Service Manual for: UR-6-85-5-A
Contents
1. Size 1 joint wrist 3 Screw set for one size 1 joint or tool 8 x RF M3 screws Tool complete Wire set for size 1 joint Wire set for size 3 joint Wire set for upper arm Wire set for lower arm Flatring for upper arm Flatring for Size 1 joint Flatring for Size 3 joint Fan filter for controller box Side 22 af 26 UR FK 2011 UNIVERSAL ROBOTS Tools Item number Item designation 09001 Open ended spanner 5 5mm USAG 250N 09002 Open ended spanner 7 0mm USAG 250N 09010 Torx screwdriver T10 09020 Torx spanner 10 09050 Torque wrench with 5 5 mm and 7 0 mm open ended spanners 09060 Nozzle for greasegun 09061 Greasenipple 00000 Fixtur for led Size 1 00000 Fixtur for led Size 3 Side 23 af 26 UR FK 2011 UNIVERSAL ROBOTS Packing of the UR robot Packing of robotic arm for shipment Use the program PUT INTO BOX which is on the controller Load the program Put_into_box2 urp on the controller Remove first screw in base press Continue Remove second screw in base press Continue The robot folds together hold a piece of bubble wrap between the pipe and surface 5 If the robot cannot run it is possible to pack it manually by removing the cap on the affected joints and trigger the brakes see illustration oY 6 Follow the packing instructions below Side 24 af 26 UNIVERSAL ROBOTS Side 25 af 26 UR FK 2011 UNIVERSAL ROBOTS Own notes Side 26 af 26 UR FK 20112. 250 N Size 1 e 7 0 mm open ended spanner flat model e g USAG 250 N Size 3 e Torx T10 screwdriver e Torque wrench with 5 5 mm or 7 0 mm jaw Steps required to replace a joint Disconnect the robot from the power supply Remove the wires Remove the gaskets Loosen the screws Disassemble the joint Clean the surfaces Adjust the length of the screws Assemble the joint i oa as Tighten the screws 10 Fit the gaskets 11 Fit the wires 12 Reset the robot joint The tool flange and base plate are usually replaced when the joint is replaced as the assembly method is the same for all joint assemblies in the robot Special precautions to be taken when replacing the tool flange and base plate are described at the end of this manual Side 6 af 26 UR FK 2011 UNIVERSAL ROBOTS Procedure The robot must always be disconnected from the power supply before any work is carried out on the robot s mechanical components Turn off the robot using the touch screen and remove the plug from the socket supplying the robot Remove the blue plastic cover on the joint using a Torx T10 screwdriver spanner Removing the wires Remove the live wire connector with red and black wire and the BUS wire green connector with black and white wire from their respective connection terminals in the joint Size 1 Size 3 Side 7 af 26 UR FK 2011 UNIVERSAL ROBOTS Removing the joint gaskets The gaskets
3. between the joints both on size 1 and size 3 joints is a flatring made of rubber Carefully remove it by pulling them out using a small screwdriver and then rolling the gaskets away from the assembly with your fingers The Teflon ring can then be pushed up into the joint providing access to the screws holding the joint together Remove the M3 screw for grease filling Loosen all screws 8 x M3 for size 1 and 10 x M4 for size 3 by approximately two turns using an open ended spanner use 5 5 mm spanner for a size 1 joint and 7 mm spanner for a size 3 joint Side 8 af 26 UR FK 2011 UNIVERSAL ROBOTS Disassemble the joint by rotating the joints in opposite directions and pulling them away from one another The screw assembly is shown here on a separated joint in order to show the screw tracks which are the reason why the joints have to be rotated in order to separate them Before fitting the new joint clean the surfaces of dirt and grease Side 9 af 26 UR FK 2011 UNIVERSAL ROBOTS Assembling the joint Before assembling the joints take the flatring which are to be fitted in the seal and push it over the joint We recommend fitting new gaskets See the spare parts list on page 18 for item numbers Adjust the length of the screws so that they stick out by 10 11 mm including washers Assemble the joint by pushing the screws through the screw tracks The grease filling holes will indica
4. Tools required e Torx T10 screwdriver e Pressure lubrication press e Heavy duty gloves Procedure To top up the grease remove the M3 screw between the cover and the contacting surface of the robot joint Use a pressure gun to insert grease in the hole thereby distributing it to the gear Top up as follows for every 10 000 hours of operation Each size 1 joint 3 5 g of grease Each size joint 15 g of grease Replace the screw in the hole and tighten to 0 6 Nm Throughly clean away any excess grease Side 4 af 26 UR FK 2011 UNIVERSAL ROBOTS Please note that there should be no grease in the screw holes closest to the robot s upper arm and lower arm tubes Screw x2 on the upper arm not suitable for topping up grease Screw on the lower arm not suitable for topping up grease Side 5 af 26 UR FK 2011 UNIVERSAL ROBOTS Replacement of robot joint Size 1 joints are the three small joints that form the robot s hand joint Size joints are the three large joints that form the robot s elbow shoulder and base Size 1 and size 3 joints like other spare parts and tools may be ordered from Universal Robots IMPORTANT Please indicate which joint is being replaced when ordering The joints are pre programmed and must be fitted to the robot in a specific position Se reservedelsliste med varenumre pa side 18 Tools required e 5 5 mm open ended spanner flat model e g USAG
5. UNIVERSAL ROBOTS Service Manual for UR 6 85 5 A Serial numbers from and including 2010200093 Robot Arm Version 2011 RO1 Side 1 af 26 UR FK 2011 UNIVERSAL ROBOTS Table of Contents Pa KOUN LEE MEE E SEE E E ESSENS Lubricating joints using special PROCCO UNG PROCCOUIS Removing the joint gaskets Assembling the JOINC c cc ecccceeeeecccssccccccueeneeeereeeeeeenseeeeeguennaaenresgs Fitting the gaskets PIECING WINGS VE Replacing the tool Fange Replacing the base Replacement OF ECOG EF Service the fan AE EDER ERE Spare REE Packing of the robot for SHIDIMEG I Criiciwnisiinscraceccdatnndanniveaserbdadievntisedessnsswdsenaiamedentouss OWN NOTICO S EPE EA EA EA Side 2 af 26 ee 17 UR FK 2011 UNIVERSAL ROBOTS Background Universal Robots Industrial Robots are a quality product designed and produced in Denmark by highly qualified technicians and engineers The robot has a service interval of 7 000 to 10 000 hours of operation At this point it should be lubricated with new grease Different circumstances may mean t
6. hat it is necessary to service the robot sooner than the interval indicated above For example the robot may have been overloaded on an overrun or it may have been dropped on the floor when relocating or have run with a load not recommended by Universal Robots Purpose The purpose of this Service Manual is to help the reader perform general servicing and replace defective components in the robot Universal Robots recommends that you do not attempt repair adjustment or other intervention in the mechanical or electrical systems of the robot Any unauthorised intervention will invalidate the guarantee In the event of a defect Universal Robots recommends ordering a new component from the Universal Robots dealer who supplied the robot Alternatively you can order from your nearest dealer whose details you can obtain by contacting Universal Robots at the following address Universal Robots ApS Svendborgvej 102 DK 5260 Odense Denmark Tel 45 89 93 89 89 Fax 45 38 79 89 89 Sales universal robots com WWW Universal robots com Side 3 af 26 UR FK 2011 UNIVERSAL ROBOTS Lubricating joints using special grease To ensure that the gears function correctly and have the optimum life only special grease supplied by Universal Robots must be used This special grease is manufactured by Harmonic Drive AG specifically for use in the gears Special grease like other spare parts and tools may be ordered from Universal Robots
7. r is mounted on the new bracket Side 19 af 26 UR FK 2011 UNIVERSAL ROBOTS Fixture is to be put on so the correct distance is achieved tighten the screws but not too much Tighten Hexagonscrews 5 NM remove fixture mount aluplate and blue cap Then the joint s that have had new encoder must be reset have new firmware update and be initialized The manual for resetting the robot is available on the UR Support page Side 20 af 26 UR FK 2011 UNIVERSAL ROBOTS Service on the fan filter In exposed factory environments it may be need to clean or replace fan filter of the controller box Pull out the plastic of the filter to snap it off Change the filter or use a compressor to clean it See list of spare parts Side 21 af 26 UR FK 2011 Spare parts list Item number 08001 03011 03013 04101 04103 02050 02031 02032 02033 03003 02011 02012 02013 03001 02040 04050 04051 04041 04042 03105 03106 03306 07753 UNIVERSAL ROBOTS Item designation Flexolub grease 1 kg Screw for grease hole size 1 joint Screw for grease hole size 3 joint Plastic cover for size 1 joint includes screws and gaskets Plastic cover for size 3 joint includes screws and gaskets Base plate complete with 6 metres of cable and connectors Size 3 joint Base Size 3 joint Shoulder Size 3 joint Elbow Screw set for one size 3 joint 10 x RF M4 screws Size 1 joint wrist 1 Size 1 joint wrist 2
8. s for replacing a joint see page 8 The robot must always be disconnected from the power supply before any work is carried out on the robot s mechanical components Turn off the robot using the touch screen and remove the plug from the socket supplying the robot When the base plate is fitted to the joint it is important that the wires are not caught up Connect the connector terminals as shown in the image below If necessary rotate the base plate one whole turn in relation to the joint in order to make the wires twist and so be positioned in the middle under the tool flange when it is fitted on the joint Side 15 af 26 UR FK 2011 UNIVERSAL ROBOTS Tighten the screws in the base plate to 1 2 Nm initially and then to 2 4 Nm Side 16 af 26 UR FK 2011 UNIVERSAL ROBOTS Exchange of encoders Exchange of new encoder type Fixture for Jointencoder sizel Fixture for jointencoder size3 Side 17 af 26 UR FK 2011 UNIVERSAL ROBOTS Encoder kit Joint size 1 Encoder kit Joint size 3 Side 18 af 26 UR FK 2011 UNIVERSAL ROBOTS Exchange of encoders 1 Disconnect power 2 Blue cap has to be removed 3 Dismounting of plugs F Dismantle encoder The bracket that the encoder is mounted on Is replaced with the new type Remove hub with encoder disk Mount New hub mount new encoder disk Shim End slices is to be mounted with UR marks up Encoder senso
9. te whether the joints are turning correctly Side 10 af 26 UR FK 2011 UNIVERSAL ROBOTS It is important that the washers are also pushed through otherwise the joints may not rotate into place The grease filling holes must be properly aligned once the joints have been rotated into position There is a guide groove opposite the grease filling section and it is important that this groove falls into place when the joints are rotated into position Tighten the screws alternately a little at a time until all screws are tightened to the torque set out below Size 1 tighten screws to 0 5 Nm and then 1 0 Nm Size 3 tighten screws to 1 2 Nm and then 2 4 Nm A special torque wrench is recommended for this procedure see the spare parts list on page 18 for item number Side 11 af 26 UR FK 2011 UNIVERSAL ROBOTS Fitting the gaskets Push the Teflon into place so that it covers the screws Fit the flatring into the seal by pulling carefully Side 12 af 26 UR FK 2011 UNIVERSAL ROBOTS Fitting the wires Fit the wires as shown in the image Size 1 Insert the white connector with the red and black live wire into the pin on the circuit board Insert the green communications connector into the pin on the circuit board Size 3 Insert the red and black live wire on the spade lug on the circuit board Insert the green communications connector into the pin on the circuit board Replace the blue plastic protecti
10. ve cover perform a reset and the robot is ready for use Side 13 af 26 UR FK 2011 UNIVERSAL ROBOTS Replacing the tool flange The tool flange like other spare parts and tools may be ordered from Universal Robots Tools required e 5 5 mm open ended spanner flat model e g USAG 250 N e Torx T10 screwdriver e Torque wrench with a 5 5mm jaw The procedure for replacing the tool flange is the same as for replacing a joint see page 8 The robot must always be disconnected from the power supply before any work is carried out on the robot s mechanical components Turn off the robot using the touch screen and remove the plug from the socket Supplying the robot When the tool flange is fitted to the joint it is important that the wires are not caught up If necessary rotate the tool flange one whole turn in relation to the joint in order to make the wires twist and so be positioned in the middle under the tool flange when it is fitted on the joint When fitting the tool flange on the joint tighten the screws to 0 5 Nm and then to 1 0 Nm Side 14 af 26 UR FK 2011 UNIVERSAL ROBOTS Replacing the base plate The base plate including 10 metres of cable like other spare parts and tools may be ordered from Universal Robots Tools required e 7 0 mm open ended spanner flat model e g USAG 250 N e Torx T10 screwdriver e Torque wrench with a 7 0mm jaw The procedure for replacing the base plate is the same a
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