Introduction

CONTENTS
Page

1 Introduction ..................................................................................................................... 3
1.1 How to use this Manual .......................................................................................... 3
1.2 What you must know before you use the Robot..................................................... 3
1.3 Identification........................................................................................................... 3
1.4 Structure Manipulator............................................................................................. 4

Product Manual 1
2 Product Manual
 Introduction

1 Introduction

1.1 How to use this Manual

This manual provides information on installation, preventive maintenance, and
how to carry out repairs on the manipulator. Its intended audience is trained
maintenance personnel with expertise in both mechanical and electrical
systems. The manual does not in any way assume to take the place of the
maintenance course offered by ABB Flexible Automation.
Servicing and maintenance routines are described in the chapter on
Maintenance.
There are chapters and paragraphs in this manual that refers to functionality
related to a complete robot system (controller and manipulator). As the
IBR340A is delivered from ABB Flexible Automation as a mechanical unit
these chapters are not fully applicable to this delivery. The following chapters or
parts of the chapters will include information that refers to a complete robot
system.
Chapter 1. Introduction
1.4 Structure manipulator
Chapter 3. Safety
1.1 General
1.1.1 Introduction
1.5.1 Normal operations
1.6 Programming. testing and servicing
1.7 Safety functions
1.7.1 The safety control chain of operation
1.7.2 Emergency stops
1.7.3 Mode selection using the operating mode selector
1.7.4 Programming and testing at reduced speed
1.7.5 Testing at full speed
1.7.6 Automatic operation
1.7.7 Enabling device
1.7.8 Hold-to-run control
1.7.9 General mode safeguard stop connection
1.7.10 Automatic mode safeguard stop connection
1.7.11 Limiting the working space
1.7.12 Supplementary functions
1.10 Risks during installation and service
1.12 Risks associated with live electric parts
Chapter 4. Decommissioning
1.1.1 Manipulators

Product Manual 3
Introduction

1.1.2 Controller
Chapter 5.Installation and commissioning
1.1 System diskette
Chapter 7. Repairs
8 Calibration
8.1 General

1.2 What you must know before you use the Robot
Normal maintenance and repair work

Usually requires only standard tools. Some repairs, however, require specific tools.
These repairs and the type of tool required, are described in more detail in the chapter
Repairs.
The power supply

Must always be switched off whenever work is carried out in the controller cabinet.

All personnel working with the robot system must be very familiar with the safety
regulations outlined in the chapter on Safety. Incorrect operation can damage the
robot or injure someone.

1.3 Identification
Identification plates indicating the type of robot and serial number, etc., are located on
the manipulator (see Figure 1).
Note! The identification plates and label shown in the figures below, only serve as
examples. For exact identification see the plates on the robot in question.

4 Product Manual
 Introduction

ABB Robotics Products AB

S-721 68 Västerås Sweden Made in Sweden
Identification plate showin
Type: IRB 6400R M2000
the IRB 6400R / M2000
Robot version: IRB 6400R/2.5-150
Man. order: XXXXXX
Nom. load See instructions
Serial. No: 6400R-XXXX
Date of manufacturing: 2000-XX-XX
Net weight
2,5.120 : 2060 kg 2,8-150 : 2240 kg
2.5-150 : 2060 kg 2,8-200 : 2390 kg
2,5-200 : 2230 kg 3.0-100 : 2250 kg

IRB 140(0) IRB 2400 IRB 4400 IRB 6400R

IRB 640 IRB 340 IRB 140

IRB 840/A

Figure 1 Examples of identification plate and its location on different manipulator types.

1.4 Structure Manipulator

The robot is made up of two main parts, the manipulator and controller. The controller
is described in the Adept Manual.
The Manipulator is equipped with maintenance-free AC motors, which have
electromechanical brakes. The brakes lock the motors when the robot is inoperative
Product Manual 5
Introduction
for more than 1000 hours. The time can be configured by the user.
The following figures show the various ways in which the different manipulators
move and their component parts.

Motor axis 5
Motor axis 6
Axis 3

Axis 4 Axis 5
Axis 6

Motor axis 4

Upper arm

Axis 2 Lower arm

Motor axis 1 Motor axis 2

Motor axis 3

Axis 1

Base
Figure 2 The motion patterns of the IRB 1400 and IRB 140.

6 Product Manual
 Introduction

Motor unit axis 4

Motor unit axis 5
Motor unit axis 6 Upper arm

Axis 4 Axis 3

Axis 6

Axis 5
Motor unit and
gearbox axis 1 Lower arm

Axis 2
Motor unit and
Motor unit and gearbox axis 2
gearbox axis 3

Axis 1

Base

Figure 3 The motion patterns of the IRB 2400.

Upper arm
Axis 5 Axis 4 Motor axis 4
Motor axis 5
Motor axis 6
Axis 6
Axis 3

Lower arm
Axis
Motor axis
Motor axis

Motor axis
Axis 1

Base

Figure 4 The motion patterns of the IRB 4400

Product Manual 7
Introduction

Axis 3 Upper arm

Motor axis 4 Axis4 Motor axis 5

Axis 5
Motor axis 6

Axis 6
Axis 2
Motor axis 1

Motor axis 2

Motor axis 3 Lower arm

Axis 1

Base
Figure 5 The motion patterns of the IRB 6400R M99.

Upper arm
Axis 3 Motor axis 6

Axis 6
Axis 2
Motor axis 2
Motor axis 3
Lower arm
Motor axis 1
Axis 1

Figure 6 The motion patterns of the IRB 640.

8 Product Manual
 Introduction

Motor 1(X)-axis
Motor 3(Z)-axis

Motor 2(Y)-axis
Motor 4(C)-axis

2(Y)-axis

3(Z)-axis

4(C)-axis
1(X)-axis

Figure 7 The motion patterns of the IRB 840/A

Product Manual 9
Introduction

Axis 3
Axis 3
Axis 2 Upper arm (x3)
Y
Axis 2

Base box
Motors
encapsulated Bars (x3)

Axis 1

Axis 4,
telescopic shaft
Swivel (option)
X Z

Figure 8 The motion patterns of the IRB 340.

Motor axis 4
Motor axis 5 Axis 3
Motor axis 6
Axis 4
Upper arm
Lower arm Axis 5

Axis 2
Motor axis 1 Axis 6

Motor axis 3
Motor axis 2
Axis 1

Base

Figure 9 The motion patterns of the IRB 140.

10 Product Manual
 Product Specifikation IRB 340

1 Description ...................................................................................................................... 3
1.1 Structure ................................................................................................................. 3
Figure 1 Different robot version........................................................................... 3
1.2 Safety/Standards..................................................................................................... 5
1.3 Installation.............................................................................................................. 5
Operating requirements ......................................................................................... 5
Mounting the manipulator .................................................................................... 6
Load diagrams ....................................................................................................... 7
Maximum Pressure Force...................................................................................... 9
Extra equipment mounted on the manipulator arms.............................................. 10
1.4 Maintenance and Troubleshooting ......................................................................... 11
1.5 Robot Motion ......................................................................................................... 12
2 Specification of Variants and Options .......................................................................... 15
3 Index ................................................................................................................................ 17

Product Specification IRB 340 M2000 1

Product Specification IRB 340

2 Product Specification IRB 340 M2000

 Description

1 Description

1.1 Structure
The IRB 340A family consists of 4-axes industrial robots in a modular design,
specifically for industries with a great need for flexible automation. The IRB 340A is
available as a manipulator only, designed to work only with a controller provided by
Adept Technology Inc.

Axis 1
Axis 2

Axis 4
Axis 3

TCP 0

Figure 1 The IRB 340A manipulator.

Different robot version

The IRB 340A is available in two versions:

- IRB 340A, the 4-axes version with x, y, z and θ movements

- IRB 340ASA, the 4-axes Wash Down version with x, y, z and θ=movements

Weight: Manipulator 140 kg

Airborne noise level:
The sound pressure level outside < 70 dB (A) Leq (acc. to
the working space Machinery directive 89/392 EEC)

Product Specification IRB 340A M2000 3

Description

330

Axis 2 Axis 1

860

Axis 3

250

R=566
Axis 2

Axis 1

Axis 3

Figure 2 Views of the manipulator (dimensions in mm).

4 Product Specification IRB 340A M2000

 Description

1.2 Safety/Standards
The mechanical unit conforms to the following standards:
EN 292-1 Safety of machinery, terminology
EN 292-2 Safety of machinery, technical specifications
EN 775 Robot Safety
EN 60204 Electrical equipment of industrial machines
IEC 529 Degrees of protection provided by enclosures

Safety lamp (option)

As an option, the robot can be equipped with a safety lamp. This is activated when the
motors are in the MOTORS ON/HIGH POWER state.

1.3 Installation
An end effector, max. weight 0.5 kg including payload, can be mounted on the robot’s
mounting flange. See Load diagrams on page 7-9. Other equipment, such as a hose, can
be mounted on the upper and lower arm, max weight 300 g/m. See Extra equipment
mounted on the manipulator arms on page 10.

Operating requirements

Protection standards

Manipulator IRB 340A IP55

Manipulator IRB 340ASA IP67

Explosive environments
The robot must not be located or operated in an explosive environment.

Ambient temperature
Manipulator during operation +5oC (41oF) to +52oC (125oF)
Manipulator during transportation and storage -25oC (13oF) to +55oC (131oF)

Note If the robot operates in a temperature > +35oC, the air flow, generated by the fan,
must be evacuated. The short cut hose (a) or the tube bend (for SA-version) should be
replaced by inlet/outlet for external air (b). Air out b a b Air in

Hard environment and a lot of starts and stops can cause condensation inside the base!.
For the SA-variants a plate for air circulation, option 061, have to be mounted for
external air.

Product Specification IRB 340A M2000 5

Description

Relative humidity
Manipulator during transportation and storage Max. 95% at constant temperature
Manipulator during operation Max. 95% at constant temperature

Mounting the manipulator

Maximum force in the fixing points is 1000 N referring to the z-direction in the base
coordinate system.
Robot frame is not included in the delivery.
Required stiffness of frame: Lowest natural frequency of frame with robot > 17 Hz.

The working space is shown Axis 2

R 370
in Figure 9

120
A A

o
(3x
A

)
Y

Axis 3
Clamping plane 40
12
Area for
calibration tool X

6
M1
o

0 03)3
30
A

.
( 0
H8 +
Axis 1

25
Clamping plane A-A

39

Figure 3 Hole configuration (dimensions in mm).

6 Product Specification IRB 340A M2000

 Description

Load diagrams

Note The weight permitted for loads includes grippers etc.

IRB 340A and 340ASA

4-axes
Load 100 g
0

10 20 30 40 50 60 70
0 L (mm)
10
20
30
40
50
60
70
80
90
100
110
120
130
140
100%
150
160
170

Z (mm)
Z = See the above diagram and the coordinate system in Adept manuals.
L = Distance in X-Y plane from Z-axis to the mass centre of gravity of the load.

Figure 4 Maximum weight permitted for load (100 g) mounting on the mounting flange at different
positions (centre of gravity).

Product Specification IRB 340A M2000 7

Description

Note The weight permitted for loads includes grippers etc.

IRB 340A and 340ASA

4-axes
Load 300 g
0

10 20 30 40 50 60 70

0 L (mm)
10
20
30
40
50
60
70
80
90
100
110
100%
120
130
140
150
160
170

Z (mm)
Z = See the above diagram and the coordinate system in Adept manuals.
L = Distance in X-Y plane from Z-axis to the mass centre of gravity of the load.

Figure 5 Maximum weight permitted for load (300 g) mounting on the mounting flange at different
positions (centre of gravity).

8 Product Specification IRB 340A M2000

 Description

Note The weight permitted for loads includes grippers etc.

IRB 340A and 340ASA

4-axes
Load 500 g

10 20 30 40 50

0 L (mm)
10
20
30
40
50
60
70
80
90
100%
100
110

Z (mm)
Z = See the above diagram and the coordinate system in Adept Manuals.
L = Distance in X-Y plane from Z-axis to the mass centre of gravity of the load.

Figure 6 Maximum weight permitted for load (500 g) mounting on the mounting flange at different
positions (centre of gravity).

Maximum Pressure Force

Maximum pressure force in X, Y and Z-direction is allowed to be 100 N.

Maximum torque of axis 4 = 1,0 Nm.

Product Specification IRB 340A M2000 9

Description

Extra equipment mounted on the manipulator arms

300
100
50

40
20
30

Limitation lines
0

for centre of gravity

for M2 40
20
50
0

Limitation lines
for centre of gravity
for M1
TCP 0
Figure 7 Definition of extra load on robot arms (measures in mm).

The robot is prepared for the medium hose (option 045). If this options is used no extra
load should be defined.

If the medium hose is not chosen:

- and both M1 and M2 are less than 175 g each, the robot can run with full
performance and no extra load should be defined
- and M1 is more than 175 g, an extra load should be defined in the load
definition. The extra load should be M1−175 g.
Maximum extra load allowed is 175 g (M1 max = 350 g)
- and M2 is more than 175 g, an extra load should be defined in the load
definition. The extra load should be M2−175 g.
Maximum extra load allowed is 175 g (M2 max = 350 g)

The extra load should be defined in TCP 0.

10 Product Specification IRB 340A M2000

 Description

2xR1/4”

Key grip 22 mm, h 6 mm

Ø52

Ø25 Mounting flange R3/8”, depth 14 mm

Figure 8 The mechanical interface (mounting flange), four axis version.

1.4 Maintenance and Troubleshooting

The robot requires only a minimum of maintenance during operation. It has been
designed to make it as easy to service as possible:

- Maintenance-free AC motors are used.

- Oil is used for the gear boxes.
- The cabling is routed for longevity, and in the unlikely event of a failure, its
modular design makes it easy to change.
The maintenance intervals depends on the use of the robot. For detailed information on
maintenance procedures, see the Maintenance section in the Product Manual.

Product Specification IRB 340A M2000 11

Description

1.5 Robot Motion

The extreme positions of robot arm

is shown in Figure 10

860

250
X

Maximum working space inside cylinder.

Working space can be reduced in x-y-z coordinates

Base coordinate system Axis 2

6
56
R

X Axis 1

Axis 3

The numbers of the axes are marked

at the bottom of the clamping surface respectively

Figure 9 Working space of IRB 340A (dimensions in mm).

12 Product Specification IRB 340A M2000

 Description

Extreme values of arm angles:

P2
Position P1
U = 100o
V = 95,5o
W = 134,5o

Position P2
- U = -46,1o
0
+ V = -50,6o
W = 43,9o

U Angles defined according to figure

V

W Mechanical hard-stop:
When angle U< -46,1o hard-stop
is reached.
P1

Figure 10 The extreme positions of robot arms.

Product Specification IRB 340A M2000 13

Description

14 Product Specification IRB 340A M2000

 Specification of Variants and Options

2 Specification of Variants and Options

The different variants and options for the IRB 340A are described below.
The same numbers are used here as in the Specification form.

1 MANIPULATOR
026 IRB 340A
The 4-axes variant
028 IRB 340ASA
The 4-axes variant, Wash Down

APPLICATION INTERFACE
Hose to tool point
044 Small hose, D = 6/4 mm
045 Medium hose, D = 15/10 mm

Connection to cabinet (Cable lengths)

632 7m
633 15m
634 22m
635 30m

Equipment
691 Safety lamp
A safety lamp with an orange fixed light can be mounted on the manipulator.
The lamp is active in MOTORS ON mode.
061 In/outlet for external air
Plate for connecting external air into the base of the manipulator (inlet and outlet,
diameter 76 mm) for internal air circulation. Recommended for warm or cold
environments.

Product Specification IRB 340A M2000 15

Specification of Variants and Options

16 Product Specification IRB 340A M2000

 Description

C
cooling device 3
E
extra equipment 10
H
hard-stop 13
humidity 6
I
installation 5
L
load 5
load diagrams 7
M
maintenance 11
mechanical interface 11
motion 12
mounting
extra equipment 10
robot 6
mounting flange 11
N
noise level 3
O
operating requirements 5
options 15
P
payload 5
protection standards 5
S
safety 5
safety lamp 5, 15
service 11
space requirements 3
standards 5
structure 3
T
temperature 5
troubleshooting 11
V
variants 15
W
weight 3
working space 12

Product Specification IRB 340A M2000 17

 Safety
CONTENTS
Page

1 Safety ................................................................................................................. 3
1.1 General...................................................................................................... 3
1.2 Fire-Extinguishing...................................................................................... 3
1.3 Safe Working Procedures ......................................................................... 3
1.3.1 Normal operations ........................................................................... 3
1.4 Programming, Testing and Servicing......................................................... 3
1.5 Safety Functions........................................................................................ 4
1.5.1 Emergency stops............................................................................. 4
1.5.2 Mode selection using the operating mode selector ......................... 5
1.5.3 Programming and testing at reduced speed.................................... 5
1.5.4 Automatic operation......................................................................... 5
1.6 Safety Risks Related to End Effectors ...................................................... 5
1.6.1 Gripper............................................................................................. 5
1.6.2 Tools/workpieces ............................................................................. 6
1.6.3 Pneumatic/hydraulic systems .......................................................... 6
1.7 Risks during Operation Disturbances........................................................ 6
1.8 Risks during Installation and Service ........................................................ 6
1.9 The following standards are of interest when the robot is parts of a cell... 8
1.10 Risks Associated with Live Electric Parts................................................ 8
1.11 Emergency Release of Mechanical Arm ................................................. 9
1.12 Limitation of Liability ................................................................................ 9
1.13 Related Information ................................................................................. 9

Product Manual 1
2 Product Manual
 Safety

1 Safety

1.1 General
This information on safety covers functions that have to do with the operation of the
industrial robot.
The information does not cover how to design, install and operate a complete system,
nor does it cover all peripheral equipment, which can influence the safety of the total
system.
To protect personnel, the complete system has to be designed and installed in
accordance with the safety requirements set forth in the standards and regulations of
the country where the robot is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable
safety laws and regulations in the country concerned are observed and that the safety
devices necessary to protect people working with the robot system have been
designed and installed correctly.
People who work with robots must be familiar with the operation and handling of the
industrial robot, described in applicable documents, e.g. Adept Manuals and Product
Manual.

1.2 Fire-Extinguishing
Use a CARBON DIOXIDE extinguisher in the event of a fire in the robot (manip-
ulator or controller).

1.3 Safe Working Procedures

Safe working procedures must be used to prevent injury. No safety device or circuit
may be modified, bypassed or changed in any way, at any time.

1.3.1 Normal operations

All normal operations in automatic mode must be executed from outside the
safeguarded space.

1.4 Programming, Testing and Servicing

The robot is extremely heavy and powerful, even at low speed. When entering into the
robot’s safeguarded space, the applicable safety regulations of the country concerned
must be observed.
Operators must be aware of the fact that the robot can make unexpected movements.
A pause (stop) in a pattern of movements may be followed by a movement at high
speed. Operators must also be aware of the fact that external signals can affect robot

Product Manual 3
Safety

programs in such a way that a certain pattern of movement changes without warning.
If work must be carried out within the robot’s work envelope, the following
points must be observed:
- The operating mode selector on the controller must be in the manual mode
position to render the enabling device operative and to block operation from
a computer link or remote control panel.
- The robot’s speed is limited to max. 250 mm/s (10 inches/s) when the operat-
ing mode selector is in position < 250 mm/s. This should be the normal posi-
tion when entering the working space. The position 100% – full speed – may
only be used by trained personnel who are aware of the risks that this entails.

Note! do not change “Transm gear ratio” or other kinematic parameters from
the teach pendant or a PC. This will affect the safety function Reduced speed
250 mm/s.

- During programming and testing, the enabling device must be released as

soon as there is no need for the robot to move.

Note! the enabling device must never be rendered inoperative in any way.

- The programmer must always take the teach pendant with him/her when
entering through the safety gate to the robot’s working space so that no-one
else can take over control of the robot without his/her knowledge.

1.5 Safety Functions

The Safety Functions for the controller and the handling of the robot are further
described in the Adept Manuals.

1.5.1 Emergency stops

An emergency stop should be activated if there is a danger to people or equipment.
Built-in emergency stop buttons are located on the operator’s panel of the robot
controller and on the teach pendant.
External emergency stop devices (buttons, etc.) can be connected to the safety chain
by the user (see Adept Manuals). They must be connected in accordance with the
applicable standards for emergency stop circuits.
Before commissioning the robot, all emergency stop buttons or other safety equipment
must be checked by the user to ensure their proper operation.

Before switching to MOTORS ON mode again, establish the reason for the stop
and rectify the fault.

4 Product Manual
 Safety

1.5.2 Mode selection using the operating mode selector

The applicable safety requirements for using robots, laid down in accordance with
ISO/DIS 10218, are characterised by different modes, selected by means of control
devices and with clear-cut positions.
One automatic and two manual modes are available:
Manual mode:
< 250 mm/s - max. speed is 250mm/s
100% - full speed

Automatic mode: The robot can be operated via a remote control device

The manual mode, < 250 mm/s or 100%, must be selected whenever anyone enters
the robot’s safeguarded space. The robot must be operated using the teach pendant
and, if 100% is selected, using Hold-to-run control.
In automatic mode, the operating mode selector is switched to , and all safety
arrangements, such as doors, gates, light curtains, light beams and sensitive mats, etc.,
are active. No-one may enter the robot’s safeguarded space. All controls, such as
emergency stops, the control panel and control cabinet, must be easily accessible from
outside the safeguarded space.

1.5.3 Programming and testing at reduced speed

Robot movements at reduced speed can be carried out as follows:
◆ Set the operating mode selector to <250 mm/s
◆ Programs can only be started using the teach pendant with the enabling device
activated.
The automatic mode safeguarded space stop (AS) function is not active in this mode.

1.5.4 Automatic operation

Automatic operation may start when the following conditions are fulfilled:
◆ The operating mode selector is set to
◆ The MOTORS ON mode is selected
Either the teach pendant can be used to start the program or a connected remote
control device. These functions should be wired and interlocked in accordance with
the applicable safety instructions and the operator must always be outside the
safeguarded space.

1.6 Safety Risks Related to End Effectors

1.6.1 Gripper
If a gripper is used to hold a workpiece, inadvertent loosening of the workpiece must
be prevented.

Product Manual 5
Safety

1.6.2 Tools/workpieces
It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that
guards remain closed until the cutters stop rotating.
Grippers must be designed so that they retain workpieces in the event of a power
failure or a disturbance of the controller. It should be possible to release parts by
manual operation (valves).

1.6.3 Pneumatic/hydraulic systems

Special safety regulations apply to pneumatic and hydraulic systems.
Residual energy may be present in these systems so, after shutdown, particular care
must be taken.
The pressure in pneumatic and hydraulic systems must be released before starting to
repair them. Gravity may cause any parts or objects held by these systems to drop.
Dump valves should be used in case of emergency. Shot bolts should be used to
prevent tools, etc., from falling due to gravity.

1.7 Risks during Operation Disturbances

If the working process is interrupted, extra care must be taken due to risks other than
those associated with regular operation. Such an interruption may have to be rectified
manually.
Remedial action must only ever be carried out by trained personnel who are familiar
with the entire installation as well as the special risks associated with its different
parts.
The industrial robot is a flexible tool which can be used in many different industrial
applications. All work must be carried out professionally and in accordance with
applicable safety regulations. Care must be taken at all times.

1.8 Risks during Installation and Service

Never use the robot as a ladder, i.e. do not climb on the robot motors or other parts
during service work. There is a serious risk of slipping because of the high temper-
ature of the motors or oil spills that can occur on the robot.

Note! to prevent injuries and damage during the installation of the robot system,
the regulations applicable in the country concerned and the instructions of ABB
Robotics must be complied with. Special attention must be paid to the following
points:

- The supplier of the complete system must ensure that all circuits used in the
safety function are interlocked in accordance with the applicable standards for

6 Product Manual
 Safety

that function.
- The instructions in the Product Manual/Installation must always be followed.
- The mains supply to the robot must be connected in such a way that it can be
turned off outside the robot’s working space.
- The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance with
the applicable standards for the emergency stop function.
- Emergency stop buttons must be positioned in easily accessible places so that
the robot can be stopped quickly.
- Safety zones, which have to be crossed before admittance, must be set up in
front of the robot’s working space. Light beams or sensitive mats are suitable
devices.
- Turntables or the like should be used to keep the operator away from the
robot’s working space.
- Those in charge of operations must make sure that safety instructions are
available for the installation in question.
- Those who install the robot must have the appropriate training for the robot
system in question and in any safety matters associated with it.
Although troubleshooting may, on occasion, have to be carried out while the power
supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.

Even if the power supply for the robot is turned off, you can still injure yourself.

- The axes are affected by the force of gravity when the brakes are released. In
addition to the risk of being hit by moving robot parts, you run the risk of
being crushed by the tie rod.
- Energy, stored in the robot for the purpose of counterbalancing certain axes,
may be released if the robot, or parts thereof, is dismantled.

Product Manual 7
Safety

- When dismantling/assembling mechanical units, watch out for falling objects.

- Be aware of stored energy (DC link) and hot parts in the controller.
- Units inside the controller, e.g. I/O modules, can be supplied with external
power.

1.9 The following standards are of interest when the robot is parts of a
cell

EN 294 Safety of machinery - Safety distance to prevent danger

zones being reached by the upper limbs.
EN 349 Safety of machinery - Minimum gaps to avoid crushing of
parts of the human body.
EN 811 Safety of machinery - Safety distance to prevent danger
zones being reached by the lower limbs.
Pr EN 999 Safety of machinery - The positioning of protective equip-
ment in respect of approach speeds of the human body.
EN 1088 Safety of machinery - Inter locking device associated with
guards principles for design and selection.

1.10 Risks Associated with Live Electric Parts

Controller

A danger of high voltage is associated with the following parts:

- The mains supply/mains switch
- The power unit
- The power supply unit for the computer system
- The rectifier unit
- The drive unit
- The service outlets
- The power supply unit for tools, or special power supply units for the machin-
ing process

8 Product Manual
 Safety

- The rectifier unit

- The drive unit
- The service outlets
- The power supply unit for tools, or special power supply units for the machin-
ing process
- The external voltage connected to the control cabinet remains live even when
the robot is disconnected from the mains.
- Additional connections

Manipulator

A danger of high voltage is associated with the manipulator in:

- The power supply for the motors (up to 370 V DC)
- The user connections for tools or other parts of the installation (see Installa-
tion, max. 230 V AC)

Tools, material handling devices, etc.

Tools, material handling devices, etc., may be live even if the robot system is in the
OFF position. Power supply cables which are in motion during the working process
may be damaged.

1.11 Emergency Release of Mechanical Arm

If an emergency situation occur where a person is trapped by the mechanical robot
arm, the brake release buttons should be pressed whereby the arms can be moved to
release the person. To move the arms by manpower is normally possible on the
smaller robots (1400 and 2400), but for the bigger ones it might not be possible
without a mechanical lifting device, like an overhead crane.
If power is not available the brakes are applied, and therefore manpower might not be
sufficient for any robot.

Before releasing the brakes, be sure that the weight of the arms does not enhance
the pressure on the trapped person.

1.12 Limitation of Liability

The above information regarding safety must not be construed as a warranty by
ABB Robotics that the industrial robot will not cause injury or damage even if all
safety instructions have been complied with.

1.13 Related Information

See the Adept Manuals

Product Manual 9
Safety

10 Product Manual
 Decommissioning
CONTENTS
Page

1 Decommissioning ............................................................................................. 3
1.1 General...................................................................................................... 3
1.1.1 Manipulators .................................................................................... 3
1.1.2 Controller ......................................................................................... 4
1.2 Scrapping .................................................................................................. 4
1.2.1 General warning .............................................................................. 4
1.2.2 Oil and grease ................................................................................. 4
1.2.3 Parts requiring special treatment when scrapping........................... 4
1.3 IRB 4400 ................................................................................................... 5
1.4 IRB 6400 and IRB 640 .............................................................................. 5
1.4.1 Scraping Balancing cylinders .......................................................... 6

Product Manual 1
Decommissioning
CONTENTS
Page

2 Product Manual
 Decomissioning

1 Decommissioning

1.1 General
The components of the robot are manufactured from many different materials. Some
of them are listed below to facilitate scrapping, i.e. so that the components can be
disposed of in a way that does not have a detrimental effect on anyone’s health or the
environment.

1.1.1 Manipulators

Material Examples of components Part of

Lead Counter-weight IRB 6400

Batteries, Serial measurement board All robot types

NiCad or Lithium

Copper Cables, motors All robot types

Cast iron/nodular iron Base, lower arm, upper arm, parallel All robot types
bar/arm

Steel Gears, screws, base-frame, etc. All robot types

Samarium-Cobalt Brakes, motors IRB 1400, 2400, 4400

Neodymium Brakes, motors IRB 6400, 640

Plastic/rubber (PVC) Cables, connectors, drive belts, etc. All robot types

Oil, grease Gearboxes All robot types

Aluminium Covers, sync. brackets All robot types

Castings in wrist, upper arm tubular IRB 1400, 2400

Product Manual 3
Decomissioning

1.1.2 Controller

Material Examples of components

Copper Transformers, cables

Tin Cables

Alu-Zinc sheet- Control cabinets, various sheet metal parts

ing

Iron Transformers
Polyester Circuit boards

Plastic/rubber Cables, connectors, teach pendant, covers (drive units, I/O units)
(PVC) etc.

Lithium Batteries

1.2 Scrapping
The Counter-weight for 6400 and 640 contains lead and must therefore always be
recycled.

1.2.1 General warning

Before removing any parts from the manipulator, study the dismantling instruc-
tions for the component in question. Dismantling instructions can be found in
under Repairs.

1.2.2 Oil and grease

Where possible, arrange for the oil and grease to be recycled. Dispose of via an
authorised person/contractor in accordance with local regulations. Do not dispose of
oil and grease near lakes, ponds, ditches, down drains, or on to soil. Incineration may
be carried out under controlled conditions in accordance with local regulations.
Also note that:
- Spills may form a film on water surfaces causing damage to organisms. Oxy-
gen transfer could also be impaired.
- Spillage may penetrate the soil causing ground water contamination.

4 Product Manual
 Decomissioning

1.2.3 Parts requiring special treatment when scrapping

Special care is needed when removing certain parts from the robot, before scrapping
the part in question. The types of robot on which there are such parts are listed below
together with a description of how they should be removed.

IRB 140, 1400, 2400 and 4400

Motors

The manipulators mentioned above are equipped with spring-loaded brakes.

There a tensioned spring inside the brake. When the unit is scrapped the spring
can fly out and cause an eye injury.

IRB 4400

Balancing cylinder

The balancing cylinder contains 3 preloaded spiral springs. Before scrapping (melting
down, or other form of destruction) the springs must be unloaded in a safe way.

Spiral spring

Free length of spiral spring:

L = 470 mm
Figure 1Balancing cylinder IRB 4400.

IRB 6000/6400/6400R and IRB 640

Balancing cylinder

The balancing cylinder contains 1-2 preloaded spiral springs. (see Balancing cylinder,
IRB 6400 and 640. on page 6) Before scrapping (melting down, or other form of
destruction) the springs must be unloaded in a safe way, (see chapter Scraping
Balancing cylinders on page 6).
There are different types of balancing cylinder with a preloading force between 4500-
8000 N.
Free length of unloaded springs = is about 300 - 400 mm. besides the length of the
balancing cylinder.

Product Manual 5
Decomissioning

Double Spiral spring

Singel Spiral spring

Figure 2Balancing cylinder, IRB 6400 and 640.

1.2.4 Scraping Balancing cylinders

Normal way to Scrap the balancing cylinders is using a so-called shredder or
scrapping mill, all the balancing cylinders can be treated this in way.
An all covered mill where the scrap is ground to ships by e.g “Newell heavy duty
shredder plant 2205” or similar, scrapping mills are available at all bigger scrap-
merchants.

Alternative ways

If scrapping mills are not available the balancing cylinders except 3HAA 0001-EZ can
be opened by means of a blowpipe acc. to the sketches (see Scraping Balancing
cylinders on page 7).

It is most important that no closed rooms remains when the scrap is shipped to the
steel plant for recycling.

6 Product Manual
 Decomissioning

◆ Balancing unit for IRB 6X00/6400R.

Cut a hole (250 x 150 mm) in the mantel surface, and then cut all the uncovered
spring. Finally cut a hole (40 mm) in the piston rod (alt.A) or cut off the piston rod
end (alt.B) see Scraping Balancing cylinders on page 8.
◆ Balancing unit for Shelf version.
Cut a hole (250 x 150 mm) in the outer mantel surface and cut the uncovered spring
so it will be possible to cut another hole (200 x 100 mm) in the inner mantel
surface, cut the inner spring., cut off the piston rod end see Scraping Balancing
cylinders on page 7.
◆ Part no. 3HAA 0001-EZ and 3HAA 0001-EX (IRB 6000).
This type of Balancing cylinder has an outer jacket of aluminium which means it
can not be opened by means of a blowpipe, besides, the aluminium must be
separated from steel before recycling, and that can only be done in a shredder or by
the manufacturer. see Scraping Balancing cylinders on page 9.

ca. 250 Cut off Piston rod

ca. 200

Figure 3Scraping Balancing cylinders

Product Manual 7
Decomissioning

ca. 250
Ca Ø 40mm

Cut off Spiral spring

Hole in the Piston rod

Alternative A

ca. 250 Cut off Piston rod

Cut off Spiral spring

Alternative B

Figure 4Scraping Balancing cylinders

8 Product Manual
 Decomissioning

Figure 5Scraping Balancing cylinders

Product Manual 9
Decomissioning

10 Product Manual
 Installation and Commissioning

CONTENTS
Page

1 Transporting and Unpacking ......................................................................................... 3

1.1 System diskette ....................................................................................................... 3
2 On-Site Installation ......................................................................................................... 5
2.1 Lifting the manipulator........................................................................................... 5
2.2 Assembling the robot.............................................................................................. 7
2.2.1 Manipulator.................................................................................................. 7
2.2.2 Mounting the arm system and movable plate .............................................. 8
2.2.3 Mounting the telescopic shaft, axis 4........................................................... 8
2.2.4 Mounting the ventilation hose...................................................................... 8
2.2.5 Hose to tool point......................................................................................... 9
2.3 Stress forces ............................................................................................................ 9
2.3.1 Stiffness........................................................................................................ 9
2.3.2 Forces ........................................................................................................... 9
2.4 Amount of space required....................................................................................... 9
2.4.1 Manipulator.................................................................................................. 10
2.5 Manually engaging the brakes................................................................................ 11
2.6 Mounting equipment on the manipulator ............................................................... 11
2.7 Loads ...................................................................................................................... 12
2.8 Cabling.................................................................................................................... 12

Product Manual IRB 340A 1

Installation and Commissioning
CONTENTS
Page

2 Product Manual IRB 340A

Installation and Commissioning Transporting and Unpacking

1 Transporting and Unpacking

NB:
Before starting to unpack and install the robot, read the safety regulations and
other instructions very carefully.

The installation shall be made by qualified installation personnel and should con-
form to all national and local codes.

When you have unpacked the robot, check that it has not been damaged during
transport or while unpacking.

Check especially following items:

- composite arms (upper arms and bar system); no hacks

- joint balls; no scratches
- ventilation hose; no holes

Operating conditions:

Ambient temperature + 5° to +52°C (manipulator)

Relative humidity Max. 95% at constant temperature

Storage conditions:

If the equipment is not going to be installed straight away, it must be stored in a dry
area at an ambient temperature between -25°C and +55°C.

When air transport is used, the robot must be located in a pressure-equalized area.

The net weight of the manipulator is approximately 140 kg.

Whenever the manipulator is transported, it must be in mounting position, it’s not

allowed to turn the manipulator up side down.

1.1 System diskette

The diskette, should be copied (in a PC) before it is used. Never work with the original
diskette. When you have made copies, store the original in a safe place.

Do not store the diskette near the controller due to the high temperatures there.

Product Manual IRB 340A 3

Transporting and Unpacking Installation and Commissioning

4 Product Manual IRB 340A

Installation and Commissioning On-Site Installation

2 On-Site Installation

2.1 Lifting the manipulator

Never walk under a suspended load.

The best way to lift the manipulator is to use lifting straps and a traverse crane.
Attach the straps to the three lifting eyes on the base box (see Figure 1). The lifting
strap dimensions must comply with the applicable standards for lifting.

Crane lift

L=1000 mm / 40 inch
Ventilation hose

Figure 1 Lifting the manipulator using a traverse crane.

Product Manual IRB 340A 5

On-Site Installation Installation and Commissioning

It is also possible to lift the manipulator using a fork lift. To do that let the manipulator
rest in it’s standard delivery loading stool.

Fork lift

Figure 2 Lifting the manipulator using a fork lift.

6 Product Manual IRB 340A

Installation and Commissioning On-Site Installation

2.2 Assembling the robot

2.2.1 Manipulator

The three support points of the manipulator base box shall be mounted against three
flat surfaces with a flatness within the specification. Use shims if necessary. The rest
of the surface must be flat within ± 2 mm. Footprint diagram, see Figure 3. The level-
ness requirement for the surface is as follows:

0.5

Area for
calibration tool

60
28
R7

o
7

67
o
67
40

= available footprint of frame

Axis 2
R 370
120

A A
o
(3x

A
)

B y
Axis 3
12 40

x
6
M1
30 o

3
)

B
( 00.03
H8 +

A
25

Axis 1
Clamping plane A-A

Figure 3 Bolting the manipulator (dimensions in mm).

Product Manual IRB 340A 7

On-Site Installation Installation and Commissioning

The manipulator is fixed with three M16 bolts, tightened alternately.

Suitable bolts: M16x45 8.8 Socket screw with washer

(the length of the screws depends on the design of the frame)

Tightening torque: 150 Nm (oil lubricated)

Guide sleeves can be added to two of the bolt holes, to allow the same manipulator to
be re-mounted without program adjustment (see Figure 3).

The screw joint must be able to withstand the stress loads defined in Chapter 2.3.

2.2.2 Mounting the arm system and movable plate

After the manipulator has been mounted, as described in section 2.2.1, the arm system
and movable plate are assembled as described in the chapter regarding repairs.

2.2.3 Mounting the telescopic shaft, axis 4

After the arm system has been mounted, as described in section 2.2.2, the telescopic
shaft is assembled as described in chapter 7, Repairs.

2.2.4 Mounting the ventilation hose

Standard

Mount the ventilation hose (see Figure 1) with two hose clips, 3HAC 4428-1, supplied
with the robot.

340SA (Wash Down)

Mount the ventilation tube with seven screws, 9ADA 181-11 and gasket
3HAC 3400-1 supplied with the robot, tightening torque 4 Nm.

8 Product Manual IRB 340A

Installation and Commissioning On-Site Installation

2.2.5 Hose to tool point

Mount the hose from the Air filler down to the movable plate as shown in chapter 8,
Spare Parts, foldout 1.

2.3 Stress forces

2.3.1 Stiffness

The stiffness of the frame must be designed to minimize the influence on the dynamic
behaviour of the robot. For optimal performance the frequency of the frame with the
robot weight must be higher than 17 Hz.

2.3.2 Forces

Maximum force in the fixing points is 1000 N referring to the z-direction in the base
coordinate system, regarding coordinate system see Product Specification IRB 340A.

Robot frame is not included in the delivery.

2.4 Amount of space required

The amount of working space required to operate the manipulator is illustrated in Fig-
ure 4.

If work must be carried out within the robot’s work envelope, the robot’s speed
should not exceed 250 mm/s (10 inches/s).

Product Manual IRB 340A 9

On-Site Installation Installation and Commissioning

2.4.1 Manipulator

R=362.5
∅=1246
324 397
34

270

795

1110

Figure 4 The working space required for the manipulator.

10 Product Manual IRB 340A

Installation and Commissioning On-Site Installation

2.5 Manually engaging the brakes

All axes (except axis 4) come equipped with holding brakes. When the position of a
manipulator axis needs to be changed without connecting the controller, an external
voltage supply (24 V DC) must be connected to enable engagement of the brakes. The
voltage supply should be connected to the Burndy contact under the cover (see Figure
5).

2 3
1
4 5 6 0V
7
8 91 + 24 V DC
10 11 12

13 14 15

Internal connector
Burndy contact: R1.MP4-6

Figure 5 Connection of external voltage to enable engagement of the brakes.

When the controller or the voltage device is connected, illustrated above, the brakes
can be engaged by means of the push-button, location shown in Figure 6.

Brake release button

Figure 6 Location of brake release button.

2.6 Mounting equipment on the manipulator

External equipment, e.g. hoses and wiring mounted on the arms of the manipulator
must have a maximum weight of 300 g/m, also see Product Specification.

NB: Never drill a hole in the manipulator without first consulting maintenance
staff or the design department at ABB Flexible Automation.

Product Manual IRB 340A 11

On-Site Installation Installation and Commissioning

NB: The key grip must be used when mounting any equipment at the mechanical
interface to prevent a large torque on the telescopic shaft.

2xR1/4”

Key grip 22 mm, h 6 mm

Ø52
Mounting flange R3/8”, depth 14 mm
Ø25

Figure 7 The mechanical interface (mounting flange), four axis version.

2.7 Loads
It is important to define the loads properly (with regard to the position of centre
of gravity and inertia factor) in order to avoid breakdown of arm system.

For more information see Product Specification IRB 340A (Technical specification) for
load diagrams, permitted extra loads (equipment) and their positions. The loads must
also be defined in the software, see Adept Documentation.

2.8 Cabling
When the controller is coupled up to the mechanical unit, the signal cable must be con-
nected to ground; both at the controller and in the mechanical unit. The shield is
exposed at both sides of the cable and can be connected directly, or via a cable, to a
ground connection.

The shield of the control cable must be connected to ground both in the mechani-
cal unit and the controller.

12 Product Manual IRB 340A

 Maintenance

CONTENTS
Page

1 Maintenance Schedule .................................................................................................... 3

2 Instruction for Maintenance .......................................................................................... 3
2.1 General instructions for the manipulator ................................................................. 3
2.2 Telescopic shaft, axis 4 ............................................................................................ 4
2.3 Bar system ............................................................................................................... 4
2.4 Joint Balls ................................................................................................................ 5
2.5 Upper arms .............................................................................................................. 5
2.6 Hoses ....................................................................................................................... 6
2.7 Spring units.............................................................................................................. 6
2.8 Movable plate and swivel ........................................................................................ 6
2.9 Gearboxes, axes 1-3................................................................................................. 6
2.10 Manipulator fan ..................................................................................................... 7
2.11 Location of maintenance points............................................................................. 8

Product Manual IRB 340A 1

 Maintenance

Maintenance

The robot is designed to be able to work under very demanding conditions with a min-
imum of maintenance. Nevertheless, certain routine checks and preventative mainte-
nance must be carried out at specified periodic intervals, as shown in the table below.

• The exterior of the robot should be cleaned as required. Use a vacuum cleaner
or wipe it with a cloth. Compressed air and harsh solvents that can damage the
sealing joints, bearings, lacquer or cabling, must not be used.
• Check that the sealing joints and cable glands are really airtight so that dust and
dirt are not sucked into the mechanical unit.
• Lubricate sealings at regular intervals and when needed, recommended lubrica-
tion see 2.4 Section Bar system

1 Maintenance Schedule

Prescribed maintenance Maintenance intervals

Check Check 4.000 h 12,000 h 30,000h

every twice a or or or
500 h year 2 years 3 years 5 years

Telescopic shaft, axis 4 X X

MANIPULATOR

Bar system X X

Upper arms X

Spring unit X

Movable plate and swivel X

Gearboxes, axis 1, 2 and 3

X X

Manipulator Fan
X1

1. Check Roller Bearing.

2 Instructions for Maintenance

Number inside < > refers to maintenance points on the manipulator, see Figure 3.

2.1 General instructions for the manipulator

Check regularly:

Product Manual IRB 340A 3

Maintenance

• wear of bearing ring in joints of the arm system, lubricate.

• wear of plain bearings in telescopic shaft (SA version).
• for any oil leaks. If a major oil leak is discovered, call for service personnel.
• for excessive play in gears. If play develops, call for service personnel.
• that the cabling between the control cabinet and robot is not damaged.

Cleaning:

• Clean the robot exterior with a cloth when necessary. Do not use aggressive sol-
vents which may damage the mechanical unit.
• Cleaning instructions for Wash Down version see section 3.

2.2 Telescopic shaft, axis 4, ball bushing

Interval 500 h

Apply grease at <1>.

Type of grease: Mobilgrease FM 102

Optimol Obeen UF 2

Volume: 1.3 ml

Check and retighten set screws.

Interval 4,000 h or 2 years

Exchange the part as described in chapter 7, Repairs.

2.3 Telescopic shaft, axis 4, plain bearing

The wear on the bearings depends on the payload, cycle, environment and lubrication.

Interval 500 h

Rods
Check the wear of the rods on the inside of the plain bearing. If the rods are damaged or
worn out, replace the telescopic shaft as described in section 3.3, Repairs.

4 Product Manual IRB 340A

 Maintenance

Apply a small amount of grease on the rods.

Plain bearing
If the plain bearings are worn out or if the becklash is excessive, replace the plain bear-
ings as described in section 3.4, Repairs.

Interval 4,000 h or 2 years

Replace the part of bearings as described in 3.4, Repairs.

Type of grease: Mobilgrease FM 102

Optimol Obeen UF 2

2.4 Bar system

The wear on the bearings depends on the payload, cycle , environment and lubrication.

Interval 500 h

Check wear rings <5>. Listen for screech. If necessary apply grease.

Type of grease: Mobilgrease FM 102

Optimol Obeen UF 2

Volume: 0.5 ml

Interval 4,000 h or 2 years

Check surface of tube <10> for cracks or damages.

Check the distance between the wear ring holders <11>.

Normal dimension should be 126 mm. If distance is less than 124 mm, the ring is worn
out and must be replaced, see Figure 1.

If necessary, replace parts as described in chapter 3, Repairs.

Product Manual IRB 340A 5

Maintenance

126 mm

Figure 1 Wear ring holder distance

2.5 Joint Balls

Check surface of the joint balls. If cracks or burrs replace them, else excessive wear on
rings.

If necessary replace the part according to chapter 7, Repairs.

2.6 Upper arms

Check the surface of tube <12>, no cracks.

If necessary exchange the part according to chapter 7, Repairs.

2.7 Hoses

Interval 500 h

Check the entire hose <6> so that there are no folds or surface damages.

If necessary exchange the part according to chapter 7, Repairs.

2.8 Spring units

Check the roller <7> for wear.

If necessary exchange the part according to chapter 7, Repairs.

6 Product Manual IRB 340A
 Maintenance

2.9 Movable plate and swivel

Check joint balls <13, 14> and axis rotation joint <15> for surface damage, and that
the rotation is smooth.

If necessary, replace the part as described in chapter 7, Repairs.

2.10 Gearboxes, axes 1-3

Interval 4,000 h or 2 years

Check for backlash in outgoing shafts <17>. Total backlash should be < ±0.0167o (1
minute of arc).

If necessary exchange the part according to chapter 7, Repairs.

Interval 12,000 h or 3 years

Oil should only be changed the first 12,000 h

Change oil according to below.

Type of oil: Mobil DTE FM 220

Volume: 0.9l (per gearbox)

Drain the gearbox, alt. no. 1:

• Unscrew base cover.

• Remove oil plugs (see Figure 2).

Motor/gear box for axis 4

must be removed.

Oil plug (3x) Also the consol must be

removed.

Figure 2 Location of oil plugs.

• Suck up the oil with a smooth hose.

• The oil is filled through the plug holes, with specified volume.
Product Manual IRB 340A 7
Maintenance

• Mount base cover.

Drain the gearbox, alt. no. 2:

• Remove the transmission cover and arms.

• The oil is drained through the lower drain plug <18> holes (see Figure 3).
• The oil is filled through the upper plug holes, with specified volume.
• Mount transmission cover and arms.
• Calibrate axes 1-3, according to the Adept manual.

2.11 Manipulator Fan

Interval 30,000 h or 5 years

Check Roller Bearings.

If necessary, replace the part as described in chapter Repairs.

8 Product Manual IRB 340A

 Maintenance

2.12 Location of maintenance points

19

5, 11 (12x)

12 (3x)

13

14

7
10
8

9(2x) 2(2x)
Upper oil plug
15

17
Lower oil plug, 18

Figure 3 Maintenance points.

Product Manual IRB 340A 9

Maintenance

3 Cleaning of robot
The manipulator is tested to fulfil IP66 (Standard) and IP 67 (Wash Down) according
to IEC 529.

The test is performed under the following conditions:

IP66
The capping is sprayed with water from all possible angles with a nozzle.
- Nozzle inside diameter: 12.5 mm.
- Water flow: 100 l/min. ± 5%.
- Water pressure1 at the nozzle: approx. 100 kN/m² (1bar).
- Test time / m² of the capping area: 1 min.
- Shortest test time: 3 min.
- Distance from the nozzle to the capping: approx. 3 m.

IP67
The capping is lowered into water to fulfil the following conditions.
- The water surface should be min. 150 mm above the highest part of the
capping.
- The lowest part of the capping should be at least 1 m below the water surface.
- The length of the test should be at least. 30 min.
- The water temperature should not deviate more than 5° C from the
temperature of the material.
This requirement could be changed by the technical committee in question if
the test is to be done when the material is powered or in motion.

3.1 Standard cleaning

The standard version of IRB 340A is not manufactured for wash down applications and
should only be cleaned by wiping off the dirt and dust using a dry or moistened cloth.

3.2 Wash Down cleaning

Note! Only for IRB 340A SA, Wash Down version.

1. Flush with water max 60°C, low pressure, see Figure 4 for sensitive points.

2. Foam with “P3-Topax 12” with a concentration of approximately 3% depending

on the type of dirt. The water temperature should be 40-60°C. The solvent should
be applied to the whole external surface.

1. The pressure is adjusted so that the given amount of water is obtained. At 100 kN/m², the free vertical
piezometric level should be 8 m.

10 Product Manual IRB 340A

 Maintenance

3. Wait about 15 minutes so the solvent takes effect. To retain effective cleaning
properties, ensure that the solvent does not dry on the surface.

4. Flush thoroughly with water.

5. Apply the disinfectant, we recommend “P3-Topax 99”. Time, concentration, and

water temperature are chosen to reach the desired effect.

- Concentration = 1-2%
- Temperature = 10-40°C
- Time approx. 20 min.

6. Flush thoroughly with water. Sealings and joints should be lubricated after clean-
ing, for good functionality.
Be careful flushing sealings.

Due to the risk of damaging the roller

After cleaning bearing races and bearing do not clean with any detergent
“swivel cup” sealing, lubricate them when the “swivel cup” is removed. Only
with provision classified grease. use a moistened cloth.

Figure 4 Sensitive points

Product Manual IRB 340A 11

Maintenance

12 Product Manual IRB 340A

 Repairs

CONTENTS
Page

1 General Description ........................................................................................................ 3

1.1 Document Guidance ............................................................................................... 5
1.2 Caution.................................................................................................................... 6
1.3 Mounting Instructions for Bearings and Seals ....................................................... 6
1.3.1 Bearing rings ................................................................................................ 6
1.3.2 Seals ............................................................................................................. 6
1.4 Instructions for Tightening Screw Joints................................................................ 8
1.5 Tightening Torques ................................................................................................. 9
1.5.1 Collar screw ................................................................................................. 9
1.5.2 Torx screw.................................................................................................... 9
1.5.3 Screws with hexagon socket head................................................................ 9
1.5.4 Special screws .............................................................................................. 10
2 Axis 1, 2 and 3................................................................................................................. 11
2.1 Replacing motor/gearbox unit......................................................................... 11
2.2 Exchange of motor or gearbox ............................................................................... 12
2.3 Replacing the upper arm......................................................................................... 13
2.4 Replacement of joint balls ...................................................................................... 14
2.5 Replacement of hard stops...................................................................................... 14
3 Axis 4 ................................................................................................................................ 15
3.1 Replacing motor/gearbox unit ................................................................................ 15
3.2 Exchange of motor or gearbox ............................................................................... 16
3.3 Replacing the telescopic shaft ................................................................................ 17
3.4 Replacing the plain bearings, Wash Down version ................................................ 18
3.5 Replacing on-board calibration .............................................................................. 19
4 Movable plate and swivel................................................................................................ 21
4.1 Dismounting movable plate.................................................................................... 21
4.2 Replacement of joint balls ...................................................................................... 21
5 Parallel arm system......................................................................................................... 23
5.1 Replacing parallel arms .......................................................................................... 23
5.2 Replacing the spring units ...................................................................................... 23
5.3 Exchange of wear rings .......................................................................................... 24
6 Cabling ............................................................................................................................. 27
6.1 Dismounting the complete cabling ......................................................................... 27
6.2 Replacing pushbutton unit and warning lamp ........................................................ 27
6.3 Replacing the fan .................................................................................................... 28
6.4 Replacing on-board calibration .............................................................................. 28

Product Manual IRB 340A 1

Repairs
CONTENTS
Page

7 Hoses................................................................................................................................. 29
7.1 Exchange of hoses .................................................................................................. 29
8 Calibration....................................................................................................................... 31
8.1 General ................................................................................................................... 31
9 Special Tools List............................................................................................................. 33

2 Product Manual IRB 340A

Repairs General Description

1 General Description

The industrial robot system IRB 340A comprises a separate unit; the mechanical unit.
The service of the mechanical unit is described in this document.

As regards service, the mechanical unit is divided into the following main parts:

• Electrical System
• Motor Units
• Mechanical System

The Electrical System is routed for longevity. The power cabling feeds the robot axes'
motor units. The signal cabling feeds the various controlling parameters like axis posi-
tions, motor revs, etc.

The AC type Motor Units provide the motive power for the various robot axes via
gears. Mechanical brakes, electrically released, lock the motor units when the robot is
inoperative.

The Mechanical System a 4 axes version, enabling the flexible robot motions.

Axis 1
Axis 2

Axis 4

Axis 3

TCP0

Figur 1 The robot axes and working space, IRB 340A.

Product Manual IRB 340A 3

General Description Repairs

Axis No. 1, 2 and 3 moves the end effector parallel with the working surface.

Axis No. 4 is a telescopic shaft that rotates the tool.

The Control Cabinet must be switched off during all service work on the robot!

The Brake Release Button should be connected as indicated in Section 5, Installation

and Commissioning, to enable movements of the axes.

Special care must be taken when the brakes are operated manually. This applies
particularly when the robot is started up, either for the first time or after a stop-
page. The safety instructions in the Manual must be complied with at all times.

4 Product Manual IRB 340A

Repairs General Description

1.1 Document Guidance

The subsequent chapters describe the type of service work that can be carried out by
the Customer´s own service staff on site. Certain types of work, requiring special expe-
rience or special aids, are not dealt with in this manual. In such cases, the defective
module or component should be replaced on site. The faulty item should be sent to
ABB Flexible Automation for service.

Calibration. A power-on calibration have to be carried out after each power down or
restart of the system. During the process axis 1-3 are using hardstops and axis 4 a sen-
sor positioned inside the gearbox. The procedure is described in detail in the Adept
Manuals.

IMPORTANT! When work is done on the robot signal cabling, this may result in
the robot moving to incorrect positions.

Tools. Two types of tools are required for various service jobs involving dismantling;
on the one hand, conventional tools like socket and ratchet spanners, etc.; on the other
hand, special tools may be necessary, depending on what type of service is being car-
ried out. The conventional tools are not dealt with in this manual, based on the assump-
tion that the service personnel have sufficient technical basic competence. However,
service work requiring the use of special tools is described in this manual.

Foldouts. In the Spare Parts chapter of this manual, there are a number of foldouts
illustrating the robot parts, intended to facilitate quick identification of both the type of
service required and the composition of the various components. The parts are item
numbered on the foldouts. The foldouts are referred to in the Manual text within
“arrow heads” (< >) as exploded view numbers. Where reference is made to foldouts,
other than those specified in the paragraph title, the foldout number is included in the
item number reference, for example <5/19> or <10:2/5>, the digit(s) before the stroke
referring to the foldout number.

Numbers in brackets ( ) refer to figures in the text.

The foldouts also include information such as article number, designation and relevant
data.

N.B. This manual is not to be considered as a substitute for a proper training

course. This document is intended for use after the course has been completed.

Product Manual IRB 340A 5

General Description Repairs

1.2 Caution
The mechanical unit contains several parts which are too heavy to lift manually. As
these parts must be moved with precision during any maintenance and repair work, it
is important to have a suitable lifting device available.

Entering the robot working space when the HIGH POWER (motors on) light is illumi-
nated can result in severe injury.

1.3 Mounting Instructions for Bearings and Seals

1.3.1 Bearing rings

1. Let a new bearing remain in its wrapping until it is time for fitting, to avoid contamina-
tion of the bearing.

2. Ensure that all parts included in the bearing fitting are free from burrs, grinding
waste and other contamination.

3. The bearing must be greased after fitting. The main reason for this is the requirement
for cleanliness and a minimum of wear.

4. The bearings must not be completely filled with grease. However, if space is
available beside the bearing fitting, the bearing may be totally filled with grease
when mounted, as surplus grease will be thrown out from the bearing when the
robot is started up.

5. During operation, the bearing should be filled to 70-80% of the available volume.

6. Ensure that grease is handled and stored properly, to avoid contamination.

1.3.2 Seals

1. The commonest cause of leakage is incorrect fitting.

Rotating Seals

2. The sealing surfaces should be protected during transport and mounting.

3. The seal should be kept in the original wrappings or be well protected.

4. Sealing surfaces must be inspected before mounting. If scratches or damage are

found, that may result in future leakage, the seal must be replaced.

6 Product Manual IRB 340A

Repairs General Description

5. Seals should also be checked before mounting to ensure that:

• there is no damage to the sealing edge (feel with a fingernail)

• the seal is of the correct type (provided with cutting edge)
• there is no other damage.

6. Grease the seal just before fitting it, but not too early as there is a risk of dirt and
foreign particles adhering to the seal. The space between the dust tongue and
sealing lip should be filled to 2/3 with grease. The rubber coated external diame-
ter must also be greased.

7. The fitting of seals and gears must be carried out on clean workbenches.

8. Mount the seal correctly. If it is misaligned, there is a risk of leakage due to the
pumping effect.

9. Always mount the seal with a mounting tool. Never hammer directly on the seal,
as this may result in leakage.

10. Use a protective sleeve for the sealing lip during mounting, when sliding over
threads, keyways, etc.

Flange Seals and Static Seals

11. Check the flange surfaces. They must be even and free from pores. It is easy to
check flatness using a gauge on the fastened joint (without sealing compound).

12. Differences in surface level or the presence of burrs due to incorrect machining
are not permissible. If flange surfaces are defective, the parts must not to be used,
because leakage could result.

13. The surfaces must be properly cleaned in accordance with ABB ROBOTICS
PRODUCTS recommendations.

14. Distribute the sealing compound evenly over the surface, preferably with a brush.

15. Tighten the screws evenly when fastening the flange joint.

O-rings

16. Check the O-ring grooves. The grooves must be geometrically correct and free
from pores and contamination.

17. Check the O-ring with regard to surface defects, burrs, shape accuracy, etc.

18. Ensure that the correct O-ring size is used.

Product Manual IRB 340A 7

General Description Repairs

19. Tighten the screws evenly when assembling.

20. Defective O-rings and O-ring grooves must not be used.

21. Fitting defective parts will result in leakage. Grease the O-ring with lubricant
before mounting.

1.4 Instructions for Tightening Screw Joints

General

It is of the utmost importance that all screw joints be tightened with the correct torque.

Application

The following tightening torques are to be used for all screw joints in metallic materials
unless otherwise specified in the text.

These instructions do not apply to screw joints comprising soft or brittle materials.

For screws with a higher property class than 8.8, the data for 8.8 must be used unless
otherwise specified.

Screws treated with Gleitmo (lubricated)

When handling screws treated with Gleitmo, protective gloves of nitrile rubber
type should be used.

Screws treated with Gleitmo can be unscrewed and screwed in again 3-4 times before
the slip coating disappears. Screws can also be treated with Molycote 1000.

When screwing in new screws that are not Gleitmo treated, these should first be lubri-
cated with Molycote 1000 and tightened to the specified torque.

Assembly

Lubrication with molybdenum disulphide grease (Molycote 1000) should only be used
when specified in the text.

Screws lubricated with Molycote 1000 and then torque tightened, should also to be
lubricated between the washer and the head of the screw.

Screws must be tightened with a torque-wrench.

8 Product Manual IRB 340A

Repairs General Description

1.5 Tightening Torques

1.5.1 Collar screw

Tightening torque - Nm
Dimension class 12.9
M6 11.0

1.5.2 Torx screw

Tightening torque - Nm
Dimension class 8.8
Gleitmo 610
Molycote 1000
M6 7.0

1.5.3 Screws with hexagon socket head

Tightening torque - Nm
Dimension class 8.8 class 8.8 class 12.9
Molycote 1000 Oil Molycote 1000
Gleitmo 610 Loctite Gleitmo 610
M4 2.8
M6 7 11
M8 17
M 10 33

Product Manual IRB 340A 9

General Description Repairs

1.5.4 Special screws

Tightening torque - Nm
Dimension Loctite Location
M8 11.0 ball joints
M12 20 swivel

10 Product Manual IRB 340A

Repairs Axis 1, 2 and 3

2 Axis 1, 2 and 3

2.1 Replacing motor/gearbox unit

Refer to foldout no. 3 and 4.

Dismounting:

1. Remove the parallel arms according to chapter 5.1.

2. Dismount the upper arms according to section 2.3.

3. Dismount telescopic shaft according to 3.3.

4. Remove flange cover <3/16>.

5. Dismount the transmission cover <10>.

6. Unscrew screws <4/38> for the base cover <4/33>.

7. Disconnect the cable for the fan, contact R4.FAN, and the manipulator cables.

8. Remove the base cover.

9. Disconnect the motor cabling.

If motor/gearbox for axis 3 is to be dismounted must axis 4 be dismounted first

(see chapter 3).
If motor/gearbox for axis 2 is to be dismounted must axis 4 and the consol be
removed first (see chapter 3 and 6).

10. Unscrew screws <3/5> and remove the motor/gearbox unit.

Mounting:

11. Place the motor/gearbox in position, 2 guide pins.

12. Mount the unit with screws <3/5> and washers <3/4>. Tightening torque 33 Nm.

13. Connect the motor cabling.

14. Mount back the transmission cover <3/10> with screws >3/9>, torque 9 Nm.

15. Mount back flange cover<3/16> and telescopic shaft.

16. Connect the cable for the fan, R4.FAN.

17. Tighten screws <4/38> for the base cover <4/33> with torque 14 Nm.

18. Mount the upper arm according to section 2.3.

19. Mount the parallel arms according to chapter 5.1.

Product Manual IRB 340 11

Axis 1, 2 and 3 Repairs
Tightening torque:

Screw joint motor unit/base box, item <3/5>: 33 Nm

Screw joint base cover/base box, item <4/38>: 14 Nm
Screws for transmission cover, item <3/10>: 9 Nm

2.2 Exchange of motor or gearbox

Motor

1. Remove the transmission cover according to section 2.1.

2. Drain the gearbox according to chapter Maintenance.

3. Unscrew the three screws (1) holding to motor to the gearbox (see Figure 2).
1

Figure 2 Motor and gearbox axis 1-3.

4. Remove the motor.

5. Mount O-ring (2) onto the motor flange (see Figure 3).

Figure 3 Mounting of motor axis 1-3.

6. Insert the new motor, do not tighten the screws (1).

12 Product Manual IRB 340

Repairs Axis 1, 2 and 3

7. Mount back the upper arm temporarily, to be used to feel the backlash.

8. Push the motor gently downwards with help of a screw driver at the same time as
you feel for the backlash by moving the upper arm back and forward.

9. Tighten the screws (1) with torque 11 Nm.

10. Check through the upper oil level hole that gear wheel (3) is axially movable (see
Figure 3).

11. Fill the gearbox with oil according to chapter Maintenance.

12. Mount back transmission cover according to section 2.1.

Gearbox

13. Dismount the motor/gear unit according to section 2.1.

14. Follow points 2. to 11. above.

15. Mount back the unit (motor/gearbox) according to section 2.1.

2.3 Replacing the upper arm

Refer to foldout no. 1 and 3.

Dismounting:

1. Remove the parallel arms <1/1> according to section 5.1

2. Remove the VK-cover <3/42>. Knock a screw driver or similar through the VK-
cover and bend it out. A new cover must be mounted back.

3. Unscrew screws <3/41>.

4. Pull the upper arm <3/40> out.

Mounting:

5. Remove the flange cover <3/16>, screws <3/19>.

6. Mount the flange cover onto the upper arm shaft. Make sure that the sealing ring
<3/17> is in the right position on the shaft.

7. Place the upper arm <3/40> in position, on the guide pin.

8. Tighten screws <3/41> with torque 11 Nm.

9. Tighten screws <3/19> with torque 9 Nm.

10. Perform a new calibration procedure according to the Adept manual.

11. Mount back the parallel arms according to section 5.1.

Product Manual IRB 340 13
Axis 1, 2 and 3 Repairs

Tightening torque:

Screw joint upper arm/gearbox, item <3/41>: 11 Nm

Screw joint flange cover/gearbox, item <3/19>: 9 Nm

2.4 Replacement of joint balls

Refer to foldout no. 1.

Dismounting:

1. Remove the parallel arms according to section 5.1.

2. Unscrew the joint balls <6> in the upper arm.

Mounting:

3. Mount new joint balls, torque 11 Nm. Use Loctite 243.

4. Mount parallel arm system according to 5.1.

Tightening torque:

Joint balls/upper arm, item <6>: 11 Nm

2.5 Replacement of hard stops

1. Remove the two screws holding the hard stop

2. Mount the new hard stops, torque 9 Nm.

3. Perform a new calibration procedure according to the Adept manual.

Tightening torque:

Screw joint hard stops/base cover: 9 Nm

14 Product Manual IRB 340

Repairs Axis 4

3 Axis 4

3.1 Replacing motor/gearbox unit

Refer to foldout no. 1, 3 and 4.

Dismounting:

1. Remove base cover <4/33>, screws <4/38>.

2. Disconnect the cable for the fan, contact R4.FAN, and the manipulator cables.

3. Disconnect the motor contacts, R3.FB4 and R3.MP4.

4. Disconnect the sensor according to section 8.4.

5. Loosen the set screw <1/12> at the upper coupling on the telescopic shaft.

6. Unscrew screws <3/24>.

7. Remove the motor/gearbox <4/22>.

Mounting:

8. Mount motor and gearbox with screws <3/24>, tightening torque 9 Nm.

9. Remount the telescopic shaft, lock with set screw <1/12> and Loctite 243, tight-
ening torque 4 Nm.

10. Connect the cables to the motor.

11. Connect the sensor according to section 8.4.

12. Connect the cabling and mount cover <4/33> with screws <4/38>, tightening
torque 14 Nm.

Tightening torque:

Screw joint motor/basebox, item <3/24>: 9 Nm

Screw joint base cover/basebox, item <4/38>: 14 Nm

Product Manual IRB 340A 15

Axis 4 Repairs

3.2 Exchange of motor or gearbox

Motor

1. Remove motor/gearbox unit according to section 3.1.

2. Knock a screw driver or similar through the VK-cover (2) and bend it out, be care-
full not to hit the on-board calibration device. A new cover must be mounted (see
Figure 4).

3. Pour out the oil.

4. Unscrew screws (1) and remove the motor.

6 1

5
3

Figure 4 Motor/gear unit axis 4.

5. Open screw (3) a bit and wind the gear (5) down.

6. Mount O-ring (4) in the gear house.

7. Mount the motor with screws (1), tightening torque 9 Nm.

8. Rotate gear (5) upwards so that there is no play between the gears.

9. Ensure that the gear is kept absolutely still. Apply Loctite 243 and tighten the
screw (3), torque 9 Nm.

10. Check the play again.

11. Apply Loctite 290 to lock the shaft (see Figure 4).

16 Product Manual IRB 340A

Repairs Axis 4

12. Calibate the robot as specified in Chapter 8, Calibration.

13. Fill the gearbox with oil to the centre of the motor pinion (see Figure 4).

14. Unscrew screw (6) so that the sealing ring does not pop out when mounting the
VK cover.

15. Mount the VK cover (2).

16. Remount screw (6).

Tightening torque:

Screw joint motor/gearbox, item (1): 9 Nm

Locking screw, item (3): 9 Nm

3.3 Replacing the telescopic shaft

Refer to foldout no. 1 and 3.

Dismounting:

1. Lift up the sealing ring (v-ring) and unscrew the lower set screw <1/12>.

2. Unscrew the upper set screw <1/12> , see Figure 5.

3. Push the shaft together and remove it.

Set Screws

Figure 5 Set Screws

Mounting:

The set screws for the telescopic shaft must be tightened as described below oth-

Product Manual IRB 340A 17

 erwise there is a risk that the shaft becomes loose and damages the arms and can
Axis 4 cause personal injuries. Repairs
4. Tighten set screws <1/12> with torque 4 Nm. Use Loctite 243.

5. Press the sealing ring back in place.

Note! Do not press the sealing down to hard when this will cause heavy wear,
see Figure 6.

Push against
chamfer(9mm)

Figure 6 Sealing ring.

3.4 Replacing the plain bearings, Wash Down version

1. Remove the telescopic shaft as described in section 3.3.

2. Unscrew the nuts (1) gently (see Figure 7).

3. Take the components apart.

4. Remove the three plain bearings in each bearing holder (see Figure 7).

5. Replace with new plain bearings. Ensure that the small notch is located so it fits in
the hole.

18 Product Manual IRB 340A

Repairs Axis 4

6. Assemble the parts of the telescopic shaft together, torque 4 Nm. Check that the
bars are parallel.

7. Test that the movement of the telescopic shaft is smooth along its whole length.

8. Mount the telescopic shaft as described in section 3.3.

1 1

Plain bearing

Figure 7 Plain bearings, Wash Down version.

Tightening torque:

Nuts, telescopic shaft, item (1): 4 Nm

3.5 Replacing on-board calibration

Refer to foldout no. 5.

Dismounting:

1. Remove the cable <5/68> from the sensor.

2. Loosen the lock nut.

3. Remove the sensor from the housing.

Product Manual IRB 340A 19

Axis 4 Repairs

Mounting:

4. Knock a screw driver or similar through the VK-cover (2) and bend it out, be care-
full not to hit the on-board calibration device. A new cover must be mounted (see
Figure 4)

5. Screw the new sensor about a centimeter into the housing.

6. Apply Loctite 542 on the sensor and screw it into the housing. The distance
between the sensor and giver should be 0.9 mm (use a thickness gauge).

7. Attach the lock nut to the sensor and tighten it.

8. Calibrate the sensor for axis 4 as specified in Adept Manuals.

20 Product Manual IRB 340A

Repairs Movable plate and swivel

4 Movable plate and swivel

4.1 Dismounting movable plate

Refer to foldout no. 1

Dismounting:

1. Pull the parallel arms apart by hand or use tool 3HAC 5819-1, and remove the plate.

Mounting:

2. Mount the movable plate by pulling the parallel arms apart by hand or use
tool 3HAC 5819-1.

4.2 Replacement of joint balls

Refer to foldout no. 1.

Dismounting:

1. Dismount movable plate according to sections 4.1.

2. Unscrew joint balls <6>.

Mounting:

3. Mount new joint balls, torque 11 Nm. Use Loctite 243.

4. Mount movable plate according to section 4.1

Tightening torque:

Joint balls/movable plate, item <6>: 11 Nm

Product Manual IRB 340 21

Movable plate and swivel Repairs

22 Product Manual IRB 340

Repairs Parallel arm system

5 Parallel arm system

5.1 Replacing parallel arms

Refer to foldout no. 1

Dismounting:

1. Remove the vacuum hose from the arm system.

2. Use tool 3HAC 5819-1 (or by hand), and pull the arms apart in both ends
(see Figure 8).

Figure 8 Parallel arms with spring units.

3. Remove the arms.

Mounting:

4. Mount in reversed order.

5.2 Replacing the spring units

Refer to foldout no. 1

Dismounting:

1. Remove the affected arm system according to section 5.1.

2. Push the bar as shown in Figure 9.

Product Manual IRB 340 23

Parallel arm system Repairs

Rollers (x4)

Figure 9 Removing the spring unit.

3. Take out the rollers (see Figure 9).

4. Remove the spring unit.

5. Both sides identical.

Mounting:

6. Place the spring unit in position.

7. Mount the rollers onto the pin (see Figure 9).

8. Pull the arm backwards into position.

9. Mount back the arm system according to section 5.1

5.3 Exchange of wear rings

Refer to foldout no. 1

Dismounting:

1. Remove the parallel arm according to section 5.1.

2. Remove the spring unit according to section 5.2.

3. Insert a screw driver, and bend carefully the wear ring out (see Figure 10).

Mounting:

4. Place a new wear ring into the joint socket (see Figure 10).

24 Product Manual IRB 340

Repairs Parallel arm system

5. Place the arm bar in dolly 3HAC 4182-1.

6. Put drifter 3HAC 4184-1 into the wear ring and knock it gently down to its
position.

7. Mount the spring units back according to section 5.2.

8. Apply grease according to chapter Maintenance.

Drifter 3HAC 4184-1

Wear ring

Dolly 3HAC 4182-1

Figure 10 Exchange of wear rings.

9. Mount the parallel arms according to section 5.1.

Product Manual IRB 340 25

Parallel arm system Repairs

26 Product Manual IRB 340

Repairs Cabling

6 Cabling

6.1 Dismounting the complete cabling

Refer to foldout no. 5

Dismounting:

1. Remove the base cover according to first points in chapter 3.1, Replacing motor/
gearbox unit.

2. Make a note or small drawing of the location of the cabling.

3. Cut all the straps holding the cabling.

4. Disconnect all contacts.

5. Dismount the transmission cover according to the first points in chapter 2.2,
Exchange of motor or gearbox.

6. Disconnect the cables for the warning lamp and brake release button.

Mounting:

7. In reversed order.

Note!
Make sure that no cables are in the marked area according to foldout 5.

6.2 Replacing pushbutton unit and warning lamp

Refer to foldout no. 3 and 5

Dismounting:

1. Remove the parallel arm system according to chapter 5, Parallel arm system.

2. Remove the upper arms according to chapter 2, Axis 1, 2 and 3.

3. Dismount the transmission cover <3/10>, screws <3/59>.

4. Disconnect and unscrew the push button or lamp unit.

Mounting:

5. Mount in reversed order.

Product Manual IRB 340 27

Cabling Repairs

6.3 Replacing the fan

Refer to foldout no. 4

Dismounting:

1. Remove the ventilation connection <46>, screws <19>.

2. Remove the base cover <33>, screws <38>.

3. Remove the fan cover <37>, screws <60>.

4. Disconnect the cable <35>, R4.FAN.

5. Unscrew screws <36> and remove the fan <34>.

One of the screws <36> is hidden under the ventilation gasket.

Mounting:

6. Mount in reversed order.

6.4 Replacing on-board calibration

Refer to foldout no. 3 and 5.

Dismounting:

1. Remove the cable </> from the sensor.

2. Loosen the lock nut </>.

3. Remove the sensor from the housing.

Mounting:

4. Knock a screw driver or similar through the VK-cover (2) and bend it out, be care-
full not to hit the on-board calibration device. A new cover must be mounted (see
Figure 4)

5. Screw the new sensor about a centimeter into the housing.

6. Apply Loctite 542 on the sensor and screw it into the housing. The distance
between the sensor and giver should be 0.9 mm (use a thickness gauge).

7. Attach the lock nut to the sensor and tighten it.

8. Calibrate the sensor for axis 4 as specified in Adept Manuals

28 Product Manual IRB 340

Repairs Hoses

7 Hoses

7.1 Exchange of hoses

Dismount and mount according to foldout 6.

1. Open straps <12>.

2. Pull the hose out from the swivel

3. Pull the hose out from the air filter.

4. Mount a new hose on the swivel.

5. Fix the hose, do not tighten, against the three clamps <11> on the parallel arm.

6. Twist the hose and mount it on the air filter.

7. Then adjust the hose according to foldout no. 6.

8. Tighten the straps.

9. Make a small program (low velocity) and check that the hose runs freely

Product Manual IRB 340A 29

Hoses Repairs

30 Product Manual IRB 340A

Repairs Calibration

8 Calibration

8.1 General
The IRB340A does not involve a serial measurement board that keeps track of the
robot positions at power off. Due to this a power-on calibration has to take place after
each restart. The power-on calibration is described more in detail in the Adept Manu-
als.

Make sure that all the arms are below -10o before a power-on calibration takes
place. In other cases the spring unit of the axis that performs the calibration can
hit the upper arm.

For axes 1-3 the calibration is made so each upper arm is running into a mechanical
hard-stop. For axis 4 the calibration is performed as a sensor is placed in the axis 4
gearbox (on-board calibration). If the gearbox is changed or the sensor in other ways
is removed a new calibration procedure must take place. During this procedure a cali-
bration tool (3HAC 4456-1) must be used. The calibration can be ordered from ABB
Flexible Automation, see section 8, Spare Parts List. The new calibration procedure is
further described in the Adept Manuals.

Do not power-on calibrate axes with incorrect calibration offset.

If a new calibration procedure has been done, always make a course check of the new
calibration offset by jogging the robot to a well known position and read the degrees
of each axis from the teach pendant (some positions are described in the IRB340A
Product Specification).

Product Manual IRB 340 31

Calibration Repairs

32 Product Manual IRB 340

Repairs Special Tools List

9 Special Tools List

The need for special tools has been reduced to a minimum. When tools are needed for
dismounting/mounting work, a description is given in that section.

During the ordinary service training courses arranged by ABB Flexible Automation,
detailed descriptions of the tools are given together with their use.

Calibration
Calibration fixture 3HAC 9596-1

Arm system
Tool for mounting the parallel arms 3HAC 6194-1
Drifter for mounting wear rings 3HAC 4184-1
Dolly for joint socket when inserting new 3HAC 4182-1
wear rings

Product Manual IRB 340 33

Special Tools List Repairs

34 Product Manual IRB 340

 Spare Parts

CONTENTS
Page

1 Manipulator ............................................................................................................. 3
1.1 Arm system and external details ..................................................................... 3
1.2 Manipulator base............................................................................................. 7

Product Manual IRB 340 A 1

Spare Parts

Spare Parts

1 Manipulator
Item numbers refer to item numbers on the foldouts. Article numbers in bold text are spe-
cially designed as spare parts (painted etc.).

Remark Text
- IRB 340A = 4 Axes Standard version
- IRB 340ASA = 4 Axes Wash Down version

1.1 Arm system and external details

Itm Qty Name Art. no. Remark

1 6 Bar 3HAC 2090-1

2 12 Wear-ring 3HAC 2091-1
3 6 Spring unit 3HAC 3958-1
4 24 Roller 3HAC 3062-1

6 12 Joint ball 3HAC 5176-1

7 4x3ml Locking liquid 3 ml cont. 3HAC 7181-1 Loctite 243
8 1 Movable Plate with Swivel 3HAC 6913-1 (incl. items 24-31)

10 1 Sealing ring (V-ring) 3HAB 3732-16 V-20S

11 1 Telescopic shaft, axis 4 3HAC 5115-1 (incl. item 12)
IRB340A
12 2 Set screw, dog point 9ADA 203-5 M5x16

15 1 Customer connection 3HAC 4256-1 Not IRB340A/ASA

16 1 Dust cap 5217 649-9 Not IRB340A/ASA
17 1 Dust cap 3HAA 1001-630 Not IRB340A/ASA
18 1 Cover 3HAC 7024-1 opt. 041
19 8 Hexagon head screw 9ADA 181-12 M6x16 8.8
20 1 External cable connection 3HAC 4285-1 Not IRB340A/ASA
21 1 Dust cap 5217 649-9 Not IRB340A/ASA
22 1 Labels IRB 340 3HAC 3919-1
23 3 Parallel arms 3HAC 5234-1 Incl. items 1, 2, 3,
4
24 1 Movable Plate 3HAC 6921-1

Product Manual IRB 340A 3

Spare Parts

25 1 Parallel Pin 3HAC 6912-1 3x6

26 1 Swivel Cup 3HAC 6922-1
27 1 Swivel Axis 3HAC 6923-1
28 1 Lock nut 3HAC 6925-1
29 2 Groove Ball Bearing 3HAB 3643-16 25x37x7
30 1 Sealing 3HAC 3296-4 25x32x4
31 1 Spring Washer 3HAC 2864-14

33 3 Arm Stop 3HAC 9193-1

34 9 Hexagon head screw 9ADA 123-22 M6x20
35 9 Plain washer 9ADA 316-3
36 9 O-ring 3HAB 3772-35 Not IRB340A/ASA
37 1 Internal Control cable 7m 3HAC 9316-1
37 1 Internal Control cable 15m 3HAC 9316-3
37 1 Internal Control cable 22m 3HAC 9316-4
37 1 Internal Control cable 30m 3HAC 9316-5
38 1 External Air Connection 3HAC 7056-1
39 1 Telescopic Shaft, axis 4 3HAC 9265-1 IRB340ASA

Product Manual IRB 340A 4

 Axis 2

Axis 2

Foldout 1
Axis 3
Axis 2

Axis 1

Foldout 2
Spare Parts

1.2 Manipulator base

Itm Qty Name Art. no. Remark

Manipulator base, complete 3HAC 2108-1

1 1 Basebox 3HAC 5354-1 White

2 3 Gear-motor unit, axis 1-3
3 Motor axis 1-3 3HAC 5226-1 White
3 Gear axis 1-3 3HAC 5228-1 White
3 6 Parallel pin, hardened 3HAC 3785-3
4 18 Plain washer 9ADA 312-8 10.5x20x2
5 18 Hex socket head cap screw 3HAB 3402-51 M10x30 8.8
Gleitmo 610
6 6 Distance screw 3HAC 3030-11 M8
7 3 Distance screw 3HAC 3030-12 M6
8 1 Sealing strip 3HAC 2989-1
9 30 ml Cyanoacrylate adhesive 1234 1919-37 Loctite 406
10 1 Transmission cover axis 1-3 3HAC 5153-1 White, Flex logo
11 1 Push-button 1SFA616100R1006 Black
12 1 Bracket SK 616 013-F
13 1 Membrane SK 615 503-2
14 1 Lamp unit 3HAC 4401-1 opt. 691
15 7 Hexagon head screw 9ADA 123-20 M6x12
16 3 Flange cover 3HAC 4250-1
17 3 Sealing ring 3HAC 3934-1 D=60/70 B=10
18 3 Flange gasket, axis 1-3 3HAC 4309-1
19 9 Hexagon head screw 9ADA 123-22 M6x16
20 1 Console 3HAC 4272-1
21 4 Connector bracket 3HAC 4232-1
22 1 Gearbox axis 4 3HAC 5093-1 IRB340A/ASA
1 Gearbox axis 4 3HAC 5124-1 Not IRB340A/ASA
1 Inductive switch 3HAC 6003-1
1 Motor-pin, axis 4 3HAC 5113-1
23 3 Plain washer 9ADA 312-6 6.4x12x1.6
24 3 Hex socket head cap screw 9ADA 183-25 M6x20 8.8
25 1 Back-up washer 3HAC 0110-1
26 1 Flange gasket axis 4 3HAC 5329-1
27 1 Jumper 3HAC 4298-1 Not IRB340A/ASA
28 1 Serial measurement board
with bracket 3HAB 3700-1 Not IRB340A/ASA

Product Manual IRB 340A 7

Spare Parts

29 5 Torx pan head screw 9ADA 618-44 M5x12 8.8

30 1 Power cable 3HAC 1761-1
31 1 Signal cable 3HAC 1762-1
32 1 Base cover gasket 3HAC 3399-1
33 1 Base cover 3HAC 5355-1 Orange
1 Base cover 3HAC 5356-1 White
34 1 Fan 3HAB 7311-1
35 1 Fan cable 3HAC 3196-1
36 2 Torx counters roll screw 9ADA 633-37 M4x25 8.8
37 1 Fan cover 3HAC 3029-1
38 6 Hexagon head bolt 9ADA 59-20 M8x50
39 3 Lifting eye 3HAC 3175-1
40 3 Upper arm 3HAC 2078-1
41 18 Hex socket head cap screw 3HAB 3409-29 M6x40 12.9 Gleitmo
610
42 3 VK-cover 3HAA 2166-21 D=68, B=8
43 1 Ventilation gasket 3HAC 3400-1
44 1 Top cover gasket 3HAC 3401-1
45 1 Gasket 3HAB 7957-1
46 1 Internal Air Tube 3HAC 7095-1 IRB340ASA
47 1 Internal Ventilation hose 3HAC 7108-1 IRB340A
48 2 Hose clip 3HAC 4428-1 D=73-83 IRB340A
49 17 Cable straps, outdoors 2166 2055-3 4.8x208
50 1 Earth symbol 3HAB 5617-1
51 1 Membrane SK 615 503-2 opt. 691
52 3 Sync. cover 3HAC 2094-1
53 3 Hex socket head cap screw 9ADA 183-34 M8x12 8.8
54 1 Label 3HAC 2151-1 Resolver values
55 10 ml Grease 3HAC 3262-1 Approved for
consumer goods
industry
56 1 Cover 3HAC 5330-1 Not IRB340A/ASA
57 1 Flange cover axis 4 3HAC 5328-1
58 1 Sealing ring with dust lip 3HAB 3701-2
59 6 Hexagon head screw 9ADA 123-20 M6x12
60 3 Hexagon head screw 9ADA 123-20 M6x12
61 18 Plain washer 9ADA 312-6 6.4x12x1.6

Product Manual IRB 340A 8

Spare Parts

63 1 Battery pack 4944 026-4 NiCd 7.2V 4Ah

Not IRB340A/ASA
64 2 Cable straps, outdoors 2166 2055-6 7.6x368
Not IRB340A/ASA
65 1 Instruction plate 3HAC 2589-1 Not IRB340A/ASA
66 7 Hexagon head screw 9ADA 123-20 M6x12
67 1 Signal Cable 3HAC 9880-1 Not IRB340A/ASA
68 1 Sync. Cable set 3HAC 9318-1

Product Manual IRB 340A 9

 Axis 1

Axis 3

Axis 2

Axis 1

Axis 2, 4

Axis 3

Axis 3

Axis 2

Axis 1

Foldout 3
 Axis 3

Axis 2

Axis 3

Axis 1

Axis 2

Axis 1

Foldout 4
 Axis 2, 4

Axis 1

Axis 3

Foldout 5
 Circuit Diagram

CONTENTS
Page

1 Manipulator, diagram 3HAC 10043-1, Rev. 0 ..............................................................101-106

Product Manual IRB 340

 List of contents

Product Manual IRB 340A

Product Manual IRB 340A
Connection point Locations
 Motor axis 1-3

Product Manual IRB 340A

 Axis 4

Product Manual IRB 340A

 Feed-Back Axis 1-4

Product Manual IRB 340A