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5.4 Calibrating with Axis Calibration method

5.4.1 Description of Axis Calibration

Instructions for Axis Calibration procedure given on the FlexPendant

The actual instructions of how to perform the calibration procedure and what to
do at each step is given on the FlexPendant. You will be guided through the
calibration procedure, step by step.

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

Overview of the Axis Calibration procedure

The Axis Calibration procedure applies to all axes, and is performed on one axis
at the time. The robot axes are both manually and automatically moved into position,
as instructed on the FlexPendant.

A fixed calibration pin/bushing is installed on each robot axis at delivery.

The Axis Calibration procedure described roughly:

1 A removable calibration tool is inserted by the operator into a calibration

bushing on the axis chosen for calibration, according to instructions on the
FlexPendant.

WARNING

Calibrating the robot with Axis Calibration requires special calibration tools
from ABB. Using other pins in the calibration bushings may cause severe
damage to the robot and/or personnel.

WARNING

The calibration tool must be fully inserted into the calibration bushing, until
the steel spring ring snaps into place.

2 During the calibration procedure, RobotWare moves the robot axis chosen

for calibration so that the calibration tools get into contact. RobotWare records
values of the axis position and repeats the coming-in-contact procedure
several times to get an exact value of the axis position.

WARNING

Risk of pinching! The contact force for large robots can be up to 150 kg.
Keep a safe distance to the robot.

3 The axis position is stored in RobotWare with an active choice from the

operator.

Continues on next page

Product manual - IRB 8700

701

3HAC052853-001 Revision: M

© Copyright 2015-2020 ABB. All rights reserved.

5 Calibration

5.4.1 Description of Axis Calibration

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Summary of Contents for IRB 8700

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

Page 2: ...Trace back information Workspace 20C version a3 Checked in 2020 09 14 Skribenta version 5 3 075 ...

Page 3: ...Product manual IRB 8700 550 4 20 IRB 8700 800 3 50 IRC5 Document ID 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved Specifications subject to change without notice ...

Page 4: ...ty by ABB for losses damage to persons or property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission Keep for future reference Additional copies of this manual may be obtained f...

Page 5: ...3 1 Lifting the robot with fork lift accessory set installed 58 2 3 2 Attaching the robot and removing the fork lift accessory set 60 2 3 3 Lifting the base plate 62 2 3 4 Securing the base plate 66 2 3 5 Lifting the robot with roundslings 70 2 3 6 Returning of the ABB pallet 71 2 3 7 Manually releasing the brakes 74 2 3 8 Orienting and securing the robot 77 2 3 9 Loads fitted to the robot stoppin...

Page 6: ... 6 gearbox 168 3 4 8 Replacing the SMB battery 171 3 5 Lubrication activities 171 3 5 1 Lubricating the spherical roller bearings balancing device 173 3 5 2 Lubricating the cross roller bearing 175 3 6 Cleaning activities 175 3 6 1 Cleaning the IRB 8700 177 4 Repair 177 4 1 Introduction 178 4 2 General procedures 178 4 2 1 Performing a leak down test 179 4 2 2 Mounting instructions for bearings 18...

Page 7: ...on movement directions for all axes 697 5 3 Updating revolution counters 701 5 4 Calibrating with Axis Calibration method 701 5 4 1 Description of Axis Calibration 704 5 4 2 Calibration tools for Axis Calibration 706 5 4 3 Installation locations for the calibration tools 708 5 4 4 Axis Calibration Running the calibration procedure 713 5 4 5 Reference calibration 715 5 5 Calibrating with Wrist Opti...

Page 8: ...This page is intentionally left blank ...

Page 9: ...igns of the IRB 8700 Some variants and designs may have been removed from the business offer and are no longer available for purchase Organization of chapters The manual is organized in the following chapters Contents Chapter Safety information that must be read through before performing any installation or service work on robot Contains general safety aspects as well as more specific information ...

Page 10: ...ons Description Revision First edition The following updates are made in this revision A Repair chapter added Edited information regarding deciding calibration routine in each repair section Added a warning that calibration pin must be inserted in the calib ration bushing until it snaps see Description of Axis Calibration on page 701 Added warning regarding risk of pinching in Description of Axis ...

Page 11: ...hanged from Tribol GR 100 0 PD to Mobilux EP2 Bending radius for static floor cables added Motors updated M12 instead of M14 holes for removal tool on motors axis 1 3 Removal tool changed from 14 to 12 in required tools on axis 4 and 5 Added information that re calibration is needed after replacement of hub Added replacement information in Replacing the hub Replacing the hub on page 527 Published ...

Page 12: ...ABB Business Portal added Added Nickel in Environmental information Added article numbers for cooling fan cabling between robot base and control cabinet Published in release 19B The following updates are made in this revision G Lifting capacity of roundslings updated Suggested lifting equip ment is according to local regulations Special tools list updated Replacement methods for following spare pa...

Page 13: ...e made in this revi sion K Minor editions throughout the manual added caution when putting down balancing device during removal rotating lifting eye added note VLBG to lifting eye 3HAC16131 1 Added article numbers for floor cabling Replaced article number and name of grease previously 3HAB3537 1 Clarified and added information in mounting instructions for rotat ing sealings see Mounting instructio...

Page 14: ...ioning Reference information safety standards unit conversions screw joints lists of tools Spare parts list with corresponding figures or references to separate spare parts lists References to circuit diagrams Technical reference manuals The technical reference manuals describe reference information for robotics products for example lubrication the RAPID language and system parameters Application ...

Page 15: ...s The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters Product manual IRB 8700 15 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved Product documentation Continued ...

Page 16: ... include specific safety information when dangerous steps are to be performed Read more in the chapter Safety on page 17 Illustrations The product is illustrated with general figures that does not take painting or protection type in consideration Likewise certain work methods or general information that is valid for several product models can be illustrated with illustrations that show a different...

Page 17: ...ration of the robot when the safety devices are defective not in their intended location or in any other way not working When instructions for operation and maintenance are not followed Non authorized design modifications of the robot Repairs on the robot and its spare parts carried out by in experienced or non qualified personnel Foreign objects Force majeure Spare parts and equipment ABB supplie...

Page 18: ...ence of alcohol drugs or any other intoxicating substances are not allowed to install maintain service repair or use the robot The plant liable must make sure that the personnel is trained on the robot and on responding to emergency or abnormal situations Personal protective equipment Use personal protective equipment as stated in the product manual 18 Product manual IRB 8700 3HAC052853 001 Revisi...

Page 19: ...on which if not avoided will result in ser ious injury DANGER Signal word used to indicate a potentially hazardous situation which if not avoided could result in serious injury WARNING Signal word used to indicate a potentially hazardous situation related to electrical hazards which if not avoided could result in serious injury ELECTRICAL SHOCK Signal word used to indicate a potentially hazardous ...

Page 20: ...d to indicate where to find additional information or how to do an operation in an easier way TIP 20 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 1 Safety 1 2 1 Safety signals in the manual Continued ...

Page 21: ...ription Symbol Warning xx0900000812 Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc Caution xx090000...

Page 22: ...o not disassemble xx0900000815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the robot arm can fall down Continues on next page 22 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights rese...

Page 23: ... over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page Product manual IRB 8700 23 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 24: ...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 24 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 25: ...01242 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 25 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 26: ...t this part is pressurized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller Do not step xx1400002648 Warns that stepping on these parts can cause damage to the parts 26 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Cont...

Page 27: ...rotective stops and emergency stops are described in the product manual for the controller For more information see Product manual IRC5 Product manual IRB 8700 27 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 1 Safety 1 3 Robot stopping functions ...

Page 28: ...t if dropped or released at maximum speed The maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot The maximum TCP speed and the maximum velocity of the robot axes are detailed in the section Robot motion in the product specification for the respective manipulator Consider exposure to hazards such as slipping tripping and falling Consider...

Page 29: ...When integrating the robot with external devices to a robot system The integrator of the robot system must ensure that emergency stop functions are interlocked in accordance with applicable standards The integrator of the robot system must ensure that safety functions are interlocked in accordance with applicable standards Other hazards WARNING Never stay beneath a robot arm Gravity and the releas...

Page 30: ...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 All pipes hoses and connections have to be inspected regularly for leaks and damage Damage must be repaired immediately Verify the safety functions Before the robot system is put into operation verify that the safety functions are working as intended and that any remai...

Page 31: ... release of braking devices can create additional hazards A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment Product manual IRB 8700 31 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 1 Safety 1 5 1 Unexpected movement of robot arm ...

Page 32: ...ubricants oil or grease When handling oil grease or other chemical substances the safety information of the respective manufacturer must be observed Note Take special care when handling hot lubricants Elimination 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 h...

Page 33: ...ecified amount de pends on drained volume For lifetime reasons always drain as much oil as possible from the gearbox The magnetic oil plugs will gather residual metal chips Contaminated oil in gearboxes Hazards related to batteries Under rated conditions the electrode materials and liquid electrolyte in the batteries are sealed and not exposed to the outside There is a hazard in case of abuse mech...

Page 34: ...erform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment Related information See also the safety information related to installation and operation 34 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 1 Safety 1 6 1 Maintenance and repair Continued ...

Page 35: ...ire using an overhead crane or similar equipment Increased injury Before releasing the brakes make sure that the weight of the manipulator does not result in additional hazards for example even more severe injuries on a trapped person DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unexpected ways Make sure no personnel is near or beneath the robot Pr...

Page 36: ...s described below 1 Run each axis to a position where the combined weight of the manipulator and any load is maximized maximum static load 2 Switch the motor to the MOTORS OFF 3 Inspect and verify that the axis maintains its position If the manipulator does not change position as the motors are switched off then the brake function is adequate 36 Product manual IRB 8700 3HAC052853 001 Revision M Co...

Page 37: ...d engineers A risk assessment must be done to address both robot and robot system specific hazards WARNING Never stay beneath a robot arm Gravity and the release of braking devices can create additional hazards A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment Related information See also the safety informatio...

Page 38: ...m Gravity and the release of braking devices can create additional hazards A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment 38 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 1 Safety 1 8 Decommissioning ...

Page 39: ... extremely important that all safety information is observed There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page17 before performing any installation work Note If the IRB 8700 is connected to power always make sure that the robot is connected ...

Page 40: ...quired is suitable to handle the weight of the robot as specified in Weight robot on page 41 5 If the robot is not installed directly it must be stored as described in Storage condi tions robot on page 42 6 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 43 7 Before taking the robot to its installation...

Page 41: ... robots xy xy z z T F F T xx1100000521 Force in any direction in the XY plane Fxy Force in the Z plane Fz Bending torque in any direction in the XY plane Txy Bending torque in the Z plane Tz The table shows the various forces and torques working on the robot during different kinds of operation Note These forces and torques are extreme values that are rarely encountered during operation The values ...

Page 42: ...tion flexibility see Application manual Control ler software IRC5 section Motion Process Mode i The minimum resonance frequency given should be interpreted as the frequency of the robot mass inertia robot assumed stiff when a foundation translational torsional elasticity is added i e the stiffness of the pedestal where the robot is mounted The minimum resonance frequency should not be interpreted ...

Page 43: ...ity i At low environmental temperature below 10 C a warm up phase is recommended to be run with the robot Otherwise there is a risk that the robot stops or runs with lower performance due to temperature dependent oil and grease viscosity Protection classes robot The table shows the available protection types of the robot with the corresponding protection class Protection class Protection type IP67...

Page 44: ...olutions The default working range for axis 6 can be extended by changing parameter values in the software Option 610 1Independent axis can be used for resetting the revolu tion counter after the axis has been rotated no need for rewind ing the axis Working range axis 5 and axis 6 for LeanID option 780 4 Allowed working area for axis 6 related to axis 5 position is shown in the figure Continues on...

Page 45: ...ation shows the unrestricted working range of the robot 1197 5131 4157 R1174 Continues on next page Product manual IRB 8700 45 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range Continued ...

Page 46: ...This illustration shows the unrestricted working range of the robot 3487 4093 507 R928 46 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range Continued ...

Page 47: ...ows the robot in its shipping position and transportation position xx1400002584 Move the robot to this position 90 Axis 1 65 Axis 2 2 Axis 3 90 Axis 4 90 Axis 5 0 Axis 6 WARNING The robot will be mechanically unstable if not properly secured to the foundation Product manual IRB 8700 47 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 2 Installation and commissioning 2 2 3 Risk...

Page 48: ...5 600 IRB 8700 550 4 2 3106 1000 1580 310 149 R 340 515 R 955 257 328 G G 505 LeanID IRB 8700 800 3 5 1010 xx1400002868 48 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 2 Installation and commissioning 2 2 4 Main dimensions ...

Page 49: ...ndling Note Action Wrist straps must be tested frequently to ensure that they are not damaged and are operating cor rectly Product manual IRC5 Use a wrist strap The wrist strap button is located inside the control ler 1 The mat must be grounded through a current limit ing resistor Use an ESD protective floor mat 2 The mat should provide a controlled discharge of static voltages and must be grounde...

Page 50: ...t accessory set is only allowed if lifting is done using all four fork lift accessories Do not lift a robot with the Fork lift accessory set if any of the pockets or attachment screws are damaged or missing The operator of the fork lift truck must be fully trained and authorized to operate a fork lift truck The fork lift truck being used must have the lifting capacity to handle the weight 4 750 kg...

Page 51: ...h the fork lift accessory 3HAC055664 001 Directions for use Fork lift ac cessory for IRB 8700 Preparations before attaching the fork lift accessory set Note Action Note No extra load is permitted on the robot DressPack cable package can stay fitted as long as the tool has been removed Remove any tool attached on the turning disc Note No tool is permitted to be fitted on the robot when lifting the ...

Page 52: ...he robot before entering the safeguarded space 3 Attachment points for the fork lift accessory set Note Action The attachment points for the fork lift accessory set can be found in the four corners of the base 1 Attaching the fork lift accessory set Note Action CAUTION Each fork lift accessory pocket weights 18 kg Use caution when handling them 1 Continues on next page 52 Product manual IRB 8700 3...

Page 53: ...ury or damage 2 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 Remove the protection plugs 4 Continues on next page Product manual IRB 8700 53 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 2 Installation and commissioning 2 3 1 Lifting the robot with fork lif...

Page 54: ...robot to the foundation will be removed after the fork lift truck has its forks inserted into the fork lift accessory pockets 7 Lifting with the fork lift accessory set Preparations before lifting Note Action Note No extra load is permitted on the robot DressPack cable package can stay fitted as long as the tool has been removed Make sure that any tool attached on the turning disc has been removed...

Page 55: ...that the fork lift accessory set is properly attached and secured before lifting 4 Lifting the robot Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Release the torque on the remaining screws that secure the robot to the foundation DANGER DO NOT unscrew the attachment screws com pletely but only a few millimeters At this poin...

Page 56: ...e trucks forks into the fork lift accessory pockets without damaging anything on the robot or other equipment 5 Use caution and lift the forks of the truck up until they start touching the fork lift accessory set but not taking the weight of the robot CAUTION Do not lift up too much This will make it more difficult to remove the remaining attachment screws that secure the robot to the foundation 6...

Page 57: ...ot 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 Product manual IRB 8700 57 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 2 Installation and commissioning 2 3 1 Lifting the robot with fork lift accessory set installed Continued ...

Page 58: ...on which the robot shall be placed is clean Make sure that all foreign objects has been removed prior to putting down the robot 1 Use caution and put down the robot in its new location 2 Molykote 1000 Lubricate the attachment screws used to secure the robot to the foundation 3 Attachment screws M24x100 one in each pocket Secure the robot to the foundation while the fork lift truck is still holding...

Page 59: ...x100 one in each pocket Secure the robot to the foundation with the remain ing attachment screws DANGER DO NOT power up the robot until it is secured to the foundation with all 12 attachment screws 7 Tightening torque Lubricated screws Molykote 1000 550 Nm Tightening torque not lightly lubric ated screws 600 750 Nm typical 650 Nm Attach the protection plugs in the holes for the fork lift accessory...

Page 60: ...ent 1 pc Lifting eye M24 1 pc Lifting slings Length approx 2 m Hole configuration xx1400002587 Continues on next page 60 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 2 Installation and commissioning 2 3 3 Lifting the base plate ...

Page 61: ...le of the base plate 2 Fit the roundsling to the lifting eye and lifting accessory Use caution and lift the base plate CAUTION Lift and move the base plate very slowly If the base plate starts to swing it is a risk for injuries or damage 3 Product manual IRB 8700 61 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 2 Installation and commissioning 2 3 3 Lifting the base plate C...

Page 62: ...10 465 320 240 4x11 4x 45 4 x 4 5 4 x 1 1 4 x 9 0 320 610 465 240 E 4x 4 3 12x M24 A A 3 2 0 2 A B C D 0 5 18 1 20 1 4x 12 H7 0 018 0 1 X 45 32 1 M5 B B 0 1 F xx1500000820 Common tolerance zone accuracy all over the base plate from one contact surface to the other A B C D Continues on next page 62 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 2 Insta...

Page 63: ...ling bolts in the base plate A A A A B B B B xx1400002594 Orienting grooves 4 pcs A Levelling bolts attachment holes M20 through 4 pcs B Continues on next page Product manual IRB 8700 63 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 2 Installation and commissioning 2 3 4 Securing the base plate Continued ...

Page 64: ... page 733 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Base plate This section details how to secure the base plate to the foundation Note Action Make sure the foundation is levelled 1 CAUTION The base plate weighs 760 kg All lifting ac cessories used m...

Page 65: ...he base plate and use the levelling bolts to level the base plate 6 If required fit strips of sheet metal underneath the base plate to fill any gaps 7 Secure the base plate to the foundation with screws and sleeves 8 Maximum allowed deviation all over the base plate from one contact surface to the other 0 3 mm Recheck the four contact surfaces on the base plate to make sure the base plate is level...

Page 66: ... the roundslings 3550 200 50 1150 50 2x L 2 1m 2x L 2m A B Continues on next page 66 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 2 Installation and commissioning 2 3 5 Lifting the robot with roundslings ...

Page 67: ...Certex TPG 4 or equivalent 3HAC038295 003 Lifting eyes M24 Lifting capacity 5 000 kg 4 pcs i Roundsling 2 m When lifting use them to lengthen the roundsling to 2 1 m Adjustable lifting chain i This is a recommendation according to standard EN 1492 Always conform to local regulations Continues on next page Product manual IRB 8700 67 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reser...

Page 68: ...le if not secured to the foundation 1 CAUTION The weight of the IRB 8700 robot is 4 750 kg All lifting accessories used must be sized accordingly 2 A A Lifting eye M24 4 pcs Fit lifting eyes to the holes on frame and counter weight respectively 3 Continues on next page 68 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 2 Installation and commissioning ...

Page 69: ...lings fitted to the lifting eyes on the counter weight on the out side of the balancing devices CAUTION If the lifting eyes have sharp edges that might damage the roundslings lifting shackles must be used to attach the roundslings to the lifting eyes 4 Stretch the roundslings to take the weight of the robot 5 WARNING Personnel must not under any circum stances be present under the suspended load 6...

Page 70: ... of ABB It must therefore be returned within the specified time after the arrival of the robot system If the pallet is not returned it will be invoiced For more information and instructions see http new abb com Irb8700pallet 70 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 2 Installation and commissioning 2 3 6 Returning of the ABB pallet ...

Page 71: ...unit on page 71 The internal brake release unit is equipped with buttons for controlling the axes brakes The buttons are numbered according to the numbers of the axes If the robot is not connected to the controller power must be supplied to the connector R1 MP according to the section Supplying power to connector R1 MP on page 72 1 Note The IRB 8700 has two R1 MP connectors R1 MP A and R1 MP B How...

Page 72: ...rder to enable the brake release buttons Note The IRB 8700 has two R1 MP connectors R1 MP A and R1 MP B See table how to supply power to the connectors Note Action DANGER Incorrect connections such as supplying power to the wrong pin may cause all brakes to be released simultaneously 1 MP A MP B 24V pin 11 MP B 0V pin 12 MP A xx1500001989 Valid for axes 1 2 and 3 Supply 0V on pin 12 R1 MP A Supply...

Page 73: ...n 12 R1 MP B Supply 24V on pin 11 R1 MP B Note Only R1 MP B contact is used when relas ing the brakes on axis 4 5 and 6 3 Product manual IRB 8700 73 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 2 Installation and commissioning 2 3 7 Manually releasing the brakes Continued ...

Page 74: ...ioning 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 Description Pos Holes for guide pins x2 Section K K Continues on next page 74 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 2 Installation and commissioning 2 3 ...

Page 75: ...foundation M24 x 100 Suitable screws lightly lubricated 12 pcs Quantity 8 8 Quality 90 v 0 9 Screw tightening yield point utilization factor v according to VDI2230 4 mm flat washer Suitable washer 550 Nm screws lubricated with Molykote 1000 Tightening torque 600 725 Nm typical 650 Nm screws none or lightly lubricated Continues on next page Product manual IRB 8700 75 3HAC052853 001 Revision M Copyr...

Page 76: ...t 2 Move robot close to its installation location 3 Make sure the robot base is correctly fitted onto the guide sleeves Guide the robot gently using two M24 screws while lowering it into its mounting position 4 Specified in Attachment screws on page 75 Fit the bolts and washers in the base attachment holes Note Lightly lubricate screws before assembly 5 Tighten bolts in a crosswise pattern to ensu...

Page 77: ... robot References Load diagrams permitted extra loads equipment and their positions are specified in the product specification The loads must be defined in the software Operating manual IRC5 with FlexPendant Stopping time and braking distances The performance of the motor brake depends on if there are any loads attached to the robot For more information see product specification for the robot Prod...

Page 78: ... arm load and robot payload Frame hip load Extra load can be fitted on the frame Description JH 200 kgm2 Permitted extra load on frame JH JH0 M4 x R2 Recommended position see the fol lowing figure where JH0 is the moment of inertia of the equipment R is the radius m from the center of axis 1 M4 is the total mass kg of the equipment including bracket and harness 500 kg R xx1400002873 Continues on n...

Page 79: ...00 mm from the center of gravity in the axis 3 extension a A M1 M1 xx1400002874 Mass center A 510 400 A xx1400002875 Center of gravity 50 kg A Continues on next page Product manual IRB 8700 79 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 2 Installation and commissioning 2 3 10 Fitting equipment Continued ...

Page 80: ...15 4x M12 22 A 106 4xM12 A A 57 57 R152 5 4x M8 15 A A 38 B B C C xx1400002876 Holes located on both sides A Continues on next page 80 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 2 Installation and commissioning 2 3 10 Fitting equipment Continued ...

Page 81: ...8 A 257 A D D E E xx1500000869 Measure from center axis 6 A Continues on next page Product manual IRB 8700 81 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 2 Installation and commissioning 2 3 10 Fitting equipment Continued ...

Page 82: ... 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 82 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 2 Installation and commissioning 2 3 10 Fitting equipment Continued ...

Page 83: ... C D 0 2 DC B 160 H7 0 040 0 14 8 35 0 1 315 h8 0 0 081 1 X 45 290 13 12 8 SECTION B B 1 6 1 6 2 5 0 02 A C 3 0 3 5 M A X SECTION C C xx1400002878 Fastener quality Use suitable screws and tightening torque for your application Product manual IRB 8700 83 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 2 Installation and commissioning 2 3 10 Fitting equipment Continued ...

Page 84: ... of the following axes may be restricted Axis 1 hardware mechanical stop This section describes how to install hardware that restricts the working range Note Adjustments must also be made in the robot configuration software system parameters References to relevant manuals are included in the installation procedures 84 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All ri...

Page 85: ...standard without working range limitation 4 3 5x15 75 32 6x15 90 6x15 90 9 2 5x15 75 Min angle 17 positive direction Min angle 32 negative direction Max angle 73 negative direction Min angle 122 negative direction Max angle 43 positive direction Min angle 92 positive direction Max angle 118 positive direction Min angle 167 positive direction xx1400002593 Continues on next page Product manual IRB 8...

Page 86: ...chanical stops axis 1 Use this procedure to fit the additional mechanical stops to axis 1 of the robot An assembly drawing is also enclosed with the product Note Action DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot air pressure supply to the robot Before entering the robot working area 1 Continues on next page 86 Product manual IRB 8700 3HAC052853 00...

Page 87: ...g range limitations system parameter configuration to corres pond to the mechanical limitations 3 WARNING If the mechanical stop pin is deformed after a hard collision it must be replaced Deformed movable stops and or additional stops as well as deformed attachment screws must also be replaced after a hard collision 4 Product manual IRB 8700 87 3HAC052853 001 Revision M Copyright 2015 2020 ABB All...

Page 88: ...cables also handle databus communication See the product manual for the controller see document number in References on page 10 Handles signals process media and power feeding for customer use regarding material handling or spot welding DressPack cables option See the Product manual DressPack SpotPack IRB 8700 see document number in References on page 10 Robot cables These cables are included in t...

Page 89: ...C2566 1 30 m Bending radius for static floor cables The minimum bending radius is 10 times the cable diameter for static floor cables A B xx1600002016 Diameter A Diameter x10 B Continues on next page Product manual IRB 8700 89 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 2 Installation and commissioning 2 5 1 Robot cabling and connection points Continued ...

Page 90: ... the motor cooling fans on page 93 Cabling between robot base and control cabinet cooling fans The cables specified below are specific for the IRC5 controller and used when the robot is equipped with cooling fans The cabling for the cooling fans runs all the way from the robot base to the inside of the cabinet Fans can also be ordered without cables If equipping the robot with cooling fans use the...

Page 91: ...SW2 3 3HAC022723 005 Harness cooling 22 m Inside cabinet A43 X10 and A43 X11 Distributing cable R1 FAN SW2 3 3HAC022723 006 Harness cooling 30 m Inside cabinet A43 X10 and A43 X11 Product manual IRB 8700 91 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 2 Installation and commissioning 2 5 1 Robot cabling and connection points Continued ...

Page 92: ...mbly instruction delivered with the signal lamp Function The lamp is active in MOTORS ON mode Further information Further information about the MOTORS ON MOTORS OFF mode may be found in the product manual for the controller 92 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 2 Installation and commissioning 2 6 1 Signal lamp option ...

Page 93: ...n All required installation information is enclosed with the fan packages sent from ABB Service Product manual IRB 8700 93 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 2 Installation and commissioning 2 6 2 Installing the motor cooling fans ...

Page 94: ...must manually be changed from first ADU to third ADU because the manipulator uses the two first See type Drive Unit in topic Motion in Technical reference manual System parameters xx2000001771 94 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 2 Installation and commissioning 2 6 3 Installing additional motor units or gear units ...

Page 95: ...regulated with the RAPID instruction VelSet Start the robot with its normal program but with reduced speed 1 Adjusting the speed and acceleration during warm up Depending on how cold the environment is and what program is being used the speed might need to be ramped up until reached maximum The table shows examples of how to adjust the speed Speed velocity AccSet Work cycles v100 100 mm s 20 20 3 ...

Page 96: ...This page is intentionally left blank ...

Page 97: ...intenance activity Safety information Observe all safety information before conducting any service work There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page 17 before performing any service work Note If the IRB 8700 is connected to power always...

Page 98: ...with the functionality Service Information System activated can show active counters in the device browser in RobotStudio or on the FlexPendant Overhaul Depending on application and operational environment a complete overhaul may be necessary in average around 40000 hours ABB Connected Services and its Assessment tools can help you to identify the real stress level of your robot and define the opt...

Page 99: ... in axis 1 gearbox on page 102 x Inspecting the oil level in axis 1 gearbox Inspecting the oil level in axis 2 and 3 gearboxes on page105 x Inspecting the oil level in axis 2 gearbox Inspecting the oil level in axis 2 and 3 gearboxes on page105 x Inspecting the oil level in axis 3 gearbox Inspecting the oil level in axis 4 primary gearbox on page108 x Inspecting the oil level in axis 4 primary gea...

Page 100: ...box Replacing the SMB battery on page 168 x iii Replacing the SMB battery pack Lubrication activities Lubricating the spherical roller bearings balancing device on page 171 x iv Lubricating the balancing device bearings Lubricating the cross roller bearing on page 173 x Lubricating the cross roller bearing Overhaul Contact your local ABB Cus tomer Service office www abb com robotics xv Overhaul of...

Page 101: ...movement most material handling applications ii Severe chemical or thermal environments or similar environments can result in shortened life expectancy iii Examples of extreme usage in regard to movement press tending very severe palletizing applications major use of axis 1 movement iv The given life for the balancing device is based on a test cycle of 4 000 000 cycles that starts from the initial...

Page 102: ... 733 Standard toolkit Required consumable Note Article number Consumable Information about the oil is found in Technical reference manu al Lubrication in gearboxes Lubrication oil Required documents Note Document number Document 3HAC042927 001 Technical reference manual Lub rication in gearboxes Continues on next page 102 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB Al...

Page 103: ...g shall be opened prior to the inspection plug in order to release possible pressure inside 4 Open the inspection plug 5 Inspect the oil level 6 Required oil level is a few millimeters below the lower edge of the inspection hole 7 Type of oil and total amount is de tailed in Technical reference manual Lubrication in gearboxes Add or drain oil if required 8 Further information about how to drain or...

Page 104: ...afety requirements are met when performing the first test run 10 104 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 3 Maintenance 3 3 1 Inspecting the oil level in axis 1 gearbox Continued ...

Page 105: ... toolkit Required consumable Note Article number Consumable Information about the oil is found in Technical reference manu al Lubrication in gearboxes Lubrication oil Required documents Note Document number Document 3HAC042927 001 Technical reference manual Lub rication in gearboxes Continues on next page Product manual IRB 8700 105 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights rese...

Page 106: ...ion plug Note The ventilation plug shall be opened prior to the inspection plug in order to release possible pressure inside 4 Open the inspection plug 5 Inspect the oil level 6 Required oil level is a few millimeters below the lower edge of the inspection hole 7 Type of oil and total amount is de tailed in Technical reference manual Lubrication in gearboxes Add or drain oil if required 8 Further ...

Page 107: ...y requirements are met when performing the first test run 10 Product manual IRB 8700 107 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 3 Maintenance 3 3 2 Inspecting the oil level in axis 2 and 3 gearboxes Continued ...

Page 108: ...toolkit Required consumable Note Article number Consumable Information about the oil is found in Technical reference manu al Lubrication in gearboxes Lubrication oil Required documents Note Document number Document 3HAC042927 001 Technical reference manual Lub rication in gearboxes Continues on next page 108 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reser...

Page 109: ...The ventilation plug shall be opened prior to the inspection plug in order to release possible pressure inside 4 Open the inspection plug 5 Inspect the oil level 6 Required oil level is a few millimeters below the lower edge of the inspection hole 7 Type of oil and total amount is de tailed in Technical reference manual Lubrication in gearboxes Add or drain oil if required 8 Further information ab...

Page 110: ...GER Make sure all safety requirements are met when performing the first test run 10 110 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 3 Maintenance 3 3 3 Inspecting the oil level in axis 4 primary gearbox Continued ...

Page 111: ...ut the oil is found in Technical reference manu al Lubrication in gearboxes Lubrication oil Required documents Note Document number Document 3HAC042927 001 Technical reference manual Lub rication in gearboxes Inspecting the oil level in axis 4 secondary gearbox Note Action Jog axis 2 to 60 position approximately 1 Jog axis 3 to 10 position approximately 2 Continues on next page Product manual IRB ...

Page 112: ...wly to approximately 3 5 position until oil starts to spill out 7 Required oil level is when oil starts to spill out with axis 3 in 3 5 position 8 Type of oil and total amount is de tailed in Technical reference manual Lubrication in gearboxes Add or drain oil if required 9 Further information about how to drain or fill with oil is found in sec tion Changing oil axis 4 secondary gearbox on page 15...

Page 113: ...toolkit Required consumable Note Article number Consumable Information about the oil is found in Technical reference manu al Lubrication in gearboxes Lubrication oil Required documents Note Document number Document 3HAC042927 001 Technical reference manual Lub rication in gearboxes Continues on next page Product manual IRB 8700 113 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reser...

Page 114: ...side that will be released when the plug is opened 4 Jog axis 4 very slowly until oil is visible in the in spection hole approximately 54 position 5 Inspect the oil level 6 Required oil level is when the oil level is visible just below the lower edge of the inspection hole with axis 4 approximately in 54 position 7 Type of oil and total amount is de tailed in Technical reference manual Lubrication...

Page 115: ...the oil is found in Technical reference manu al Lubrication in gearboxes Lubrication oil Required documents Note Document number Document 3HAC042927 001 Technical reference manual Lub rication in gearboxes Inspecting the oil level in axis 6 gearbox Note Action Jog the robot to a comfortable working position in regard of getting access to the axis 6 gearbox 1 Continues on next page Product manual I...

Page 116: ... 3 Jog axis 5 approximately 75 4 CAUTION The gearbox can contain an excess of pressure that can be hazardous Use caution when the oil plug is opened in order to let out the excess pressure 5 Open the combined inspection and ventilation plug 6 Inspect the oil level by slowly jogging the axis 5 further 7 to approximately 82 totally CAUTION Excessive oil can be spilled 7 Continues on next page 116 Pr...

Page 117: ...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 163 Tightening torque 24 Nm Refit the oil plug 10 DANGER Make sure all safety requirements are met when performing the first test run 11 Product manual IRB 8700 117 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 3 Mainte...

Page 118: ...ng the transparent oil plugs The gearboxes are equipped with transparent plugs through which oil leakage from the hubs can be detected If an oil leakage is detected remove the hub and replace the defective part radial sealing or o ring Note If only a few drops of oil are detected is not necessarily a sign of an oil leakage A few drops of oil inside can normally be released from the hub But if oil ...

Page 119: ...lip Tip Add an extra 2 mm shim between the hub and the radial sealing to eliminate the problem Tip In a clean environment the transparent oil plugs can be removed Do not remove the transparent oil plugs in other than clean environments Product manual IRB 8700 119 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 3 Maintenance 3 3 7 Inspecting the transparent plugs Continued ...

Page 120: ...e space Inspection points balancing devices The balancing devices are located on either side of the lower arm as shown in the figure The figure also shows the inspection points further described in the instructions Required tools Visual inspection no tools are required Continues on next page 120 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 3 Mainten...

Page 121: ... such as scratches general wear uneven surfaces or incorrect positions Action Inspection points If damage is detected perform maintenance according to given instructions in the maintenance set Check for damage on the part of the piston rod that is visible on the balancing device 1 Inspection for leakage The upper and lower ears of the balancing devices are lubricated with grease Leaks at V rings e...

Page 122: ...ic power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Keep the areas around the balancing devices clean and free from objects such as service tools etc 2 122 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 3 Maintenance 3 3 8 Inspecting the balancing devices Continued ...

Page 123: ...ply air pressure supply to the robot before entering the robot working area 1 Pay special attention to the areas of axis 2 and axis 3 movement Make sure the cabling is not dam aged in any way between the cable brackets in these areas Perform an overall inspection of the cable harness in order to detect wear and damage 2 Continues on next page Product manual IRB 8700 123 3HAC052853 001 Revision M C...

Page 124: ...ect the cable harness running through the protection tube in the frame to detect possible cable chafing Use a hand inside the tube to feel the cables Ensure that the cables are undam aged 6 Remove any objects that may cause possible cable chafing Replace the cable harness if wear cracks or other damage is detected 7 124 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All ...

Page 125: ... symbols are described in section Safety symbols on manipulator labels on page21 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 Product manual IRB 8700 125 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 3 Maintenance 3 3 10 Inspecting the information labels ...

Page 126: ...700000979 Calibration label A 3HAC 4517 1 03 xx1700000980 Warning label Risk of crush injuries B Oil specification label C Continues on next page 126 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 3 Maintenance 3 3 10 Inspecting the information labels Continued ...

Page 127: ...ut off with handle See user documentation Moving robot Brake release buttons E Complete oil specification F 4 xx1700000981 Warning label Tip risk when loosening bolts G Grease specification label H 29454489 16 xx1700000984 Instruction plate Heat J Continues on next page Product manual IRB 8700 127 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 3 Maintenance 3 3 10 Inspecting...

Page 128: ... no tools are required Inspecting labels Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 1 Inspect the labels located as shown in the figures 2 Article numbers for the labels and plate set is specified in Spare parts on page 741 Replace any missing or damaged labels 3 128 Product manual IRB 8700 ...

Page 129: ...ting mechanical stop pin Use this procedure to inspect the axis 1 mechanical stop pin Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 1 Continues on next page Product manual IRB 8700 129 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 3 Maintenance 3 3 11 Inspecting the axis...

Page 130: ... damaged it must be replaced Note The expected life of gearboxes can be reduced after collision with the mechanical stop 130 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 3 Maintenance 3 3 11 Inspecting the axis 1 mechanical stop pin Continued ...

Page 131: ...nical stop pin axis 1 C Required equipment Note Article number Equipment etc Includes Mechanical stop 2 pcs Attachment screw and washer 4 4 pcs Document for mechanical stop pin 3HAC053706 001 Movable mechanical stop axis 1 Content is defined in section Standard toolkit on page 733 Standard toolkit Continues on next page Product manual IRB 8700 131 3HAC052853 001 Revision M Copyright 2015 2020 ABB ...

Page 132: ... 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 page131 If any damage is detected the mechanical stops must be replaced Correct attachment screws M16x90 quality 12 9 Gleitmo 603 2 pcs per additional mechanical stop 4 132 Product manual IRB 8700 3HAC052853 001 Re...

Page 133: ...re A B C CE label A Fork lift pocket 4 pcs B Attachment screws MC6S 20x60 8 8 2x4 pcs C Required equipment Note Article number Equipment 3HAC053662 003 Fork lift accessory Continues on next page Product manual IRB 8700 133 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 3 Maintenance 3 3 13 Inspecting the fork lift accessories ...

Page 134: ...or damage 2 Inspect the attachment screws for deformation and other type of damage 3 Tightening torque 300 Nm Make sure the fork lift pockets are properly attached 4 pcs 4 Article number is specified in Required equipment on page131 If any damage is detected the fork lift pockets and attachment screws must be replaced 5 Attachment screws M20x60 quality steel 8 8 A3F 134 Product manual IRB 8700 3HA...

Page 135: ...t 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 safeguarded space 2 Article number is specified in Re quired tools and equipment on page 135 If the lamp is not lit trace the fault by inspecting whether the signal lamp is broken If so replace it inspecting ...

Page 136: ...e supply to the robot before entering the robot working area 1 Inspect all dampers for damage cracks or existing impressions larger than 1 mm 2 Inspect the attachment screws for deformation 3 Damper lower and parallel arms 3HAC12991 1 7 pcs If any damage is detected the damper and or screws must be replaced with new ones 4 Attachment screws M6x20 1x7 pcs Damper wrist 3HAC050601 001 2 pcs Attachmen...

Page 137: ...as the amount in the specific gearbox can be found in Technical reference manual Lubrication in gearboxes available for registered users on myABB Business Portal www mypo rtal abb com Location of gearboxes The figure shows the location of the gearboxes Equipment Note Equipment Includes pump with outlet pipe Oil dispenser Use the suggested dispenser or a similar one Orion OriCan article number 2259...

Page 138: ...for use of a oil dispenser when filling or draining oil Left Required consumable Note Material Information about the oil is found in Technical refer ence manual Lubrication in gearboxes Lubricating oil See Type and amount of oil in gearboxes on page137 Required tools and equipment Note Article number Equipment etc The capacity of the vessel must be sufficient to take the complete amount of oil Oil...

Page 139: ...gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 32 2 CAUTION The gearbox may contain an excessive pressure that can be hazardous Open the oil plug carefully to let the excess pressure out 3 Open the ventilation plug WARNING If the ventilation hole is closed when the oil dispenser is in use there is a risk of damaging vital parts in the gear 4 Continues on nex...

Page 140: ...d oil is hazardous material and must be disposed of in a safe way See section Decommissioning on page719 for more in formation 8 Remove the oil dispenser 9 Remove the oil filling nipple put the protect ive cap on and put the oil filling hose into the connection box 10 Continues on next page 140 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 3 Maintena...

Page 141: ...electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 32 2 Continues on next page Product manual IRB 8700 141 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 3 Maintenance 3 4 2 Changing oil axis 1 gearbox ...

Page 142: ... Lubrication in gearboxes Refill the gearbox with oil by using the oil dispenser Note The amount of oil to be filled depends on the amount previously being drained 6 See Type and amount of oil in gearboxes on page 137 Inspect the oil level 7 Required oil level 58 mm 5 mm below the sealing surface of the oil plug Remove the oil dispenser 8 Continues on next page 142 Product manual IRB 8700 3HAC0528...

Page 143: ...fter all repair and maintenance work 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 12 Product manual IRB 8700 143 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 3 Maintenance 3 4 2 Changing oil axis 1 gearbox Continued ...

Page 144: ...ricating oil See Type and amount of oil in gearboxes on page137 Required tools and equipment Note Article number Equipment etc The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel One example of oil dispenser can be found in section Type of lubrication in gearboxes on page 137 Oil dispenser Content is defined in section Standard toolkit on page 733...

Page 145: ...CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 3 Remove the plug from the ventilation hole WARNING If the ventilation hole is not open when the oil dispenser is working there is a risk of damaging vital parts in the gear 4 Remove the protection cap from the nipple of the oil draining plug and connect ...

Page 146: ...f the oil draining plug 8 Tightening torque 24 Nm Refit the ventilation plug 9 Filling oil into the axis 2 and axis 3 gearboxes Use this procedure to refill the gearbox with oil Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Continues on next page 146 Product manual IRB 8700 3HAC052853 001 Re...

Page 147: ...ling plug and connect the oil dispenser 5 Type of oil and total amount is detailed in Technical reference manual Lubrication in gearboxes Refill the gearbox with oil using the oil dispenser Note The amount of oil to be filled depends on the amount previously being drained 6 See Type of lubrication in gearboxes on page 137 Continues on next page Product manual IRB 8700 147 3HAC052853 001 Revision M...

Page 148: ...he oil dispenser and refit the protection cap to the nipple of the oil filling plug 8 Tightening torque 24 Nm Refit the inspection plug 9 Tightening torque 24 Nm Refit the ventilation plug 10 DANGER Make sure all safety requirements are met when performing the first test run 11 148 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 3 Maintenance 3 4 3 Cha...

Page 149: ...ricating oil See Type and amount of oil in gearboxes on page137 Required tools and equipment Note Article number Equipment etc The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel One example of oil dispenser can be found in section Type of lubrication in gearboxes on page 137 Oil dispenser Content is defined in section Standard toolkit on page 733...

Page 150: ...ain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 4 Remove the plug from the ventilation hole WARNING If the ventilation hole is not open when the oil dispenser is working there is a risk of damaging vital parts in the gear 5 Remove the protection cap from the nipple of the oil draining plug and connect the oil dispenser 6 Continue...

Page 151: ...ation 8 Remove the oil dispenser and refit the protection cap to the nipple of the oil draining plug 9 Tightening torque 24 Nm Refit the ventilation plug 10 Filling oil into the axis 4 primary gearbox Note Action Jog the robot to a comfortable working position 1 Continues on next page Product manual IRB 8700 151 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 3 Maintenance 3 ...

Page 152: ...ge 32 3 Open the ventilation plug Note The ventilation plug is opened to let out air during the filling process WARNING If the ventilation hole is not open when the oil dispenser is working there is a risk of damaging vital parts in the gear 4 Open the inspection plug 5 Continues on next page 152 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 3 Mainte...

Page 153: ...amount previously being drained 7 See Type and amount of oil in gearboxes on page 137 Required oil level is 0 10 mm below the oil plug hole Inspect the oil level 8 See Inspecting the oil level in axis 4 primary gearbox on page 108 Remove the oil dispenser and refit the protection cap to the nipple of the oil filling plug 9 Continues on next page Product manual IRB 8700 153 3HAC052853 001 Revision ...

Page 154: ...4 Nm Refit the ventilation plug 11 DANGER Make sure all safety requirements are met when performing the first test run 12 154 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 3 Maintenance 3 4 4 Changing oil axis 4 primary gearbox Continued ...

Page 155: ...e and amount of oil in gearboxes on page137 Required tools and equipment Note Article number Equipment etc The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel Content is defined in section Standard toolkit on page 733 Standard toolkit Required documents Note Document number Document name 3HAC042927 001 Technical reference manu al Lubrication in ge...

Page 156: ...ssure supply to the robot before entering the robot working area 2 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 32 3 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 4 Place the oil collecting vessel underneath the oil drain plug 5 Remove the oi...

Page 157: ...n position Ax1 No significance as long as the robot is secured to the founda tion Ax2 comfortable working position Ax3 3 5 Ax4 0 Ax5 0 Ax6 No significance 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on pa...

Page 158: ...pe and amount of oil in gearboxes on page 137 The level is measured at the fill hole Inspect the oil level 7 Required oil level is 0 10 mm below the oil plug hole See Inspecting the oil level in axis 4 sec ondary gearbox on page 111 Tightening torque 24 Nm Refit the oil plugs 8 DANGER Make sure all safety requirements are met when performing the first test run 9 158 Product manual IRB 8700 3HAC052...

Page 159: ...ing oil See Type and amount of oil in gearboxes on page137 Required tools and equipment Note Article number Equipment etc The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel Content is defined in section Standard toolkit on page 733 Standard toolkit Required documents Note Document number Document name 3HAC042927 001 Technical reference manu al Lu...

Page 160: ...he robot working area 2 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 32 3 CAUTION The gearbox may contain an overpressure that can be hazardous Open the oil plug carefully to let the excess pressure out 4 Place the oil collecting vessel underneath the oil draining plug 5 Remove the oil draining plug and let the oil run into the vessel 6 Co...

Page 161: ... the oil plugs 10 Filling oil into the axis 5 gearbox Note Action Jog the robot to the specified position Axis 1 no significance as long as the robot is secured to the founda tion Axis 2 as far forward as possible Axis 3 0 Axis 4 60 approximately Axis 5 0 Axis 6 no significance 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering th...

Page 162: ...5 See Type and amount of oil in gearboxes on page 137 See Inspecting the oil level in axis 5 gear box on page 113 Inspect the oil level at the combined oil filling inspection ventilation hole 6 Tightening torque 24 Nm Refit the oil plugs 7 DANGER Make sure all safety requirements are met when performing the first test run 8 162 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ...

Page 163: ...ment Note Article number Equipment etc The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel Content is defined in section Standard toolkit on page 733 Standard toolkit Required documents Note Document number Document name 3HAC042927 001 Technical reference manu al Lubrication in gearboxes Draining the axis 6 gearbox Note Action Jog the robot to a c...

Page 164: ...NG Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 32 4 Place the oil collecting vessel underneath the oil draining plug 5 CAUTION The gearbox may contain an overpressure that can be hazardous Open the oil plug carefully to let the excess pressure out 6 Remove the oil plug from the combined filling inspection ventilation hole Note The plug is opened ...

Page 165: ... 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 Jog axis 5 so that the tilt house is horizont al turning disc points straight forward 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot wor...

Page 166: ...6 See Type and amount of oil in gearboxes on page 137 Jog axis 5 approximately 75 7 Inspect the oil level by slowly jogging the axis 5 further 7 to approximately 82 totally CAUTION Excessive oil can be spilled 8 Required oil level is when the oil level is visible just below the lower edge of the in spection hole with axis 5 approximately jogged 82 from the starting position 9 Continues on next pag...

Page 167: ...o drain or fill with oil is found in section Changing oil axis 6 gearbox on page 163 Tightening torque 24 Nm Refit the oil plug 11 DANGER Make sure all safety requirements are met when performing the first test run 12 Product manual IRB 8700 167 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 3 Maintenance 3 4 7 Changing oil axis 6 gearbox Continued ...

Page 168: ...eep the power to the controller turned on until the battery is to be replaced Required tools Note Article number Equipment etc Content is defined in section Standard toolkit on page 733 Standard toolkit Required spare parts Note Article number Spare part Battery includes protection circuits Only replace with a specified spare part or an ABB approved equivalent For spare part number see Spare parts...

Page 169: ... 49 3 Remove the SMB battery cover CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures 4 Pull out the battery and disconnect the battery cable 5 Remove the SMB battery Note Battery includes protection circuits Only replace with a specified spare part or with an ABB ap proved equivalent 6 WARNING A used batter...

Page 170: ...mation in the sec tion The unit is sensitive to ESD on page 49 2 Reconnect the battery cable and install the battery pack into the SMB battery recess 3 Secure the SMB battery cover with its attachment screws 4 See Updating revolution counters on page 697 Update the revolution counters 5 DANGER Make sure all safety requirements are met when performing the first test run 6 170 Product manual IRB 870...

Page 171: ... and lower ends of the balancing devices Consumable Note Article number Equipment etc Tribol GR 100 0 PD 50 ml 3HAC042534 001 Grease Used for lubrication of the spherical roller bearing Continues on next page Product manual IRB 8700 171 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 3 Maintenance 3 5 1 Lubricating the spherical roller bearings balancing device ...

Page 172: ... Grease 3HAC042534 001 Unscrew both screws on either side of the bearing and fill grease from one of the holes until grease appears in the other hole 2 Refit the two screws 3 Wipe clean from residual grease 4 Note Inspect the bearings after a few days run ning Some of the refilled grease may have emerged from the bearing Wipe clean from residual grease 5 172 Product manual IRB 8700 3HAC052853 001 ...

Page 173: ...ller bearing Lubricating the cross roller bearing Use this procedure to lubricate the cross roller bearing Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Continues on next page Product manual IRB 8700 173 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 3 Maintenance 3 5 ...

Page 174: ...the two screws 3 Wipe clean from residual grease 4 Note Inspect the cross roller bearing after a few days running Some of the refilled grease may have emerged from the bearing Wipe clean from residual grease 5 174 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 3 Maintenance 3 5 2 Lubricating the cross roller bearing Continued ...

Page 175: ...ations see Inspection activities on page 102 2 Write down the oil level 3 Inspect the oil level again after for example 6 months 4 If the oil level is decreased then replace the gearbox Special cleaning considerations This section specifies some special considerations when cleaning the robot Always use cleaning equipment as specified Any other cleaning equipment may shorten the life of the robot A...

Page 176: ...encapsulation 0 4 meters Maximum flow 20 liters minI I Typical tap water pressure and flow Instructions for steam or high pressure water cleaning ABB robots with protection types Foundry Plus Wash or Foundry Prime can be cleaned using a steam cleaner or high pressure water cleaner 2 The following list defines the prerequisites Maximum water pressure at the nozzle 2500 kN m2 25 bar Fan jet nozzle s...

Page 177: ... the article number and the revision of both the replaced unit and the replacement unit This is particularly important for safety equipment to maintain the safety integrity of the installation Safety information Make sure to read through the chapter Safety on page 17 before commencing any service work Note If the IRB 8700 is connected to power always make sure that the IRB 8700 is connected to pro...

Page 178: ...he pressure must under no circumstance be higher than 0 25 bar 20 25 kPa Also during the time when the pressure is raised 3 0 2 0 25 bar 20 25 kPa Disconnect the compressed air supply 4 If the compressed air is signific antly colder or warmer than the gearbox to be tested a slight pressure increase or decrease may occur This is quite normal Wait for approximately 8 10 minutes and make sure that no...

Page 179: ...exposed to any stresses during the assembly work 3 Assembly of tapered bearings Follow the preceding instructions for the assembly of the bearings when mounting a tapered bearing on the robot In addition to those instructions the following procedure must be carried out to enable the roller elements to adjust to the correct position against the race flange Note Action Tension the bearing gradually ...

Page 180: ...arted During operation the bearing should be filled to 70 80 of the available volume Ensure that grease is handled and stored properly to avoid contamination Grease the different types of bearings as following description Grooved ball bearings must be filled with grease from both sides Tapered roller bearings and axial needle bearings must be greased in the split condition 180 Product manual IRB 8...

Page 181: ...ction Check the sealing to ensure that The sealing is of the correct type There is no damage on the main lip 1 Inspect the shaft surface before mounting If scratches or damage are found the shaft must be replaced since it may result in future leakage Do not try to grind or polish the shaft surface to get rid of the defect 2 Article number is specified in Equipment on page 181 A B C xx2000000071 A ...

Page 182: ...d because leakage could occur Clean the surfaces properly in accordance with the recommendations of ABB 2 Distribute the sealing compound evenly over the surface preferably with a brush 3 Tighten the screws evenly 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 damag...

Page 183: ...ontamination Lubricate the o ring with grease 4 Tighten the screws evenly while assembling 5 Check that the o ring is not squashed outside the o ring groove 6 Product manual IRB 8700 183 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 2 3 Mounting instructions for sealings Continued ...

Page 184: ...int Standard Foundry Plus ABB Orange 3HAC037052 001 Touch up paint Standard Foundry Plus Removing Description Action xx0900000121 Cut the paint with a knife in the joint between the part that will be removed and the struc ture to avoid that the paint cracks 1 Carefully grind the paint edge that is left on the structure to a smooth surface 2 184 Product manual IRB 8700 3HAC052853 001 Revision M Cop...

Page 185: ...e to the robot Elimination To eliminate the danger after service work has been performed inside the SMB recess follow the procedure below Action Make sure the power is turned off 1 Remove the push button guard if necessary 2 Verify that the push buttons of the brake release unit are working by pressing them down one by one 3 Make sure none of the buttons are jammed in the tube If a button gets jam...

Page 186: ...d for lifting upper arm Lifting capa city 2 000 kg on each roundsling Roundsling 2 5 m 1 pcs Roundsling 3 m 1 pcs VLBG M12 3HAC16131 1 Lifting eye Outer diameter minimum 26 mm hole diameter 13 mm thickness 3 mm Fender washer Continues on next page 186 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 3 1 Attaching lifting accessories to the up...

Page 187: ...ignificance 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Attaching lifting accessories to the upper arm complete Note Action CAUTION The complete upper arm weighs 900 kg All lifting accessories used must be sized accordingly 1 Mobile platform ladder If needed use a Mobile platform ladder or similar t...

Page 188: ...er washer Outer diameter minimum 26 mm hole diameter 13 mm thickness 3 mm Roundsling 2 5 m with lifting capacity 2 000 kg i xx1500002713 Attach a roundsling looped to the Lifting eye and to an overhead crane or similar xx1400002599 5 Continues on next page 188 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 3 1 Attaching lifting accessories ...

Page 189: ...ch the lifting accessories to take the weight of the upper arm 7 Adjust the lifting accessories if needed 8 i This is a recommendation according to standard EN 1492 Always conform to local regulations Product manual IRB 8700 189 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 3 1 Attaching lifting accessories to the upper arm Continued ...

Page 190: ...IRB 6700 but the principle is the same Required tools and equipment Note Article number Equipment etc Lifting capacity 1 000 kg Roundsling 1 m Continues on next page 190 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 3 2 Attaching lifting accessories to the wrist ...

Page 191: ...6 no significance 1 Attaching lifting accessories to the wrist Note Action CAUTION The complete wrist weighs 500 kg All lifting accessories used must be sized accordingly 1 Mobile platform ladder xx1500001985 Use a Mobile platform ladder or similar to attach the lifting accessories DANGER Never use the robot as ladder 2 Continues on next page Product manual IRB 8700 191 3HAC052853 001 Revision M C...

Page 192: ...the lifting accessories to take the weight of the wrist 4 Adjust the lifting accessories if needed 5 i This is a recommendation according to standard EN 1492 Always conform to local regulations 192 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 3 2 Attaching lifting accessories to the wrist Continued ...

Page 193: ...latest spare parts of the IRB 8700 via myABB Business Portal www mypo rtal abb com Note Article number Spare part 3HAC050792 001 Cable harness Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 733 Standard toolkit ESD bag Continues on next page Product manual IRB 8700 193 3HAC052853 001 Revision M Copyright 2015 2020 ABB All right...

Page 194: ... axis 5 as close as possible to 90 2 Jog the robot to the specified position Axis 1 0 Axis 2 comfortable working position Axis 3 comfortable working position Axis 4 0 Axis 5 90 Axis 6 Depending on which tool is used if still fitted 3 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 4 Retrieving access to the...

Page 195: ... Cut the cable tie that secures the axis 6 motor cable 3 Disconnecting the axis 6 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 8700 195 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 196: ...Unscrew the attachment screws and re move the motor cover Note Do not damage the gasket Replace if damaged 3 xx1300000488 Disconnect the motor cables 4 xx1300000484 Unscrew the attachment screws holding the cable bracket 5 Continues on next page 196 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 197: ...tion and pull out the axis 6 motor cables by holding the cables at the motor with one hand and the other one at the carrier 8 Disconnecting the axis 5 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 8700 197 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights res...

Page 198: ... 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 198 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 199: ...es 6 Disconnecting the axis 1 axis 2 axis 3 and axis 4 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws with washers and remove the motor cover 2 Continues on next page Product manual IRB 8700 199 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Rep...

Page 200: ...s facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Removing the cable harness in the upper arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 200 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ...

Page 201: ...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 screw is reached from the outside 5 Continues on next page Product manual IRB 8700 201 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 202: ... remove the cable harness out of the upper arm 9 Disconnecting the cable harness in the base Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 202 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 203: ...wrench xx1500003084 Disconnect R1 SMB Tip Use a Sparkplug wrench or similar xx1200000888 4 xx1500003085 Remove the two earth cables 5 Continues on next page Product manual IRB 8700 203 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 204: ...R Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Axis 2 motor cable xx1500003091 Cut the cable ties that secure the axis 2 and axis 3 motor cables to the cable fixing brackets 2 Axis 3 motor cable xx1500003090 Continues on next page 204 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 4 1...

Page 205: ...le harness in the lower arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1500002695 If not already done unscrew the screws that hold the two cable brackets inside the lower arm Note The screws are reached from the outside 2 Continues on next page Product manual IRB 8700 205 3HAC052853 001 Revision M Copyright 2015 2020 A...

Page 206: ... pressure supply to the robot before entering the robot working area 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 49 2 xx1300000829 Open the small battery cover on the SMB cover dis connect the battery cable and remove the battery 3 Continues on next page 206 Product manual...

Page 207: ...re are turned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 49 2 xx1300000670 If needed disconnect the brake release unit connect ors X8 X9 and X10 3 xx1300000730 Remove the screws with washers that hold bracket with the SMB unit 4 Continues on next page Product manual I...

Page 208: ... unit 6 ESD bag Keep the SMB unit in an ESD bag until it shall be re fitted 7 Removing the SMB BU cables Note Action DANGER Make sure that all supplies for electrical power hy draulic pressure and air pressure are turned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 49 2...

Page 209: ...500003089 Use caution and pull out the cable harness from the SMB recess 4 Concluding procedure Note Action Use caution and remove the cable harness from the robot 1 Product manual IRB 8700 209 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 210: ...a myABB Business Portal www mypo rtal abb com Note Article number Spare part 3HAC050792 001 Cable harness Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 733 Standard toolkit Used to remove and refit the R1 SMB in the base Sparkplug wrench Continues on next page 210 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 201...

Page 211: ...ower hydraulic pressure and air pressure are turned off 1 Attachment screws M6x16 stainless steel A2 70 4 pcs Refit the connection plate in the base if it has been removed 2 Tightening torque 6 Nm xx1500003088 Use caution and run the cable harness through the hole in the frame and out to the base plate 3 Continues on next page Product manual IRB 8700 211 3HAC052853 001 Revision M Copyright 2015 20...

Page 212: ... twisted or tangled Do not fasten the axis 1 bracket yet 4 A B xx1600000078 A Bar code B Hole for pin 1 Before refitting the R1 MP A and R1 MP B contacts make sure that the hole for pin 1 as well as the bar code will be on the left side See figure 5 xx1500003083 Refit the R1 MP A and R1 MP B contacts Note Run the cables on top of each other through the base without being twisted 6 Screws M6x20 sta...

Page 213: ... the two earth cables 9 Refitting the cable harness in the lower arm Note Action Run the cable harness up through the lower arm 1 Note Make sure the cable harness is rotated one revolution between the upper and lower bracket inside the lower arm when refitted 2 Continues on next page Product manual IRB 8700 213 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 4 2 Re...

Page 214: ...ews are reached from the outside 3 xx1600000075 Refit upper and lower cable guides 4 The figure show the positions of the cable guides Continues on next page 214 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 215: ...n the cables for SMB and brake release units into the SMB recess 5 Attachment screws M6x16 4 pcs xx1500003086 Use caution and refit the SMB BU cover in its hole from inside the SMB recess without damaging the o ring Note Do not tighten the screws fully It must still be possible to adjust the position of the cable harness by rotating the SMB BU cover in its hole a little 6 Continues on next page Pr...

Page 216: ...e cables must be placed so that they don t rub against any part of the robot 7 xx1500003086 Secure the SMB BU cover from inside the SMB recess 8 Refitting the SMB unit Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 216 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights...

Page 217: ...tors to the SMB board R1 SMB1 3 R1 SMB4 6 and R2 SMB 4 xx1300000730 Carefully push the SMB unit into position and refit the bracket 5 X9 X8 X10 xx1700000978 If disconnected reconnect the connectors X8 X9 and X10 to the brake release board Be careful not to damage the sockets or pins Make sure the connector and its locking arms are snapped down properly 6 Continues on next page Product manual IRB 8...

Page 218: ...6 Nm 9 Refitting the SMB battery Note Action ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 49 1 Get a hold of the battery cable in the recess for the battery and reconnect 2 xx1300000829 Place the battery in the recess 3 Continues on next page 218 Product manual IRB 8700 3HAC0...

Page 219: ...ints down through the hole in the frame to the base plate to the axis 1 motor to the axis 2 motor to the axis 3 motor to the SMB BU recess Adjust the cables if needed The different cables must not be twisted or tangled Do not fasten the axis 1 bracket yet 1 xx1600000080 Run the cables to axis 1 and axis 3 motors through the hole on the right side of the frame 2 xx1600000079 Run the cables to axis ...

Page 220: ...s 2 and axis 3 motor cables with cable ties 6 xx1500003090 Connecting the axis 1 axis 2 axis 3 and axis 4 motor cables Note Action xx1300000738 Push the motor cables in through the cable gland opening 1 Continues on next page 220 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 221: ...n o ring and o ring groove 4 xx1200001070 Inspect the o ring Note Replace if damaged 5 O ring 3HAC054692 002 Refit the o ring 6 CAUTION When refitting the motor cover make sure none of the cables inside will be damaged 7 Continues on next page Product manual IRB 8700 221 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 222: ...ly sealed 9 Refitting the cable harness in the upper arm Note Action Carefully push the cable harness in through the upper arm and out of the wrist 1 Nut M6 xx1500002720 Refit the cable clamp inside the upper arm Note The screw is attached from the outside 2 Attachment screw M8 xx1500002719 Refit the protection cover 3 Continues on next page 222 Product manual IRB 8700 3HAC052853 001 Revision M Co...

Page 223: ...094 Make sure that the gasket on the cover is correctly fitted Note Replace if damaged The gasket is covered with adhesive on the side facing the upper arm cover The three washers are pressed into the holes in the gasket Make sure all three washers are fitted 7 Continues on next page Product manual IRB 8700 223 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 4 2 Re...

Page 224: ...les in through the cable gland opening 1 Attachment screws M5x16 2 pcs xx1200001016 Refit the cable gland cover Note Replace the gasket if damaged 2 Continues on next page 224 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 225: ...les inside will be dam aged 5 Attachment screws M5x12 8 8 7 pcs xx1200001013 Refit the motor cover Note Do not reuse the self threading attachment screws Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is properly fitted and undamaged 6 Continues on next page Product manual IRB 8700 225 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights re...

Page 226: ...result will be damage to the cable harness 1 xx1300001113 Use caution and push the carrier into posi tion 2 Attachment screws M4x10 xx1300000485 Secure the carrier with the M4 screw Note The screw is located at the bottom of the carrier Tip The screw that secure the carrier may be difficult to fit Make sure the carrier is level and completely pressed against the bottom 3 Continues on next page 226...

Page 227: ...cable underneath the motor cable 5 xx1500003095 Make sure the gasket on the motor cover is undamaged Note Replace if damaged 6 CAUTION Make sure not to damage the cables inside the motor when refitting the motor cover 7 Continues on next page Product manual IRB 8700 227 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 228: ... sealant and other contamination from the contact sur faces of the wrist cover 10 xx1600000046 Make sure the contact surface of the wrist cover is undamaged 11 Loctite 574 Apply flange sealant on the wrist cover flange 12 Place the cable harness so it will not be damaged when fitting the cover 13 Continues on next page 228 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB A...

Page 229: ...5 12 9 17 pcs Tightening torque 24 Nm Concluding procedure Note Action See Updating revolution counters on page 697 Update the revolution counters 1 DANGER Make sure all safety requirements are met when performing the first test run 2 Product manual IRB 8700 229 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 230: ...he IRB 8700 via myABB Business Portal www mypo rtal abb com Note Article number Spare part RMU102 3HAC043904 001 SMB Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 733 Standard toolkit ESD bag Continues on next page 230 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 4 3 ...

Page 231: ...ve to ESD on page 49 2 xx1300000829 Open the small battery cover on the SMB cover dis connect the battery cable and remove the battery 3 xx1300000669 Remove the SMB cover CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures 4 Disconnecting and removing the SMB unit Note Action DANGER Make sure that all supplie...

Page 232: ...that hold bracket with the SMB unit 4 xx1300000728 Carefully pull the SMB unit out a little and disconnect the connectors from the SMB board R1 SMB1 3 R1 SMB4 6 and R2 SMB Battery cable connector R2 G Disconnect the battery cable by pressing down the upper lip of the R2 G connector to release the lock while pulling the connector upwards 5 xx1700000993 Continues on next page 232 Product manual IRB ...

Page 233: ...ulic pressure and air pressure are turned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 49 2 xx1300000729 Connect the battery cable to the SMB unit Make sure the lock snaps into place during refit ting 3 Continues on next page Product manual IRB 8700 233 3HAC052853 001 R...

Page 234: ...tors X8 X9 and X10 to the brake release board Be careful not to damage the sockets or pins Make sure the connector and its locking arms are snapped down properly 6 xx1300000834 Take a hold of the SMB cover and pull the battery cable out through the recess for the battery 7 Continues on next page 234 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Rep...

Page 235: ...he unit is sensitive to ESD on page 49 1 Get a hold of the battery cable in the recess for the battery and reconnect 2 xx1300000829 Place the battery in the recess 3 Attachment screws M6x16 8 8 2 pcs Refit the battery cover 4 Tightening torque 6 Nm Concluding procedure Note Action See Updating revolution counters on page 697 Update the revolution counter 1 DANGER Make sure all safety requirements ...

Page 236: ...700 via myABB Business Portal www mypo rtal abb com Note Article number Spare part Brake release unit DSQC1052 and harness 3HAC065021 001 Brake release unit Required tools and equipment Note Article number Equipment etc ESD bag Content is defined in section Standard toolkit on page 733 Standard toolkit Continues on next page 236 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020...

Page 237: ...tion The unit is sensitive to ESD on page 49 2 xx1300000743 Remove the push button guard from the SMB cover The push button guard must be removed to ensure a correct refitting of the brake release unit 3 xx1300000742 Remove the SMB cover 4 The battery can stay connected to avoid needing to synchronize the robot CAUTION Carefully put the SMB cover down to avoid damaging the battery cable connectors...

Page 238: ...d to the brake release board 3 xx1300000670 Use caution and remove the connectors X8 X9 and X10 from the brake release board 4 Removing the brake release unit Note Action DANGER Make sure that all supplies for electrical power hy draulic pressure and air pressure are turned off 1 Unscrew the attachment screws securing the brake release unit bracket 2 xx1300000744 Remove the bracket with the brake ...

Page 239: ...to the bracket 2 xx1300000744 Refit the bracket with the brake release unit fitted Make sure the unit is placed as straight as possible on the bracket The push buttons can otherwise get jammed when the SMB cover is refitted 3 X9 X8 X10 xx1700000978 Reconnect the connectors X8 X9 and X10 to the brake release unit Be careful not to damage the sockets or pins Make sure the connector and its locking a...

Page 240: ...hment screws M6x16 8 8 6 pcs xx1300000742 Refit the SMB cover with its attachment screws Note Do not refit the push button guard at this point 6 WARNING Before continuing any service work follow the safety procedure in section The brake release buttons may be jammed after service work on page 185 7 Attachment screws M5x16 8 8 6 pcs xx1300000743 Refit the push button guard to the SMB cover 8 Contin...

Page 241: ...ng revolution counters on page 697 The revolution 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 11 Product manual IRB 8700 241 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 4 4 Replacing the brake release unit Continued ...

Page 242: ...rt numbers that are listed in the table can be out of date See the latest spare parts of the IRB 8700 via myABB Business Portal www mypo rtal abb com Note Article number Spare part 3HAC048079 006 Upper arm excluding wrist Continues on next page 242 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm ...

Page 243: ...354 001 Press tools parallel rod shaft To be used with the hydraulic cylinder Maximum allowed working pressure 700 bar Hydraulic pump 700 bar Used when replacing the parallel rod and mechanical stop pin as a safety measure Piece of wood D 152 L 220 3HAC069154 009 Sleeve KM nut Used to replace upper arm shafts to gether with a glycerine press tool Glycerine adapter Set of tools User instructions 3H...

Page 244: ...eference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values fo...

Page 245: ...2310 Jog the robot to calibration position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Unloading the pressure of the balancing devices Use this procedure to unload both balancing devices Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turne...

Page 246: ...vice Note Keep the screws They shall be refitted after the work is done 3 M16x35 Screw M16x80 Fully threaded 2 pcs 2 pcs Apply some Molykote on threads and at the bottom end of two fully threaded screws used for unloading the balancing device 4 Apply Molykote on colored areas xx1500002303 Continues on next page 246 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All right...

Page 247: ...e removed unload the pressure of the other in the same way 6 Removing both balancing devices Use this procedure to remove both balancing devices Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Mobile platform ladder xx1500001985 Use a mobile platform ladder to reach the upper end of the balancing device DANGER Do not use the ...

Page 248: ...o lift the balancing device on the axis 4 motor side xx1500001983 A lifting tool is required on the axis 4 motor side to avoid pressure on the motor during lifting Stretch the lifting accessories to unload the balancing device weight 5 Sleeve KM nut M10 3HAC071313 001 xx1500001973 Remove upper and lower KM nuts V rings and support rings 6 Continues on next page 248 Product manual IRB 8700 3HAC0528...

Page 249: ...ing the balan cing device bearings on page 454 8 Pallet Put the balancing device down CAUTION Be careful when putting down the balancing device The balancing device ear and pis ton rod should not take any weight 9 Tip Turn a pallet upside down and place the balancing device in the opening for the trucks forks This will prevent the balancing device from starting to move unexpectedly Continues on ne...

Page 250: ...ectric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Retrieving access to the wrist cabling Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1500003100 Remove the wrist cover Note Do not damage the sealing Replace if damaged Note The position of axis 4 depend...

Page 251: ... that the axis 5 is as close to 90 or 90 position as possible depend ing on what repair work is being done Note Not needed if only replacing the axis 6 unit 2 xx1200001080 Unscrew the attachment screws and re move the motor cover Note Do not damage the gasket Replace if damaged 3 Continues on next page Product manual IRB 8700 251 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserve...

Page 252: ...ding the cable bracket 5 xx1300000485 Unscrew the screw holding the carrier Note The screw is located at the bottom of the carrier 6 Continues on next page 252 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 253: ...the other one at the carrier 8 Disconnecting the axis 5 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws with washers and remove the motor cover 2 Continues on next page Product manual IRB 8700 253 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Re...

Page 254: ...cover Tip Make a note in which direction the cable exit hole is facing if the motor shall be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Continues on next page 254 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 255: ...ed off 1 xx1200001135 Unscrew the attachment screws and washers and remove the 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 255 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 256: ...harness in the upper arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1500003092 Remove the cable clamp on the axis 3 bracket between axis 4 motor and arm housing 2 xx1500002718 Unscrew the screw that holds the cable clamp at the end of the axis 3 bracket 3 Continues on next page 256 Product manual IRB 8700 3HAC052853 00...

Page 257: ...e the upper arm Note The screw is reached from the outside 5 xx1500002721 Cut the cable tie located underneath the axis 4 motor 6 xx1500002722 Unscrew the screws that secure the cover 7 Continues on next page Product manual IRB 8700 257 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 258: ... upper arm weighs 900 kg All lifting accessories used must be sized accordingly 1 Mobile platform ladder If needed use a Mobile platform ladder or similar to attach the lifting accessories DANGER Never use the robot as ladder 2 Continues on next page 258 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 259: ...LBG M12 Fender washer Outer diameter minimum 26 mm hole diameter 13 mm thickness 3 mm Roundsling 2 5 m with lifting capacity 2 000 kg i xx1500002713 Attach a roundsling looped to the Lifting eye and to an overhead crane or similar xx1400002599 5 Continues on next page Product manual IRB 8700 259 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the uppe...

Page 260: ...s 2 motor Note Action xx1500002724 Before continuing make sure that the upper arm is secured in the lifting accessories and overhead crane Stretch the lifting accessories to unload the upper arm weight CAUTION The upper arm including the wrist weighs approx imately 900 kg All lifting accessories must be sized accordingly 1 In order to release the brakes connect the 24 VDC power supply 2 Connect co...

Page 261: ...ure 1 xx1400002600 Remove the attachment screw with washer that secure the rod shaft 2 This is done to prevent the upper arm wings from pinching when pressing the shaft and thereby making it more difficult to press the shaft in or out Remove the protection plugs 4 4 pcs and fit 2 2 M10x80 screws in the holes Adjust the screws against the parallel rod from both sides Note Keep the protection plugs ...

Page 262: ...e tool incorrectly may cause serious injury Read and follow enclosed user instructions for the tool Note Action This is to be able to remove the parallel rod without problems and to be able to find the correct position of the parallel rod when refitting it xx1500002710 Unscrew two of the M10x80 screws approx imately 5 mm on one side of the parallel rod Leave the screws on the other side 5 Continue...

Page 263: ...ly later 6 xx1500001965 Move the parallel rod down and let it rest on the piece of wood which was put there earlier 7 Strap xx1500002716 Secure bearing thrust washer and cover washer with a strap or similar to prevent them from dropping out of its position 8 Continues on next page Product manual IRB 8700 263 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 1 Repla...

Page 264: ...axis 2 and axis 3 shaft ends and around the KM nuts on both sides 2 Sleeve KM nut D 152 L 220 3HAC069154 009 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 3 Continues on next page 264 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 1 Replaci...

Page 265: ...the removal on the same side until the shaft is removed completely Leave the other shaft fitted for now 6 xx1500003125 Remove the magnetic plug and wipe hole and shaft end meticulously clean 7 Continues on next page Product manual IRB 8700 265 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 266: ... and follow enclosed user instructions for the tool Removing the upper arm Note Action DANGER Make sure that all supplies 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 Lift away the upper arm 3 Pallet 2 pcs Put the upper arm down on two pallets 4 Continues...

Page 267: ...h the lifting accessories DANGER Never use the robot as ladder 2 xx1500002712 Remove the plastic plug from 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 3HAC16131 1 VLBG M12 Fender washer Outer diameter minimum 26 mm hole diameter 13 mm thickness 3 mm Continues on next page Product manual IRB 8700 2...

Page 268: ...ing looped to the wrist and to an overhead crane or similar 6 xx1500002724 Stretch the lifting accessories to take the weight of the upper arm 7 Adjust the lifting accessories if needed 8 i This is a recommendation according to standard EN 1492 Always conform to local regulations Continues on next page 268 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserve...

Page 269: ...e refitted 1 Scotch brite abrasive cleaning hand pad xx1500002749 Use a Scotch brite abrasive cleaning hand pad and rub the contact surfaces on follow ing parts contact surfaces on the shafts contact surfaces in the holes for the shafts outer ring of bearings and sealing rings 2 xx1500002750 Continues on next page Product manual IRB 8700 269 3HAC052853 001 Revision M Copyright 2015 2020 ABB All ri...

Page 270: ...s outer ring of bearings and sealing rings Note Do not touch the cleaned surfaces with anything after cleaning 3 xx1500002979 xx1500002750 xx1500002748 Inspect the sealing rings and then wipe them clean with Isopropanol Replace if damaged 4 Continues on next page 270 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm...

Page 271: ...ngs the upper arm shafts and the KM nuts xx0900000813 Press tools upper arm shaft 3HAC069154 001 User instructions upper arm shaft press tools 3HAC069154 038 WARNING Handling the tool incorrectly may cause serious injury Read and follow enclosed user instructions for the tool Refitting parallel rod upper end Note Action Note If the parallel rod has been removed from the robot always start refittin...

Page 272: ...er side of the bearing and make sure that they are correctly fitted Note Make sure that the washers are on the correct sides of the bearing 12 Unscrew two of the M10x80 screws only on one side of the parallel rod approxim ately 5 mm Leave the screws fastened on the other side Note This is done to be able to refit the parallel rod without problems and to be able to find the correct position of the ...

Page 273: ...od shaft xx0900000813 Press tools parallel rod shaft 3HAC071354 001 User instructions parallel rod shaft press tools 3HAC071354 002 WARNING Handling the tool incorrectly may cause serious injury Read and follow enclosed user instructions for the tool Note Action xx1500001967 Refit the protection plug 15 Attachment screw M10x16 8 8 Apply locking liquid on the attachment screw and secure shaft 16 Lo...

Page 274: ...in through the upper arm and out of the wrist 1 Nut M6 xx1500002720 Refit the cable clamp inside the upper arm Note The screw is attached from the outside 2 Attachment screw M8 xx1500002719 Refit the protection cover 3 Continues on next page 274 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 275: ...03094 Make sure that the gasket on the cover is correctly fitted Note Replace if damaged The gasket is covered with adhesive on the side facing the upper arm cover The three washers are pressed into the holes in the gasket Make sure all three washers are fitted 7 Continues on next page Product manual IRB 8700 275 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 1 ...

Page 276: ... Push the motor cables through the cable gland opening 1 xx1200001067 Refit the cable gland cover Note Replace the gasket if damaged 2 Continues on next page 276 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 277: ... O ring axis 4 3HAC054692 002 xx1200001070 Wipe clean o ring and o ring groove 5 Refit the o ring Tip Lubricate the o ring with some grease for a better fitting in the groove 6 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 7 Continues on next page Product manual IRB 8700 277 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Rep...

Page 278: ...ads will be damaged Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Connecting the axis 5 motor cables Note Action xx1500002717 Push the motor cables in through the cable gland opening 1 Continues on next page 278 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upp...

Page 279: ...h the markings on the connectors 3 O ring 3HAC054692 002 xx1200001070 Inspect the o ring Note Replace if damaged 4 CAUTION When refitting the motor cover make sure that none of the cables inside will be dam aged 5 Continues on next page Product manual IRB 8700 279 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 280: ... 1 Note Since this procedure requires the axis 5 to be put in 90 position the connecting and refitting of the axis 6 motor cables must be done in two steps This procedure describes the first of these steps Note Action With axis 5 in 90 position use caution and temporarily connect the axis 6 motor cables outside the motor 1 xx1300000488 Reconnect the connectors to the axis 6 motor 2 Continues on ne...

Page 281: ...any of the axis 6 motor cables 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Disconnect the axis 6 motor cables 3 Connecting the axis 6 motor cables Step 2 Note Action Make sure that the axis 5 now is in 90 position before continuing 1 If not the cable spiral will be attached in the wrong position and...

Page 282: ...e attachment screw that secure the car rier may be difficult to fit Make sure the carrier is level and completely pressed against the bottom 3 Attachment screws M6x16 2 pcs xx1300000484 Secure the cable bracket with its attach ment screws 4 Continues on next page 282 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm...

Page 283: ...able 5 Gasket 3HAC033489 001 xx1200001095 Inspect the gasket Note Replace if damaged 6 xx1600000047 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 7 Continues on next page Product manual IRB 8700 283 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 284: ...ly hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Preparations before refitting the balancing device Note Action CAUTION The balancing device weighs 200 kg All lifting accessories used must be sized accordingly 1 Continues on next page 284 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 ...

Page 285: ...e caution and lift the balancing device up an let it hang in the lifting accessories 4 Wipe clean the contact surfaces 5 Grease xx1500002304 Apply some grease on shafts and in bear ing holes Note Do not apply any grease on the threads for the KM nut 6 If needed fit bearings into the balancing device ears according to Replacing the balancing device bearings on page 454 7 Continues on next page Prod...

Page 286: ... DANGER Do not use the robot as ladder 1 xx1500002735 Use caution and raise the balancing device into mounting position 2 xx1500002306 Note Make sure the bearings are axially centered in the balancing device ears before putting them on the shafts 3 Continues on next page 286 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the u...

Page 287: ...er shafts 5 Press tools balancing device lower end 3HAC057130 015 xx1500002305 Press the upper and lower part onto the shafts using the press tool Locking liquid Loctite 243 xx1900001235 Apply locking liquid on the threads of the lock nuts 6 Inspect that the bearings are axially centered in the balancing device ears 7 Continues on next page Product manual IRB 8700 287 3HAC052853 001 Revision M Cop...

Page 288: ...e bearings Lubricate each bearing with 30 gram of bearing grease 10 Wipe away surplus grease and refit the M6x10 screws 11 If both balancing devices shall be refitted refit the other in the same way 12 Restoring the pressure of the balancing device Note Action Mobile platform ladder xx1500001985 Use a Mobile platform ladder or similar to reach the upper end of the balancing device DANGER Do not us...

Page 289: ...M16x35 screws in the holes on top of the balancing device 4 Concluding procedure Note Action Clean the wrist cover from residues of sealant and other contamination 1 xx1600000046 Make sure the contact surface on the wrist cover is undamaged 2 Continues on next page Product manual IRB 8700 289 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper a...

Page 290: ... position of axis 4 depends on the on going procedure 5 Tightening torque 24 Nm xx1500003100 xx1500002330 Axis Calibration is described in Calibrating with Axis Calibration method on page 701 Recalibrate the robot 6 General calibration information is included in section Calibration on page 691 DANGER Make sure all safety requirements are met when performing the first test run 7 290 Product manual ...

Page 291: ... table can be out of date See the latest spare parts of the IRB 8700 via myABB Business Portal www mypo rtal abb com Note Article number Color Spare part 3HAC048653 006 Graphite White Wrist 3HAC048653 004 ABB Orange Wrist Continues on next page Product manual IRB 8700 291 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist ...

Page 292: ... the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in...

Page 293: ... Mobile platform ladder xx1500001985 Use a Mobile platform ladder or similar to reach the wrist DANGER Do not use the robot as ladder 4 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 5 Retrieving access to the wrist cabling Note Action DANGER Make sure that all supplies for electrical power hydraulic press...

Page 294: ...2331 Cut the cable tie that secures the axis 6 motor cable 3 Disconnecting the axis 6 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 294 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 295: ...80 Unscrew the attachment screws and re move the motor cover Note Do not damage the gasket Replace if damaged 3 xx1300000488 Disconnect the motor cables 4 xx1300000484 Unscrew the attachment screws holding the cable bracket 5 Continues on next page Product manual IRB 8700 295 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 296: ... caution and pull out the axis 6 motor cables by holding the cables at the motor with one hand and the other one at the carrier 8 Disconnecting the axis 5 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 296 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights...

Page 297: ...over 2 xx1200001070 Note Make sure the o ring is present when re moving the cover 3 xx1200001066 Disconnect the motor cables 4 Continues on next page Product manual IRB 8700 297 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 298: ...capacity 1 000 kg xx1300000673 The figure show the IRB 6700 but the prin ciple is the same Attach a roundsling choked as shown in the figure CAUTION It is very important that the roundsling is placed as shown in the figure in order to keep the wrist balanced when it is removed Placed at a different position there is a risk of sudden change in the balance which may cause damage or injury WARNING Do...

Page 299: ...essure are turned off 1 xx1500003103 Remove two attachment screws in opposite holes and replace them with guide pins Tip Lubricate the guide pins with some grease to make the wrist slide better 2 xx1500003104 Remove the remaining attachment screws 3 Continues on next page Product manual IRB 8700 299 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 2 Replacing the ...

Page 300: ...5 xx1500003107 CAUTION When the wrist is hanging free the front end will tend to lean slightly downwards 6 Put down the wrist on a pallet or similar 7 Refitting the wrist Use these procedures to refit the wrist Preparations before refitting the wrist Note Action Clean the contact surfaces on wrist and arm tube flange 1 Continues on next page 300 Product manual IRB 8700 3HAC052853 001 Revision M Co...

Page 301: ...n in the figure CAUTION It is very important that the roundsling is placed as shown in the figure in order to keep the wrist balanced when it is removed Placed at a different position there is a risk of sudden change in the balance which can cause damage or injury CAUTION Make sure the roundsling is fitted as tightly as possible in order not to risk that the wrist starts moving out of position 2 N...

Page 302: ...and arm tube flange 2 xx1500003107 CAUTION When the wrist is hanging free the front end will tend to lean slightly downwards 3 Run the cable harness into the wrist carefully 4 Use caution and slide the wrist into fitting position against the arm tube flange CAUTION Make sure not to damage any parts of the cable harness 5 Continues on next page 302 Product manual IRB 8700 3HAC052853 001 Revision M ...

Page 303: ...ning screws 7 Tightening torque 120 Nm Secure the wrist 8 Remove the lifting accessories 9 Connecting the axis 5 motor cables Note Action xx1500002717 Push the motor cables in through the cable gland opening 1 Continues on next page Product manual IRB 8700 303 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 304: ...ith the markings on the connectors 3 O ring 3HAC054692 002 xx1200001070 Inspect the o ring Note Replace if damaged 4 CAUTION When refitting the motor cover make sure that none of the cables inside will be dam aged 5 Continues on next page 304 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 305: ...otor cables Note Action Make sure that the axis 5 is in 90 position before continuing If not the cable spiral will be attached in the wrong position and cause damage to the cable harness CAUTION Make sure that the cable spiral is not turned an extra revolution The result will be damage to the cable harness 1 xx1300001113 Use caution and push the carrier into posi tion 2 Continues on next page Prod...

Page 306: ...level and completely pressed against the bottom 3 Attachment screws M6x16 2 pcs xx1300000484 Secure the cable bracket with its attach ment screws 4 xx1300000488 Reconnect the connectors to the axis 6 motor Note Place the resolver cable underneath the motor cable 5 Continues on next page 306 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 2...

Page 307: ...ke sure not to damage the cables inside the motor when refitting the motor cover 7 Attachment screws M5x20 5 pcs xx1200001080 Refit the motor cover 8 Continues on next page Product manual IRB 8700 307 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 308: ...ion from the contact sur faces of the wrist cover 10 xx1600000046 Make sure the contact surface of the wrist cover is undamaged 11 Loctite 574 Apply flange sealant on the wrist cover flange 12 Place the cable harness so it will not be damaged when fitting the cover 13 Continues on next page 308 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4...

Page 309: ...cedure Note Action Axis Calibration is described in Calibrating with Axis Calibration method on page 701 Re calibrate the robot 1 General calibration information is included in section Calibration on page 691 DANGER Make sure all safety requirements are met when performing the first test run 2 Product manual IRB 8700 309 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repai...

Page 310: ...numbers that are listed in the table can be out of date See the latest spare parts of the IRB 8700 via myABB Business Portal www mypo rtal abb com Note Article number Spare part 3HAC048651 006 Axis 6 Unit Continues on next page 310 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 3 Replacing the axis 6 unit ...

Page 311: ... Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proce...

Page 312: ...e robot is secured to the founda tion Axis 2 60 Axis 3 35 Axis 4 0 Axis 5 50 Axis 6 no significance 3 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 4 Retrieving access to the wrist cabling Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned of...

Page 313: ...1 Cut the cable tie that secures the axis 6 motor cable 3 Disconnecting the axis 6 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 8700 313 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 3 Replacing the axis 6 unit Continued ...

Page 314: ...Unscrew the attachment screws and re move the motor cover Note Do not damage the gasket Replace if damaged 3 xx1300000488 Disconnect the motor cables 4 xx1300000484 Unscrew the attachment screws holding the cable bracket 5 Continues on next page 314 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 3 Replacing the axis 6 unit Continued ...

Page 315: ...tion and pull out the axis 6 motor cables by holding the cables at the motor with one hand and the other one at the carrier 8 Removing the axis 6 motor Note Action 24 VDC power supply To release the brakes connect the 24 VDC power supply 1 Connect to R2 MP6 connector pin 2 24V pin 5 0V Continues on next page Product manual IRB 8700 315 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights r...

Page 316: ...ON The motor weighs 14 kg 5 xx1500003098 Remove the motor by lifting it straight up from the gear Make sure the motor pinion is not dam aged 6 Disconnect the 24 VDC power supply 7 Attaching lifting accessories to the axis 6 unit Note Action CAUTION The axis 6 unit weighs 165 kg All lifting accessories must be sized accordingly 1 Continues on next page 316 Product manual IRB 8700 3HAC052853 001 Rev...

Page 317: ...l VK covers on the axis 5 gearbox cover Always replace VK covers with a new one Note Do not remove any other VK cover 1 Note Before removing the attachment screws on the axis 5 side plan in advance in which order the screws are removed When the last three of the 21 screws is removed the turning disc on the axis 6 unit shall be fa cing upwards 2 xx1600000195 Slowly rotate the axis 6 unit upwards un...

Page 318: ...he axis 6 unit weight the unit will start to rotate uncontrolled Make sure that the axis 6 unit is securely attached to the lifting accessory before the last screw is removed 6 Removing the axis 6 unit Note Action Make sure the lifting accessories still are attached securely and takes the weight of the axis 6 unit 1 This is done to be able to reach the attach ment screws that secure the axis 6 uni...

Page 319: ...imilar on the floor to be used for putting the axis 6 unit on 6 Lower the axis 6 unit towards the pallet Grab the roundslings by hand to be able to force the axis 6 unit to lay on the side on the pallet CAUTION Be very careful not to damage the motor if still fitted The axis 6 must never rest on the motor 7 Continues on next page Product manual IRB 8700 319 3HAC052853 001 Revision M Copyright 2015...

Page 320: ... or similar 3 Use caution and raise the axis 6 unit up and let it hang in the lifting accessories 4 Refitting the support shaft side Note Action Wipe clean all contact surfaces including the o ring grooves 1 xx1600000200 Use caution and move the axis 6 unit to its mounting position 2 Wipe clean and inspect the o rings Re place damaged o rings 3 Refit the o rings in the grooves Tip Lubricate the o ...

Page 321: ...ing 7 Tightening torque 24 Nm xx1600000197 Refitting the axis 5 gearbox side Note Action Refitting of the axis 6 unit must start with the turning disc facing upwards When the last screws are attached the axis 5 shall be as close as possible to 90 position 1 Continues on next page Product manual IRB 8700 321 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 3 Replac...

Page 322: ...ws M16x80 Attach and secure these three screws 5 Tightening torque 300 Nm Continue to lower the axis 6 unit in steps until all 21 screws are attached and se cured in the same way 6 Note Make sure that all 21 screws are attached and secured before removing the lifting accessories and continuing the procedure 7 Continues on next page 322 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 20...

Page 323: ...f 10 Remove old paint residues and other contamina tion from the contact surfaces on both motor and gearbox 11 Wipe clean the contact surfaces from any remain ing contamination 12 Also wipe clean the o ring groove O ring 3HAB3772 107 xx1200001019 Make sure the o ring is undamaged Replace if damaged 13 Continues on next page Product manual IRB 8700 323 3HAC052853 001 Revision M Copyright 2015 2020 ...

Page 324: ...a new spare part remove the motor cover 16 Securing the axis 6 motor Note Action To release the brakes connect the 24 VDC power supply 1 Connect to connector R2 MP6 pin 2 24V pin 5 0V CAUTION Parting mating motor pinion and hub may damage the splines if excessive force is used 2 Continues on next page 324 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved...

Page 325: ...h its attachment screws 5 Screw dimension M8x25 quality 12 9 Gleitmo 4 pcs xx1200001090 Make sure that the gasket is fitted correctly Disconnect the 24 V DC power supply 6 Continues on next page Product manual IRB 8700 325 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 3 Replacing the axis 6 unit Continued ...

Page 326: ...h the carrier into posi tion 2 Attachment screws M4x10 xx1300000485 Secure the carrier with the M4 screw Note The screw is located at the bottom of the carrier Tip The screw that secure the carrier may be difficult to fit Make sure the carrier is level and completely pressed against the bottom 3 Attachment screws M6x16 2 pcs xx1300000484 Secure the cable bracket with its attach ment screws 4 Conti...

Page 327: ... cover is undamaged Note Replace if damaged 6 CAUTION Make sure not to damage the cables inside the motor when refitting the motor cover 7 Attachment screws M5x20 5 pcs xx1200001080 Refit the motor cover 8 Continues on next page Product manual IRB 8700 327 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 3 Replacing the axis 6 unit Continued ...

Page 328: ... from the contact sur faces of the wrist cover 10 xx1600000046 Make sure the contact surface of the wrist cover is undamaged 11 Loctite 574 Apply flange sealant on the wrist cover flange 12 Place the cable harness so it will not be damaged when fitting the cover 13 Continues on next page 328 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 ...

Page 329: ...ure Note Action Axis Calibration is described in Calibrating with Axis Calibration method on page 701 Re calibrate the robot 1 General calibration information is included in section Calibration on page 691 DANGER Make sure all safety requirements are met when performing the first test run 2 Product manual IRB 8700 329 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4...

Page 330: ...t spare parts of the IRB 8700 via myABB Business Portal www mypo rtal abb com Note Article number Spare part 3HAC048445 003 Turning disc Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 733 Standard toolkit Continues on next page 330 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 R...

Page 331: ...fore entering the robot working area 2 Remove any tools or other equipment fitted to the turning disc 3 Removing the turning disc Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1500002318 Unscrew the 27 M12x40 screws and washers that secure the turning disc 2 Continues on next page Product manual IRB 8700 331 3HAC052853 00...

Page 332: ...ng disc Refitting the turning disc Note Action xx1500002319 Wipe clean the contact surfaces 1 xx1500002984 Make sure the sealing ring is fitted 2 Continues on next page 332 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 4 Replacing the turning disc Continued ...

Page 333: ...cribed in a separate calib ration manual enclosed with the calibration tools Re calibrate the robot 1 General calibration information is included in section Calibration on page 691 DANGER Make sure all safety requirements are met when performing the first test run 2 Product manual IRB 8700 333 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 4 Replacing the turnin...

Page 334: ...latest spare parts of the IRB 8700 via myABB Business Portal www mypo rtal abb com Note Article number Spare part 3HAC051003 005 Process turning disc Required tools and equipment Note Article number Equipment etc Lifting capacity 1 000 kg Roundsling 1 m Content is defined in section Standard toolkit on page 733 Standard toolkit Continues on next page 334 Product manual IRB 8700 3HAC052853 001 Revi...

Page 335: ...on DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION The process turning disk weighs 50 kg All lifting accessories must be sized accord ingly 2 Roundsling 1 m Lifting capacity 1 000 kg Attach the a roundsling to the process turning disc and to an overhead crane or similar 3 Stretch the lifting accessories to take the weight of the ...

Page 336: ...n the correct position 4 Attachment screws M12x40 12 9 Gleitmo 603 22 pcs Secure the process turning disc with its attachment screws and washers 5 Tightening torque 120 Nm Concluding procedure Note Action Calibration is described in a separate calib ration manual enclosed with the calibration tools Re calibrate the robot 1 General calibration information is included in section Calibration on page ...

Page 337: ...ts Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the IRB 8700 via myABB Business Portal www mypo rtal abb com Note Article number Spare part 3HAC048081 005 Graphite White 3HAC048081 006 ABB Orange Lower arm Continues on next page Product manual IRB 8700 337 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5...

Page 338: ...tructions 3HAC071354 002 are enclosed with the tool 3HAC071354 001 Press tools parallel rod shaft User instructions 3HAC071378 002 are enclosed with the tool 3HAC071378 001 Hydraulic cylinder parallel rod shaft User instructions 3HAC071377 002 are enclosed with the tool 3HAC071377 001 Hydraulic cylinder bearing To be used with the hydraulic cylinder Maximum allowed working pressure 700 bar Hydraul...

Page 339: ...ber Document Enclosed with the toolkit 3HAC069154 038 User instructions upper arm shaft press tools Enclosed with the toolkit 3HAC071354 002 User instructions parallel rod shaft press tools Deciding calibration routine Decide which calibration routine to be used based on the information in the table Depending on which routine is chosen action might be required prior to beginning the repair work of...

Page 340: ...ve all external cable packages DressPack and tools from the robot Removing the complete lower arm Use these procedures to remove the lower arm and parallel arm Preparations before removing the lower arm Note Action Decide which calibration routine to use and take actions accordingly prior to begin ning the repair procedure 1 Remove any tool or other equipment fitted to the robot 2 Robot position w...

Page 341: ...es 3 Lifting accessory chain 3HAC15556 1 4 chains required Attach the lifting accessory chain with four chains to the lifting eyes 4 Lifting instruction 3HAC15880 2 enclosed Stretch the lifting accessory to take the weight of the counterweight 5 Attachment screws M16x70 10 pcs xx1500001981 Unscrew the attachment screws with washers that hold the counterweight 6 Continues on next page Product manua...

Page 342: ...g the pressure of balancing device Note Action xx1500002310 Jog the robot to calibration position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Continues on next page 342 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete...

Page 343: ...obot as ladder 2 xx1500001971 Remove the screws fitted in the screw holes on top of the balancing device Note Keep the screws They shall be refitted after the work is done 3 M16x35 Screw M16x80 Fully threaded 2 pcs 2 pcs Apply some Molykote on threads and at the bottom end of two fully threaded screws used for unloading the balancing device 4 Apply Molykote on colored areas xx1500002303 Continues ...

Page 344: ...moved unload the pressure of the other in the same way 6 Removing the balancing devices Use this procedure to remove both balancing devices Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Mobile platform ladder xx1500001985 Use a mobile platform ladder to reach the upper end of the balancing device DANGER Do not use the robot...

Page 345: ...ft the balancing device on the axis 4 motor side xx1500001983 A lifting tool is required on the axis 4 motor side to avoid pressure on the motor during lifting Stretch the lifting accessories to unload the balancing device weight 5 Sleeve KM nut M10 3HAC071313 001 xx1500001973 Remove upper and lower KM nuts V rings and support rings 6 Continues on next page Product manual IRB 8700 345 3HAC052853 0...

Page 346: ...the balan cing device bearings on page 454 8 Pallet Put the balancing device down CAUTION Be careful when putting down the balancing device The balancing device ear and pis ton rod should not take any weight 9 Tip Turn a pallet upside down and place the balancing device in the opening for the trucks forks This will prevent the balancing device from starting to move unexpectedly Continues on next p...

Page 347: ...ir pressure supply to the robot before entering the robot working area 2 Removing the attachment screws in the first area Remove attachment screws in the first of the three areas of screws Remove screws that secure the axis 2 gearbox to the lower arm as well as the ones that secure the axis 3 gearbox to the parallel arm Note Action Unscrew and remove screws that secure the axis 2 gearbox to the lo...

Page 348: ...e screws are reached from the outside 1 xx1500002695 Robot position when removing the upper arm Note Action xx1700001306 Turn on the power and jog the robot to the specified position Axis 1 no significance as long as the robot is fitted to the foundation Axis 2 65 Axis 3 approximately 2 upper arm as horizontal as possible to the foundation Axis 4 90 Axis 5 approximately 90 to bal ance the weight o...

Page 349: ...all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1500003100 Remove the wrist cover Note Do not damage the sealing Replace if damaged Note The position of axis 4 depends on the on going procedure 2 xx1500002330 Continues on next page Product manual IRB 8700 349 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the ...

Page 350: ...900 kg All lifting accessories used must be sized accordingly 1 Mobile platform ladder If needed use a Mobile platform ladder or similar to attach the lifting accessories DANGER Never use the robot as ladder 2 Continues on next page 350 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 351: ...12 Fender washer Outer diameter minimum 26 mm hole diameter 13 mm thickness 3 mm Roundsling 2 5 m with lifting capacity 2 000 kg i xx1500002713 Attach a roundsling looped to the Lifting eye and to an overhead crane or similar xx1400002599 5 Continues on next page Product manual IRB 8700 351 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete ...

Page 352: ...otor Note Action xx1500002724 Before continuing make sure that the upper arm is secured in the lifting accessories and overhead crane Stretch the lifting accessories to unload the upper arm weight CAUTION The upper arm including the wrist weighs approx imately 900 kg All lifting accessories must be sized accordingly 1 In order to release the brakes connect the 24 VDC power supply 2 Connect connect...

Page 353: ... xx1400002600 Remove the attachment screw with washer that secure the rod shaft 19 This is done to prevent the upper arm wings from pinching when pressing the shaft and thereby making it more difficult to press the shaft in or out Remove the protection plugs 4 4 pcs and fit 2 2 M10x80 screws in the holes Adjust the screws against the parallel rod from both sides Note Keep the protection plugs They...

Page 354: ...ol incorrectly may cause serious injury Read and follow enclosed user instructions for the tool Note Action This is to be able to remove the parallel rod without problems and to be able to find the correct position of the parallel rod when refitting it xx1500002710 Unscrew two of the M10x80 screws approx imately 5 mm on one side of the parallel rod Leave the screws on the other side 22 Continues o...

Page 355: ...er 23 xx1500001965 Move the parallel rod down and let it rest on the piece of wood which was put there earlier 24 Strap xx1500002716 Secure bearing thrust washer and cover washer with a strap or similar to prevent them from dropping out of its position 25 Continues on next page Product manual IRB 8700 355 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacin...

Page 356: ...nd ing on what repair work is being done Note Not needed if only replacing the axis 6 unit 2 xx1200001080 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 Continues on next page 356 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replac...

Page 357: ... and pull out the carrier Tip If needed use a screwdriver to help pulling out the carrier 7 xx1300000666 Use 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 Continues on next page Product manual IRB 8700 357 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete low...

Page 358: ...5 Unscrew the attachment screws with washers and remove the motor cover 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 358 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 359: ...motor cables 6 Disconnecting the axis 4 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 Continues on next page Product manual IRB 8700 359 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replac...

Page 360: ... will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Removing the cable harness in the upper arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 360 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserv...

Page 361: ...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 screw is reached from the outside 5 Continues on next page Product manual IRB 8700 361 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 362: ...move the cable harness out of the upper arm 9 Removing the cable harness in the lower arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 362 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 363: ... outside 2 xx1600000075 Remove the upper and lower cable guides 3 The figure show the positions of the cable guides Use caution and remove the cable harness from the lower arm 4 Continues on next page Product manual IRB 8700 363 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 364: ... 2 and axis 3 shaft ends and around the KM nuts on both sides 2 Sleeve KM nut D 152 L 220 3HAC069154 009 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 3 Continues on next page 364 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing t...

Page 365: ...removal on the same side until the shaft is removed completely Leave the other shaft fitted for now 6 xx1500003125 Remove the magnetic plug and wipe hole and shaft end meticulously clean 7 Continues on next page Product manual IRB 8700 365 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 366: ...m Note Action DANGER Make sure that all supplies 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 Lift away the upper arm 3 Pallet 2 pcs Put the upper arm down on two pallets 4 Removing the parallel rod lower end Note If the parallel rod shall be removed from...

Page 367: ...ough the parallel rod and to an overhead crane or similar 27 Stretch the roundsling to start taking the weight of the parallel rod 28 xx1500001966 Remove the attachment screw with washer that secure the rod shaft 29 Continues on next page Product manual IRB 8700 367 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 368: ...ING Handling the tool incorrectly may cause serious injury Read and follow enclosed user instructions for the tool Note Action xx1500002098 Right side Left side Cover washer Thrust washer Make sure the thrust washer and cover washer on either side of the bearing are present Tip Make a note on which side the respective washer is fitted for a correct assembly later 31 Continues on next page 368 Prod...

Page 369: ...ping out of its position 33 Preparations of axis 2 before lifting the lower arm complete off Note Action CAUTION The lower arm complete weighs 600 kg All lifting accessories used must be sized accordingly 1 Continues on next page Product manual IRB 8700 369 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 370: ...the brakes on axis 2 connect the 24 VDC power supply 4 Connect to connector R2 MP2 pin 2 24V pin 5 0V xx1500002705 Release the brakes on axis 2 and with the help of an overhead crane lift the lower arm up as close as possible to calibration position 5 Remove the 24 VDC power supply 6 Continues on next page 370 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights res...

Page 371: ...wer arm complete The lower arm complete consists of lower arm and parallel arm together Note Action Roundsling 2 m Lifting capacity 5 000 kg i xx1500002707 Attach a roundsling to the parallel arm and to an overhead crane or similar 1 CAUTION The parallel arm weighs 255 kg All lifting accessories used must be sized accordingly 2 Continues on next page Product manual IRB 8700 371 3HAC052853 001 Revi...

Page 372: ...t the lower arm 5 Endless ratchet lashing belt xx1500002709 Secure the parallel arm to the lower arm with a Endless ratchet lashing belt 6 With the brakes still released on axis 3 use the ratchet belt and manually move the parallel arm the last bit against the lower arm 7 Secure with the ratchet belt Remove the 24 VDC power supply 8 Continues on next page 372 Product manual IRB 8700 3HAC052853 001...

Page 373: ...e lower arm complete weighs 600 kg All lifting accessories used must be sized accordingly 1 Roundsling 2 m Lifting capacity 5 000 kgi xx1500002733 Attach a roundsling to the lower arm as sembly and to an overhead crane or simil ar Attach the roundsling through the holes in the upper end of the lower arm 2 Continues on next page Product manual IRB 8700 373 3HAC052853 001 Revision M Copyright 2015 2...

Page 374: ...aining attachment screws that secure the lower arm to the axis 2 gearbox and the parallel arm to the axis 3 gearbox 4 Crowbar small Use a Crowbar small or similar and press the lower arm and parallel arm togeth er as much as possible 5 xx1500002700 Use caution and lift the lower arm complete off 6 Continues on next page 374 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB ...

Page 375: ...r arm assembly consists of the lower arm and the parallel arm Note Action CAUTION The lower arm complete weighs 600 kg All lifting accessories used must be sized accordingly 1 Endless ratchet lashing belt DANGER Make sure that the parallel arm is secured to the lower arm with an Endless ratchet lashing belt to prevent the parallel arm from falling down uncontrolled when the lower arm complete is l...

Page 376: ...tical position 4 xx1500002700 Move the lower arm assembly into mount ing position 5 Continues on next page 376 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 377: ...le pattern between lower arm and axis 2 gearbox Tip Use caution and rotate the small gear on the axis 2 gearbox 2 xx1500002740 Attach as many screws as possible with the robot in this position Tip Begin by fitting screws in the outer holes in the outer ring of holes to make sure the hole pattern will match If needed carefully turn the small gear in the gearbox to find the hole pattern 3 Tightening...

Page 378: ...tting screws in the most outer holes in the outer ring of holes to make sure the hole pattern will be matching If needed use caution and turn the small gear in the gearbox to find the hole pattern 6 Tightening torque 300 Nm Secure the attached screws that secure the parallel arm to the axis 3 gearbox 7 Continues on next page 378 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020...

Page 379: ... 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 Product manual IRB 8700 379 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 380: ... Action Roundsling 2 m Lifting capacity 5 000 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 380 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 381: ...ximately 30 mm 3 Remove the 24 VDC power supply 4 Remove the lifting accessories 5 Refitting the axis 1 bracket Note Action xx1500002372 Refit the axis 1 cable bracket with the screws 1 Continues on next page Product manual IRB 8700 381 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 382: ...her and cover washer and wipe them clean Note Make a note on which side the covers are placed 2 Wipe the shafts and the holes for the shafts clean 3 Mercasol xx1500002100 Apply corrosion protection on both sides of the bearings and on all machined sur faces on the parallel rod 4 Continues on next page 382 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved...

Page 383: ...el rod has been removed from the robot always start refitting at the lower end 34 CAUTION The parallel rod weighs 55 kg 35 Roundsling 1 m Lifting capacity 1 000 kg Attach a roundsling to the parallel rod and to an overhead crane or similar 36 Continues on next page Product manual IRB 8700 383 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complet...

Page 384: ... plate 38 xx1500002098 Thrust washer Left side Cover washer Right side Make sure that the thrust washer and cover washer on either side of the bearing are in position Note Make sure that the washers are on the correct sides of the bearing 39 Continues on next page 384 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete...

Page 385: ...rallel rod shaft press tools 3HAC071354 002 WARNING Handling the tool incorrectly may cause serious injury Read and follow enclosed user instructions for the tool Note Action xx1500001968 Refit the protection plug 41 Attachment screw M10x16 8 8 Apply locking liquid on the screw and se cure the shaft 42 Loctite 243 xx1500001966 Continues on next page Product manual IRB 8700 385 3HAC052853 001 Revis...

Page 386: ...use the robot as ladder 2 xx1500002712 Remove the plastic plug from 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 3HAC16131 1 VLBG M12 Fender washer Outer diameter minimum 26 mm hole diameter 13 mm thickness 3 mm Continues on next page 386 Product manual IRB 8700 3HAC052853 001 Revision M Copyright ...

Page 387: ...looped to the wrist and to an overhead crane or similar 6 xx1500002724 Stretch the lifting accessories to take the weight of the upper arm 7 Adjust the lifting accessories if needed 8 i This is a recommendation according to standard EN 1492 Always conform to local regulations Continues on next page Product manual IRB 8700 387 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 ...

Page 388: ...fitted 1 Scotch brite abrasive cleaning hand pad xx1500002749 Use a Scotch brite abrasive cleaning hand pad and rub the contact surfaces on follow ing parts contact surfaces on the shafts contact surfaces in the holes for the shafts outer ring of bearings and sealing rings 2 xx1500002750 Continues on next page 388 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights...

Page 389: ...er ring of bearings and sealing rings Note Do not touch the cleaned surfaces with anything after cleaning 3 xx1500002979 xx1500002750 xx1500002748 Inspect the sealing rings and then wipe them clean with Isopropanol Replace if damaged 4 Continues on next page Product manual IRB 8700 389 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower...

Page 390: ...13 Press tools upper arm shaft 3HAC069154 001 User instructions upper arm shaft press tools 3HAC069154 038 WARNING Handling the tool incorrectly may cause serious injury Read and follow enclosed user instructions for the tool 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 t...

Page 391: ...ble guides 4 The figure show the positions of the cable guides Refitting the cable harness in the upper arm Note Action Carefully push the cable harness in through the upper arm and out of the wrist 1 Continues on next page Product manual IRB 8700 391 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 392: ...it the protection cover 3 xx1500002718 Refit the cable clamp on the axis 3 bracket 4 xx1500003092 Refit the cable clamp on the axis 3 bracket between axis 4 motor and arm housing 5 Continues on next page 392 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 393: ...t is covered with adhesive on the side facing the upper arm cover The three washers are pressed into the holes in the gasket Make sure all three washers are fitted 7 xx1500002722 Refit the cover 8 Continues on next page Product manual IRB 8700 393 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 394: ... 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 394 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 395: ...sure that none of the cables inside will be dam aged 7 Attachment screws M5x12 8 8 7 pcs xx1200001135 Refit the motor cover with its attachment screws Note Do not reuse the self threading attachment screws Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Continues on ne...

Page 396: ... 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 396 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 397: ... inside will be dam aged 5 Attachment screws M5x12 8 8 7 pcs xx1200001013 Refit the motor cover Note Do not reuse the self threading attachment screws Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is properly fitted and undamaged 6 Continues on next page Product manual IRB 8700 397 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reser...

Page 398: ...else of the axis 6 mo tor cables at this point The remaining refit ting must wait until the axis 5 has been moved into 90 position Axis 5 must be in 90 position when the carrier and cable bracket are refitted If not the spiral of the cable harness will be in the wrong position and it will be damaged when axis 5 is moving 3 Robot position when refitting the axis 6 motor cables Note Action Turn on t...

Page 399: ...N Make sure that the cable spiral is not twis ted an extra revolution The result will be damage to the cable harness xx1300001113 Use caution and push the carrier into posi tion 2 Attachment screw M4x10 xx1300000485 Secure the carrier with the M4 screw Note The screw is located at the bottom of the carrier Tip The attachment screw that secure the car rier may be difficult to fit Make sure the carr...

Page 400: ...or and make sure they are connected Note The resolver cable shall be placed under neath the motor cable 5 Gasket 3HAC033489 001 xx1200001095 Inspect the gasket Note Replace if damaged 6 Continues on next page 400 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 401: ...bot to the spe cified position Axis 2 No significance as long as the ro bot is secured to the foundation Axis 2 20 Axis 3 0 Axis 4 0 Axis 5 0 Axis 6 No significance 1 Refit the remaining screws that secure the lower arm and parallel arm to the axis 2 and axis 3 gearboxes 2 Attachment screws M16x70 12 9 Gleitmo Secure the attachment screws 3 Tightening torque 300 Nm Continues on next page Product m...

Page 402: ...used as pro tection to prevent the rod from moving un expectedly during the procedure 45 xx1500001964 Right side Left side Cover washer Thrust washer Place the thrust washer and cover washer on either side of the bearing and make sure that they are correctly fitted Note Make sure that the washers are on the correct sides of the bearing 46 Continues on next page 402 Product manual IRB 8700 3HAC0528...

Page 403: ...om being deformed when pressing the shaft and thereby making it more difficult to press the shaft in or out 48 Go to the user instructions enclosed with the press tool to refit the parallel rod shaft xx0900000813 Press tools parallel rod shaft 3HAC071354 001 User instructions parallel rod shaft press tools 3HAC071354 002 WARNING Handling the tool incorrectly may cause serious injury Read and follo...

Page 404: ...tion when replacing the balancing device Note Action xx1500002310 Jog the robot to calibration position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Continues on next page 404 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the co...

Page 405: ...000 kg xx1500001983 Attach a roundsling to the lifting hole on top of the balancing device and to an overhead crane or similar 3 Use caution and lift the balancing device up an let it hang in the lifting accessories 4 Wipe clean the contact surfaces 5 Grease xx1500002304 Apply some grease on shafts and in bear ing holes Note Do not apply any grease on the threads for the KM nut 6 Continues on next...

Page 406: ...ion Mobile platform ladder xx1500001985 Use a Mobile platform ladder or similar to reach the upper end of the balancing device DANGER Do not use the robot as ladder 1 xx1500002735 Use caution and raise the balancing device into mounting position 2 Continues on next page 406 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the co...

Page 407: ...ng device is put on the shafts 4 Press tools balancing device upper end 3HAC057130 015 Use caution and put the balancing device onto upper and lower shafts 5 Press tools balancing device lower end 3HAC057130 015 xx1500002305 Press the upper and lower part onto the shafts using the press tool Continues on next page Product manual IRB 8700 407 3HAC052853 001 Revision M Copyright 2015 2020 ABB All ri...

Page 408: ...M nut M10 3HAC071313 001 xx1500001973 Remove the lifting accessories 9 Bearing grease Tribol GR 100 2 PD xx1500002055 Remove the M6x10 torx pan head screws on either side of the balancing device bearings Lubricate each bearing 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 Conti...

Page 409: ...02308 Restore the pressure of the balancing device by unscrewing the two M16x80 screws alternately little by little 2 Remove the screws 3 Attachment screws M16x35 2 pcs xx1500001971 Refit the M16x35 screws in the holes on top of the balancing device 4 Continues on next page Product manual IRB 8700 409 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing th...

Page 410: ...ting the counterweight Note Action CAUTION The counter weight weighs 1200 kg All lifting accessories used must be sized accordingly 1 xx1500002087 Attach lifting eyes if not already done 2 Lifting accessory chain 3HAC15556 1 Attach the lifting accessory chain with four chains to the lifting eyes 3 Lifting instruction 3HAC15880 2 enclosed Stretch the lifting accessory to take the weight of the coun...

Page 411: ...llel arm 6 Attachment screws M16x70 Gleitmo 10 pcs Fit attachment screws with washers and secure the counterweight to the parallel arm 7 Tightening torque 300 Nm xx1500001981 Remove lifting accessories lifting chains and the lifting eyes 8 Continues on next page Product manual IRB 8700 411 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete l...

Page 412: ...xis Calibration method on page 701 Recalibrate the robot 1 General calibration information is included in section Calibration on page 691 DANGER Make sure all safety requirements are met when performing the first test run 2 412 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 5 6 Replacing the complete lower arm Continued ...

Page 413: ...equired spare parts Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the IRB 8700 via myABB Business Portal www mypo rtal abb com Continues on next page Product manual IRB 8700 413 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 6 1 Replacing the counterweight ...

Page 414: ...t Removing the counterweight Use these procedures to remove the counterweight Robot position when removing the counterweight Note Action xx1500002096 Jog the robot to a position so that the area where the counterweight is fitted to the parallel arm is horizontal to the foundation 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering ...

Page 415: ... eyes 3 Lifting accessory chain 3HAC15556 1 4 chains required Attach the lifting accessory chain with four chains to the lifting eyes 4 Lifting instruction 3HAC15880 2 enclosed Stretch the lifting accessory to take the weight of the counterweight 5 Attachment screws M16x70 10 pcs xx1500001981 Unscrew the attachment screws with washers that hold the counterweight 6 Continues on next page Product ma...

Page 416: ...to refit the counterweight Robot position when refitting the counterweight Note Action xx1500002096 If not already in this position turn on the power and jog to a position where the area the counterweight is fitted to the parallel arm is horizontal to the foundation 1 Continues on next page 416 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4...

Page 417: ... done 2 Lifting accessory chain 3HAC15556 1 Attach the lifting accessory chain with four chains to the lifting eyes 3 Lifting instruction 3HAC15880 2 enclosed Stretch the lifting accessory to take the weight of the counterweight 4 Flange sealant Loctite 574 xx1600000049 Apply flange sealant Loctite 574 on the contact surface between parallel arm and counterweight 5 Continues on next page Product m...

Page 418: ...e the counterweight to the parallel arm 7 Tightening torque 300 Nm xx1500001981 Remove lifting accessories lifting chains and the lifting eyes 8 xx1500001980 If used refit the plastic plugs in the holes for the lifting eyes 9 418 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 6 1 Replacing the counterweight Continued ...

Page 419: ...e parts of the IRB 8700 via myABB Business Portal www mypo rtal abb com Note Article number Spare part 3HAC048180 001 Mechanical stop pin Required tools and equipment Note Article number Equipment etc Used when replacing the parallel rod and mechanical stop pin as a safety measure Piece of wood Continues on next page Product manual IRB 8700 419 3HAC052853 001 Revision M Copyright 2015 2020 ABB All...

Page 420: ...bot position when replacing the mechanical stop pin Note Action xx1500002093 Jog axis 1 to the position where it is pos sible to replace the mechanical stop pin 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Removing the mechanical stop pin Note Action CAUTION The mechanical stop pin weighs 13 kg 1 Con...

Page 421: ...on the stop pin with one hand 3 xx1500002090 Unscrew the set screw with the other hand 4 xx1500002299 Hold the stop pin with one hand and re move the piece of wood or similar with the other hand 5 Continues on next page Product manual IRB 8700 421 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 6 2 Replacing the mechanical stop pin Continued ...

Page 422: ...op pin Note Action xx1500002093 Make sure that axis 1 is in the position where it will be possible to replace the mechanical stop pin If not turn on the power use caution and jog axis 1 to that position 1 Clean the stop pin as well as the hole for it 2 Continues on next page 422 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 6 2 Replacing t...

Page 423: ...002091 Put a piece of wood or similar underneath the stop pin to prevent it from falling down uncontrolled when the set screw is refitted 5 Locking liquid Loctite 243 xx1500002090 Apply locking liquid Loctite 243 on the set screw 6 Continues on next page Product manual IRB 8700 423 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 6 2 Replacing the mechanical stop pi...

Page 424: ...the set screw making sure that the screw will secure the stop pin in the groove 7 Tightening torque 35 Nm Secure the mechanical stop pin with the set screw 8 Concluding procedure Note Action DANGER Make sure all safety requirements are met when performing the first test run 1 424 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 6 2 Replacing ...

Page 425: ... table can be out of date See the latest spare parts of the IRB 8700 via myABB Business Portal www mypo rtal abb com Note Article number Color Spare part 3HAC048077 003 Graphite White Parallel bar 3HAC048077 004 ABB Orange Parallel bar Continues on next page Product manual IRB 8700 425 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 6 3 Replacing the parallel rod ...

Page 426: ...re 700 bar Hydraulic pump 700 bar Velcro strap Lifting capacity 1 000 kg Roundsling 1 m Content is defined in section Standard toolkit on page 733 Standard toolkit Required consumables Note Article number Consumable Grease Mercasol 3110 Waxcoat Recom mended drying time is 24h 3HAC034903 001 Rust preventive Loctite 243 3HAB7116 1 Locking liquid Required documents Note Document number Document Enclo...

Page 427: ... the procedure Axis 6 No significance 1 The figure shows a suggestion of robot position that gives a comfortable working position and does not require the axis 2 to be secured with a lock screw xx1700001306 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Removing the parallel rod upper end Note Action xx1...

Page 428: ...in or out Remove the protection plugs 4 4 pcs and fit 2 2 M10x80 screws in the holes Adjust the screws against the parallel rod from both sides Note Keep the protection plugs They shall be refitted when the work is done 54 Fixing screw M10x80 4 pcs xx1500001961 Continues on next page 428 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 6 3 Re...

Page 429: ... tool incorrectly may cause serious injury Read and follow enclosed user instructions for the tool Note Action This is to be able to remove the parallel rod without problems and to be able to find the correct position of the parallel rod when refitting it xx1500002710 Unscrew two of the M10x80 screws approx imately 5 mm on one side of the parallel rod Leave the screws on the other side 56 Continue...

Page 430: ...he piece of wood which was put there earlier 58 Strap xx1500002716 Secure bearing thrust washer and cover washer with a strap or similar to prevent them from dropping out of its position 59 Removing the parallel rod lower end Note If the parallel rod shall be removed from the robot always disassemble the upper end shaft first Continues on next page 430 Product manual IRB 8700 3HAC052853 001 Revisi...

Page 431: ...through the parallel rod and to an overhead crane or similar 61 Stretch the roundsling to start taking the weight of the parallel rod 62 xx1500001966 Remove the attachment screw with washer that secure the rod shaft 63 Continues on next page Product manual IRB 8700 431 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 6 3 Replacing the parallel rod Continued ...

Page 432: ...ARNING Handling the tool incorrectly may cause serious injury Read and follow enclosed user instructions for the tool Note Action xx1500002098 Right side Left side Cover washer Thrust washer Make sure the thrust washer and cover washer on either side of the bearing are present Tip Make a note on which side the respective washer is fitted for a correct assembly later 65 Continues on next page 432 P...

Page 433: ...osed with the press tool to re place the parallel rod bearing xx0900000813 Press tools parallel rod bearing 3HAC071353 001 User instructions parallel rod bearing press tools 3HAC071353 002 WARNING Handling the tool incorrectly may cause serious injury Read and follow enclosed user instructions for the tool Continues on next page Product manual IRB 8700 433 3HAC052853 001 Revision M Copyright 2015 ...

Page 434: ... strap which was used to keep bearing thrust washer and cover washer in position 1 xx1500002098 Right side Left side Cover washer Thrust washer Remove the thrust washer and cover washer and wipe them clean Note Make a note on which side the covers are placed 2 Wipe the shafts and the holes for the shafts clean 3 Continues on next page 434 Product manual IRB 8700 3HAC052853 001 Revision M Copyright...

Page 435: ...t washer left side and cover washer right side 5 Refitting the parallel rod lower end Note Action xx1500001965 Note If the parallel rod has been removed from the robot always start refitting at the lower end 68 CAUTION The parallel rod weighs 55 kg 69 Continues on next page Product manual IRB 8700 435 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 6 3 Replacing th...

Page 436: ... apply the press tool parts Assembly tool Press plate and Round plate 72 xx1500002098 Thrust washer Left side Cover washer Right side Make sure that the thrust washer and cover washer on either side of the bearing are in position Note Make sure that the washers are on the correct sides of the bearing 73 Continues on next page 436 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 202...

Page 437: ... parallel rod shaft press tools 3HAC071354 002 WARNING Handling the tool incorrectly may cause serious injury Read and follow enclosed user instructions for the tool Note Action xx1500001968 Refit the protection plug 75 Attachment screw M10x16 8 8 Apply locking liquid on the screw and se cure the shaft 76 Loctite 243 xx1500001966 Continues on next page Product manual IRB 8700 437 3HAC052853 001 Re...

Page 438: ... side Remove thrust washer and cover washers and wipe them clean 2 Wipe clean the shafts and the holes for the shafts 3 Mercasol xx1500002100 Apply corrosion protection Mercasol on both sides of the bearings and on all ma chined surfaces on the parallel rod 4 Continues on next page 438 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 6 3 Repl...

Page 439: ... 77 xx1500001965 Take a firm grip of the parallel rod and lift it up into mounting position 78 xx1500001963 Put a piece of wood or similar between parallel arm and parallel rod used as pro tection to prevent the rod from moving un expectedly during the procedure 79 Continues on next page Product manual IRB 8700 439 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 6 ...

Page 440: ...earing 80 Unscrew two of the M10x80 screws only on one side of the parallel rod approxim ately 5 mm Leave the screws fastened on the other side Note This is done to be able to refit the parallel rod without problems and to be able to find the correct position of the parallel rod 81 Continues on next page 440 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reser...

Page 441: ...d shaft xx0900000813 Press tools parallel rod shaft 3HAC071354 001 User instructions parallel rod shaft press tools 3HAC071354 002 WARNING Handling the tool incorrectly may cause serious injury Read and follow enclosed user instructions for the tool Note Action xx1500001967 Refit the protection plug 83 Attachment screw M10x16 8 8 Apply locking liquid on the attachment screw and secure shaft 84 Loc...

Page 442: ... manual enclosed with the calibration tools Re calibrate the robot 1 General calibration information is included in section Calibration on page 691 DANGER Make sure all safety requirements are met when performing the first test run 2 442 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 6 3 Replacing the parallel rod Continued ...

Page 443: ... the table can be out of date See the latest spare parts of the IRB 8700 via myABB Business Portal www mypo rtal abb com Note Article number Color Spare part 3HAC048239 003 Graphite White Balancing device 3HAC048239 004 ABB Orange Balancing device 3HAC048239 006 Balancing device material set Continues on next page Product manual IRB 8700 443 3HAC052853 001 Revision M Copyright 2015 2020 ABB All ri...

Page 444: ...ding the pressure of balancing device Note Action xx1500002310 Jog the robot to calibration position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Unloading the pressure of the balancing device Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are ...

Page 445: ...Keep the screws They shall be refitted after the work is done 3 M16x35 Screw M16x80 Fully threaded 2 pcs 2 pcs Apply some Molykote on threads and at the bottom end of two fully threaded screws used for unloading the balancing device 4 Apply Molykote on colored areas xx1500002303 Continues on next page Product manual IRB 8700 445 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved...

Page 446: ...e removed unload the pressure of the other in the same way 6 Restoring the pressure of the balancing device Use these procedures to restore the pressure of the balancing device Restoring the pressure of the balancing device Note Action Mobile platform ladder xx1500001985 Use a Mobile platform ladder or similar to reach the upper end of the balancing device DANGER Do not use the robot as ladder 1 C...

Page 447: ...x35 2 pcs xx1500001971 Refit the M16x35 screws in the holes on top of the balancing device 4 Concluding procedure Note Action DANGER Make sure all safety requirements are met when performing the first test run 1 Product manual IRB 8700 447 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 6 4 Unloading and restoring the balancing device Continued ...

Page 448: ...n the table can be out of date See the latest spare parts of the IRB 8700 via myABB Business Portal www mypo rtal abb com Note Article number Color Spare part 3HAC048239 003 Graphite White Balancing device 3HAC048239 004 ABB Orange Balancing device 3HAC048239 006 Balancing device material set Continues on next page 448 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All r...

Page 449: ...3HAC071377 002 are enclosed with the tool 3HAC071377 001 Hydraulic cylinder bearing To be used with the hydraulic cylinder Maximum allowed working pressure 700 bar Hydraulic pump 700 bar 3HAC057130 015 Press tools balancing device upper end 3HAC057130 016 Press tools balancing device lower end Content is defined in section Standard toolkit on page 733 Standard toolkit Required consumables Note Art...

Page 450: ...t working area 2 Unloading the pressure of the balancing device Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Mobile platform ladder xx1500001985 Use a mobile platform ladder or similar to reach the upper end of the balancing device DANGER Do not use the robot as ladder 2 Continues on next page 450 Product manual IRB 8700 3...

Page 451: ...ply Molykote on colored areas xx1500002303 Screw M16x80 Fully threaded 2 pcs 2 pcs xx1500002309 Unload the pressure of the balancing device by inserting the screws 1 Attach the screws until the screws reaches the piston xx1900001209 2 Then alternately little by little attach the screws at least another five milli meters The pressure is now un loaded xx1900001210 5 Continues on next page Product ma...

Page 452: ... kg All lifting accessories used must be sized accordingly 3 Roundsling 1 m Lifting capacity 1 000 kg Attach a roundsling to the lifting hole on top of the balancing device and to an overhead crane or similar 4 Lifting accessory balancing device Re quired to lift the balancing device on the axis 4 motor side xx1500001983 A lifting tool is required on the axis 4 motor side to avoid pressure on the ...

Page 453: ...lp pressing the balancing device out 7 xx1500001976 Verify that the support ring V ring and spacer ring are present on the shaft No need to remove If a bearing remains seated on the shaft remove it according to Replacing the balan cing device bearings on page 454 8 Continues on next page Product manual IRB 8700 453 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 6 ...

Page 454: ...52 002 are enclosed with the tool Hydraulic cylinder bearing 3HAC071377 001 User instructions 3HAC071377 002 are enclosed with the tool If the bearing remains fitted to the shaft use a bearing puller Bearing puller New bearing is included in Fit new bearings to the balancing device ears using the press tool kit and a hydraulic cylinder 2 Balancing device material set 3HAC048239 006 The lubrication...

Page 455: ...pper end of the balancing device DANGER Do not use the robot as ladder 2 Roundsling 1 m Lifting capacity 1 000 kg xx1500001983 Attach a roundsling to the lifting hole on top of the balancing device and to an overhead crane or similar 3 Use caution and lift the balancing device up an let it hang in the lifting accessories 4 Wipe clean the contact surfaces 5 Continues on next page Product manual IRB...

Page 456: ... Refitting the balancing device Note Action Mobile platform ladder xx1500001985 Use a Mobile platform ladder or similar to reach the upper end of the balancing device DANGER Do not use the robot as ladder 1 xx1500002735 Use caution and raise the balancing device into mounting position 2 Continues on next page 456 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights ...

Page 457: ...ng device is put on the shafts 4 Press tools balancing device upper end 3HAC057130 015 Use caution and put the balancing device onto upper and lower shafts 5 Press tools balancing device lower end 3HAC057130 015 xx1500002305 Press the upper and lower part onto the shafts using the press tool Continues on next page Product manual IRB 8700 457 3HAC052853 001 Revision M Copyright 2015 2020 ABB All ri...

Page 458: ...M nut M10 3HAC071313 001 xx1500001973 Remove the lifting accessories 9 Bearing grease Tribol GR 100 2 PD xx1500002055 Remove the M6x10 torx pan head screws on either side of the balancing device bearings Lubricate each bearing 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 Conti...

Page 459: ... 2 Remove the screws 3 Attachment screws M16x35 2 pcs xx1500001971 Refit the M16x35 screws in the holes on top of the balancing device 4 Concluding procedure Note Action Calibration is described in a separate calib ration manual enclosed with the calibration tools Re calibrate the robot 1 General calibration information is included in section Calibration on page 691 Continues on next page Product ...

Page 460: ...ure all safety requirements are met when performing the first test run 2 460 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 6 5 Replacing the balancing devices Continued ...

Page 461: ... listed in the table can be out of date See the latest spare parts of the IRB 8700 via myABB Business Portal www mypo rtal abb com Note Article number Color Spare part 3HAC058949 003 Graphite White Rotating AC motor including pinion Continues on next page Product manual IRB 8700 461 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 motor ...

Page 462: ...ction might be required prior to beginning the repair work of the robot see the table Note Action Decide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ...

Page 463: ...bot to the calibration position 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 Disconnecting the motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws with washers and remove the m...

Page 464: ...ng if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Removing the axis 1 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 464 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved ...

Page 465: ...s and washers Use a bits extender to reach the screws 5 Guide pin M10x150 3HAC15521 2 Fit guide pins in opposite holes 6 Always use guide pins in pairs CAUTION Whenever parting mating motor pinion and hub the splines may be damaged if excess ive force is used 7 Removal tool motor M12 3HAC14631 1 If needed use removal tools to help re move the motor 8 Used to push out the motor if necessary Always ...

Page 466: ... axis 1 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Remove old paint residues and other contamina tion from the contact surfaces on both motor and gearbox 2 Wipe clean the contact surfaces from any remain ing contamination 3 Also wipe clean the o ring groove Continues on next page 466 Product manual IRB 8700 3HAC052...

Page 467: ... groove Tip Lubricate the o ring with some grease for a better fitting in the groove 5 Flange sealant Loctite 574 xx1500002357 Apply flange sealant on the motor flange 6 Continues on next page Product manual IRB 8700 467 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 motor Continued ...

Page 468: ...cessory 3 Rotation tool 3HAC7887 1 Fit the rotation tool 4 Grease Castrol Molub Alloy 777 1 NG xx1500002346 Make sure that there is enough grease on the splines before fitting If not apply 1 gram of grease 5 Connect the 24 VDC power supply to re lease the brakes 6 To release the brakes connect the 24 VDC power supply as described in the list Connect to R2 MP1 connector pin 2 pin 5 Continues on nex...

Page 469: ...he correct way 8 Lifting accessory motor 3HAC14459 1 xx1500002084 Bits extender 3HAC12342 1 Secure the motor with its attachment screws and washers 9 Tightening torque 50 Nm Use a bits extender to reach the screws Screws M10x40 quality 12 9 Gleitmo 4 pcs xx1500002083 See Performing a leak down test on page 178 Perform a leak down test if not already done 10 Disconnect the 24 VDC power supply 11 Co...

Page 470: ...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 470 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 motor Continued ...

Page 471: ...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 Concluding procedure Note Action Axis Calibration is described in Calibrating with Axis Calibration method on page 701 Re calibrate the robot 1 General calibration information is included in section Calibratio...

Page 472: ... sure all safety requirements are met when performing the first test run 2 472 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 motor Continued ...

Page 473: ...n be out of date See the latest spare parts of the IRB 8700 via myABB Business Portal www mypo rtal abb com Note Article number Color Spare part 3HAC058949 003 Graphite White Rotating AC motor including pinion 3HAC058949 004 ABB Orange Rotating AC motor including pinion Continues on next page Product manual IRB 8700 473 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair...

Page 474: ...n which routine is chosen action might be required prior to beginning the repair work of the robot see the table Note Action Decide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instr...

Page 475: ... the plug is accessible 2 Lock screw quality 12 9 M20x150 Valid for replacement of the axis 2 motor 3 Tightening torque 100 Nm xx1500002322 Insert the lock screw through the frame and into the hole in the lower arm to secure the weight of the lower arm If needed adjust the position of axis 2 to make it possible to insert the lock screw Note Tighten the lock screw manually No tools needed DANGER Fa...

Page 476: ... to secure the weight of the parallel arm If needed adjust the position of axis 3 to make it possible to insert the lock screw Note Tighten the lock screw manually No tools needed DANGER Failure to secure the weight of the parallel arm will cause the parallel arm to fall when the brakes of the axis 3 motor are released xx1500002085 Jog the robot to the calibration position 6 Continues on next page...

Page 477: ...motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 xx1200001070 Make sure the o ring is present 3 Continues on next page Product manual IRB 8700 477 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 7 2...

Page 478: ... Action DANGER When releasing the holding brakes of the motor the lower arm and or the parallel arm will move and may fall down Before continuing make sure the lower arm and or parallel arm are secured with lock screws 1 To release the brake connect the 24 VDC power supply to the motor in question 2 Connect to connector R2 MP2 axis 2 mo tor or R2 MP3 axis 3 motor pin 2 24V pin 5 0V Continues on ne...

Page 479: ...the motor out of position by using the removal tool in opposite holes of the motor 6 CAUTION The motor weighs 27 kg All lifting accessories used must be sized accordingly 7 Lifting accessory motor 3HAC15534 1 Attach the lifting accessory 8 xx1500002325 Use caution and lift the motor out on the guide pins in order to get the pinion away from the hub Let the motor rest on the guide pins 9 Disconnect...

Page 480: ...pressure are turned off 1 Remove old paint residues and other contamina tion from the contact surfaces on both motor and gearbox 2 Wipe clean the contact surfaces from any remain ing contamination 3 Also wipe clean the o ring groove O ring 3HAB3772 107 xx1200001019 Inspect the o ring Note Replace if damaged 4 Continues on next page 480 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 20...

Page 481: ... the motor is a new spare part remove the cover 7 Securing the motor Note Action Guide pin M10x150 3HAC15521 2 Fit guide pins in opposite holes 1 Always use guide pins in pairs CAUTION The motor weighs 27 kg All lifting accessories used must be sized accordingly 2 Continues on next page Product manual IRB 8700 481 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 7 2...

Page 482: ...ve the lifting accessory and allow the motor to rest on the guide pins 7 Rotation tool 3HAC7887 1 Apply the rotation tool and use it to rotate the pinion when mating it into the gear 8 Valid for the axis 2 motor 9 To release the brakes connect the 24 VDC power supply Connect to connector R2 MP2 axis 2 mo tor pin 2 24V pin 5 0V Valid for the axis 3 motor 10 To release the brakes connect the 24 VDC ...

Page 483: ...he cable exit is facing the correct way 12 Screw dimension M10x40 quality 12 9 Gleitmo 4 pcs Fit two of the attachment screws 13 Remove the guide pins and replace with the remaining attachment screws 14 Bits extender 3HAC12342 1 Secure the motor with its attachment screws and washers 15 Tightening torque 50 Nm Use a bits extender in order to reach the screws Screw dimension M10x40 quality 12 9 Gle...

Page 484: ...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 484 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 7 2 Replacing the axis 2 and axis 3 motors Continued ...

Page 485: ...e that none of the cables inside will be dam aged 7 Attachment screws M5x12 8 8 7 pcs xx1200001135 Refit the motor cover with its attachment screws Note Do not reuse the self threading attachment screws Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Continues on next ...

Page 486: ...tic plug in lower arm 2 xx1500002321 Valid for replacement of the axis 3 motor Use caution and jog axis 3 until it is pos sible to remove the lock screw 3 xx1500002365 Valid for replacement of the axis 3 motor Refit the plastic plug in parallel arm 4 Continues on next page 486 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 7 2 Replacing the...

Page 487: ...eneral calibration information is included in section Calibration on page 691 DANGER Make sure all safety requirements are met when performing the first test run 6 Product manual IRB 8700 487 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 7 2 Replacing the axis 2 and axis 3 motors Continued ...

Page 488: ...table can be out of date See the latest spare parts of the IRB 8700 via myABB Business Portal www mypo rtal abb com Note Article number Spare part 3HAC058950 003 Graphite White 3HAC049837 003 ABB Orange Rotating AC motor including pinion Continues on next page 488 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 7 3 Replacing the axis 4 motor...

Page 489: ... Action Decide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to ...

Page 490: ...c power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 Disconnecting the axis 4 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 Continues on next page 490 Product manual ...

Page 491: ... hole is facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Removing the axis 4 motor Note Action CAUTION Use caution when releasing the brakes Axis 4 can move unexpectedly 1 Continues on next page Product manual IRB 8700 491 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 7 3 Repl...

Page 492: ... gear box the gears may be damaged if excess ive force is used 5 Removal tool M12 3HAC14631 1 Press the motor out of position by fitting the removal tool in the remaining attach ment holes for the motor 6 Always use removal tools in pairs CAUTION The motor weighs 27 kg All lifting accessories used must be sized accordingly 7 Lifting accessory motor 3HAC15534 1 Attach the lifting accessory 8 Discon...

Page 493: ...c pressure and air pressure are turned off 1 Remove old paint residues and other contamina tion from the contact surfaces on both motor and gearbox 2 Wipe clean the contact surfaces from any remain ing contamination 3 Also wipe clean the o ring groove O ring 3HAB3772 107 xx1200001019 Make sure the o ring is undamaged Note Replace if damaged 4 Continues on next page Product manual IRB 8700 493 3HAC...

Page 494: ... spare part remove the cover 7 Securing the axis 4 motor Note Action Guide pin M10x150 3HAC15521 2 Apply two guide pins in opposite holes 1 Always use guide pins in pairs Lifting accessory motor 3HAC15534 1 CAUTION The motor weighs 27 kg All lifting accessories used must be sized accordingly 2 Continues on next page 494 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All ...

Page 495: ...nect the 24 VDC power supply 8 Connect to connector R2 MP2 pin 2 24V pin 5 0V CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 9 Push the motor carefully in position while at the same time the motor pinion is slightly rotated Make sure that the motor pinion is properly mated into the hub Make sure that the motor pinion does not get damaged Mak...

Page 496: ...s xx1600000064 Disconnect the 24 VDC power supply 13 Connecting the axis 4 motor cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 xx1200001067 Refit the cable gland cover Note Replace the gasket if damaged 2 Continues on next page 496 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 7 3 Replacing the axi...

Page 497: ... ring axis 4 3HAC054692 002 xx1200001070 Wipe clean o ring and o ring groove 5 Refit the o ring Tip Lubricate the o ring with some grease for a better fitting in the groove 6 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 7 Continues on next page Product manual IRB 8700 497 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repai...

Page 498: ... sure that the covers are tightly sealed 9 Concluding procedure Note Action Axis Calibration is described in Calibrating with Axis Calibration method on page 701 Re calibrate the robot 1 General calibration information is included in section Calibration on page 691 DANGER Make sure all safety requirements are met when performing the first test run 2 498 Product manual IRB 8700 3HAC052853 001 Revis...

Page 499: ...part 3HAC058949 003 Graphite White Rotating AC motor including pinion 3HAC058949 004 ABB Orange Rotating AC motor including pinion Required tools and equipment Note Article number Equipment etc 3HAC14459 1 Lifting accessory motor Used to release the motor brakes 24 VDC power supply 300 mm bits 1 2 3HAC12342 1 Bits extender Always use guide pins in pairs 3HAC15521 2 Guide pin M10x150 Continues on n...

Page 500: ...ack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val...

Page 501: ... no significance 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 Retrieving access to the wrist cabling Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1500003100 Remove the wrist cover Note Do not damage the sealing Replace if d...

Page 502: ...that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws with washers and remove the motor cover 2 Continues on next page 502 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 7 4 Replacing the axis 5 motor Continued ...

Page 503: ...ver Tip Make a note in which direction the cable exit hole is facing if the motor shall be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Continues on next page Product manual IRB 8700 503 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 7 4 Replacing the axis 5 motor Continued ...

Page 504: ...e the motor using a bits extender 3 CAUTION Whenever parting mating motor pinion and hub the splines may be damaged if excess ive force is used 4 Removal tool M12 If needed fit removal tools in opposite holes 5 CAUTION The motor weighs 27 kg All lifting accessories used must be sized accordingly 6 Lifting accessory motor 3HAC14459 1 Attach the lifting accessory to the motor 7 Continues on next pag...

Page 505: ...ions before refitting the axis 5 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 8700 505 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 7 4 Replacing the axis 5 motor Continued ...

Page 506: ...07 Make sure the o ring is undamaged Note Replace if damaged 3 Lubricate the o ring with some grease 4 xx1200001020 Make sure the o ring is seated in the groove 5 Continues on next page 506 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 7 4 Replacing the axis 5 motor Continued ...

Page 507: ...AC7887 1 Attach the rotation tool and use it to rotate the pinion when mating it into the gear 2 24 VDC power supply To release the brakes connect the 24 VDC power supply 3 Connect to connector R2 MP5 pin 2 24V pin 5 0V CAUTION The motor weighs 27 kg All lifting accessories used must be sized accordingly 4 Attach the lifting accessory and lift the motor up 5 Continues on next page Product manual I...

Page 508: ... posi tion on the guide pins while at the same time rotating the motor pinion slightly Make sure that the motor pinion is properly mated into the hub the motor pinion does not get dam aged the direction of the cable exit is fa cing the correct way 7 xx1200001018 Remove the guide pins 8 Continues on next page 508 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights r...

Page 509: ...uality 12 9 Gleitmo 4 pcs xx1200001017 Disconnect the 24 VDC power supply 10 Connecting the axis 5 motor cables Note Action xx1500002717 Push the motor cables in through the cable gland opening 1 Continues on next page Product manual IRB 8700 509 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 7 4 Replacing the axis 5 motor Continued ...

Page 510: ...the markings on the connectors 3 O ring 3HAC054692 002 xx1200001070 Inspect the o ring Note Replace if damaged 4 CAUTION When refitting the motor cover make sure that none of the cables inside will be dam aged 5 Continues on next page 510 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 7 4 Replacing the axis 5 motor Continued ...

Page 511: ... cover is tightly sealed 7 Concluding procedure Note Action xx1600000046 Make sure the contact surface on the wrist cover is undamaged 1 Loctite 574 xx1600000048 Apply flange sealant Loctite 574 on the wrist cover flange 2 Place the cable harness in a way so it will not be damaged when the wrist cover is fitted 3 Continues on next page Product manual IRB 8700 511 3HAC052853 001 Revision M Copyrigh...

Page 512: ... Calibrating with Axis Calibration method on page 701 Re calibrate the robot 5 General calibration information is included in section Calibration on page 691 DANGER Make sure all safety requirements are met when performing the first test run 6 512 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 7 4 Replacing the axis 5 motor Continued ...

Page 513: ...r Spare part 3HAC058951 003 Graphite White 3HAC049875 004 ABB Orange Rotating AC motor including pinion Required tools and equipment Note Article number Equipment etc Used to release the motor brakes 24 VDC power supply Used to push out the motor if neces sary Removal tool M10 Leak down tester Content is defined in section Standard toolkit on page 733 Standard toolkit Continues on next page Produc...

Page 514: ...he robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 702 If no...

Page 515: ...obot before entering the robot working area 3 Retrieving access to the wrist cabling Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1500003100 Remove the wrist cover Note Do not damage the sealing Replace if damaged Note The position of axis 4 depends on the on going procedure 2 xx1500002330 Continues on next page Product ...

Page 516: ...that the axis 5 is as close to 90 or 90 position as possible depend ing on what repair work is being done Note Not needed if only replacing the axis 6 unit 2 xx1200001080 Unscrew the attachment screws and re move the motor cover Note Do not damage the gasket Replace if damaged 3 Continues on next page 516 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved...

Page 517: ...ing the cable bracket 5 xx1300000485 Unscrew the screw holding the carrier Note The screw is located at the bottom of the carrier 6 Continues on next page Product manual IRB 8700 517 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis 6 motor Continued ...

Page 518: ...e hand and the other one at the carrier 8 Removing the axis 6 motor Note Action 24 VDC power supply To release the brakes connect the 24 VDC power supply 1 Connect to R2 MP6 connector pin 2 24V pin 5 0V xx1500003097 Unscrew the attachment screws with washers 2 Continues on next page 518 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 7 5 Rep...

Page 519: ...pply 7 Refitting the motor Use these procedures to refit the motor Preparations before refitting the axis 6 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 contam...

Page 520: ... o ring with some grease for a better fitting in the groove 14 Flange sealant Loctite 574 xx1500002357 Apply flange sealant on the motor flange 15 If the motor is a new spare part remove the motor cover 16 Continues on next page 520 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis 6 motor Continued ...

Page 521: ... 2 xx1300001113 Use caution and push the carrier into posi tion Tip Use a screwdriver or similar to press the carrier into position 3 Attachment screw M4x10 xx1300000485 Secure the carrier with the M4 screw 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 Continues on next p...

Page 522: ...4 VDC power supply 2 Connect to connector R2 MP6 pin 2 24V pin 5 0V Grease Castrol Molub Alloy 777 1 NG xx1500002346 Make sure that there is enough grease on the splines before fitting If not apply 1 gram of grease 3 CAUTION Whenever parting mating motor pinion and hub the splines may be damaged if excess ive force is used 4 Continues on next page 522 Product manual IRB 8700 3HAC052853 001 Revisio...

Page 523: ... into its mounting position while at the same time pushing the motor cables in through the cable gland recess Make sure the motor pinion is properly mated into the hub Make sure the motor pinion is not dam aged 7 Continues on next page Product manual IRB 8700 523 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis 6 motor Continued ...

Page 524: ...axis 6 motor cables step 2 Note Action xx1300000488 Reconnect the the axis 6 motor connectors Note Place the resolver cable underneath the motor cable 1 xx1500003095 Make sure the gasket on the motor cover is undamaged Note Replace if damaged 2 Continues on next page 524 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis ...

Page 525: ...ket with a cable tie Note The position of axis 4 depends on the on going procedure 5 xx1500002331 Remove all residues of old sealant and other contamination from the wrist cover contact surfaces 6 Flange sealant Loctite 574 Apply flange sealant Loctite 574 on the wrist cover flange 7 Continues on next page Product manual IRB 8700 525 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights res...

Page 526: ...procedure Note Action Axis Calibration is described in Calibrating with Axis Calibration method on page 701 Re calibrate the robot 1 General calibration information is included in section Calibration on page 691 DANGER Make sure all safety requirements are met when performing the first test run 2 526 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Re...

Page 527: ...isted in the table can be out of date See the latest spare parts of the IRB 8700 via myABB Business Portal www mypo rtal abb com Note Article number Spare part 3HAC049795 003 Hub with pinion Required tools and equipment Note Article number Equipment etc Used for removal and refitting of the hub 3HAC071355 001 Hub tool Leak down tester Content is defined in section Standard toolkit on page 733 Stan...

Page 528: ...xes Axis 6 Axis 5 Axis 4 Axis 3 Axis 2 Axis 1 4 pcs 6 pcs 4 pcs 8 pcs 8 pcs 6 pcs Pinion on the hub There are three different pinions on the hub Pinion axis 5 Pinion axis 4 and axis 6 Pinion axis 1 axis 2 and ax is 3 xx1500002978 xx1500002977 xx1500002976 Removing the hub Use these procedures to remove the hub Preparations before removing the hub Note Action DANGER Turn off all electric power supp...

Page 529: ...estion 3 Removing the hub Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1500002038 Unscrew the M6x30 hex socket head cap screws that secure the hub Note Do not remove the M6x16 torx pan head screws 2 CAUTION Whenever parting mating the hub pinion and gearbox the gears may be damaged if excessive force is used 3 Continues ...

Page 530: ...rom the gear 5 xx2000001381 Lift out the hub carefully 6 Refitting the hub Use these procedures to refit the hub Preparations before refitting the hub Note Action Wipe the hub clean 1 Inspect the hole where the hub shall be refitted Wipe clean if needed 2 Continues on next page 530 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 1 Replacin...

Page 531: ...amine the pinion and the splines in the hub for damages 5 Grease Castrol Molub Alloy 777 1 NG xx1500002346 Make sure that there is enough grease on the splines before fitting If not apply 1 gram of grease 6 Continues on next page Product manual IRB 8700 531 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 1 Replacing the hub Continued ...

Page 532: ...e The number of attachment screws differ depending on gearbox Quantity Axis 1 6 pcs Axis 2 8 pcs Axis 3 8 pcs Axis 4 4 pcs Axis 5 6 pcs Axis 6 4 pcs Tightening torque 14 Nm Secure the hub 5 Concluding procedure Note Action See Performing a leak down test on page 178 Perform a leak down test 1 See procedures in Motors on page 461 Refit the motor of the axis in question 2 See procedures in Replaceme...

Page 533: ...e robot 4 General calibration information is included in section Calibration on page 691 DANGER Make sure all safety requirements are met when performing the first test run 5 Product manual IRB 8700 533 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 1 Replacing the hub Continued ...

Page 534: ...bers that are listed in the table can be out of date See the latest spare parts of the IRB 8700 via myABB Business Portal www mypo rtal abb com Note Article number Spare part 3HAC048963 002 Reduction gear RV 700CS Continues on next page 534 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox ...

Page 535: ...airs 3HAC15521 2 Guide pin M10x150 Used to push out the motor if neces sary Always use removal tools in pairs 3HAC14631 1 Removal tool M12 2 pcs Fully threaded Used as removal tools when removing the hub Screw M6x110 Always use guide pins in pairs 3HAC13120 5 Guide pin M16x300 M16 3HAC14457 4 Lifting eye Nova Torque Torque Multiplier Always use guide pins in pairs 3HAC13120 3 Guide pin M16x200 Alw...

Page 536: ...ration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 702 If no previous reference values exist and no new refere...

Page 537: ...he robot working area 2 Removing the mechanical stop pin Note Action CAUTION The mechanical stop pin weighs 13 kg 1 xx1500002091 Put a piece of wood or similar underneath the stop pin to prevent it from falling down uncontrolled when the set screw is re moved 2 Take a firm grip on the stop pin with one hand 3 Continues on next page Product manual IRB 8700 537 3HAC052853 001 Revision M Copyright 20...

Page 538: ...the piece of wood or similar with the other hand 5 xx1500002089 Remove the stop pin by sliding it down out off its hole and moving it slightly forwards 6 Continues on next page 538 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Continued ...

Page 539: ...fting accessories used must be sized accordingly 2 A xx1400002590 A Lifting eye M24 4 pcs Fit two lifting eyes to the holes in the frame and two lifting eyes to the holes in the counter weight DANGER Never use the robot as ladder Use a Mobile platform ladder or similar to reach 3 Continues on next page Product manual IRB 8700 539 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserve...

Page 540: ... eyes have sharp edges that might damage the roundslings lifting shackles must be used to attach the roundslings to the lifting eyes Make sure the roundslings do not rub against any sharp edges xx1700000969 A Lifting chains with shortener 2 pcs B Roundsling 2 m Lifting capacity 5 000 kg 2 pcs C Lifting eye M24 3HAC038295 003 4 pcs Stretch the lifting accessories to take the weight of the robot 5 C...

Page 541: ...ent screws 4 Tightening torque 325 Nm Use caution and lower the robot slowly down onto the supporting pillars making sure the holes in robot base will match the holes in the pillars 5 Follow user instructions enclosed with the pillars Secure the base to the supporting pillars with the robot attachment screws 6 Tightening torque 325 Nm xx1700000928 Disconnecting the cable harness in the base Note A...

Page 542: ...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 542 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Continued ...

Page 543: ...xis 1 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws with washers and remove the motor cover 2 Continues on next page Product manual IRB 8700 543 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Continued ...

Page 544: ...t hole is facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Removing the axis 1 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 544 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All ri...

Page 545: ... and washers Use a bits extender to reach the screws 5 Guide pin M10x150 3HAC15521 2 Fit guide pins in opposite holes 6 Always use guide pins in pairs CAUTION Whenever parting mating motor pinion and hub the splines may be damaged if excess ive force is used 7 Removal tool motor M12 3HAC14631 1 If needed use removal tools to help re move the motor 8 Used to push out the motor if necessary Always u...

Page 546: ... electrical power hydraulic pressure and air pressure are turned off 1 xx1500002038 Unscrew the M6x30 hex socket head cap screws that secure the hub Note Do not remove the M6x16 torx pan head screws 2 CAUTION Whenever parting mating the hub pinion and gearbox the gears may be damaged if excessive force is used 3 Continues on next page 546 Product manual IRB 8700 3HAC052853 001 Revision M Copyright...

Page 547: ...hub 4 xx2000001380 Alternately thread the nuts clockwise on the two rods to pull out the hub from the gear 5 xx2000001381 Lift out the hub carefully 6 Continues on next page Product manual IRB 8700 547 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Continued ...

Page 548: ...nch 2 xx1500003120 With lifting accessories stretched unscrew the M16x70 screws 18 pcs that secure the cross roller bearing to the frame Tip This procedure is best done with two per sons working together Person one working under the base holding the torque wrench in place and making sure the bit is correctly fitted Person two working beside the ro bot working with the torque wrench 3 Make sure tha...

Page 549: ...stem on a flat surface the arm system will rest on the screw heads and be unstable 1 xx1700000931 Guide pin M16x300 2 pcs Fit two guide pins in opposite holes of the cross roller bearing 2 Always use guide pins in pairs xx1700000929 CAUTION The complete arm system weighs 4 300 kg All lifting accessories used must be sized accordingly 3 Continues on next page Product manual IRB 8700 549 3HAC052853 ...

Page 550: ... the same time using force to test if the arm system remains stable If not adjust the position of the robots axes 6 Remove the lifting accessories WARNING The robot is likely to be mechanically un stable if not secured to the foundation Test if the robot is stable before the lifting ac cessories are removed 7 Removing the axis 1 gearbox Note Action Lifting eye M16 3HAC14457 4 2 pcs Fit lifting eye...

Page 551: ...nscrew the M20x60 screws that secure the axis 1 gearbox to the base Tip Use a Torque Multiplier between the screw 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 Product manual IRB 8700 551 3HAC052853 001 Revision M Copyright 2015 2020 ABB Al...

Page 552: ...ting accessory chain to the axis 1 gearbox 3 Stretch the lifting chain and lift the axis 1 gearbox up 4 Remove old residues of sealant and other contamination from the axis 1 gearbox and base DANGER Let only one hand stay underneath the hanging gearbox while cleaning 5 Clean the contact surfaces between gear box and base DANGER Let only one hand stay underneath the hanging gearbox while cleaning 6...

Page 553: ... guide pins 6 Attachment screws M20x60 12 9 Gleitmo xx1500003122 Attach the 16 of the 18 attachment screws that will secure the gearbox to the base Tip This procedure is best done with two per sons working together Person one working under the base holding the torque wrench in place making sure the bit is correctly fitted Person two working beside the ro bot working with the torque wrench 7 Remove...

Page 554: ...Tightening torque step 2 450 Nm Torque Multiplier xx1500003127 Attaching lifting accessories complete arm system If the lifting accessories have been removed from the arm system refit them accordingly Note Action CAUTION The complete armsystem weighs 4 300 kg All lifting accessories used must be sized accordingly 1 Continues on next page 554 Product manual IRB 8700 3HAC052853 001 Revision M Copyri...

Page 555: ...ave sharp edges that might damage the roundslings lifting shackles must be used to attach the roundslings to the lifting eyes Make sure the roundslings do not rub against any sharp edges xx1700000969 A Lifting chains with shortener 2 pcs B Roundsling 2 m Lifting capacity 5 000 kg 2 pcs C Lifting eye M24 3HAC038295 003 4 pcs Stretch the lifting accessories and adjust if needed to make the lift leve...

Page 556: ...ed must be sized accordingly 3 Use caution and lift the complete arm sys tem up 4 Clean contact surfaces between base in cluding gearbox cross roller bearing and frame DANGER Let only one hand stay underneath the hanging gearbox while cleaning 5 Flange sealant Loctite 574 xx1600000045 Apply flange sealant Loctite 574 on the sealing surface for the cross roller bearing on the base 6 Continues on ne...

Page 557: ...er bearing One of the guide pins shall be matched against the hole closest to the small dowel pin in the bas 7 xx1700000933 Continues on next page Product manual IRB 8700 557 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Continued ...

Page 558: ...e guide pins 9 Securing the complete arm system to base and axis 1 gearbox Note Action Attachment screws M16x70 12 9 Gleitmo 18 pcs xx1500003120 Attach the screws that hold the cross roller bearing to the frame Do not tighten yet Tip This procedure is best done with two per sons working together Person one working under the base holding the torque wrench in place making sure the bit is correctly f...

Page 559: ...be very difficult to reach Using a magnet will probably be the only way to get hold of the lost screw 3 Attachment screws M16x110 12 9 Gleitmo 18 pcs xx1500003119 Fit the attachment screws that hold the gearbox to the frame Do not tighten yet Tip This procedure is best done with two per sons working together Person one working under the base holding the torque wrench in place making sure the bit i...

Page 560: ...ng of the screws 6 Tightening torque step 2 300 Nm xx1600000040 xx1500003118 Refit the plastic plugs 7 xx1700000934 Refit the cable bracket inside the frame 8 Preparations before refitting the hub Note Action Wipe the hub clean 1 Inspect the hole where the hub shall be refitted Wipe clean if needed 2 Continues on next page 560 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 A...

Page 561: ...the pinion and the splines in the hub for damages 5 Grease Castrol Molub Alloy 777 1 NG xx1500002346 Make sure that there is enough grease on the splines before fitting If not apply 1 gram of grease 6 Continues on next page Product manual IRB 8700 561 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Continued ...

Page 562: ...crews for the hub 4 Loctite 243 Apply locking liquid Loctite 243 on the screws Note The number of attachment screws differ depending on gearbox Quantity Axis 1 6 pcs Axis 2 8 pcs Axis 3 8 pcs Axis 4 4 pcs Axis 5 6 pcs Axis 6 4 pcs Tightening torque 14 Nm Secure the hub 5 Performing a leak down test Note Action See Performing a leak down test on page 178 Perform a leak down test 1 Continues on next...

Page 563: ...an the contact surfaces from any remain ing contamination 3 Also wipe clean the o ring groove O ring 3HAB3772 107 xx1200001019 Inspect the o ring Note Replace if damaged 4 xx1200001020 Make sure the o ring is seated in the groove Tip Lubricate the o ring with some grease for a better fitting in the groove 5 Continues on next page Product manual IRB 8700 563 3HAC052853 001 Revision M Copyright 2015...

Page 564: ...de pins in opposite holes 1 Always use guide pins in pairs CAUTION The motor weighs 27 kg All lifting accessories used must be sized accordingly 2 Lifting accessory motor 3HAC14459 1 Apply the lifting accessory 3 Rotation tool 3HAC7887 1 Fit the rotation tool 4 Continues on next page 564 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 2 Re...

Page 565: ...ng motor pinion and hub the splines may be damaged if excess ive force is used 7 Lifting accessory chain 3HAC15556 1 Lower the motor into position Make sure that the motor pinion is properly mated into the hub Make sure that the motor pinion does not get damaged Make sure that the direction of the cable gland exit is facing the correct way 8 Lifting accessory motor 3HAC14459 1 xx1500002084 Continu...

Page 566: ...if not already done 10 Disconnect the 24 VDC power supply 11 Attaching lifting accessories complete robot If the lifting accessories have been removed from the arm system refit them accordingly Note Action CAUTION The complete armsystem weighs 4 300 kg All lifting accessories used must be sized accordingly 1 Continues on next page 566 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 201...

Page 567: ...ead crane CAUTION If the lifting eyes have sharp edges that might damage the roundslings lifting shackles must be used to attach the roundslings to the lifting eyes Make sure the roundslings do not rub against any sharp edges xx1700000969 A Lifting chains with shortener 2 pcs B Roundsling 2 m Lifting capacity 5 000 kg 2 pcs C Lifting eye M24 3HAC038295 003 4 pcs Continues on next page Product manu...

Page 568: ...lars 2 Unscrew the attachment screws that secure the supporting pillars to the foundation 3 Remove the supporting pillars 4 Screws M24 x 100 12 pcs 8 8 Lower the robot onto the foundation and secure 5 Washers 4 mm flat washer Tightening torque 550 Nm screws lubricated with Molykote 1000 600 725 Nm typical 650 Nm screws none or lightly lubricated Refitting the cable harness in the base Note Action ...

Page 569: ...s from the axis 1 bracket runs untangled to all connection points down through the hole in the frame to the base plate to the axis 1 motor to the axis 2 motor to the axis 3 motor to the SMB BU recess Adjust the cables if needed The different cables must not be twisted or tangled Do not fasten the axis 1 bracket yet 4 A B xx1600000078 A Bar code B Hole for pin 1 Before refitting the R1 MP A and R1 ...

Page 570: ... R1 MP cables through the base 7 Sparkplug wrench xx1500003084 Refit the R1 SMB cable with the large re cess pointing upwards to the right Tip Use a Sparkplug wrench or similar xx1200000888 8 Attachment screw M6x16 stainless steel A2 70 xx1500003085 Refit the two earth cables 9 Continues on next page 570 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved ...

Page 571: ...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 8700 571 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Continued ...

Page 572: ...5 Refit the motor cover with its attachment screws Note Do not reuse the self threading attachment screws Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Continues on next page 572 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights res...

Page 573: ...osition 1 Clean the stop pin as well as the hole for it 2 Corrosion protection Mercasol xx1500002094 Apply corrosion protection on the marked area on the stop pin and on the matching area in the hole 3 CAUTION The mechanical stop pin weighs 13 kg 4 Continues on next page Product manual IRB 8700 573 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the a...

Page 574: ...anical stop pin Tip Use caution and move the stop pin a little up and down while at the same time care fully fitting the set screw making sure that the screw will secure the stop pin in the groove 7 Tightening torque 35 Nm Secure the mechanical stop pin with the set screw 8 Concluding procedure Note Action See Changing oil axis 1 gearbox on page 138 Refill oil in the gearbox 1 Continues on next pa...

Page 575: ... calibrate the robot 3 General calibration information is included in section Calibration on page 691 DANGER Make sure all safety requirements are met when performing the first test run 4 Product manual IRB 8700 575 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Continued ...

Page 576: ...table can be out of date See the latest spare parts of the IRB 8700 via myABB Business Portal www mypo rtal abb com Note Article number Spare part 3HAC048392 003 Reduction gear RV 900N incl input gear 3HAC052423 001 Sealing ring Continues on next page 576 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox ...

Page 577: ...NA1 Lifting shackle Always use guide pins in pairs Used 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 5 000 kg Roundsling 2 m Lifting capacity 5 000 kg Roundsling 2 5 m M16 3HAC14457 4 Lifting eye M24 3HAC038295 003 Lifting eye Used to rotate the motor pinion 3HAC7887 1 Rotation tool Used to push out the motor if...

Page 578: ...of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 702 If no previous reference values exist and no new reference values can be created then reference calibration is not possible If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack...

Page 579: ... 2 3 The order when removing the attachment screws area 1 then area 2 and last area 3 The order when attaching the axis 2 gearbox to the lower arm is reversed area 3 then area 2 and last area 1 Robot position when removing screws in area 1 With the robot in this position it is possible to reach the screws in area 1 of screws that secure the axis 2 gearbox to the lower arm Note Action Jog the robot...

Page 580: ...on This procedure describes how to reach the screws in area 1 Note Action DANGER Never remove the screws on both axis 2 and axis 3 at the same time One side must always be attached when the gearbox on the other side is removed If not there is a potential risk that a severe accident will happen 1 1 2 3 1 2 3 Find area 1 Note Do not remove screws in area 2 or area 3 at this point 2 Remove the screws...

Page 581: ...ure 2 Remove the plastic plugs covering axis 2 lock screw hole Note Keep the plastic plugs It shall be refitted after the work is done 3 Jog axis 3 to the area shown in the figure 4 Continues on next page Product manual IRB 8700 581 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Continued ...

Page 582: ...position 1 Tightening torque 100 Nm Secure the axis 2 with a lock screw 2 Lock screw quality 12 9 M20x150 24 VDC power supply Release the brakes on axis 2 using the brake release button and let the axis rest on the lock screw 3 Continues on next page 582 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Continu...

Page 583: ...lease button and let the axis rest on the lock screw 5 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 6 Continues on next page Product manual IRB 8700 583 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Continued ...

Page 584: ...e sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Mobile platform ladder xx1500001985 Use a mobile platform ladder or similar to reach the upper end of the balancing device DANGER Do not use the robot as ladder 2 Continues on next page 584 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 3 Re...

Page 585: ...pply Molykote on colored areas xx1500002303 Screw M16x80 Fully threaded 2 pcs 2 pcs xx1500002309 Unload the pressure of the balancing device by inserting the screws 1 Attach the screws until the screws reaches the piston xx1900001209 2 Then alternately little by little attach the screws at least another five milli meters The pressure is now un loaded xx1900001210 5 Continues on next page Product m...

Page 586: ...at all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 xx1200001070 Make sure the o ring is present 3 Continues on next page 586 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Continued ...

Page 587: ... Action DANGER When releasing the holding brakes of the motor the lower arm and or the parallel arm will move and may fall down Before continuing make sure the lower arm and or parallel arm are secured with lock screws 1 To release the brake connect the 24 VDC power supply to the motor in question 2 Connect to connector R2 MP2 axis 2 mo tor or R2 MP3 axis 3 motor pin 2 24V pin 5 0V Continues on ne...

Page 588: ...ress the motor out of position by using the removal tool in opposite holes of the motor 6 CAUTION The motor weighs 27 kg All lifting accessories used must be sized accordingly 7 Lifting accessory motor 3HAC15534 1 Attach the lifting accessory 8 xx1500002325 Use caution and lift the motor out on the guide pins in order to get the pinion away from the hub Let the motor rest on the guide pins 9 Disco...

Page 589: ...ned off 1 xx1500002038 Unscrew the M6x30 hex socket head cap screws that secure the hub Note Do not remove the M6x16 torx pan head screws 2 CAUTION Whenever parting mating the hub pinion and gearbox the gears may be damaged if excessive force is used 3 Continues on next page Product manual IRB 8700 589 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing t...

Page 590: ...hub 4 xx2000001380 Alternately thread the nuts clockwise on the two rods to pull out the hub from the gear 5 xx2000001381 Lift out the hub carefully 6 Continues on next page 590 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Continued ...

Page 591: ...ews 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 Use caution and move the motor flange out over the guide pins 5 Continues on next page Product manual IRB 8700 591 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Contin...

Page 592: ...0 Attach two additional guide pins in opposite hole below the present ones 1 Always use guide pins in pairs 1 2 3 1 2 3 Find area 2 2 Remove the attachment screws in area 2 3 Continues on next page 592 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Continued ...

Page 593: ...rame 4 Always use guide pins in pairs Removing the axis 2 gearbox from the lower arm step 3 screws in area 3 Note Action 1 2 3 1 2 3 Find area 3 1 Remove the attachment screws that secure the gearbox to the lower arm in area 3 2 Continues on next page Product manual IRB 8700 593 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Contin...

Page 594: ...the set collars 1 Attach three screws in a triangle and use them as removal tools 2 Slide the gearbox out on the four guide pins just enough to be able to attach the lifting accessories 3 Continues on next page 594 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Continued ...

Page 595: ...g accessories used must be sized accordingly 1 Lifting accessory gearbox 3HAC054404 001 Attach the lifting accessory to the gearbox 2 Roundsling 2 m Lifting capacity 5 000 kg Attach a roundsling to the lifting accessory 3 Continues on next page Product manual IRB 8700 595 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Continued ...

Page 596: ... the gearboxes must stay fitted when the other one is replaced The complete arm system will loose its connection to the frame and thereby be a great security risk Note The attachment screws that secure the gearboxes are arranged in three areas with 15 screws in each area It will not be possible to reach all screws with the robot in only one position Removal and refitting must be performed with the...

Page 597: ... 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 Fit a new sealing ring 2 Clean the contact surfaces between gear box and frame 3 Continues on next page Product manual IRB 8700 597 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Continued...

Page 598: ...it guide pins as shown in the figure 6 Always use guide pins in pairs Guide pin M16x150 2 pcs 3HAC13120 2 Fit guide pins to the back of the gearbox if replaced 7 Always use guide pins in pairs Continues on next page 598 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Continued ...

Page 599: ...lifting accessory 3 Shackle SA 10 8 NA1 Connect another roundsling to the first one with a shackle 4 Attach the roundslings to an overhead crane or similar and raise to take the weight of the gearbox 5 Attaching the axis 2 gearbox to frame step 1 Note Action Mercasol Apply 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 ar...

Page 600: ...pattern does not match carefully turn the small gear in the gearbox very slowly in order to find the hole pattern 3 Lift the gearbox onto the guide pins 4 Note The axis 2 gearbox shall on the side shown in the figure be attached to the frame The other side of the gearbox shall be attached to the lower arm 5 Continues on next page 600 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015...

Page 601: ...Note Action 1 2 3 1 2 3 Find area 3 1 Begin attaching the screws M16x70 in the outer most holes of the outer ring of holes Tip Make sure that the hole pattern match If needed use extreme caution and turn the small gear in the gearbox to find the hole pattern 2 Attachment screws M16x70 12 9 Gleitmo Attach the screws with washers in area 3 Note Do not torque the screws at this point 3 Continues on n...

Page 602: ...hat the hole pattern match If needed use extreme caution and turn the small gear in the gearbox to find the hole pattern 3 Attachment screws M16x70 12 9 Gleitmo Attach the screws with washers in area 2 Note Do not torque the screws at this point 4 Continues on next page 602 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the ax...

Page 603: ...s 5 Attach the smaller o ring in the gearbox groove 6 Attach the larger o ring on the motor flange 7 Before lifting the motor flange onto the guide pins make sure the oil inspection glass is facing at six o clock 8 Lift the motor flange onto the guide pins 9 Make sure the o rings are in position and slide the motor flange into position 10 Continues on next page Product manual IRB 8700 603 3HAC0528...

Page 604: ... the four six hole washers 12 Remove the guide pins and attach the remaining screws 13 Securing the motor flange together with gearbox Note Action Tightening torque 300 Nm Secure motor flange together with the gearbox to the frame 1 Continues on next page 604 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Co...

Page 605: ...ipe the hub clean 1 Inspect the hole where the hub shall be refitted Wipe clean if needed 2 xx1500002039 Make sure the o ring on the hub is undam aged Note Replace if damaged 3 Apply some grease on the o ring for a bet ter fitting 4 xx1500002082 Examine the pinion and the splines in the hub for damages 5 Continues on next page Product manual IRB 8700 605 3HAC052853 001 Revision M Copyright 2015 20...

Page 606: ...55 001 xx2000001377 Fit the hub tool 1 CAUTION Whenever parting mating the hub pinion and gearbox the gears may be damaged if excessive force is used 2 xx2000001381 Lift the hub to the gear and mate the pinon carefully into the gear 3 Continues on next page 606 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox ...

Page 607: ...rform a leak down test 1 Preparations before refitting the motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Remove old paint residues and other contamina tion from the contact surfaces on both motor and gearbox 2 Wipe clean the contact surfaces from any remain ing contamination 3 Also wipe clean the o ring groove O ring ...

Page 608: ...f the motor is a new spare part remove the cover 7 Securing the axis 2 motor Note Action Guide pin M10x150 3HAC15521 2 Fit guide pins in opposite holes 1 Always use guide pins in pairs CAUTION The motor weighs 27 kg All lifting accessories used must be sized accordingly 2 Continues on next page 608 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repa...

Page 609: ...pin 5 0V CAUTION Whenever parting mating motor pinion and hub the splines may be damaged if excess ive force is used 9 Fit the motor in its final position while at the same time rotating the motor pinion slightly using the rotation tool Make sure that the motor pinion is properly mated into the hub Make sure that the motor pinion does not get damaged Make sure that the direction of the cable exit ...

Page 610: ...40 quality 12 9 Gleitmo 4 pcs Connecting the axis 2 cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 xx1200001067 Refit the cable gland cover Note Replace the gasket if damaged 2 Continues on next page 610 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Continued ...

Page 611: ...ring axis 4 3HAC054692 002 xx1200001070 Wipe clean o ring and o ring groove 5 Refit the o ring Tip Lubricate the o ring with some grease for a better fitting in the groove 6 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 7 Continues on next page Product manual IRB 8700 611 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair...

Page 612: ... Restoring the pressure of the balancing device Note Action Mobile platform ladder xx1500001985 Use a Mobile platform ladder or similar to reach the upper end of the balancing device DANGER Do not use the robot as ladder 1 xx1500002308 Restore the pressure of the balancing device by unscrewing the two M16x80 screws alternately little by little 2 Remove the screws 3 Continues on next page 612 Produ...

Page 613: ...ly jogging axis 2 until it is possible to unscrew the lock screw completely 2 Begin unscrewing the axis 3 lock screw while at the same time very slowly jogging axis 3 until it is possible to unscrew the lock screw completely 3 Jog axis 2 to be able to attach the plastic plug 4 Continues on next page Product manual IRB 8700 613 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4...

Page 614: ... 1 2 Attachment screws M16x70 Secure the screws in area 1 Tip Mark the screw with a marker pen after each torque This is to make sure that all screws have been torqued 3 Tightening torque 300 Nm Examine that all screws have been torqued 4 Concluding procedure Note Action See Performing a leak down test on page 178 Perform a leak down test if not already done 1 Continues on next page 614 Product ma...

Page 615: ...ion method on page 701 Re calibrate the robot 3 General calibration information is included in section Calibration on page 691 DANGER Make sure all safety requirements are met when performing the first test run 4 Product manual IRB 8700 615 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Continued ...

Page 616: ...able can be out of date See the latest spare parts of the IRB 8700 via myABB Business Portal www mypo rtal abb com Note Article number Spare part 3HAC048392 003 Reduction gear RV 900N incl in put gear 3HAC052423 001 Sealing ring Continues on next page 616 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox ...

Page 617: ...s in pairs Used 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 5 000 kg Roundsling 2 m Lifting capacity 5 000 kg Roundsling 2 5 m M16 3HAC14457 4 Lifting eye M24 3HAC038295 003 Lifting eye Used to rotate the motor pinion 3HAC7887 1 Rotation tool Used to push out the motor if neces sary Always use removal tools in ...

Page 618: ...lity to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 702 If no previous reference values exist and no new reference values can be created then reference calibration is not possible If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the gearbox Use...

Page 619: ...ews that secure the axis 3 gearbox to the parallel arm are removed is area 1 area 2 and then area 3 The order when attaching the axis 3 gearbox to the parallel arm is reversed area 3 area 2 and then area 1 Robot position when removing axis 3 from parallel arm screws in area 1 With the robot in this position it is possible to reach the screws in the first of the three areas of screws that secure th...

Page 620: ...5 screws in each area All attachment screws can not be reached with the robot in the same position This procedure describes how to reach the screws in the first area Only remove the screws in this area at this point Use this procedure to remove the screws that secure the axis 3 gearbox to the parallel arm in area 1 Note Action DANGER Never remove the screws on both axis 2 and axis 3 at the same ti...

Page 621: ...pressure supply to the robot before entering the robot working area 2 Removing the axis 3 gearbox from parallel arm step 2 screws in area 2 Use this procedure to remove the screws that secure the axis 3 gearbox to the parallel arm in area 2 Note Action DANGER Never remove the screws on both axis 2 and axis 3 at the same time One side must always be attached when the gearbox on the other side is re...

Page 622: ...rations before jogging the robot into calibration position Note Action Turn the power to the robot on 1 Jog axis 2 to within the area shown in the figure 2 Continues on next page 622 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox Continued ...

Page 623: ...he plastic plug It shall be refitted after the work is done 3 Jog axis 3 to the area shown in the figure 4 Continues on next page Product manual IRB 8700 623 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox Continued ...

Page 624: ...position 1 Tightening torque 100 Nm Secure the axis 2 with a lock screw 2 Lock screw quality 12 9 M20x150 24 VDC power supply Release the brakes on axis 2 using the brake release button and let the axis rest on the lock screw 3 Continues on next page 624 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox Continu...

Page 625: ...lease button and let the axis rest on the lock screw 5 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 6 Continues on next page Product manual IRB 8700 625 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox Continued ...

Page 626: ...e sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Mobile platform ladder xx1500001985 Use a mobile platform ladder or similar to reach the upper end of the balancing device DANGER Do not use the robot as ladder 2 Continues on next page 626 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 4 Re...

Page 627: ...pply Molykote on colored areas xx1500002303 Screw M16x80 Fully threaded 2 pcs 2 pcs xx1500002309 Unload the pressure of the balancing device by inserting the screws 1 Attach the screws until the screws reaches the piston xx1900001209 2 Then alternately little by little attach the screws at least another five milli meters The pressure is now un loaded xx1900001210 5 Continues on next page Product m...

Page 628: ...at all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 xx1200001070 Make sure the o ring is present 3 Continues on next page 628 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox Continued ...

Page 629: ... 6 Removing the motor Note Action DANGER When releasing the holding brakes of the motor the lower arm and or parallel arm will be movable and may fall down Before continuing the lower arm and parallel arm must be secured 1 24 VDC power supply In order to release the brakes connect the 24 VDC power supply 2 Connect connector R2 MP3 pin 2 24V pin 5 0V Continues on next page Product manual IRB 8700 6...

Page 630: ...quired press the motor out of position by using the removal tools in opposite holes of the motor 6 CAUTION The motor weighs 27 kg All lifting accessories used must be sized accordingly 7 Lifting accessory motor 3HAC15534 1 Attach the lifting accessory 8 Lift the motor out on the guide pins in or der to get the pinion away from the hub Let the motor rest on the guide pins 9 Disconnect the 24 VDC po...

Page 631: ...d off 1 xx1500002038 Unscrew the M6x30 hex socket head cap screws that secure the hub Note Do not remove the M6x16 torx pan head screws 2 CAUTION Whenever parting mating the hub pinion and gearbox the gears may be damaged if excessive force is used 3 Continues on next page Product manual IRB 8700 631 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 4 Replacing the...

Page 632: ...wise on the two rods to pull out the hub from the gear 5 xx2000001381 Lift out the hub carefully 6 Removing the axis 3 gearbox from parallel arm step 3 screws area 3 Note Action 1 2 3 1 2 3 Find area 3 1 Continues on next page 632 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox Continued ...

Page 633: ... arm removed to better show guide pin placement Removing the motor flange Note Action Remove two attachment screws in opposite holes 1 Mounting set gear axis 2 and 3 3HAC059801 001 Fit guide pins in the holes 2 Continues on next page Product manual IRB 8700 633 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox Continued ...

Page 634: ... is removed Put some paper or similar to absorb the surplus oil 4 Use caution and move the motor flange out over the guide pins 5 Make sure the o rings are present 6 Continues on next page 634 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox Continued ...

Page 635: ...esent ones 1 Attach three screws in a triangle and use as removal tools for the gearbox 2 Slide the gearbox out on the four guide pins just enough to be able to attach the lifting accessories 3 Continues on next page Product manual IRB 8700 635 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox Continued ...

Page 636: ...slings to an overhead crane or similar and raise to take the weight of the gearbox 4 Lift the gearbox off 5 Refitting the gearbox Use these procedures to refit the axis 3 gearbox DANGER Never remove both the axis 2 and axis 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 an...

Page 637: ... are described in the procedures Robot position Note Action Note Make sure that the position of the robot has not been changed Correct position is cal ibration position 1 Preparations before refitting the gearbox Note Action Use caution and lift the gearbox up and let it rest on its side CAUTION Make sure the gearbox is resting in a stable position 1 Continues on next page Product manual IRB 8700 ...

Page 638: ...arallel arm The area where the gear box will enter 4 Grease Apply some grease on the thin chamfer on the gearbox 5 Mounting set gear axis 2 and 3 3HAC059801 001 Fit guide pins as shown in the figure 6 Continues on next page 638 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox Continued ...

Page 639: ...ssories used must be sized accordingly 1 Lifting accessory gearbox 3HAC054404 001 Attach the lifting accessories to the gear box 2 Roundsling 2 m Lifting capacity 5 000 kg 2 pcs Attach a roundsling to the lifting accessor ies 3 Attach the roundslings to an overhead crane or similar and raise to take the weight of the gearbox 4 Continues on next page Product manual IRB 8700 639 3HAC052853 001 Revis...

Page 640: ...sealing ring is attached cor rectly on the gearbox 2 Orient the gearbox to match the hole patterns before lifting the gearbox onto the guide pins If the hole pattern does not match carefully turn the small gear in the gearbox very slowly in order to find the hole pattern 3 Lift the gearbox up onto the guide pins 4 Continues on next page 640 Product manual IRB 8700 3HAC052853 001 Revision M Copyrig...

Page 641: ...ox into position Note The six hole washers are needed for protection of the gearbox surface when screws are attached 6 Attachment screws M16x130 12 9 Gleitmo Attaching the axis 3 gearbox to parallel arm screws in area 3 Note Action 1 2 3 1 2 3 Find area 3 1 Remove the guide pins 2 Lower arm is hidden in this figure to get a better view Continues on next page Product manual IRB 8700 641 3HAC052853 ...

Page 642: ... hidden in this figure to get a better view Refitting the motor flange Note Action Remove the three M16x130 screws and six hole washers previously attached in a triangle 1 Clean the contact surfaces on gearbox and motor flange 2 Clean o rings and o ring groove on gearbox 3 Inspect the o rings Replace if damaged 4 Continues on next page 642 Product manual IRB 8700 3HAC052853 001 Revision M Copyrigh...

Page 643: ... rings are in position and slide the motor flange into position 10 Note When the four six hole washers are fitted make sure that the three holes in the gearbox will be covered See figure 11 Attachment screws M16x130 12 9 Gleitmo 603 Attach 20 of the 24 attachment screws with the four six hole washers 12 Remove the guide pins and attach the remaining screws 13 Continues on next page Product manual ...

Page 644: ...300 Nm Secure the already attached screws in area 3 2 Tip To make sure that all screws in this area are torqued use a marker pen and mark each screw after it has been torqued 3 Examine that all screws in this area 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 Continues on next pa...

Page 645: ...the pinion and the splines in the hub for damages 5 Grease Castrol Molub Alloy 777 1 NG xx1500002346 Make sure that there is enough grease on the splines before fitting If not apply 1 gram of grease 6 Continues on next page Product manual IRB 8700 645 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox Continued ...

Page 646: ...crews for the hub 4 Loctite 243 Apply locking liquid Loctite 243 on the screws Note The number of attachment screws differ depending on gearbox Quantity Axis 1 6 pcs Axis 2 8 pcs Axis 3 8 pcs Axis 4 4 pcs Axis 5 6 pcs Axis 6 4 pcs Tightening torque 14 Nm Secure the hub 5 Performing a leak down test Note Action See Performing a leak down test on page 178 Perform a leak dowm test 1 Continues on next...

Page 647: ...he contact surfaces from any remain ing contamination 3 Also wipe clean the o ring groove O ring 3HAB3772 107 xx1200001019 Inspect the o ring Note Replace if damaged 4 xx1200001020 Make sure the o ring is seated in the groove Tip Lubricate the o ring with some grease for a better fitting in the groove 5 Continues on next page Product manual IRB 8700 647 3HAC052853 001 Revision M Copyright 2015 202...

Page 648: ... 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 3HAC15534 1 Apply the lifting accessory 3 Note Make sure the cable exit hole is turned the correct way 4 Continues on next page 648 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4...

Page 649: ... rotation tool Make sure that the motor pinion is properly mated into the hub Make sure that the motor pinion does not get damaged Make sure that the direction of the cable exit is facing the correct way See figure 10 Screw dimension M10x40 quality 12 9 Gleitmo 4 pcs Fit two of the attachment screws 11 Remove the guide pins and replace with the remaining attachment screws 12 Bits extender 3HAC1234...

Page 650: ...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 650 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox Continued ...

Page 651: ...e sure that none of the cables inside will be dam aged 7 Attachment screws M5x12 8 8 7 pcs xx1200001135 Refit the motor cover with its attachment screws Note Do not reuse the self threading attachment screws Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Continues on ...

Page 652: ...re of the balancing device by unscrewing the two M16x80 screws alternately little by little 2 Remove the screws 3 Attachment screws M16x35 2 pcs xx1500001971 Refit the M16x35 screws in the holes on top of the balancing device 4 Removing lock screws Note Action Turn on the power 1 Continues on next page 652 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserve...

Page 653: ...e it is possible to attach the plastic plug and attach the plug 4 Jog axis 3 to the position where it is possible to attach the plastic plug and attach the plug 5 Robot position when attaching the screws in area 2 Note Action Jog the robot to the specified position Axis 1 no significance as long as the robot is fitted to the foundation Axis 2 65 Axis 3 0 Axis 4 0 Axis 5 0 Axis 6 No significance 1 ...

Page 654: ... Gleitmo Attach and secure the screws in area 2 2 Tightening torque 300 Nm Lower arm is hidden in this figure to get a better view Tip To make sure that all screws in this area are torqued use a marker pen and mark each screw after it has been torqued 3 Examine that all screws in this area has been torqued 4 Continues on next page 654 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 201...

Page 655: ...king area 2 Refitting the axis 3 gearbox to parallel arm screws in area 1 Note Action 1 2 3 1 2 3 Find area 1 1 Attachment screws M16x70 12 9 Gleitmo Attach and secure the screws in area 1 2 Tightening torque 300 Nm Lower arm is hidden in this figure to get a better view Tip To make sure that all screws in this area are torqued use a marker pen and mark each screw after it has been torqued 3 Conti...

Page 656: ...efill the gearbox with oil 2 Axis Calibration is described in Calibrating with Axis Calibration method on page 701 Re calibrate the robot 3 General calibration information is included in section Calibration on page 691 DANGER Make sure all safety requirements are met when performing the first test run 4 656 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserv...

Page 657: ...n the table can be out of date See the latest spare parts of the IRB 8700 via myABB Business Portal www mypo rtal abb com Note Article number Spare part 3HAC043073 003 Graphite White 3HAC048293 001 ABB Orange Reduction Gear RV 500N 236 36 Continues on next page Product manual IRB 8700 657 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 5 Replacing the axis 4 prim...

Page 658: ...Standard toolkit on page 733 Standard toolkit Required consumables Note Article number Consumable Castrol Molub Alloy 777 1 NG 5 ml To be used on hub splines to prevent from fretting corrosion 3HAC063069 001 Grease Loctite 243 3HAB7116 1 Locking liquid Loctite 574 12340011 116 Flange sealant Deciding calibration routine Decide which calibration routine to be used based on the information in the ta...

Page 659: ...s from the robot Removing the axis 4 primary gearbox Use these procedures to remove the gearbox Preparations before removing the gearbox Note Action Decide which calibration routine to use and take actions accordingly prior to begin ning the repair procedure 1 Jog the robot to the most comfortable pos ition for removing the axis 4 primary gear box 2 DANGER Turn off all electric power supply hydrau...

Page 660: ...r Inspect the gasket Note Replace if damaged Tip Make a note in which direction the cable exit hole is facing if the motor will be re moved too The motor shall be refitted in the same position 5 Continues on next page 660 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 5 Replacing the axis 4 primary gearbox Continued ...

Page 661: ...Always use guide pins in pairs CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 5 Removal tool M12 3HAC14631 1 Press the motor out of position by fitting the removal tool in the remaining attach ment holes for the motor 6 Always use removal tools in pairs CAUTION The motor weighs 27 kg All lifting accessories used must be sized accordingly 7 L...

Page 662: ... air pressure are turned off 1 xx1500002038 Unscrew the M6x30 hex socket head cap screws that secure the hub Note Do not remove the M6x16 torx pan head screws 2 CAUTION Whenever parting mating the hub pinion and gearbox the gears may be damaged if excessive force is used 3 Continues on next page 662 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Rep...

Page 663: ... the hub carefully 6 Removing the gear Z3 Note Action Remove the revolution indicator for axis 4 if installed and discard it The indicator does not need to be refitted after repair Note The revolution indicator has been removed from robots from release R19C and for ward 1 Continues on next page Product manual IRB 8700 663 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repa...

Page 664: ...hment screws holding the gear 4 CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 5 Note There is a set of shims behind the gear Use caution when the gear is removed not to damage or drop the set of shims 6 Continues on next page 664 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 5 Rep...

Page 665: ...oil from leaking through the screw holes that secure the axis 4 primary gear box from the other side 9 Removing the motor flange Note Action Cut the paint and Sikaflex with a knife in the slot between motor flange and gearbox 1 Remove two attachment screws in opposite holes 2 Continues on next page Product manual IRB 8700 665 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 ...

Page 666: ...the surplus oil 5 Use caution and remove the motor flange out from the guide pins 6 Removing the axis 4 primary gearbox Note Action M10x16 3 pcs Unscrew the screws that hold the axis 3 bracket and let it hang free 1 Lifting accessory axis 4 primary gearbox Attach the lifting accessories to the primary gearbox 2 If needed use removal tools to press out the gearbox 3 Continues on next page 666 Produ...

Page 667: ...surfaces in the arm house 2 Wipe clean all contact surfaces on the axis 4 primary gearbox 3 Guide pin M12x150 3HAC13056 2 Attach guide pins in opposite holes Tip Put some grease on the guide pins for a better fitting 4 Guide pin M12x200 3HAC13056 3 Always use guide pins in pairs Clean the o rings and o ring grooves on the gearbox 5 Continues on next page Product manual IRB 8700 667 3HAC052853 001 ...

Page 668: ...he gear box 2 Roundsling 2 m Lifting capacity 5 000 kg Fit the o rings in its grooves Tip Put some grease 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 Apply flange sealant 5 Continues on next page 668 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights rese...

Page 669: ...t It will be secured together with the motor flange when the motor flange is refitted 8 Remove the lifting accessories 9 Refitting the motor flange Note Action Clean the contact surfaces on gearbox and motor flange 1 Clean o ring and o ring groove on motor flange 2 Inspect the o ring Note Replace if damaged 3 Continues on next page Product manual IRB 8700 669 3HAC052853 001 Revision M Copyright 20...

Page 670: ...flange into position 7 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 Attach 30 of the 32 attachment screws with the four six hole washers 9 Remove the guide pins and fit the remaining screws 10 Continues on next page 670 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 202...

Page 671: ...e hub clean 1 Inspect the hole where the hub shall be refitted Wipe clean if needed 2 xx1500002039 Make sure the o ring on the hub is undam aged Note Replace if damaged 3 Apply some grease on the o ring for a bet ter fitting 4 xx1500002082 Examine the pinion and the splines in the hub for damages 5 Continues on next page Product manual IRB 8700 671 3HAC052853 001 Revision M Copyright 2015 2020 ABB...

Page 672: ...01 xx2000001377 Fit the hub tool 1 CAUTION Whenever parting mating the hub pinion and gearbox the gears may be damaged if excessive force is used 2 xx2000001381 Lift the hub to the gear and mate the pinon carefully into the gear 3 Continues on next page 672 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 5 Replacing the axis 4 primary gear...

Page 673: ...tep 1 Note Action Wipe clean the contact surfaces 1 Guide pin M12x150 3HAC13056 2 Attach guide pins in opposite holes Tip Put some grease on the guide pins for a better fitting 2 Guide pin M12x200 3HAC13056 3 Always use guide pins in pairs Put 6 mm of shims on the guide pins Note The gear must never be attached with minus play Always start with 6 mm shims 3 Put the axis 4 gear on the guide pins 4 ...

Page 674: ... If the measured value is 1 14 mm and 1 14 mm of shims are removed it will theoretically end up as zero The value must never be lower than the minimum gap around a complete revolution or the gear Micrometer Put shims according to the obtained measurement and control 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...

Page 675: ...e arm house cover Note Replace if damaged 4 Loctite 574 Apply flange sealant Loctite 574 on the cover flange 5 Attachment screws M6x16 22 pcs Attach the arm house cover and tighten all screws alternately and repeat once 6 Tightening torque 10 Nm Apply locking liquid Loctite 243 on the screws See Performing a leak down test on page 178 Perform a leak down test 7 Continues on next page Product manua...

Page 676: ...rfaces from any remain ing contamination 3 Also wipe clean the o ring groove O ring 3HAB3772 107 Inspect the o ring Note Replace if damaged 4 Make sure the o ring is seated in the groove Tip Lubricate the o ring with some grease for a better fitting in the groove 5 If the motor is a new spare part remove the cover 6 Continues on next page 676 Product manual IRB 8700 3HAC052853 001 Revision M Copyr...

Page 677: ...power supply 6 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 7 Use caution and push the motor in position while at the same time the motor pinion is slightly rotated Make sure that the motor pinion is properly mated to the gear of the gearbox Make sure that the motor pinion does not get damaged...

Page 678: ...k down test 11 Disconnect the 24 VDC power supply 12 Connecting the axis 4 motor cables Note Action Push the motor cables through the cable gland opening 1 Refit the cable gland cover Note Replace the gasket if damaged 2 Continues on next page 678 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 5 Replacing the axis 4 primary gearbox Contin...

Page 679: ...maged 7 Attachment screws M5x12 8 8 7 pcs Refit the motor cover with its attachment screws Note Do not reuse the self threading attachment screws Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Continues on next page Product manual IRB 8700 679 3HAC052853 001 Revision ...

Page 680: ...s Calibration is described in Calibrating with Axis Calibration method on page 701 Re calibrate the robot 3 General calibration information is included in section Calibration on page 691 DANGER Make sure all safety requirements are met when performing the first test run 4 680 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 5 Replacing the ...

Page 681: ...the table can be out of date See the latest spare parts of the IRB 8700 via myABB Business Portal www mypo rtal abb com Note Article number Spare part 3HAC043073 003 Graphite White 3HAC048293 001 ABB Orange Reduction Gear RV 500N 236 36 Continues on next page Product manual IRB 8700 681 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 6 Replacing the axis 6 gearbo...

Page 682: ...ages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference value...

Page 683: ...ressure supply air pressure supply to the robot before entering the robot working area 3 Remove all tools and other equipment fitted to the turning disc 4 See Changing oil axis 6 gearbox on page 163 Drain the axis 6 gearbox 5 Removing the turning disc Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1500002318 Unscrew the 27...

Page 684: ...ydraulic pressure and air pressure are turned off 1 CAUTION The process turning disc weighs 50 kg All lifting accessories must be sized accord ingly 2 Roundsling 1 m Lifting capacity 1 000 kg Attach a roundsling to the process turning disc and to an overhead crane or similar 3 Stretch the roundsling to take the weight of the process turning diss 4 Unscrew the 22 attachment screws and washers that ...

Page 685: ...5 0V xx1500002981 Remove the calibration pin holder by un screwing the two M12x110 screws Note Use caution not to damage the guiding pins 3 xx1500002982 Unscrew the attachment screws that secure the axis 6 gearbox 4 CAUTION Whenever parting mating hub and gearbox the splines may be damaged if excessive force is used 5 Continues on next page Product manual IRB 8700 685 3HAC052853 001 Revision M Cop...

Page 686: ...ns before refitting the axis 6 gearbox Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Wipe clean all contact surfaces 2 Sealing ring 3HAC052423 001 xx1600000067 Fit a new sealing ring 3 Continues on next page 686 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 6 Repl...

Page 687: ...nect to connector R2 MP6 pin 2 24V pin 5 0V xx1500002983 Use caution and refit the gearbox 4 Attachment screws M12x80 12 9 Gleitmo 29 pcs Secure the gearbox with its attachment screws and washers Note Do not refit any of the M12x80 screws where the pin holder will be refitted with the M12x110 screws 5 Tightening torque 120 Nm xx1500002982 Continues on next page Product manual IRB 8700 687 3HAC0528...

Page 688: ... page 178 Perform a leak down test 7 Refitting the turning disc Note Action xx1500002319 Wipe clean the contact surfaces and refit the axis 6 gearbox 1 xx1500002984 Make sure the sealing ring is fitted on the gearbox 2 Continues on next page 688 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 4 Repair 4 8 6 Replacing the axis 6 gearbox Continued ...

Page 689: ...Attachment screws M12x40 12 9 Gleitmo 603 22 pcs 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 163 Refill the gearbox with oil 1 Axis Calibration is described in Calibrating with Axis Calibration method on page 701 Re calibrate the robot 2 General calibration information is ...

Page 690: ...This page is intentionally left blank ...

Page 691: ...eneric term for all calibration methods that aim to move the robot to calibration position Standard calibration A calibration routine that generates a new zero posi tion of the robot Fine calibration A calibration routine that in the first step generates a reference to current zero position of the robot The same calibration routine can later on be used to re calibrate the robot back to the same po...

Page 692: ...esian coordinate system for the robot Absolute accuracy calibration option al Absolute accuracy calibration data is found on the SMB serial measurement board in the robot For robots with RobotWare 5 05 or older the absolute accuracy calibration data is delivered in a file absacc cfg supplied with the robot at delivery The file replaces the calib cfg file and identifies motor positions as well as a...

Page 693: ...sses like welding and gluing and is a complement to the standard calibration method The following routines are available for the Wrist Optimization method Wrist Optimization The actual instructions of how to perform the calibration procedure and what to do at each step is given on the FlexPendant You will be guided through the calibration procedure step by step CalibWare Absolute Accuracy calibrat...

Page 694: ...unter memory is lost If the revolution counter memory is lost the counters must be updated See Updating revolution counters on page 697 This will occur when The battery is discharged A resolver error occurs The signal between a resolver and measurement board is interrupted A robot axis is moved with the control system disconnected The revolution counters must also be updated after the robot and co...

Page 695: ...tion marks and the synchronization position for each axis Synchronization marks IRB 8700 Axis 2 xx1500000946 Axis 1 xx1500000945 Axis 4 xx1500000948 Axis 3 xx1500000947 Axis 6 xx1500000950 Axis 5 xx1500000949 Product manual IRB 8700 695 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchronization position for axes ...

Page 696: ...nes will handle the calibration movements automatically and these might be different from the positive directions shown below Manual movement directions 6 axes Note The graphic shows an IRB 7600 The positive direction is the same for all 6 axis robots except the positive direction of axis 3 for IRB 6400R which is in the opposite direction xx0200000089 696 Product manual IRB 8700 3HAC052853 001 Rev...

Page 697: ... this procedure to manually run the manipulator to the synchronization position Note Action Select axis by axis motion mode 1 See Synchronization marks and synchron ization position for axes on page 695 Jog the manipulator to align the synchron ization marks CAUTION Check the position of axis 4 before continu ing see Mandatory check of cable harness prior to revolution counter update or calib rati...

Page 698: ...lowing manipulators Axis 6 Axis 4 Manipulator variant Yes Yes IRB 8700 If the synchronization marks seem to be wrong even if the motor calibration data is correct try to rotate the axis one turn update the revolution counter and check the synchronization marks again try both directions if needed Step 2 Updating the revolution counter with the FlexPendant Use this procedure to update the revolution...

Page 699: ...RobotWare 6 02 and later 3 Calibration method used at factory for each axis is shown as well as calibration method used during last field calibration Tap Manual Method Advanced xx1500000944 Continues on next page Product manual IRB 8700 699 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 5 Calibration 5 3 Updating revolution counters Continued ...

Page 700: ...s displayed warning that the updating operation cannot be undone Tap Update to proceed with updating the revolution counters Tap Cancel to cancel updating the revolution counters Tapping Update updates the selected revolution counters and removes the tick from the list of axes 7 CAUTION If a revolution counter is incorrectly updated it will cause incorrect manipulator posi tioning which in turn ma...

Page 701: ...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 Calibration requires special calibration tools from ABB Using other pins in the calibration bushings may cause severe damage to the robot and or personnel WARNING The calibration tool must be fully inser...

Page 702: ...B factory The reference value will be named according to tool name date etc Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values When reference calibration is performed the robot is restored to the status given by the reference values Update revolution counters Choose this routine to make a rough calibration of each manipulator axis by up...

Page 703: ...he axes Requirements for axis positioning during calibration Axis to calibrate Axis 6 Axis 5 Axis 4 Axis 3 Axis 2 Axis 1 Required position of axis Axis 1 0 0 Axis 2 0 0 Axis 3 Axis 4 Axis 5 Axis 6 Axis to be calibrated Unrestricted Axis is allowed to be jogged to other position than 0 degrees Axis must be put in position 0 degrees 0 Product manual IRB 8700 703 3HAC052853 001 Revision M Copyright 2...

Page 704: ...g other pins in the calibration bushings may cause severe damage to the robot and or personnel Note Article number Equipment etc Delivered as a set of calibration tools 3HAC055412 001 Calibration tool box Axis Calibration Examining the calibration tool Check prior to usage Before using the calibration tool make sure that the tube insert the plastic protection and the steel spring ring are present ...

Page 705: ...solution Note Action It is possible to use any RFID solution with the correct dimensions ABB has verifed function on some suppliers fulfilling the requirements of NFC compatible devices 13 56 Mhz according to ISO 14443 or ISO 15693 Note The maximum dimensions on the RFID chip must not exceed Ø7 9 mm x 8 0 mm Ø5 9 mm x 8 0 mm or Ø3 9 mm x 8 0 mm depending on calibra tion tool size 1 There is a cavi...

Page 706: ...ibration fixed calibration pins and or bushings Installed calibration tools are not shown A fixed calibration pin and a bushing for the movable calibration tool are located on each axis as follows xx1500000786 Continues on next page 706 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 5 Calibration 5 4 3 Installation locations for the calibration tools ...

Page 707: ...d a sealing in the bushing Replace damaged parts with new Note Article number Spare part Contains replacement calibration pin covers and protective plugs for the bushing 3HAC056806 001 Protection cover and plug set Product manual IRB 8700 707 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 5 Calibration 5 4 3 Installation locations for the calibration tools Continued ...

Page 708: ...on procedure and what to do at each step is given on the FlexPendant You will be guided through the calibration procedure step by step Use the following list to learn about the calibration procedure before running the RobotWare program on the FlexPendant It gives you a brief overview of the calibration procedure sequence After the calibration method has been called for on the FlexPendant the follo...

Page 709: ... the robot s working area is empty as the robot can make unpredictable movements 1 Use a clean cloth Wipe the calibration tool clean Note The calibration method is exact Dust dirt or color flakes will affect the calibration value 2 If the data is optimized the calibra tion routine Wrist Optimization must be re run after standard calib ration Check if the standard calibration data for axes 4 or 5 a...

Page 710: ...n 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 710 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 5 Calibration 5 4 4 Axis Calibration Running the calibration procedure Continued ...

Page 711: ...ice and press Play The three position enabling device on the FlexPendant has been released during robot movement Remove the calibration tool if it is installed and restart the calibration procedure from the beginning See Starting the calibration procedure on page 710 The RobotWare program is terminated with PP to Main If the calibration tool is in contact the robot axis needs to be jogged in order...

Page 712: ...with new spare part if missing or damaged 2 Protection cover and plug set 3HAC056806 001 xx1500000952 Reinstall the protective plug and sealing in the bushing on each axis directly after the axis has been calibrated Ensure that the sealing is not damaged Replace the plug and the sealing with new spare part if missing or damaged 3 Protection cover and plug set 3HAC056806 001 See Calibrating with Wr...

Page 713: ...to save reference values for all axes that is to be replaced Make sure that the values are saved in RobotStudio or FTP program The files are located in Active system folder name HOME RefCalibFiles 7 Perform the repair 8 Make sure that the tooling and process equipment are the same as when creating the reference Use Reference calibration to update the system with new calibration offset value for th...

Page 714: ...ie 96 3 94 2 2 1 degrees 8 Manually jog axis 4 the calculated angle difference 2 1 NOTE The direction shall be the same direction as the direction used when axis 4 was manually jogged to coincide with the verification process In the example 2 1 degrees 9 Make a new manual fine calibration of axis 4 with axis in 2 1 degrees position 10 Check again against the verification position 11 Repeat the man...

Page 715: ... will be run 1 Choose calibration routine Wrist Optimization 2 Modify targets for 4 point tool frame definition in Wrist Optimization routine en0400000906 a Jog the robot to an appropriate position A for the first approach point Use small increments to accurately posi tion the tool tip as close to the reference point as possible b Tap Modify Position to define the point c Repeat for each approach ...

Page 716: ...ion program twice Do not change the position of the robot axes after running the program 1 This is detailed in section Synchronization marks and synchronization position for axes on page 695 Adjust the synchronization marks when the calibration is done if necessary 2 Write down the values on a new label and stick it on top of the calibration label 3 The label is located on the lower arm 716 Produc...

Page 717: ... page 695 and Updating revolution counters on page 697 Check that the synchronization marks for the axes align correctly If they do not update the revolu tion counters 6 Using the jogging window Use this procedure to jog the robot to the synchronization position of all axes Note Action On the ABB menu tap Jogging 1 Tap Motion mode to select group of axes to jog 2 Tap to select the axis to jog axis...

Page 718: ...This page is intentionally left blank ...

Page 719: ...pper Base lower arm upper arm Cast iron nodular iron Gears screws base frame and so on Steel Brakes motors Neodymium Cables connectors drive belts and so on Plastic rubber Gearboxes Oil grease Covers synchronization brackets Aluminium Turning disc foundry Nickel Oil and grease Where possible arrange for oil and grease to be recycled Dispose of via an authorized person contractor in accordance with...

Page 720: ...o organisms Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination 720 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 6 Decommissioning 6 1 Environmental information Continued ...

Page 721: ...attery is exposed to heat for example from a blow torch it will explode Always remove all oil grease in gearboxes If exposed to heat for example from a blow torch the oil grease will catch fire When motors are removed from the robot the robot will collapse if it is not properly supported before the motor is removed Product manual IRB 8700 721 3HAC052853 001 Revision M Copyright 2015 2020 ABB All r...

Page 722: ...procedures in the step by step in structions below DANGER Do not under any circumstances deal with the balancing device in any other way than that detailed in the product documentation For example attempting to open the balancing device is potentially lethal Action on field decommissioning The procedure below details the actions to perform on field when the balancing device is to be decommissioned...

Page 723: ...amp the device at the working location Place the device at ground level so that the hole and spring coils are cut from a safe distance and somewhat from above 2 DANGER The hole must be cut as specified in the figure Pieces of the spring can be thrown out from the cylinder at high speed if the hole is cut larger than specified 3 Use a cutting torch with a long shaft Cut a hole in the housing as sho...

Page 724: ...This page is intentionally left blank ...

Page 725: ...pter includes general information complementing the more specific information in the different procedures in the manual Product manual IRB 8700 725 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 7 Reference information 7 1 Introduction ...

Page 726: ...ices Coordinate systems and motion nomenclatures ISO 9787 2013 Manipulating industrial robots performance criteria and related test methods ISO 9283 1998 Classification of air cleanliness EN ISO 14644 1 2015i 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 ...

Page 727: ...pects Principles for design EN 574 1996 A1 2008 UL ANSI and other standards Description Standard Safety requirements for industrial robots and robot systems ANSI RIA R15 06 Safety standard for robots and robotic equipment ANSI UL 1740 Industrial robots and robot Systems General safety require ments CAN CSA Z 434 14 Product manual IRB 8700 727 3HAC052853 001 Revision M Copyright 2015 2020 ABB All r...

Page 728: ...39 37 in 3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume 728 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 7 Reference information 7 3 Unit conversion ...

Page 729: ...d be used Screws lubricated in other ways Screws lubricated with Molycote 1000 should only be used when specified in the repair maintenance or installation procedure descriptions In such cases proceed as follows 1 Apply lubricant to the screw thread 2 Apply lubricant between the plain washer and screw head 3 Screw dimensions of M8 or larger must be tightened with a torque wrench Screw dimensions o...

Page 730: ...pair maintenance or installation procedure overrides the standard torque Tightening torque Nm Class 12 9 oil lubric ated Tightening torque Nm Class 10 9 oil lubric ated Tightening torque Nm Class 8 8 oil lubricated Dimension 6 M5 10 M6 40 34 24 M8 80 67 47 M10 140 115 82 M12 340 290 200 M16 670 560 400 M20 1150 960 680 M24 Lubricated screws Molycote Gleitmo or equivalent with allen head screws The...

Page 731: ...ning torque for water and air connectors when one or both connectors are made of brass Note A special torque specified in the repair maintenance or installation procedure overrides the standard torque Tightening torque Nm Max Tightening torque Nm Min Tightening torque Nm Nominal Dimension 15 8 12 1 8 20 10 15 1 4 25 15 20 3 8 50 30 40 1 2 90 55 70 3 4 Product manual IRB 8700 731 3HAC052853 001 Rev...

Page 732: ...essory when handling components with a weight exceeding 22 kg A wide range of lifting accessories and devices are available for each manipulator model Example Following is an example of a weight specification in a procedure Note Action CAUTION The arm weighs 25 kg All lifting accessories used must be sized accord ingly 732 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB A...

Page 733: ...it Comment Tool Qty Ring open end spanner 8 19 mm 1 Socket head cap 2 5 17 mm 1 Torx socket no 20 60 1 Box spanner set 1 Torque wrench 10 100 Nm 1 Torque wrench 75 400 Nm 1 Ratchet head for torque wrench 1 2 1 Hexagon headed screw M10x100 2 Hexagon headed screw M16x90 1 Hex bit socket head cap no 14 socket 40 mm L 100 mm 1 To be shortened to 12 mm Hex bit socket head cap no 14 socket 40 mm L 20 mm...

Page 734: ... sum of standard tools defined in the section Standard toolkit on page 733 and of special tools listed directly in the instructions and also gathered in this section Special tools Continues on next page 734 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 7 Reference information 7 7 Special tools ...

Page 735: ...2 2 2 2 2 2 2 2 2 Guide pin M10x150 3HAC15521 2 2 Guide pin M12x150 3HAC13056 2 2 Guide pin M12x200 3HAC13056 3 2 2 Guide pin M16x150 3HAC13120 2 2 2 Guide pin M16x200 3HAC13120 3 x x Mounting set gear axis 2 and 3 3HAC059801 001 Lifting accessories x Fork lift accessory set 3HAC053662 003 xi x x x xx1900001211 Lifting accessory balancing device 3HAC054236 001 x x x x 2ii xx1200001241 Lifting acce...

Page 736: ...ools can be ordered from ABB x Lifting accessory gearbox 3HAC046128 001 x x x xx1200001242 Lifting eye VLBG M12 3HAC16131 1 2 xx1200001242 Lifting eye with swivel Working load limit 2 000 kg x x 2 4 4 4 xx1200001242 Lifting eye M16 3HAC14457 4 x 4 xx1200001242 Lifting eye M24 3HAC038295 003 x xx1200001243 Lifting shackle SA 10 8 NA1 x x x Fender washer Outer diameter minimum 26 mm hole diameter 13...

Page 737: ...Hydraulic cylinder parallel rod shaft 3HAC071378 001 x x x x Hydraulic cylinder upper arm shaft 3HAC069154 017 x x x x x Hydraulic cylinder bearing 3HAC071377 001 x x x x Hydraulic pump 700 bar x Glycerine pump 1 500 bar x x x Sleeve KM nut 3HAC069154 009 D 152 L 220 x Sleeve KM nut M10 3HAC071313 001 x Press tools balancing device bearing 3HAC071352 001 x x x x Press tools upper arm shaft 3HAC069...

Page 738: ... x x x x x Calibration tool box Axis Calibration 3HAC055412 001 Delivered as a set of calibration tools x x x x x x x x x x x Leak down tester 4 Fixing screw M10x80 4 pcs 2 Screw M16x80 Fully threaded 2 pcs x x x x x Lock screw quality 12 9 M20x150 x x x x x x x Oil collecting vessel x x x x x x Oil dispenser x Supporting pillars 3HAC061213 001 Used for elevation of the robot to remove and refit a...

Page 739: ...s 6 unit Wrist Upper arm Counterweight Parallel rod Parallel arm Lower arm Brake release unit SMB Base plate Cable harness Complete robot Tools and equipment with spare part number These tools can be ordered from ABB x x x x x x x Mobile platform ladder x x x Endless ratchet lashing belt i On axis 4 motor side ii 4 chains required Continues on next page Product manual IRB 8700 739 3HAC052853 001 R...

Page 740: ...ting accessories is not detailed in the activity procedure but in the instruction delivered with each piece of lifting accessories This implies that the instructions delivered with the lifting accessories should be stored for later reference 740 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 7 Reference information 7 8 Lifting accessories and lifting ...

Page 741: ...ews are not included in the manual but delivered as a separate document for registered users on myABB Business Portal www mypo rtal abb com Product manual IRB 8700 741 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 8 Spare parts 8 1 Spare part lists and illustrations ...

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Page 743: ...B 140 type C 3HAC025611 001 Circuit diagram IRB 260 3HAC028647 009 Circuit diagram IRB 360 3HAC036446 005 Circuit diagram IRB 460 3HAC025691 001 Circuit diagram IRB 660 3HAC025691 001 Circuit diagram IRB 760 3HAC046307 003 Circuit diagram IRB 1200 3HAC2800 3 Circuit diagram IRB 1410 3HAC021351 003 Circuit diagram IRB 1600 1660 3HAC039498 007 Circuit diagram IRB 1520 3HAC6670 3 Circuit diagram IRB ...

Page 744: ...B 6650S 3HAC025744 001 3HAC025744 001 Circuit diagram IRB 6660 3HAC029940 001 3HAC043446 005 Circuit diagram IRB 6700 IRB 6790 3HAC13347 1 Circuit diagram IRB 7600 3HAC025744 001 3HAC050778 003 Circuit diagram IRB 14000 3HAC056159 002 Circuit diagram IRB 910SC 744 Product manual IRB 8700 3HAC052853 001 Revision M Copyright 2015 2020 ABB All rights reserved 9 Circuit diagrams 9 1 Circuit diagrams C...

Page 745: ...calibration Absolute Accuracy type 692 rough 697 standard type 692 verification 716 when to calibrate 694 calibration Absolute Accuracy 693 calibration manuals 693 calibration marks 695 calibration position jogging to 717 scales 695 calibration scales 695 CalibWare 692 carbon dioxide extinguisher 29 cast iron disposal 719 cleaning 175 climbing on robot 32 Cold environments 95 connecting the robot ...

Page 746: ...l 719 positive directions axes 696 PPE 18 product standards 726 protection classes 43 protection type 43 protective equipment 18 protective wear 18 R refitting cable harness 210 regional regulations 28 release brakes 35 removing cable harness 193 replacements report 177 replacing axis 6 gearbox 681 axis 6 motor 513 axis 6 unit 310 axis 5 motor 499 axis 4 motor 488 axis 2 and axis 3 motors 473 axis...

Page 747: ...695 system integrator requirements 28 T temperatures operation 43 storage 42 testing brakes 36 torques on foundation 41 troubleshooting oil spills 175 safety 37 U updating revolution counters 697 users requirements 18 V validity and responsibility 17 velocity adjusting 95 verifying calibration 716 W weight 41 axis 1 motor 465 468 545 549 554 556 564 566 base plate 61 64 robot 56 68 187 191 248 258...

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Page 750: ...Telephone 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics and Motion No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics and Motion 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC052853 001 Rev M en Copyright 2015 2020 ABB All rights reserved Specifications subject to change without notice ...

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