hoses, and connections have to be inspected regularly for leaks and
damage. Damage must be repaired immediately.

Splashed oil may cause injury or fire.

Safe design

Gravity may cause any parts or objects held by these systems to drop.

Dump valves should be used in case of emergency.

Shot bolts should be used to prevent tools, etc., from falling due to gravity.

34

Product manual - IRB 8700

3HAC052853-001 Revision: F

© Copyright 2015-2018 ABB. All rights reserved.

1 Safety

1.3.9 Safety risks related to pneumatic/hydraulic systems

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Summary of Contents for IRB 8700 Series

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: ...B 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 produ...

Page 5: ...s 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...

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...

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 dire...

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: ...rough 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 Safet...

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 A...

Page 11: ...g 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 r...

Page 12: ...s 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 DS...

Page 13: ...rence 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 t...

Page 14: ...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 Revis...

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...

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

Page 17: ...rried 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 accor...

Page 18: ...ed 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 specificat...

Page 19: ...l 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...

Page 20: ...iew 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 S...

Page 21: ...ishing 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 reserv...

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 furthe...

Page 23: ...roller 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 of...

Page 24: ...fety 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 i...

Page 25: ...ications 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 exter...

Page 26: ...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 U...

Page 27: ...ore 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 we...

Page 28: ...n 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...

Page 29: ...anipulator 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 program...

Page 30: ...ated 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 suc...

Page 31: ...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 2...

Page 32: ...ics 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 lo...

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 han...

Page 34: ...e 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 h...

Page 35: ...s 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...

Page 36: ...osion 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...

Page 37: ...on 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 lubrica...

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 g...

Page 39: ...cur 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 hi...

Page 40: ...OTE 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...

Page 41: ...ish 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 fa...

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 Pre...

Page 43: ...p 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...

Page 44: ...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 C...

Page 45: ...001242 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 3...

Page 46: ...at 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 steppi...

Page 47: ...ortant 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 pe...

Page 48: ...uired 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...

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...

Page 50: ...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...

Page 51: ...ty 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 temperatur...

Page 52: ...s 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 be...

Page 53: ...ows 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 reserve...

Page 54: ...lustration 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 Installa...

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...

Page 56: ...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...

Page 57: ...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 mi...

Page 58: ...d 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...

Page 59: ...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 corn...

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 t...

Page 61: ...e 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 lifti...

Page 62: ...e 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 ar...

Page 63: ...ks 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...

Page 64: ...he 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...

Page 65: ...h 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 Lubric...

Page 66: ...100 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 T...

Page 67: ...nt 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 ri...

Page 68: ...e 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...

Page 69: ...0 465 320 240 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 accurac...

Page 70: ...ing 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...

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...

Page 72: ...e 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 screw...

Page 73: ...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 Revisio...

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 weig...

Page 75: ...s 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...

Page 76: ...operty 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...

Page 77: ...nit 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 t...

Page 78: ...der 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...

Page 79: ...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 Al...

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 Des...

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 wash...

Page 82: ...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 moun...

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 FlexP...

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 wher...

Page 85: ...0 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 3HAC0528...

Page 86: ...5 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 2...

Page 87: ...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 co...

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...

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 to...

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...

Page 91: ...tandard 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 negati...

Page 92: ...hanical 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 pow...

Page 93: ...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 mova...

Page 94: ...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...

Page 95: ...ay 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...

Page 96: ...bly 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 man...

Page 97: ...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 Instal...

Page 98: ...egulated 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...

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 throu...

Page 100: ...s 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...

Page 101: ...n 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...

Page 102: ...ox 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 balanci...

Page 103: ...ovement 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 moveme...

Page 104: ...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 docume...

Page 105: ...sure 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 plu...

Page 106: ...t 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 2...

Page 107: ...ndard 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 Docu...

Page 108: ...n 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 ventilat...

Page 109: ...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 sec...

Page 110: ...ndard 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 Docu...

Page 111: ...in 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...

Page 112: ...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...

Page 113: ...n 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...

Page 114: ...is 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 taile...

Page 115: ...ndard 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 Docu...

Page 116: ...on 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...

Page 117: ...irst 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...

Page 118: ...ndard 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 Docu...

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...

Page 120: ...eference 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...

Page 121: ...pection 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 detect...

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 oi...

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 instru...

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 fo...

Page 125: ...c 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 servi...

Page 126: ...e 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 bet...

Page 127: ...ct 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...

Page 128: ...e 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 manu...

Page 129: ...ustration 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...

Page 130: ...t 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 294...

Page 131: ...o 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...

Page 132: ...ng 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 bef...

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 Al...

Page 134: ...ical 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 m...

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...

Page 136: ...d 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 00...

Page 137: ...k 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 Ar...

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 work...

Page 139: ...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 def...

Page 140: ...ce 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 Technic...

Page 141: ...ended 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 Lubricat...

Page 142: ...oceeding 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 hazard...

Page 143: ...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 pu...

Page 144: ...ssure 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 i...

Page 145: ...anual 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...

Page 146: ...k 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 ar...

Page 147: ...earboxes 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 com...

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 orde...

Page 149: ...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...

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 151: ...e 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 be...

Page 152: ...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...

Page 153: ...earboxes 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 com...

Page 154: ...ring 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 pr...

Page 155: ...l 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 drain...

Page 156: ...he 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 pro...

Page 157: ...reviously 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 prima...

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...

Page 159: ...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...

Page 160: ...king 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 grea...

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 supp...

Page 162: ...n 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 o...

Page 163: ...e 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 righ...

Page 164: ...nd 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 capacit...

Page 165: ...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 risk...

Page 166: ...e 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...

Page 167: ...cation 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...

Page 168: ...ls 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...

Page 169: ...ore 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 drainin...

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 ax...

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...

Page 172: ...quired 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...

Page 173: ...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 t...

Page 174: ...ndling 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 op...

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...

Page 176: ...wer 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 Continue...

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 resi...

Page 178: ...oss 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 pre...

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 re...

Page 180: ...n 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...

Page 181: ...er 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 encap...

Page 182: ...oling 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...

Page 183: ...erform 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 informa...

Page 184: ...e 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 compress...

Page 185: ...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 tho...

Page 186: ...rted 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 f...

Page 187: ...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 mu...

Page 188: ...ly 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 defor...

Page 189: ...2 001 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...

Page 190: ...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 butt...

Page 191: ...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 wa...

Page 192: ...r 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 up...

Page 193: ...m 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 xx15...

Page 194: ...es 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 Att...

Page 195: ...B 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 3HAC05...

Page 196: ...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 xx150...

Page 197: ...head 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...

Page 198: ...e 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 C...

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 whic...

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 ar...

Page 201: ...nscrew 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 holdin...

Page 202: ...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 Disconnecting the axis 5 motor cables Note Action DANGER Make sure that all...

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 C...

Page 204: ...s 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...

Page 205: ...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...

Page 206: ...is 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...

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...

Page 208: ...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 208 Product manual IRB 8700 3HAC052853 001 R...

Page 209: ...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...

Page 210: ...e 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...

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 sectio...

Page 212: ...e 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 xx13000...

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...

Page 214: ...00003089 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 3HAC052...

Page 215: ...l 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...

Page 216: ...wer 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 xx15...

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 th...

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...

Page 219: ...ws 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...

Page 220: ...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 damag...

Page 221: ...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...

Page 222: ...ors 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...

Page 223: ...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...

Page 224: ...nts 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 t...

Page 225: ...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...

Page 226: ...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 insid...

Page 227: ...y 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 t...

Page 228: ...94 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...

Page 229: ...es 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 3...

Page 230: ...es 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...

Page 231: ...esult 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 l...

Page 232: ...able 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...

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 w...

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 furthe...

Page 235: ...f 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 secti...

Page 236: ...e 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...

Page 237: ...hat 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...

Page 238: ...lic 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...

Page 239: ...ors 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 c...

Page 240: ...y 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 Atta...

Page 241: ...erforming 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...

Page 242: ...duct 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 numbe...

Page 243: ...ion 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...

Page 244: ...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 supp...

Page 245: ...o 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...

Page 246: ...ment 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 sa...

Page 247: ...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 te...

Page 248: ...are 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 e...

Page 249: ...49 001 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 Hydrau...

Page 250: ...lues 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...

Page 251: ...vices 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 ladde...

Page 252: ...ews 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 devi...

Page 253: ...ing 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...

Page 254: ...sent 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 balanc...

Page 255: ...ir 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 a...

Page 256: ...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...

Page 257: ...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 257 3HAC052853...

Page 258: ...ution 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 a...

Page 259: ...r 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...

Page 260: ...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 th...

Page 261: ...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 al...

Page 262: ...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 fro...

Page 263: ...ies 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 l...

Page 264: ...hickness 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...

Page 265: ...ce 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 w...

Page 266: ...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 shal...

Page 267: ...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 th...

Page 268: ...hat 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 approxi...

Page 269: ...C038174 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...

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 27...

Page 271: ...haft 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...

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...

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 xx15...

Page 274: ...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 ot...

Page 275: ...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...

Page 276: ...ed 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 t...

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 Glyceri...

Page 278: ...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...

Page 279: ...lycerine 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 D...

Page 280: ...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 280 Product manual IRB 8700 3HAC052853 001 Revisio...

Page 281: ...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 th...

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...

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...

Page 284: ...1965 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 r...

Page 285: ...e 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...

Page 286: ...ocking 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 Produ...

Page 287: ...s 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...

Page 288: ...asket 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...

Page 289: ...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 I...

Page 290: ...ake 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 attachme...

Page 291: ...able 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 Revis...

Page 292: ...bles 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 th...

Page 293: ...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 a...

Page 294: ...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...

Page 295: ...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...

Page 296: ...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 be...

Page 297: ...y 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...

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...

Page 299: ...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...

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 ba...

Page 301: ...16x35 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...

Page 302: ...edure 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...

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 AB...

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...

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 supp...

Page 306: ...331 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 pressur...

Page 307: ...0 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 hol...

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...

Page 309: ...ver 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...

Page 310: ...apacity 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 a...

Page 311: ...ssure 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 xx150...

Page 312: ...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...

Page 313: ...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 o...

Page 314: ...nd 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...

Page 315: ...ing 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 o...

Page 316: ...th 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...

Page 317: ...tor 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 s...

Page 318: ...evel 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 m...

Page 319: ...e 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...

Page 320: ...on 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 th...

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...

Page 322: ...te 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 et...

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 refe...

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...

Page 325: ...raulic 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...

Page 326: ...et 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...

Page 327: ...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 br...

Page 328: ...N 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 acc...

Page 329: ...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...

Page 330: ...e 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...

Page 331: ...milar 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 palle...

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 gro...

Page 333: ...ng 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 t...

Page 334: ...s 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...

Page 335: ...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...

Page 336: ...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 m...

Page 337: ...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 Produc...

Page 338: ...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...

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 cov...

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 c...

Page 341: ...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 ar...

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...

Page 343: ...ore 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 hyd...

Page 344: ...g 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 3HAC...

Page 345: ...d 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...

Page 346: ...n 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...

Page 347: ...ng 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 m...

Page 348: ...s 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 inj...

Page 349: ...re 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 3HAC048...

Page 350: ...nd 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...

Page 351: ...reate 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 re...

Page 352: ...upply 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 siz...

Page 353: ...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...

Page 354: ...ply 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 devi...

Page 355: ...500002303 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 scr...

Page 356: ...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 Lif...

Page 357: ...x1500001975 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...

Page 358: ...tric 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 f...

Page 359: ...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 robo...

Page 360: ...ll 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...

Page 361: ...00 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...

Page 362: ...ess 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...

Page 363: ...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 w...

Page 364: ...he 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...

Page 365: ...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 be...

Page 366: ...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 p...

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...

Page 368: ...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 su...

Page 369: ...x1200001070 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 Copy...

Page 370: ...otor 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 at...

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 su...

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 th...

Page 373: ...ove 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 tur...

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...

Page 375: ...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...

Page 376: ...emove 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 fi...

Page 377: ...00000081 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 3HAC0...

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 t...

Page 379: ...r 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...

Page 380: ...aking 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 b...

Page 381: ...er 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 Conti...

Page 382: ...he 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 overhe...

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 harn...

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...

Page 385: ...et 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 p...

Page 386: ...cordingly 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 upp...

Page 387: ...ining 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 a...

Page 388: ...e 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...

Page 389: ...ical 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 reser...

Page 390: ...e 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 Begi...

Page 391: ...ting 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 Ti...

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 3HAC0528...

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 manua...

Page 394: ...imately 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 ne...

Page 395: ...er 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...

Page 396: ...lel 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 r...

Page 397: ...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 ar...

Page 398: ...on 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 p...

Page 399: ...he 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 dia...

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...

Page 401: ...h 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...

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 sh...

Page 403: ...e 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 ad...

Page 404: ...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 P...

Page 405: ...ine 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...

Page 406: ...ealing 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...

Page 407: ...8174 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 ho...

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...

Page 409: ...0000192 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 w...

Page 410: ...ower 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 up...

Page 411: ...ached 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 brack...

Page 412: ...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 Cont...

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 8...

Page 414: ...ure 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 sc...

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...

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 thr...

Page 417: ...lse 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 r...

Page 418: ...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 M4x1...

Page 419: ...r 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 ne...

Page 420: ...ot 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 se...

Page 421: ...sed 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 s...

Page 422: ...ion 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 t...

Page 423: ...ion 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...

Page 424: ...00 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 lifti...

Page 425: ...ER 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 devi...

Page 426: ...ut 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 t...

Page 427: ...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 balanc...

Page 428: ...f 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 counterweig...

Page 429: ...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 counte...

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...

Page 431: ...ng 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...

Page 432: ...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 3HAC049074 003 Graphite White 3HAC049074 004 ABB O...

Page 433: ...ed 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...

Page 434: ...ropanol 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...

Page 435: ...ration 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 Not...

Page 436: ...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...

Page 437: ...ing 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 rob...

Page 438: ...vice 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...

Page 439: ...cing 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 platfor...

Page 440: ...1500001973 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 pres...

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 th...

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...

Page 443: ...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...

Page 444: ...s 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...

Page 445: ...ckness 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 0...

Page 446: ...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 wit...

Page 447: ...n 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...

Page 448: ...y 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...

Page 449: ...xis 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 a...

Page 450: ...et 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...

Page 451: ...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 Disconnecting the axis 5 motor cables Note Action DANGER Make sure that all...

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 C...

Page 453: ...e 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...

Page 454: ...or 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...

Page 455: ...is 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...

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...

Page 457: ...he 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 pa...

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 Th...

Page 459: ...d 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...

Page 460: ...x1600000081 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 3H...

Page 461: ...ft 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 Ho...

Page 462: ...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 cauti...

Page 463: ...t 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 shal...

Page 464: ...asher 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 Co...

Page 465: ...N 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 ove...

Page 466: ...se 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 h...

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 bra...

Page 468: ...tchet 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 VD...

Page 469: ...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...

Page 470: ...emaining 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 paralle...

Page 471: ...chet 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 par...

Page 472: ...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...

Page 473: ...cessories 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 xx150000270...

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 parall...

Page 475: ...g 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 n...

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 B...

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...

Page 478: ...ng 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 3HAC0...

Page 479: ...te 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 ma...

Page 480: ...roximately 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...

Page 481: ...asher 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...

Page 482: ...rallel 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 paralle...

Page 483: ...und 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...

Page 484: ...ution 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 nex...

Page 485: ...m 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...

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 oth...

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 p...

Page 488: ...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...

Page 489: ...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...

Page 490: ...ool 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 1...

Page 491: ...cerine 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...

Page 492: ...t 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...

Page 493: ...C038174 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...

Page 494: ...de 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 4...

Page 495: ...1600000192 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 nu...

Page 496: ...d 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...

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 br...

Page 498: ...ket 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 C...

Page 499: ...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 IR...

Page 500: ...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...

Page 501: ...le 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 Revisio...

Page 502: ...es 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...

Page 503: ...g 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 ar...

Page 504: ...ION 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 M...

Page 505: ...otor 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...

Page 506: ...ion 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...

Page 507: ...d 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 eithe...

Page 508: ...sition 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 pres...

Page 509: ...sition 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 t...

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 li...

Page 511: ...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...

Page 512: ...d 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 i...

Page 513: ...ith 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 bal...

Page 514: ...p 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 counterw...

Page 515: ...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 cou...

Page 516: ...nd 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 Calibrati...

Page 517: ...rming 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...

Page 518: ...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 Coun...

Page 519: ...moving 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 a...

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 Un...

Page 521: ...o 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 counterwei...

Page 522: ...es 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 coun...

Page 523: ...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 hole...

Page 524: ...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 wh...

Page 525: ...ot 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 sup...

Page 526: ...n 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 Cont...

Page 527: ...p 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 positio...

Page 528: ...02091 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...

Page 529: ...cure 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 per...

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...

Page 531: ...nder 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 Artic...

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 robo...

Page 533: ...n 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 sc...

Page 534: ...itting 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 w...

Page 535: ...ut 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 wei...

Page 536: ...001966 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...

Page 537: ...asher 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 Co...

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 w...

Page 539: ...ean 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 Pu...

Page 540: ...ndsling 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 pos...

Page 541: ...shers 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 an...

Page 542: ...00001966 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 nex...

Page 543: ...ol 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 side...

Page 544: ...d 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 eithe...

Page 545: ...sition 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 pres...

Page 546: ...alib 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 a...

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 Oran...

Page 548: ...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...

Page 549: ...303 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 At...

Page 550: ...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...

Page 551: ...orming 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...

Page 552: ...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 Ora...

Page 553: ...16 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...

Page 554: ...bot 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 co...

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 M...

Page 556: ...0001973 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 pressin...

Page 557: ...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...

Page 558: ...x1500002304 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 xx150000198...

Page 559: ...ars 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...

Page 560: ...e 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 cor...

Page 561: ...oring 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...

Page 562: ...n 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...

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 3HAC0...

Page 564: ...ation 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...

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...

Page 566: ...g 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 suppl...

Page 567: ...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 m...

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 contac...

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...

Page 570: ...essory 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 gr...

Page 571: ...e 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 reac...

Page 572: ...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...

Page 573: ...ment 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 Concludin...

Page 574: ...ming 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...

Page 575: ...le 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 pinio...

Page 576: ...utine 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 calibrati...

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...

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 sec...

Page 579: ...otor 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 t...

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...

Page 581: ...he 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 3HAC...

Page 582: ...ressure 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 Al...

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...

Page 584: ...e 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 ax...

Page 585: ...e 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 1...

Page 586: ...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 586 Product manual...

Page 587: ...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 screw...

Page 588: ...ic 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...

Page 589: ...tion 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 590: ...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 Rotat...

Page 591: ...cide 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 packa...

Page 592: ...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 f...

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 cautio...

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 moto...

Page 595: ...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...

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 3HAC15...

Page 597: ...ect 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 ca...

Page 598: ...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 gla...

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 m...

Page 600: ...uding 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 Calibra...

Page 601: ...949 003 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 Liftin...

Page 602: ...nstructions 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 th...

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 tu...

Page 604: ...hat 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 6...

Page 605: ...er 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 Co...

Page 606: ...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 opposit...

Page 607: ...ons 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...

Page 608: ...7 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 man...

Page 609: ...C7887 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...

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 directio...

Page 611: ...ality 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 Conti...

Page 612: ...he 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...

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...

Page 614: ...e 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 a...

Page 615: ...er 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...

Page 616: ...e 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...

Page 617: ...bot 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 o...

Page 618: ...raulic 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...

Page 619: ...et 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...

Page 620: ...on 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 bra...

Page 621: ...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 i...

Page 622: ...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 dam...

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...

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...

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...

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...

Page 627: ...xis 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 c...

Page 628: ...et 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 Flan...

Page 629: ...bed 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 requireme...

Page 630: ...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 e...

Page 631: ...es 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 axi...

Page 632: ...stion 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 scr...

Page 633: ...lly 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 need...

Page 634: ...mine 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 gre...

Page 635: ...hment 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 depend...

Page 636: ...ibration 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 a...

Page 637: ...t 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...

Page 638: ...5521 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...

Page 639: ...es 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...

Page 640: ...e 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 fro...

Page 641: ...he 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...

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...

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 xx17000...

Page 644: ...nt 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 instr...

Page 645: ...ench 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 Re...

Page 646: ...is 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 r...

Page 647: ...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...

Page 648: ...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 ma...

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...

Page 650: ...326 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 Produc...

Page 651: ...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 a...

Page 652: ...ng 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...

Page 653: ...e 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 agains...

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 655: ...ing 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 Le...

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 wor...

Page 657: ...ightening 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...

Page 658: ...ve 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...

Page 659: ...d 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 und...

Page 660: ...r 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...

Page 661: ...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...

Page 662: ...e 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 th...

Page 663: ...g 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...

Page 664: ...he 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...

Page 665: ...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 o...

Page 666: ...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...

Page 667: ...e 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...

Page 668: ...g 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...

Page 669: ...f 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 Ac...

Page 670: ...ad 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...

Page 671: ...ars 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...

Page 672: ...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 A...

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 Attachmen...

Page 674: ...e 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...

Page 675: ...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 rin...

Page 676: ...sition 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...

Page 677: ...nical 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 Ti...

Page 678: ...ation 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 ca...

Page 679: ...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 input gear...

Page 680: ...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...

Page 681: ...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...

Page 682: ...x 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 t...

Page 683: ...e 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...

Page 684: ...ck 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...

Page 685: ...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 Continue...

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 pressu...

Page 687: ...ER 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...

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...

Page 689: ...e 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 20...

Page 690: ...ng 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...

Page 691: ...ccessory 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 x...

Page 692: ...rbox 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...

Page 693: ...e 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...

Page 694: ...de 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 s...

Page 695: ...t 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 m...

Page 696: ...AC059801 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 pag...

Page 697: ...600001554 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 C...

Page 698: ...ty 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 gea...

Page 699: ...ws 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 t...

Page 700: ...e 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 IR...

Page 701: ...ting 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 Atta...

Page 702: ...ly 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 seali...

Page 703: ...e 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...

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...

Page 705: ...16x70 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 scre...

Page 706: ...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...

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 t...

Page 708: ...rease 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 gre...

Page 709: ...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 o...

Page 710: ...ntact 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 Not...

Page 711: ...site 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 x...

Page 712: ...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 direc...

Page 713: ...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 Product manual IRB 87...

Page 714: ...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...

Page 715: ...e 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...

Page 716: ...335 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 th...

Page 717: ...one 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 robo...

Page 718: ...ted 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...

Page 719: ...d 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...

Page 720: ...06 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 externa...

Page 721: ...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 r...

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 gearbo...

Page 723: ...y 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 th...

Page 724: ...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 72...

Page 725: ...tic 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...

Page 726: ...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 Continue...

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 pressu...

Page 728: ...ER 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...

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...

Page 730: ...e 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 20...

Page 731: ...ay 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...

Page 732: ...ized 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...

Page 733: ...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 screw...

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...

Page 735: ...or 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 attach...

Page 736: ...500002317 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 o...

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 man...

Page 738: ...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 se...

Page 739: ...n 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 contac...

Page 740: ...1500002341 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...

Page 741: ...sories 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 r...

Page 742: ...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 d...

Page 743: ...th 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 M16...

Page 744: ...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 hidde...

Page 745: ...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 ma...

Page 746: ...ith 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 toge...

Page 747: ...e 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 xx1...

Page 748: ...ng 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...

Page 749: ...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 pre...

Page 750: ...roove 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 Produ...

Page 751: ...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 mo...

Page 752: ...w 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 w...

Page 753: ...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 Product manual IRB...

Page 754: ...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...

Page 755: ...e 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...

Page 756: ...osition 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 positi...

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...

Page 758: ...pply 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...

Page 759: ...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...

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...

Page 761: ...les 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 57...

Page 762: ...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 act...

Page 763: ...tor 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 A...

Page 764: ...nding 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 se...

Page 765: ...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...

Page 766: ...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...

Page 767: ...ins 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 xx15000029...

Page 768: ...ar 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 whi...

Page 769: ...13056 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 a...

Page 770: ...16 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...

Page 771: ...ct 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 M12x2...

Page 772: ...se 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 xx1500...

Page 773: ...ve 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...

Page 774: ...ge 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 xx150000299...

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 th...

Page 776: ...he 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...

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 p...

Page 778: ...e 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 p...

Page 779: ...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...

Page 780: ...ge 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...

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...

Page 782: ...ing 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...

Page 783: ...n 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...

Page 784: ...54692 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 insi...

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 pag...

Page 786: ...e 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...

Page 787: ...tion 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...

Page 788: ...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 electr...

Page 789: ...draulic 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...

Page 790: ...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 ax...

Page 791: ...s 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...

Page 792: ...ect 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...

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...

Page 794: ...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...

Page 795: ...neric 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...

Page 796: ...ng 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 ro...

Page 797: ...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 manu...

Page 798: ...nter 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 o...

Page 799: ...ion 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 xx150...

Page 800: ...es 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 po...

Page 801: ...ulting 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 foun...

Page 802: ...BB 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 80...

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 3...

Page 804: ...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 co...

Page 805: ...able 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 Cal...

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...

Page 807: ...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...

Page 808: ...olution 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 accor...

Page 809: ...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...

Page 810: ...aling 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...

Page 811: ...n 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 be...

Page 812: ...R 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 c...

Page 813: ...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...

Page 814: ...libration 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...

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...

Page 816: ...ction 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 da...

Page 817: ...hange 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 wh...

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 th...

Page 819: ...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 Cove...

Page 820: ...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 r...

Page 821: ...ttery 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 mo...

Page 822: ...rocedures 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 atte...

Page 823: ...mp 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...

Page 824: ...This page is intentionally left blank...

Page 825: ...ter 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...

Page 826: ...15i 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 6...

Page 827: ...15 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 Revisio...

Page 828: ...9 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...

Page 829: ...ld 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 procee...

Page 830: ...air 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 o...

Page 831: ...ing 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...

Page 832: ...ry 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 specifica...

Page 833: ...t 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 wren...

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...

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...

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...

Page 837: ...ing 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 accessor...

Page 838: ...This page is intentionally left blank...

Page 839: ...ws 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 Copyrig...

Page 840: ...This page is intentionally left blank...

Page 841: ...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 I...

Page 842: ...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 diag...

Page 843: ...gh 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 calibrati...

Page 844: ...sal 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...

Page 845: ...ions 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 torqu...

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Page 847: ......

Page 848: ...65 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...

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