ABB IRB 8700 Series

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Workspace R18-1 version a12

Checked in 2018-03-27

Skribenta version 5.2.025

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Table of Contents5
Overview of this Manual9
Product Documentation13
How to Read the Product Manual15
Safety17
General Safety Information17
Limitation of Liability17
Protective Stop and Emergency Stop20
Safety Actions21
Fire Extinguishing21
Emergency Release of the Robot Axes22
Make Sure that the Main Power Has Been Switched off23
Safety Risks24
Safety Risks During Installation and Service Work on Robots24
Moving Robots Are Potentially Lethal26
First Test Run May Cause Injury or Damage27
Work Inside the Working Range of the Robot28
Enabling Device and Hold-To-Run Functionality29
Risks Associated with Live Electric Parts30
The Unit Is Sensitive to ESD32
Hot Parts May Cause Burns33
Safety Risks Related to Pneumatic/Hydraulic Systems34
Brake Testing35
Safety Risks During Handling of Batteries36
Safety Risks During Work with Gearbox Lubricants (Oil or Grease)37
Safety Signals and Symbols39
Safety Signals in the Manual39
Safety Symbols on Product Labels41
Installation and Commissioning47
Introduction47
Unpacking48
Pre-Installation Procedure48
Working Range52
Risk of Tipping/Stability55
Main Dimensions56
On-Site Installation57
Lifting the Robot with Fork Lift Accessory Set Installed57
Attaching the Robot and Removing the Fork Lift Accessory Set65
Lifting the Base Plate67
Securing the Base Plate69
Lifting the Robot with Roundslings73
Returning of the ABB Pallet76
Manually Releasing the Brakes77
Orienting and Securing the Robot80
Loads Fitted to the Robot, Stopping Time and Braking Distances83
Fitting Equipment84
Restricting the Working Range90
Axes with Restricted Working Range90
Mechanically Restricting the Working Range of Axis 191
Electrical Connections94
Robot Cabling and Connection Points94
Installation of Options96
Signal Lamp (Option)96
Installing the Motor Cooling Fans97
Start of Robot in Cold Environments98
Maintenance99
Introduction99
Maintenance Schedule and Expected Component Life100
Specification of Maintenance Intervals100
Maintenance Schedule101
Expected Component Life103
Inspection Activities104
Inspecting the Oil Level in Axis-1 Gearbox104
Inspecting the Oil Level in Axis-2 and 3 Gearboxes107
Inspecting the Oil Level in Axis-4 Primary Gearbox110
Inspecting the Oil Level in Axis-4 Secondary Gearbox113
Inspecting the Oil Level in Axis-5 Gearbox115
Inspecting the Oil Level in Axis-6 Gearbox118
Inspecting the Transparent Plugs121
Inspecting the Balancing Devices123
Inspecting the Cable Harness126
Inspecting the Information Labels128
Inspecting the Axis-1 Mechanical Stop Pin132
Inspecting the Additional Mechanical Stops134
Inspecting the Fork Lift Accessories136
Inspecting the Signal Lamp (Option)138
Inspecting Dampers139
Replacement/Changing Activities140
Type of Lubrication in Gearboxes140
Changing Oil, Axis-1 Gearbox141
Changing Oil in Axis-2 and Axis-3 Gearbox147
Changing Oil, Axis-4 Primary Gearbox153
Changing Oil, Axis-4 Secondary Gearbox159
Changing Oil, Axis-5 Gearbox164
Changing Oil, Axis-6 Gearbox168
Replacing the SMB Battery173
Lubrication Activities176
Lubricating the Spherical Roller Bearings, Balancing Device176
Lubricating the Cross Roller Bearing178
Cleaning Activities180
Cleaning the IRB 8700180
Repair183
Introduction183
General Procedures184
Performing a Leak-Down Test184
Mounting Instructions for Bearings185
Mounting Instructions for Seals187
Cut the Paint or Surface on the Robot before Replacing Parts189
The Brake Release Buttons May be Jammed after Service Work190
Attaching Lifting Accessories191
Attaching Lifting Accessories to the Upper Arm191
Attaching Lifting Accessories to the Wrist195
Cable Harness198
Removing the Cable Harness198
Refitting the Cable Harness215
Replacing the SMB235
Replacing the Brake Release Unit242
Upper and Lower Arms248
Replacing the Upper Arm248
Replacing the Wrist303
Replacing the Axis-6 Unit322
Replacing the Turning Disc342
Replacing the Process Turning Disc346
Replacing the Complete Lower Arm349
Replacing the Parallel Arm432
Frame and Base518
Replacing the Counterweight518
Replacing the Mechanical Stop Pin524
Replacing the Parallel Rod530
Unloading and Restoring the Balancing Device547
Replacing the Balancing Devices552
Motors563
Replacing the Axis-1 Motor563
Replacing the Axis-2 and Axis-3 Motors575
Replacing the Axis-4 Motor590
Replacing the Axis-5 Motor601
Replacing the Axis-6 Motor615
Gearboxes630
Replacing the Hub630
Replacing the Axis-1 Gearbox637
Replacing the Axis-2 Gearbox679
Replacing the Axis-3 Gearbox718
Replacing the Axis-4 Primary Gearbox760
Replacing the Axis-6 Gearbox786
Calibration795
Introduction to Calibration795
Introduction and Calibration Terminology795
Calibration Methods796
When to Calibrate798
Synchronization Marks and Axis Movement Directions799
Synchronization Marks and Synchronization Position for Axes799
Calibration Movement Directions for All Axes800
Updating Revolution Counters801
Calibrating with Axis Calibration Method805
Description of Axis Calibration805
Calibration Tools for Axis Calibration807
Installation Locations for the Calibration Tools809
Axis Calibration - Running the Calibration Procedure811
Verifying the Calibration817
Checking the Synchronization Position818
Decommissioning819
Environmental Information819
Scrapping of Robot821
Decommissioning of Balancing Device822
Reference Information825
Introduction825
Applicable Standards826
Unit Conversion828
Screw Joints829
Weight Specifications832
Standard Toolkit833
Special Tools834
Lifting Accessories and Lifting Instructions837
Spare Parts839
Spare Part Lists and Illustrations839

ABB IRB 8700 Series - Page 2

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