ABB IRB 8700 User manual

ROBOTICS
Product manual
IRB 8700

Trace back information:
Workspace 20C version a3
Checked in 2020-09-14
Skribenta version 5.3.075

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.

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, 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 from ABB.
Original instructions.
© Copyright 2015-2020 ABB. All rights reserved.
Specifications subject to change without notice.

Table of contents
9Overview of this manual ...................................................................................................................
14Product documentation ....................................................................................................................
16How to read the product manual ......................................................................................................
171 Safety
171.1 Safety information .............................................................................................
171.1.1 Limitation of liability .................................................................................
181.1.2 Requirements on personnel ......................................................................
191.2 Safety signals and symbols .................................................................................
191.2.1 Safety signals in the manual ......................................................................
211.2.2 Safety symbols on manipulator labels .........................................................
271.3 Robot stopping functions ....................................................................................
281.4 Installation and commissioning ............................................................................
311.5 Operation ........................................................................................................
311.5.1 Unexpected movement of robot arm ...........................................................
321.6 Maintenance and repair ......................................................................................
321.6.1 Maintenance and repair ............................................................................
351.6.2 Emergency release of the robot axes ..........................................................
361.6.3 Brake testing ..........................................................................................
371.7 Troubleshooting ................................................................................................
381.8 Decommissioning ..............................................................................................
392 Installation and commissioning
392.1 Introduction to installation and commissioning .......................................................
402.2 Unpacking .......................................................................................................
402.2.1 Pre-installation procedure .........................................................................
442.2.2 Working range ........................................................................................
472.2.3 Risk of tipping/stability .............................................................................
482.2.4 Main dimensions .....................................................................................
492.2.5 The unit is sensitive to ESD .......................................................................
502.3 On-site installation ............................................................................................
502.3.1 Lifting the robot with fork lift accessory set installed ......................................
582.3.2 Attaching the robot and removing the fork lift accessory set ............................
602.3.3 Lifting the base plate ................................................................................
622.3.4 Securing the base plate ............................................................................
662.3.5 Lifting the robot with roundslings ...............................................................
702.3.6 Returning of the ABB pallet .......................................................................
712.3.7 Manually releasing the brakes ...................................................................
742.3.8 Orienting and securing the robot ................................................................
772.3.9 Loads fitted to the robot, stopping time and braking distances .........................
782.3.10 Fitting equipment ....................................................................................
842.4 Restricting the working range ..............................................................................
842.4.1 Axes with restricted working range .............................................................
852.4.2 Mechanically restricting the working range of axis 1 ......................................
882.5 Electrical connections ........................................................................................
882.5.1 Robot cabling and connection points ..........................................................
922.6 Installation of options .........................................................................................
922.6.1 Signal lamp (option) .................................................................................
932.6.2 Installing the motor cooling fans ................................................................
942.6.3 Installing additional motor units or gear units ...............................................
952.7 Start of robot in cold environments ......................................................................
973 Maintenance
973.1 Introduction ......................................................................................................
983.2 Maintenance schedule and expected component life ...............................................
983.2.1 Specification of maintenance intervals ........................................................
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993.2.2 Maintenance schedule .............................................................................
1013.2.3 Expected component life .........................................................................
1023.3 Inspection activities ...........................................................................................
1023.3.1 Inspecting the oil level in axis-1 gearbox ......................................................
1053.3.2 Inspecting the oil level in axis-2 and 3 gearboxes ..........................................
1083.3.3 Inspecting the oil level in axis-4 primary gearbox ..........................................
1113.3.4 Inspecting the oil level in axis-4 secondary gearbox .......................................
1133.3.5 Inspecting the oil level in axis-5 gearbox ......................................................
1153.3.6 Inspecting the oil level in axis-6 gearbox ......................................................
1183.3.7 Inspecting the transparent plugs ................................................................
1203.3.8 Inspecting the balancing devices ...............................................................
1233.3.9 Inspecting the cable harness .....................................................................
1253.3.10 Inspecting the information labels ................................................................
1293.3.11 Inspecting the axis-1 mechanical stop pin ...................................................
1313.3.12 Inspecting the additional mechanical stops .................................................
1333.3.13 Inspecting the fork lift accessories ..............................................................
1353.3.14 Inspecting the signal lamp (option) .............................................................
1363.3.15 Inspecting dampers .................................................................................
1373.4 Replacement/changing activities ..........................................................................
1373.4.1 Type of lubrication in gearboxes ................................................................
1383.4.2 Changing oil, axis-1 gearbox .....................................................................
1443.4.3 Changing oil in axis-2 and axis-3 gearbox ....................................................
1493.4.4 Changing oil, axis-4 primary gearbox ..........................................................
1553.4.5 Changing oil, axis-4 secondary gearbox ......................................................
1593.4.6 Changing oil, axis-5 gearbox .....................................................................
1633.4.7 Changing oil, axis-6 gearbox .....................................................................
1683.4.8 Replacing the SMB battery ........................................................................
1713.5 Lubrication activities ..........................................................................................
1713.5.1 Lubricating the spherical roller bearings, balancing device ..............................
1733.5.2 Lubricating the cross roller bearing .............................................................
1753.6 Cleaning activities .............................................................................................
1753.6.1 Cleaning the IRB 8700 ..............................................................................
1774 Repair
1774.1 Introduction ......................................................................................................
1784.2 General procedures ...........................................................................................
1784.2.1 Performing a leak-down test ......................................................................
1794.2.2 Mounting instructions for bearings .............................................................
1814.2.3 Mounting instructions for sealings ..............................................................
1844.2.4 Cut the paint or surface on the robot before replacing parts ............................
1854.2.5 The brake release buttons may be jammed after service work .........................
1864.3 Attaching lifting accessories ................................................................................
1864.3.1 Attaching lifting accessories to the upper arm ...............................................
1904.3.2 Attaching lifting accessories to the wrist ......................................................
1934.4 Cable harness ..................................................................................................
1934.4.1 Removing the cable harness .....................................................................
2104.4.2 Refitting the cable harness ........................................................................
2304.4.3 Replacing the SMB ..................................................................................
2364.4.4 Replacing the brake release unit ................................................................
2424.5 Upper and lower arms ........................................................................................
2424.5.1 Replacing the upper arm ..........................................................................
2914.5.2 Replacing the wrist ..................................................................................
3104.5.3 Replacing the axis-6 unit ..........................................................................
3304.5.4 Replacing the turning disc ........................................................................
3344.5.5 Replacing the process turning disc .............................................................
3374.5.6 Replacing the complete lower arm ..............................................................
4134.6 Frame and base ................................................................................................
4134.6.1 Replacing the counterweight ....................................................................
4194.6.2 Replacing the mechanical stop pin ............................................................
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4254.6.3 Replacing the parallel rod .........................................................................
4434.6.4 Unloading and restoring the balancing device ...............................................
4484.6.5 Replacing the balancing devices ................................................................
4614.7 Motors ............................................................................................................
4614.7.1 Replacing the axis-1 motor .......................................................................
4734.7.2 Replacing the axis-2 and axis-3 motors ......................................................
4884.7.3 Replacing the axis-4 motor .......................................................................
4994.7.4 Replacing the axis-5 motor .......................................................................
5134.7.5 Replacing the axis-6 motor ........................................................................
5274.8 Gearboxes .......................................................................................................
5274.8.1 Replacing the hub ...................................................................................
5344.8.2 Replacing the axis-1 gearbox ....................................................................
5764.8.3 Replacing the axis-2 gearbox ....................................................................
6164.8.4 Replacing the axis-3 gearbox ....................................................................
6574.8.5 Replacing the axis-4 primary gearbox .........................................................
6814.8.6 Replacing the axis-6 gearbox ....................................................................
6915 Calibration
6915.1 Introduction to calibration ...................................................................................
6915.1.1 Introduction and calibration terminology ......................................................
6925.1.2 Calibration methods .................................................................................
6945.1.3 When to calibrate ...................................................................................
6955.2 Synchronization marks and axis movement directions .............................................
6955.2.1 Synchronization marks and synchronization position for axes .........................
6965.2.2 Calibration movement directions for all axes ................................................
6975.3 Updating revolution counters ...............................................................................
7015.4 Calibrating with Axis Calibration method ...............................................................
7015.4.1 Description of Axis Calibration ..................................................................
7045.4.2 Calibration tools for Axis Calibration ...........................................................
7065.4.3 Installation locations for the calibration tools ...............................................
7085.4.4 Axis Calibration - Running the calibration procedure ......................................
7135.4.5 Reference calibration ...............................................................................
7155.5 Calibrating with Wrist Optimization method ...........................................................
7165.6 Verifying the calibration ......................................................................................
7175.7 Checking the synchronization position ..................................................................
7196 Decommissioning
7196.1 Environmental information ..................................................................................
7216.2 Scrapping of robot .............................................................................................
7226.3 Decommissioning of balancing device ...................................................................
7257 Reference information
7257.1 Introduction ......................................................................................................
7267.2 Applicable standards .........................................................................................
7287.3 Unit conversion .................................................................................................
7297.4 Screw joints ....................................................................................................
7327.5 Weight specifications .........................................................................................
7337.6 Standard toolkit ................................................................................................
7347.7 Special tools ....................................................................................................
7407.8 Lifting accessories and lifting instructions ..............................................................
7418 Spare parts
7418.1 Spare part lists and illustrations ...........................................................................
7439 Circuit diagrams
7439.1 Circuit diagrams ................................................................................................
745Index
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Table of contents

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Overview of this manual
About this manual
This manual contains instructions for:
• mechanical and electrical installation of the robot
• maintenance of the robot
• mechanical and electrical repair of the robot.
Usage
This manual should be used during:
• installation, from lifting the robot to its work site and securing it to the
foundation, to making it ready for operation
• maintenance work
• repair work and calibration.
Who should read this manual?
This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
A maintenance/repair/installation personnel working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
Product manual scope
The manual covers covers all variants and designs of the IRB 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:
ContentsChapter
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 on how to avoid
personal injuries and damage to the product.
Safety
Required information about lifting and installation of the robot.Installation and commis-
sioning
Step-by-step procedures that describe how to perform mainten-
ance of the robot. Based on a maintenance schedule that may
be used to plan periodical maintenance.
Maintenance
Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.
Repair
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Overview of this manual

ContentsChapter
Calibration procedures and general information about calibration.Calibration
Environmental information about the robot and its components.Decommissioning
Useful information when performing installation, maintenance
or repair work. Includes lists of necessary tools, additional doc-
uments, safety standards, etc.
Reference information
Reference to the spare part list for the robot.Spare parts
Reference to the circuit diagram for the robot.Circuit diagram
References
Documentation referred to in the manual, is listed in the table below.
Document IDDocument name
3HAC052854-001Product manual, spare parts - IRB 8700
3HAC052852-001Product specification - IRB 8700
3HAC055802-001Product manual - DressPack/SpotPack IRB 8700
3HAC051028-002Circuit diagram - IRB 8700
3HAC047136-001Product manual - IRC5
3HAC050941-001Operating manual - IRC5 with FlexPendant
3HAC042927-001Technical reference manual - Lubrication in gearboxes
3HAC050948-001Technical reference manual - System parameters
Revisions
DescriptionRevision
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
Calibration on page 701.
• Added information about inspection of calibration tool prior to
usage, see Examining the calibration tool on page 704.
• Added information about the calibration procedure, see Overview
of the calibration procedure on the FlexPendant on page 708,Re-
starting an interrupted calibration procedure on page 711.
• Added information about Axis Calibration when SafeMove is in-
stalled, see Axis Calibration with SafeMove option on page 711.
• Turn motion axis-6 updated to ±360°, see Working range on
page 44.
The following updates are made in this revision:B
• Illustrations added throughout the manual.
• Minor updates throughout the manual.
Continues on next page
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Continued

DescriptionRevision
Published in release R16.2. The following updates are made in this revi-
sion:
C
• Drawing of the base plate is updated.
• Drawing of base plate is not available for purchase, faulty inform-
ation removed in Securing the base plate on page 62.
• Bearing grease 3HAC9408-1 changed name from Longtime PD2
to Tribol GR 100-2 PD
• Fork lift accessory descriptions updated.
• Working range updated.
• Main dimensions updated.
• Updated spare parts due to sealing upgrade in the motors:
- Motors
- Upper arm excluding wrist
- Wrist
- Axis 6 complete
Published in release R17.1. The following updates are made in this revi-
sion:
D
• Updates in procedure Replacing the axis-1 gearbox, Replacing
the axis-1 gearbox on page 534
• Figures in Filling oil into axis-1 gearbox updated.
• Caution with figures to ensure relieving pressure on the correct
balancing device added.
• Grease for cross roller bearing changed (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 in release R17.2. The following updates are made in this revi-
sion:
E
• Caution about removing metal residues added in sections about
SMB boards.
• Information about minimum resonance frequency added.
• Base plate article number updated. (Is 3HAC053772-003, was
3HAC053772-002)
• Orange spare parts added.
• Installation drawing updated.
•Replacement methods for following spare parts are updated/com-
pleted:
- axis-1 gearbox
- axis-2 gearbox
- axis-3 gearbox
- axis-6 gearbox
- upper arm
- brake release board
- balancing device
- cable harness
- lower arm
- hub
Continues on next page
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Continued

DescriptionRevision
• Illustrations and data for information labels corrected.
•Added text regarding overhaul in section specification of mainten-
ance intervals.
• Added article number for Grease Castrol Molub-Alloy 777-1 (used
with Hub splines).
• Section Start of robot in cold environments on page 95 added.
• Updated information regarding disconnecting and reconnecting
battery cable to serial measurement board.
• Added figures and corrected information regarding inspection of
oil level and change of oil in axis-6 gearbox.
• Changed amount of screws and image for removal/refitting of
axis-6 unit support shaft.
• Definition of reference calibration clarified.
• Updated maintenance schedule.
Published in release R18.1. The following updates are made in this revi-
sion:
F
• Information added about fatigue to Axis Calibration tool, see Cal-
ibration tools for Axis Calibration on page 704.
• Added sections in General procedures on page 178.
• Added reference manual for DressPack.
• Safety restructured.
• Updated spare parts number brake release board unit (was
BRK001, is DSQC1052).
• Note added to calibration chapter to emphasize the requirement
of equally dressed robot when using previously created reference
calibration values.
• Information about myABB Business Portal added.
• 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 parts are updated:
- parallel rod
- upper arm
- balancing device
• Corrected dimension of support screw for parallel rod during re-
moval/refitting of shaft.
• Added guide pin in cross roller bearing axis 1.
• New touch up color Graphite White available. See Cut the paint
or surface on the robot before replacing parts on page 184.
• Information about a mandatory check of cable harness added to
Updating revolution counters on page 697.
Published in release 19C. The following updates are made in this revision:H
• Added a revision note to the history for revision G regarding
mandatory check of cable harness.
• Changed information regarding refitting of revolution indicator,
during removal of gear Z3.
• Changed order in axis-2 gearbox replacement regarding removal
of motor flange prior to removing the gearbox.
•Removed information regarding the revolution indicator throughout
the manual.
Continues on next page
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Continued

DescriptionRevision
• Added KM sleeve to replacement procedure for the balancing
devices.
• Note added about the need to calibrate if the robot is other than
floor mounted. See When to calibrate on page 694.
• Clarified reference to external user instructions for press tools,
regarding replacement of upper arm shafts and KM nuts, parallel
rod shafts and bearings. In the same time deleted duplicated in-
formation, so that all information regarding the replacements are
now only found in the tools user instructions.
Published in release 19D. The following updates are made in this revision:J
• Added references to DressPack manual in Robot cabling and
connection points on page 88.
• Added information about grounding point. See Robot cabling and
connection points on page 88.
• Removed article number for leak-down tester.
Published in release R20A. The following updates are 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 instructions for sealings on page 181.
•Clarified text about position of robot and added table with depend-
encies between axes during Axis Calibration.
Published in release R20B. The following updates are made in this revi-
sion:
L
•Added information about Wrist Optimization in calibration chapter.
Published in release R20C. The following updates are made in this revi-
sion:
M
• Added hub tool to the replacement procedure for the hub.
• Pallet removed from required tools tables.
•Added information about motor units and gear units in Installation.
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Continued

Product documentation
Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories.
This listing is based on the type of information in the documents, regardless of
whether the products are standard or optional.
All documents can be found via myABB Business Portal, www.myportal.abb.com.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
•Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
•Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.
Technical reference manuals
The technical reference manuals describe reference information for robotics
products, for example lubrication, the RAPID language, and system parameters.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
•What is included (for example cables, I/O boards, RAPID instructions, system
parameters, software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
Continues on next page
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Product documentation

Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.
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Product documentation
Continued

How to read the product manual
Reading the procedures
The procedures contain all information required for the installation or service activity
and can be printed out separately when needed for a certain service procedure.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 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 product
model than the one that is described in the current manual.
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How to read the product manual

1 Safety
1.1 Safety information
1.1.1 Limitation of liability
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial robot will not cause injury or damage even if
all safety instructions are complied with.
The information does not cover how to design, install and operate a robot system,
nor does it cover all peripheral equipment that can influence the safety of the robot
system.
In particular, liability cannot be accepted if injury or damage has been caused for
any of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed.
• Non-authorized design modifications 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 supplies original spare parts and equipment which have been tested and
approved. The installation and/or use of non-original spare parts and equipment
can negatively affect the safety, function, performance, and structural properties
of the robot. ABB is not liable for damages caused by the use of non-original spare
parts and equipment.
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1 Safety
1.1.1 Limitation of liability

1.1.2 Requirements on personnel
General
Only personnel with appropriate training are allowed to install, maintain, service,
repair, and use the robot. This includes electrical, mechanical, hydraulics,
pneumatics, and other hazards identified in the risk assessment.
Persons who are under the influence 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.
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1 Safety
1.1.2 Requirements on personnel

1.2 Safety signals and symbols
1.2.1 Safety signals in the manual
Introduction to safety signals
This section specifies all safety signals used in the user manuals. Each signal
consists of:
• A caption specifying the hazard level (DANGER, WARNING, or CAUTION)
and the type of hazard.
• Instruction about how to reduce the hazard to an acceptable level.
• A brief description of remaining hazards, if not adequately reduced.
Hazard levels
The table below defines the captions specifying the hazard levels used throughout
this manual.
For more information, see standard ISO 13849.
SignificanceDesignationSymbol
Signal word used to indicate an imminently hazard-
ous situation 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
situation which, if not avoided, could result in slight
injury.
CAUTION
Signal word used to indicate a potentially hazardous
situation which, if not avoided, could result in severe
damage to the product.
ELECTROSTATIC
DISCHARGE (ESD)
Signal word used to indicate important facts and
conditions.
NOTE
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1 Safety
1.2.1 Safety signals in the manual

SignificanceDesignationSymbol
Signal word used to indicate where to find additional
information or how to do an operation in an easier
way.
TIP
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1 Safety
1.2.1 Safety signals in the manual
Continued