Universal Robots UR-6-85-5-A User manual

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Service Manual for:
UR-6-85-5-A
Serial numbers from and including: 2010200093 (Robot Arm)
Version: 2011-R01

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Table of Contents
Background.......................................................................................................3
Purpose ............................................................................................................3
Lubricating joints using special grease ..................................................................4
Procedure ......................................................................................................4
Procedure ......................................................................................................7
Removing the joint gaskets ..............................................................................8
Assembling the joint......................................................................................10
Fitting the gaskets ........................................................................................12
Fitting the wires............................................................................................13
Replacing the tool flange...................................................................................14
Replacing the base plate...................................................................................15
Replacement of Encoder………………………………………………………………………………………………..17
Service on the fan filter ....................................................................................21
Spare parts list ................................................................................................22
Packing of the robot for shipment…………………………………………………………………………………24
Own Notices……………………………………………………………………………………………………………………25

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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 that 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.: [phone]
Fax [phone]
[e-mail]
www.universal-robots.com

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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.
Tools required:
Torx T10 screwdriver
Pressure lubrication press
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 3 joint –15 g of grease.
Replace the screw in the hole and
tighten to 0.6 Nm.
Throughly clean away any excess
grease.

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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.

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Replacement of robot joint
Size 1 joints are the three small joints that form the robot’s “hand joint”.
Size 3 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 på side: 18
Tools required:
5,5 mm open-ended spanner, flat model, e.g. USAG 250 N (Size 1)
7.0 mm open-ended spanner, flat model, e.g. USAG 250 N (Size 3)
Torx T10 screwdriver
Torque wrench with 5.5 mm or 7.0 mm jaw.
Steps required to replace a joint:
1. Disconnect the robot from the power supply
2. Remove the wires
3. Remove the gaskets
4. Loosen the screws
5. Disassemble the joint
6. Clean the surfaces
7. Adjust the length of the screws
8. Assemble the joint
9. 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.

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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:

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Removing the joint gaskets
The gaskets 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 a 5.5 mm spanner for a size 1 joint and
a 7 mm spanner for a size 3 joint.

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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.

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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 indicate whether the joints are turning correctly.

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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.

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Fitting the gaskets
Push the Teflon into place so that it covers the screws.
Fit the flatring into the seal by pulling carefully.

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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 protective cover, perform a reset and the robot is ready for
use.

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Replacing the tool flange
The tool flange, like other spare parts and tools, may be ordered from Universal
Robots.
Tools required:
5,5 mm open-ended spanner, flat model, e.g. USAG 250 N
Torx T10 screwdriver
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.
Connect the (connector) terminals as shown in the image below.
When fitting the tool flange on the joint, tighten the screws to 0.5 Nm and then to 1.0
Nm.

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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:
7.0 mm open-ended spanner, flat model, e.g. USAG 250 N
Torx T10 screwdriver
Torque wrench with a 7.0mm jaw.
The procedure for replacing the base plate 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 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.

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Check whether the wires have got caught up during assembly.
Tighten the screws in the base plate to 1.2 Nm initially and then to 2.4 Nm.

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Exchange of encoders:
Exchange of new encoder type
Fixture for Jointencoder size1.
Fixture for jointencoder size3.

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Encoder kit Joint size 1.
Encoder kit Joint size 3.

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Exchange of encoders
1. Disconnect power
2. Blue cap has to be removed
3. Dismounting of plugs
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 sensor is mounted on the new bracket.

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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.