Universal Robots e Series Replacement Manual

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Joint Replacement Manual

e-Series

Original instructions (en)

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Summary of Contents for Universal Robots e Series

Page 1 Joint Replacement Manual e-Series e-Series Original instructions (en)
Page 3 The information contained herein is the property of Universal Robots A/S and shall not be reproduced in whole or in part without prior written approval of Universal Robots A/S. The information herein is subject to change without notice and should not be construed as a commitment by Universal Robots A/S.
Page 4: Table Of Contents
Contents 1. General Information 1.1. Purpose 1.2. Company Details 1.3. Disclaimer 2. Intended Use 3. Safety 3.1. General 3.2. Warnings Symbols 3.3. Safety Message Types 3.4. General Warnings and Cautions 4. Lifting and Handling 5. Tool Kits 6. Torque Values 7. Replacing Robot Arm Joints 7.1. Disassembly Clamp Connection 7.2.
Page 5: General Information
1. General Information 1.1. Purpose The purpose of this manual is to help Universal Robots (UR) users and integrators to safely perform service-related operations and troubleshooting. Universal Robots industrial robots are designed using high quality components to ensure a long lifetime. However, improper use of a robot or robot parts can potentially cause failures.
Page 6 Universal Robots continues to improve reliability and performance of its products, and therefore reserves the right to upgrade the product without prior warning. Universal Robots takes every care that the contents of this manual are precise and correct but takes no responsibility for any errors or missing information.
Page 7: Intended Use
User Manual. Universal Robots robots are intended for industrial use, to handle tools/end effectors and fixtures, or to process or transfer components or products. All UR robots are equipped with safety functions, which are purposely designed to enable collaborative applications, where the robot application operates together with a human.
Page 8 UR robots or UR products. • Misuse is prohibited as the result could be death, personal injury, and /or property damage UNIVERSAL ROBOTS EXPRESSLY DISCLAIMS ANY EXPRESS OR IMPLIED WARRANTY OF FITNESS FOR ANY PARTICULAR USE.
Page 9 WARNING Do not modify the robot. Do not modify or alter e-Series end caps. A modification can create unforeseen hazards. All authorized disassembling and reassembling shall be done at a UR service center, or can be done according to the newest version of all relevant service manuals by skilled persons.
Page 10: Safety
It is essential to observe and follow all assembly instructions in the following sections of this manual. NOTICE Universal Robots disclaims any and all liability if the robot (arm Control Box with or without Teach Pendant) is damaged, changed or modified in any way.
Page 11: Warnings Symbols
3.2. Warnings Symbols Description Safety messages are used to emphasize important information. Read all the messages to help ensure safety and to prevent injury to personnel and product damage. The safety message types are defined below. WARNING Indicates a hazardous situation that, if not avoided, can result in death or serious injury.
Page 12 NOTICE Indicates the risk of damage to equipment and/or information to be noted. READ MANUAL Indicates more detailed information that should be consulted in the manual.
Page 13: Safety Message Types
3.3. Safety Message Types Description Safety messages are used to emphasize important information. Read all the messages to help ensure safety and to prevent injury to personnel and product damage. The safety message types are defined below. WARNING Indicates a hazardous situation that, if not avoided, can result in death or serious injury.
Page 14: General Warnings And Cautions
NOTICE Indicates the risk of damage to equipment and/or information to be noted. READ MANUAL Indicates more detailed information that should be consulted in the manual. 3.4. General Warnings and Cautions Description The following warnings messages can be repeated, explained or detailed in subsequent sections.
Page 15 WARNING Failure to adhere to the general safety practices, listed below, can result in injury or death. • Verify the robot arm and tool/end effector are properly and securely bolted in place. • Verify the robot application has ample space to operate freely.
Page 16 WARNING: HOT SURFACE Prolonged contact with the heat generated by the robot arm and the Control Box, during operation, can lead to discomfort resulting in injury. • Do not handle or touch the robot while in operation or immediately after operation. •...
Page 17 READ MANUAL Verify all mechanical and electrical equipment is installed according to relevant specifications and warnings.
Page 18: Lifting And Handling
4. Lifting and Handling Description The robot arms come in different sizes and weights, so it is important to use the appropriate lifting and handling techniques for each model. Here you can find information on how to safely lift and handle the robot.
Page 19: Tool Kits
5. Tool Kits Description When replacing robot arm parts, Universal Robots are always recommending using correct and calibrated tools. Universal Robots can also provide tool kit. Contact your local Universal Robots sales representative if you need to procure a tool kit.
Page 20: Torque Values
6. Torque Values Description CAUTION Always refer to the newest version of the service manual when disassembling and assembling any part of the robot arm and the control box. CAUTION Always use the specified torque values for the joint connections. CAUTION Click the torque tools 2-3 times before use to get the correct torque.
Page 21: Replacing Robot Arm Joints
For detailed information on how to safely perform service-related operations and troubleshooting, refer to the Universal Robots service manuals at universal- robots.com/download. For direct support, create a support ticket on our customer portal, MyUR @ https://myur.universal-robots.com/.
Page 22 Connectio There are two different ways the joints are assembled. Screw Connection Clamp Connection Head Torque Torque Head Size Size Torx 0.9Nm for +0,10Nm 4.0Nm +0.50Nm Hex key countersun -0.10Nm -0.50Nm k screws Torx 2.0Nm for +0.30Nm countersun -0.30Nm k screws...
Page 23 Robot Screw connection location Joints UR3e UR5e UR10e and UR16e Clamp connection location UR5e UR10e and UR16e...
Page 24: Disassembly Clamp Connection
7.1. Disassembly Clamp Connection Description These are the steps that you need to take to disassemble a clamp connection. Remove the screws in the blue lid, then remove the blue lid. Gently remove the power and communications wires from the terminals. Remove the black flat-ring.
Page 25 Support the joint as you remove the second side of the clamp. The joint is now loose and can be removed. Remember to pull the wires out as well.
Page 26: Assembly Clamp Connection
7.2. Assembly Clamp Connection Descri The assembly is done in reverse of the disassembly. However, a few things must be noted ption before assembly is begun. NOTICE Always replace the black flexible flat ring with a new one to maintain the IP classification. Replace the foam seal on the clamps if damaged to maintain the IP classification.
Page 27 CAUTION Joints should be assembled in a vertical position to ensure proper mating between the joints. Ensure the screws are inserted in the correct clamp. Only apply to early version of brackets where one side has a circular marker.
Page 28 When tightening the clamps, it must be done in steps. Do not exceed recommended torque: • Step 1: Tighten one side so there is a gap of 1.0mm to 1.5mm. • Step 2: Tighten the other side completely with 4.0Nm. +/- 0.50 Nm. •...
Page 29: Disassembly Screw Connection
7.3. Disassembly Screw Connection Remove the screws in the blue lid, then remove the blue lid. Description Gently remove the power and communications wires from the terminals. You can use a small flathead screwdriver to push-off the flat-ring. Then slide the flat-ring over the joint. Remove Teflon-ring.
Page 30 MANDATORY ACTION The joint can fall off if not supported when removing the screws. First remove the countersunk screws(a) then the remaining(b) screws. Note: Be very careful when removing the screws. Always use a correct sized, and undamaged screwdriver. The screw head slots can easily be stripped. The joint is now loose and can be removed.
Page 31: Assembly Screw Connection
7.4. Assembly Screw Connection Description The assembly is done in reverse of the disassembly. However, a few things must be noted before assembly is begun. NOTICE Remove old Loctite residue in the screw holes with a roll tap or forming tap (Size 2 M4 the rest M3) for threads before assembling the joint to get the correct torque on the new screws.
Page 32 Orient the joints according to the marks (indicated by red arrows in the image below) and gently push the two joints together. Insert and tighten the hex countersunk screws according to the image below. Do not exceed recommended torque. Example: 1, 2, 3 Insert and tighten the hex screws according to the image below.
Page 33 7. Replacing Robot Arm Joints Software Name: PolyScope 5 Software Version: 5.20 10.13.49 Document Version:...

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