Service Bulletins, Volume 1

Transcription

1 Remote Systems Products Service Bulletins, Volume 1 For Manipulator Systems, Slave Arms,& Accessories Bulletins issued through January 14, 2005 DOCUMENT NO

2 PAGE BREAK (make Page Break) - SCHILLING ROBOTICS SCHILLING ROBOTICS, the SCHILLING ROBOTICS logo, and their frameworks are trademarks and service trademark applications of SCHILLING ROBOTICS. Other names mentioned, registered or not, are the property of their respective companies. We invite your comments about our products and technical manuals. Please contact us using the information shown below. Schilling Robotics 201 Cousteau Place Davis, CA Telephone: (530) Fax: (530) Web Site: sales@schilling.com service@schilling.com

3 Table of Contents Service Bulletin ISSUE DATE: January 17, 1996 AFFECTED PRODUCT(S) Titan 7F and Titan 2 Manipulator Systems, all serial Numbers AFFECTED COMPONENT Relief Valves for Hydraulic Return Lines SERVICE ISSUE Schilling Robotics has recently received several reports of manipulator system failures that occurred when the hydraulic return lines of Titan 2I and Titan 7F systems were subjected to pressures exceeding their maximum designed back pressures (Titan 2 = 1000 psi max./ Titan 7F = 50 psi, max.). Service Bulletin ISSUE DATE: August 12, 1996 AFFECTED PRODUCT(S) Titan 3, all serial Numbers AFFECTED COMPONENT Parker elbow fitting, hydraulic, SRS P/N , , SERVICE ISSUE When some Parker fittings were manufactured, the washer was not swaged properly, allowing a small radial gap between the inner diameter of the washer and the outer diameter of the fitting. In a high-pressure application, the o-ring may be extruded through this gap and allow fluid to leak out. Service Alert ISSUE DATE: August 20, 1996 AFFECTED PRODUCT(S) All Titan 3 slave arms and Titan 2 slave arms with a single-part shoulder clevis AFFECTED COMPONENT Shoulder Clevis Attachment Bolts, Part Number Page 3 of 10

4 SERVICE ISSUE When the Titan shoulder joint is overloaded, the bolts that attach the shoulder clevis to the azimuth housing (shown in Figure 1) may either break or have their threads stripped. Service Alert ISSUE DATE: January 31, 1997 AFFECTED PRODUCT(S) Rate manifolds , , , and AFFECTED COMPONENTS SERVICE ISSUE Each hydraulic rate manifold contains two-function modules that are fastened together to form a manifold with four, six, eight, or ten functions. Each two-function module has a clear lid (called a lens) that is sealed by an o-ring. If the o-ring is not properly installed, it may be pinched and damaged when the lens is fastened to the manifold module, causing the module to leak. SERVICE PROCEDURE Issue Date October 1997 Product All position manipulators using the master controller or master consolette Servicing Issue Editing the master controller memory, as directed by SRS service personnel, is sometimess necessary to meet specific custom installation requirements. SERVICE DIRECTIVE Issue Date 10/1/98 Product type Titan III Servicing Issue Schilling Robotics has identified a potential for damage to or failure of the pitch and yaw actuators on certain Titan III manipulator systems. Affected systems Titan III manipulator systems with the following serial numbers: SERVICE DIRECTIVE Page 4 of TOC

5 Issue Date September 1997 Product All Conan manipulators operated in sea water Servicing Issue Difficulty removing pivot pins from joints. SERVICE BULLETIN Shortening the Orion Extension Hoses The procedure for cutting the extension hoses and installing the reusable fittings is described below. Skip this section if you will be using full-length hoses. SERVICE BULLETIN Issue Date March 1999 Product Titan II and Titan III Servicing Issue Continuity Error Checking SERVICE PROCEDURE Issue Date March 1999 Product Titan II and Titan III Servicing Issue Continuity Error Threshold Adjustment SERVICE DIRECTIVE Issue Date Product Rate Manifolds supplied before July, This Service Directive does not apply to rate manifolds supplied after July, Servicing Issue Rate manifold pin plug corrosion SERVICE UPDATE Issue Date Product Conan 7R Servicing Issue Improved documentation for older Conan wrists ( ) used with the upgrade wrist base TOC Page 5 of 10

6 ( Install attached documents in Conan 7R technical manuals supporting Conan 7R models using wrist with P/N SERVICE BULLETIN ISSUE DATE September 1, 2000 PRODUCT Orion 7P Manipulator Systems COMPONENT Filter Block, P/N , a component of the Orion 7P Slave Controller SERVICE ISSUE In October of 1998, the Orion 7P slave controller filter block was modified to accept a change to the filter made by the filter manufacturer. We have determined that this change compromises the integrity of the part. TECHNICAL BULLETIN ISSUE DATE: April 27, 2001 PRODUCT Orion 7P Manipulator Systems BULLETIN We have determined that the in-line relief valve fitted on the hydraulic hoses leading to the pitch actuators is not necessary and will not be fitted to future Orion manipulators systems. SERVICE BULLETIN ISSUE DATE: November13, 2002 PRODUCT Titan III, Orion, Conan, and RigMaster Slave Arms and Manipulator Systems COMPONENT Jaw bolts SERVICE ISSUE Breaking jaw bolts SERVICE BULLETIN ISSUE DATE: January 28, 2003 PRODUCT Titan II and Titan III Manipulator Systems COMPONENT Slave Cable NEW SERVICE IINFORMATION A molded, highly flexible slave arm cable ( ) with 79 pin Glenair connectors is cur- Page 6 of TOC

7 rently supplied for Titan 2 and Titan 3 manipulator systems. To get the best performance and longest life from these cables, follow the recommendations below: SERVICE ADVISORY ISSUE DATE: July 7, 2003 TITLE Preventing Slave Controller Corrosion and Flooding PRODUCT Titan 2 and Titan 3 Manipulator Systems COMPONENTS Slave controller bottles (and other aluminum components with stainless steel caps, plugs, or connectors) ADVISORY Even though the 6061-T6 aluminum slave controller bottle is hard-anodized to provide corrosion resistance in subsea environments, localized galvanic cells between the aluminum cover plate and the stainless steel connectors, plugs, penetrators, and fasteners can cause corrosion and pitting of the aluminum (see photo, below). SERVICE BULLETIN ISSUE DATE: 15 September, 2003 PRODUCT All Conan Rate Slave Arms & Manipulator Systems COMPONENT Linear Actuator, 1.75 x 2.6-in stroke, P/N , found in slave arm pitch and yaw assemblies SERVICE ISSUE The 1/2-20 x 2 1/4-in. fasteners ( ) securing the small actuators ( ) in the pitch and yaw functions may come loose when working at full capacity for extended periods (see Figure 1). Should the fasteners come loose, there is the possibly of a hydraulic fluid leak. Service Bulletin ISSUE DATE: 14 November, 2003 AFFECTED PRODUCT(S) Titan 2 and Titan 3 Manipulator Systems AFFECTED COMPONENT Slave Cable SERVICE ISSUE A slave cable that is secured too tightly can cause conductor failure TOC Page 7 of 10

8 Service Bulletin ISSUE DATE: February 20, 2004 AFFECTED PRODUCT(S) Quest ROV Systems 1 through 5 AFFECTED COMPONENTS - Valve Pack and Quest Orion 7P Manipulator System Slave Controller Unit SERVICE ISSUE The Seanet penetrator on the valve pack and Orion slave controller unit can be forced out of its shell by compensation pressure when the SeaNet cable is disconnected (see figure, right). Field Service Instruction ISSUE DATE: July 15, 2004 AFFECTED PRODUCT Titan 3 Manipulator Systems AFFECTED COMPONENTS Pitch/Yaw Actuator , Pitch/Yaw Assembly PURPOSE OF INSTRUCTION This instruction describes the process for reducing the torque to the torque ring setscrews in the pitch and yaw actuators. The purpose is to increase actuator safety margins and greatly reduce the risk of actuator failure. Service Bulletin ISSUE DATE: December 22, 2004 AFFECTED PRODUCTS All Orion 7P systems AFFECTED COMPONENT Roll actuator sensor cable SERVICE INFORMATION A compensation bleedscrew has been added to the upper fitting on roll actuator sensor cable (see Figure 1). This new cable is installed on all new Orion 7P manipulator systems. Although it is NOT necessary to bleed this cable, the bleedscrew addresses operator service policies that require bleeding all compensated cables. Service Bulletin ISSUE DATE: January 14, 2005 AFFECTED PRODUCT(S) Titan 2, 3, and 4 Manipulator Systems AFFECTED COMPONENT Titan Slave Arm SERVICE INFORMATION Page 8 of TOC

9 If you suspect that water has entered the Titan slave arm compensation system, or if WA- TER* appears in the top dashed line of the display (Titan 4 only), take quick action as described below to minimize damage TOC Page 9 of 10

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11 Service Bulletin Remote Systems Products ISSUE DATE: January 17, 1996 Damage possible when return line exceeds rated pressure Compliance: Recommended* AFFECTED PRODUCT(S) Titan 7F and Titan 2 Manipulator Systems, all serial Numbers AFFECTED COMPONENT Relief Valves for Hydraulic Return Lines SERVICE ISSUE Schilling Robotics has recently received several reports of manipulator system failures that occurred when the hydraulic return lines of Titan 2I and Titan 7F systems were subjected to pressures exceeding their maximum designed back pressures (Titan 2 = 1000 psi max./ Titan 7F = 50 psi, max.).!caution If manipulator system hydraulic return is obstructed for any reason, or if a hydraulic supply is accidentally applied to the hydraulic return lines, THE SLAVE ARM WILL BE DAMAGED. FIELD ACTION To avoid this potential for damage, SRS has determined that an in-line hydraulic relief valve can be added to the return line near the slave arm base. This valve is designed to relieve pressure from the return circuit if pressure exceeds psi. For the Titan 7F, the relief valve must be adjusted so that it relieves pressure at psi. SRS feels that all installations of Titan II and Titan 7F manipulator systems can benefit from adding this relief valve. The part number for the relief valve is , and the price is $ The valve is supplied with -6 JIC fittings. *BULLETIN COMPLIANCE LEVELS REQUIRED Field action is REQUIRED and critical for personnel safety, equipment functionality, and/or continuation of warranty coverage. Field action is not REQUIRED but is highly RECOMMENDED and will result in significantly RECOMMENDED increased levels of personnel safety and/or equipment functionality. OPTIONAL Field action may be useful under certain circumstances. Compliance is OPTIONAL and left to the discretion of the owner/operator. Bulletin contains information to assist the owner/operator in more effective operation or INFORMATIONAL service of the product. Compliance is not rated. If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@tde.alstom.com Service Bulletin Page 1 of 2

12 This page not used. Page 2 of 2 Service Bulletin

13 Service Bulletin Remote Systems Products ISSUE DATE: August 12, 1996 Loose washer in Parker fitting may cause o-ring extrusion and leaks Compliance: Recommended* AFFECTED PRODUCT(S) Titan 3, all serial Numbers AFFECTED COMPONENT Parker elbow fitting, hydraulic, SRS P/N , , SERVICE ISSUE When some Parker fittings were manufactured, the washer was not swaged properly, allowing a small radial gap between the inner diameter of the washer and the outer diameter of the fitting. In a high-pressure application, the o-ring may be extruded through this gap and allow fluid to leak out. In Titan 3 slave arms, the failure of a Parker fitting in the upper arm may cause a high pressure leak into the wireway compensation system and damage manipulator components. FIELD ACTION First, Titan III slave arms with dry (uncompensated) wireway compensation systems should have a relief valve, with a 40 psi cracking pressure, installed to the wireway compensation port on the azimuth lid. This will protect the wireway compensation system from high pressure leaks, regardless of their source. Second, defective Parker fittings should be replaced. To determine if a fitting is defective, loosen the nut above the washer until the washer is unloaded. The washer should be tight around the outer diameter of the fitting. It is acceptable for the washer to slide along the length of the unthreaded area. However, If you detect any radial play between the inner diameter of the washer and the outer diameter of the fitting, the fitting should be replaced. If you have a defective fitting, contact SRS Customer Service. We will provide a replacement fitting at no charge. As an alternative, contact your local Parker Hydraulics supplier to obtain a *BULLETIN COMPLIANCE LEVELS REQUIRED Field action is REQUIRED and critical for personnel safety, equipment functionality, and/or continuation of warranty coverage. Field action is not REQUIRED but is highly RECOMMENDED and will result in significantly RECOMMENDED increased levels of personnel safety and/or equipment functionality. OPTIONAL Field action may be useful under certain circumstances. Compliance is OPTIONAL and left to the discretion of the owner/operator. Bulletin contains information to assist the owner/operator in more effective operation or INFORMATIONAL service of the product. Compliance is not rated. If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@tde.alstom.com Service Bulletin Page 1 of 2

14 replacement fitting. The Parker part number for the 90 fitting is 4-C50X-SS, and 4-V50X-SS for the 45 fitting. Page 2 of 2 Service Bulletin

15 Service Alert Remote Systems Products ISSUE DATE: August 20, 1996 New bolt in shoulder clevis reduces damage from overload condition Compliance: Recommended* AFFECTED PRODUCT(S) All Titan 3 slave arms and Titan 2 slave arms with a single-part shoulder clevis AFFECTED COMPONENT Shoulder Clevis Attachment Bolts, Part Number SERVICE ISSUE When the Titan shoulder joint is overloaded, the bolts that attach the shoulder clevis to the azimuth housing (shown in Figure 1) may either break or have their threads stripped. Schilling Robotics has determined that the preferred failure mode is for the bolts to break, since the remaining portion of the bolt can usually be unthreaded from the azimuth stator and a new bolt can be installed. If the threads are stripped, the stator vane may be damaged, requiring the azimuth to be disassembled and the stator vane replaced. FIELD ACTION SRS has determined that if a longer fastener is installed in the clevis, it is more likely that joint overload will result in broken bolts rather than stripped threads. (Note that using longer bolts will not increase the threshold at which failure occurs, but only produces a preferable failure outcome.) SRS will supply replacement bolts to all Titan 3 customers, and will make the bolts available for Titan 2 slave arms that have a single-piece shoulder clevis. SR will also supply a special torque adapter to tighten the bolts to the required torque, since there is limited clearance for a standard socket wrench. To determine whether you need replacement bolts, look for identifying information on the bolt head. The shorter bolts (SRS part number ) are identified by NAS 6406U12; the longer bolts (SRS part number ) are identified by NAS 6406U14. *BULLETIN COMPLIANCE LEVELS REQUIRED Field action is REQUIRED and critical for personnel safety, equipment functionality, and/or continuation of warranty coverage. Field action is not REQUIRED but is highly RECOMMENDED and will result in significantly RECOMMENDED increased levels of personnel safety and/or equipment functionality. OPTIONAL Field action may be useful under certain circumstances. Compliance is OPTIONAL and left to the discretion of the owner/operator. Bulletin contains information to assist the owner/operator in more effective operation or INFORMATIONAL service of the product. Compliance is not rated. If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@tde.alstom.com Service Bulletin Page 1 of 2

16 If you need replacement bolts and do not receive them within two weeks of receiving this notice, please contact the SRS Customer Service Department and refer to Service Alert number Page 2 of 2 Service Bulletin

17 Service Alert Remote Systems Products ISSUE DATE: January 31, 1997 Replacing lens o-ring on 2-function manifold modules Compliance: Recommended* AFFECTED PRODUCT(S) Rate manifolds , , , and AFFECTED COMPONENTS Two-function manifold modules , , , and SERVICE ISSUE Each hydraulic rate manifold contains two-function modules that are fastened together to form a manifold with four, six, eight, or ten functions. Each two-function module has a clear lid (called a lens) that is sealed by an o-ring. If the o-ring is not properly installed, it may be pinched and damaged when the lens is fastened to the manifold module, causing the module to leak. FIELD ACTION The o-ring under the lens can be replaced with another o-ring (part number ) that is easier to install and therefore less likely to be pinched and damaged. If a rate manifold module is not leaking, you do not need to replace the lens o-ring. If the module is leaking, or if you remove the lens o-ring for any reason, replace the o-ring with part number To replace the lens o-ring, follow the steps below. It is not necessary to remove the two-function module from the rate manifold to replace the o-ring. 1. Disable hydraulic power to the slave arm and/or other equipment controlled by the rate manifold. 2. Disable power to the manifold controls. *BULLETIN COMPLIANCE LEVELS REQUIRED Field action is REQUIRED and critical for personnel safety, equipment functionality, and/or continuation of warranty coverage. Field action is not REQUIRED but is highly RECOMMENDED and will result in significantly RECOMMENDED increased levels of personnel safety and/or equipment functionality. OPTIONAL Field action may be useful under certain circumstances. Compliance is OPTIONAL and left to the discretion of the owner/operator. Bulletin contains information to assist the owner/operator in more effective operation or INFORMATIONAL service of the product. Compliance is not rated. If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@tde.alstom.com Service Bulletin Page 1 of 2

18 3. For submersible models only, disconnect or otherwise isolate any compensation applied to the manifold. 4. Remove the eight socket-head cap screws and washers from the top of the manifold module. 5. Remove the strongback (the metal frame) and the clear lens that were secured by the sockethead cap screws. Remove and discard the o-ring in the lens groove. 6. Install the new o-ring (part number ) into the lens groove. Apply a light coat of o- ring lubricant to the o-ring; we recommend using Dow Corning <D> 55. Place the lens back into the manifold module. 7. Place the strongback over the lens. 8. Put the washers over the shafts of the socket-head cap screws, and install the screws into the strongback. (A small gap between the strongback and the lens is normal, since the strongback does not compress the lens.) Torque the socket-head cap screws to 30 in-lb. 9. Repeat the steps above as required for all two-function modules in the rate manifold. 10. For submersible models only: Reconnect the compensation applied to the manifold and purge air from the system. Refer to your manifold manual for startup procedures. 11. Modify the part lists in the manifold manual for all manifold modules to change the lens o- ring part number (item 18) from to If you need replacement o-rings and do not receive them within two weeks of receiving this notice, please contact the SRS Customer Service Department and refer to Service Bulletin number Page 2 of 2 Service Bulletin

19 AUTOMATION Schilling Robotics SERVICE PROCEDURE ISSUE DATE October 1997 PRODUCT SERVICING ISSUE SERVICING DIRECTIVE All position manipulators using the master controller or master consolette Editing the master controller memory, as directed by SRS service personnel, is sometimess necessary to meet specific custom installation requirements. This Service Procedure describes the general steps that should be followed to access and edit master controller memory. The Memory Edit function allows you to directly access master controller memory locations. You can view any memory location and set values in RAM or EEPROM that test or change the manipulator system operation. This function is used only to modify factory and default settings. WARNING!!! WARNING: Do not use the Memory Edit function without specific instructions from the manufacturer. Do not use this menu while slave arm hydraulics are enabled, since system operation could be affected. To display the MEMORY EDIT menu, follow these steps: 1. Ensure that the privilege level is higher than 0. If you aren t sure what the current level is, display the SET LEVEL menu and note the level displayed on the screen (see the Operation chapter of your technical manual for details). Change to a higher privilege level if necessary. 2. From the MAIN menu, select 3> SETUP. The SETUP menu will appear. 3. From the SETUP menu, select 5> MEMORY. The MEMORY EDIT menu will appear (see below).

20 SERVICE DIRECTIVEPage 2 of 4 The text [0:0000-FFFF] displays, in hexadecimal notation, the address and word of data at that address. The numerals 0:0000 represent the segment and offset of the address. The segment (the character before the colon) indicates which block of memory is being viewed. The segment values are given in the table below for the various memory types. (For example, to access EEPROM memory, set the segment value to 5.) The RAM, EEPROM, and EPROM memory blocks can all be viewed, but the values in the EPROM range cannot be changed. The 8255, 8256_main, and 8256_aux blocks represent interface integrated circuits mapped as memory, and should generally not be viewed. The four characters following the segment digit and the colon represent a memory address for the current segment or memory type. This address is valid only if it is within the actual range of the given memory type. These ranges are listed in the table below. Memory Type Segment Offset Range Type RAM FFF (8K) 8255 (Analog) _aux 4 EEPROM FF (2K) 8256_main 6 EPROM (ROM) FFF/7FFF (16/32K)

21 SERVICE DIRECTIVEPage 3 of 4 The last four characters represent the value currently stored at the displayed memory location. The value shown is a two-byte (16-bit) number. If you want to view a one-byte (8-bit) number, only the rightmost half of the word will represent the desired byte value. While in the MEMORY EDIT menu, you can edit the address shown on the screen. The cursor (^) indicates which numeral is currently selected for editing. Move the cursor to the right or left using the RT or LF key until the cursor appears below the desired number. Increment or decrement the numeral at the cursor location by using the UP or DN keys, respectively. As the address is altered, the actual memory value for the new location is displayed. Remember that the address offset for each memory block must remain within its legal range to be valid. The memory word at the displayed address can be edited and saved using the Edit function. This function is normally OFF, but can be enabled by pressing 1> EDIT. When the Edit function is enabled, the text beside 1> EDIT will change to display the current memory word with the cursor located beneath the first byte. The memory word is edited in the same way as the address value. The word can be edited in either hexadecimal or decimal notation. To edit in hexadecimal notation, enter changes to the four-digit memory word immediately to the right of the 1> EDIT notation. To edit in decimal notation, use the RT key to bypass the four-digit hexadecimal entry location, and edit the five-digit decimal entry location in parentheses (-00000). The cursor indicates which numeral is currently selected for editing. Move the cursor to the right or left using the RT or LF key until the cursor appears below the desired number. Increment or decrement the numeral at the cursor location by using the UP or DN keys, respectively. Save the edited word by pressing 1> EDIT again. The changed word will appear next to the displayed address, and the cursor will move back to the first numeral of the memory address. The displayed memory word is normally read and displayed only when you enter the MEMORY EDIT menu, when the address is changed, or when a memory word is changed. This word can be continuously displayed (and updated as it changes) if the 2> VIEW function is set to ON. (Press 2> VIEW to toggle the View function between ON and OFF.) If the View function is ON, the memory address and data word will appear in all menus at the same screen location. You can remove the address and word display by entering the MEMORY EDIT menu and setting 2> VIEW to OFF. When you are done editing memory locations, press 8> EXIT to exit the memory edit menu. Changes to RAM locations will take effect immediately, but will be lost when the master controller is rebooted. Changes to EEPROM locations will be permanent (until changed again using the process in this section), but will not take effect until you reboot the master controller. To reboot the master

22 SERVICE DIRECTIVEPage 4 of 4 controller, shut down the slave arm, then power the master controller off and on again. IMPORTANT: You must reboot the master controller before changes to EEPROM locations will take effect. QUESTIONS If you have any questions about this Service Directive, contact the SRS Customer Service Department at Document P/N:

23 SERVICE DIRECTIVE ISSUE DATE 10/1/98 PRODUCT TYPE Titan III SERVICING ISSUE Schilling Robotics has identified a potential for damage to or failure of the pitch and yaw actuators on certain Titan III manipulator systems. The initial symptom is a loss of power in these actuators. Continued operation of the manipulator system after this symptom is noted will result in damage to components and to failure of the actuators. It is essential that preventive service measures be taken as soon as possible to all systems with the serial numbers listed below, even if the initial symptom is not present. AFFECTED SYSTEMS Titan III manipulator systems with the following serial numbers: SERVICE DIRECTIVE If loss of power in the pitch or yaw actuator is noted, remove the manipulator system from service immediately. Corrective service requires that the actuators be removed from the manipulator. The bolts attaching the vane to the driveshaft must be replaced with high-strength fasteners and torqued as specified. This service must be performed by qualified personnel. Schilling Robotics or an authorized service agent will contact you and arrange the best way to perform this service with minimal disruption of your operations. QUESTIONS If you have any questions about this Service Directive, contact the Customer Service Department at DRAFTPage 1 of 2

24 Page 2 of DRAFT

25 SERVICE DIRECTIVE ISSUE DATE September 1997 PRODUCT SERVICING ISSUE SERVICING DIRECTIVE All Conan manipulators operated in sea water Difficulty removing pivot pins from joints. The Conan manipulator arm segments are made of cast aluminum that has been hard anodized. The joint pivot pins are made of passivated and electro-polished 17-4 stainless steel. These two materials have very good anticorrosive properties. However, extended use in sea water causes aluminum oxide deposits to form on the pins, making them difficult to remove. This Service Directive describes the procedures that should be followed to avoid this problem. To prevent the deposition of aluminum oxides on the stainless steel pivot pins, we recommend that you implement the following service procedure for all Conan manipulators used in a seawater or sea-spray environment: Every 100 hours of operation, the slave arm pivot pins should be removed and lubricated. (This service interval may be adjusted to suit the operating environment.) 1. Support the slave arm appropriately to permit removal of the selected pivot pin. 2. Remove the pivot pin retainer (refer to the system Technical Manual for details). 3. Remove the pivot pin and coat it and its bores in the slave arm segments with a light coating of silicone grease such as Dow Corning DC Replace the pin and pin retainer. Torque the retainer fasteners to 8 footpounds. 5. Repeat steps 1-4 until all pivot pins have been relubricated. NOTE: The slave arm should be thoroughly flushed with fresh water following each use in a sea water or sea spray environment. QUESTIONS If you have any questions about this Service Directive, contact the SRS Customer Service Department at Doc. No

26 SERVICE BULLETIN Shortening the Orion Extension Hoses The procedure for cutting the extension hoses and installing the reusable fittings is described below. Skip this section if you will be using full-length hoses. 1. Determine the required hose length and mark the hose at the cut-off point. Disconnect both ends of the hose from components. 2. Wrap the hose with masking tape at the cut-off point and cut square through the taped area using a cut-off saw fitted with an abrasive blade (you can also use a fine-tooth hacksaw, as shown in Figure 0-1). Remove the tape and trim any loose wires flush with the tube stock. Remove any burrs on the bore of the tube stock with a knife. Trim the hose jacket back about 1-1/2 in. from the end and expose the braid. Figure Match and install new hose code tags to the appropriate hoses, at least 2-in. from the hose ends. Orion hose code/functions designations are shown in Table 1. Table 1 Orion Hose Codes and Functions Actuator Hose Code Actuator Movement Hose Termination AZIMUTH YAW, LEFT 0A EXTEND FEMALE -4 JIC AZIMUTH YAW, RIGHT 0B RETRACT FEMALE -4 JIC SHOULDER PITCH, UP 1A EXTEND FEMALE -4 JIC SHOULDER PITCH, DOWN 1B RETRACT FEMALE -4 JIC ELBOW PITCH, UP 2A EXTEND FEMALE -4 JIC ELBOW PITCH, DOWN 2B RETRACT FEMALE -4 JIC FOREARM ROLL, CCW 3A CCW FEMALE -4 JIC FOREARM ROLL, CW 3B CW FEMALE -4 JIC WRIST SWING, EXTEND 4A EXTEND MALE -4 JIC WRIST SWING, RETRACT 4B RETRACT MALE -4 JIC WRIST ROTATE, CCW 5A CCW FEMALE -4 JIC Page 1 of 4

27 Actuator Hose Code Actuator Movement Hose Termination WRIST ROTATE, CW 5B CW FEMALE -4 JIC JAW, OPEN 6A EXTEND FEMALE -4 JIC JAW, CLOSED 6B RETRACT FEMALE -4 JIC FOREARM AUXILIARY 1 7A N/A FEMALE -4 JIC FOREARM AUXILIARY 2 7B N/A FEMALE -4 JIC WRIST DRAIN/1500 PSI RELIEF C N/A FEMALE -4 JIC WIREWAY COMPENSATION NONE N/A 1/4-IN TUBE RECEP- TACLE (SWAGELOK) 4. Slip the socket (see arrow) down over the end of the hose as shown in Figure 0-2. Push the new sleeve over the end of the tube and under the wire braid by hand (shown in inset). Complete positioning of the sleeve by pushing the hose end against a flat surface. It is critical that the tube stock butts against the inside shoulder of the sleeve (nearly flush with the flat end-face of the sleeve). Visually confirm this orientation. Figure Clamp the hex of the nipple in a vise (male fitting shown). Push the hose and sleeve over nipple as shown in Figure 0-3 below. Work the hose with twisting motion until it is seated against the nipple chamfer (at the base of the nipple). Figure 0-3 Page 2 of

28 6. As shown in Figure 0-4 below, push the socket forward on the hose and thread onto the nipple. Figure As shown in Figure 0-5 below, use a wrench to tighten the nipple hex until it bottoms on the socket hex and the corners of nipple and socket hexes align. Figure Clean interior of hose assembly with compressed air or flush with mineral spirits or hot water (150F max.). If the hose will not be reconnected immediately, cap or plug both end fittings. 9. Inspect the fitting assembly. The gap between the nipple hex and the socket should be 1/32-in. or less. The nut on a female fitting should swivel freely. 10. Proof testing: Testing should be conducted with adequate safeguards to protect the operator from a hose burst or hose/fitting separation. The hose assembly should be tested at twice the recommended working pressure of the hose. Test pressure should be held for not more than one minute and not less than 30 seconds. When test pressure is reached, visually inspect hose assembly for any leaks, bulges, or any movement of Page 3 of 4

29 the hose in relation to the hose fitting. Correct any defects before placing the hose into service. 11. Install the hoses between the slave arm and slave controller, matching the hose and fitting codes. Page 4 of

30 SERVICE BULLETIN ISSUE DATE March 1999 PRODUCT SERVICING ISSUE Titan II and Titan III Continuity Error Checking SERVICE BULLETIN SPECIFIC INSTRUCTIONS The Titan2/3 control system is designed to detect certain error conditions and disable manipulator hydraulics to prevent an error from causing unexpected movement of the slave arm. It has come to our attention that the Continuity error check does not operate as expected on some Titan 2 and Titan 3 system. This appears to be due to changes within the resolver to digital converter chip. The method in which the software detects this error has not changed. Although we can not guarantee that the continuity error check will work under all circumstances, we have identified a solution that will increase the system's ability to detect this error. The following procedure describes the immediate steps that should be taken. Because the default software instructions are contained within the EPROMs in the master and slave controller, updated EPROMs should be requested from the Schilling Robotics Customer Service Department. 1. Use Service Procedure number to adjust the error checking threshold values to the recommended settings. WARNING!!! System error checks are solely to prevent equipment damage should an error occur. AT NO TIME SHOULD ANYONE ENTER THE OPERATIONAL ENVELOPE OF THE MANIPUALTOR WHEN HYDRAULICS ARE ON Page 1 of 2

31 2. Contact the Alstom Automation Schilling Robotics Customer Service Department with the following information: l l System Type Serial number l Master Controller EPROM version # (located directly on the EPROM) l Slave Controller EPROM version # QUESTIONS If you have any questions about this Service Bulletin, contact the AASR Customer Service Department at Page 2 of

32 AUTOMATION Schilling Robotics SERVICE PROCEDURE ISSUE DATE March 1999 PRODUCT SERVICING ISSUE Titan II and Titan III Continuity Error Threshold Adjustment SERVICING PROCEDURE You can increase the T2/T3 system sensitivity to the continuity error check by setting the following values in the master controller EEPROM. Joint: Address Value (decimal): Azi 5: Sho 5: Elb 5: Pit 5: Yaw 5: Wri N/A N/A Jaw N/A N/A 1. Turn on master controller and establish communication with the slave controller. WARNING!!! DO NOT TURN ON THE HYDRAULICS! 2. Follow the steps below to set the values from the table above: a. Access the Set Level menu: From the Main Menu: press (5) Setup> (6) Security> (1)Set Level. b. Use the (5) INC and (6) DEC buttons to select privilege level 5> (7) Select. c. Use the (5) INC and (6) DEC buttons to enter the password > (7) Select> 3> (7) Select> 5> (7) Select> 7> (7) Select. The display should indicate Current Privilege Level:45. Press (8) Exit. d. Access the Memory menu: Press (8) Exit> (5) Memory. Cursor [0:0000-FFFF] Address Value Figure 1 Changing Address Values

33 SERVICE PROCEDUREPage 2 of 2 e. Note the cursor is under the first digit of the address (see Figure 1). Use the LEFT-RIGHT keys to move the cursor and the UP-DOWN keys to adjust the numerical values in the address and decimal fields. f. Type in the address for the Azimuth (5:0030) (see Figure 1). Note that the last four digits in the line will change as you type different values in the address fields. The last four digits are the decimal value for the address. Press (1)EDIT to edit the decimal values. Decimal Value Cursor 1> EDIT: 005A (+00000) Figure 2 Changing Decimal Values g. Move the cursor to the decimal values (see Figure 2) and change the last two digits to 90 (+00090). Press (1)EDIT to return to address selection. Continue to select each address from the table and edit the decimal values as you did for the Azimuth. 3. Power the Master Controller off, then on again, to allow these values to become active. WARNING!!! ENSURE NO PERSONS ARE WITHIN THE OPERATIONAL ENVELOPE OF THE MANIPULATOR! 4. Turn on hydraulics and move the arm to insure the error check does not trigger during normal operation. Move all joints at maximum speed. Use caution and avoid contacting hard stops while performing this test. 5. If the error triggers during normal operation, determine which joint is the causing the fault by looking in the SHOW ERRORS menu. From the Main Menu> (6)Diagnose> (3)Show Errors. The joint in error will be displayed by number (0=Azimuth 1=Shoulder, etc.). Using step 2, increase the decimal value up for that joint by 10% and retest. Setting the threshold to the recommended value will increase the chance of the continuity error triggering on a sensor error, but is not guaranteed to trigger in all cases. Therefore, at NO TIME SHOULD A PERSON BE WITHIN THE OPERA- TIONAL ENVELOPE OF THE MANIPULATOR WHEN THE HYDRAU- LICS ARE ON! QUESTIONS If you have any questions about this Service Procedure, contact the AASR Customer Service Department at

34 abcd Schilling Robotics SERVICE DIRECTIVE ISSUE DATE PRODUCT SERVICING ISSUE Rate Manifolds supplied before July, This Service Directive does not apply to rate manifolds supplied after July, Rate manifold pin plug corrosion SERVICE DIRECTIVE ALSTOM Schilling Robotics has received reports that some hydraulic manifolds show signs of pin plug corrosion (pin plugs seal the hydraulic passages created by cross drilling during manufacturing). We investigated the corrosion problem and found that although the pin plug body is made of 303 stainless steel, the pin plug s inner ball is made of 302 stainless steel which is less corrosion resistant in seawater. Note: All manifolds supplied after July, 1999 have pin plugs made entirely of 316 stainless steel and do not have the corrosion problem. Our concern was, if the corrosion continued, the pin plug could fail and leak hydraulic fluid. To test this concern, we pressure tested a severely corroded pin plug to 6000 psi without failure. To simulate the worst possible case, we removed the inner ball from the pin plug and re-tested to 6000 psi without failure. We consider a pin plug failure due to corrosion highly unlikely. However, as an added safety measure, we recommend that a sacrificial anode be added to the manifold to retard plug corrosion. We will supply an anode assembly, at no charge, for field installation. If a pin plug fails in a manifold that has been properly retrofitted with the anode assembly, ALSTOM Schilling Robotics will repair or replace the manifold. QUESTIONS? Contact the ASR Customer Service Department at Page 1 of 2

35 Page 2 of

36 abcd Schilling Robotics SERVICE UPDATE ISSUE DATE PRODUCT Conan 7R SERVICING ISSUE Improved documentation for older Conan wrists ( ) used with the upgrade wrist base ( SERVICE PROCEDURE QUESTIONS Install attached documents in Conan 7R technical manuals supporting Conan 7R models using wrist with P/N If you have any questions about this update, contact the Schilling Customer Service Department at: Tel: Fax: For additional copies of this document contact the Schilling Technical Publications Department at: Tel: Fax: Page 1 of 2

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38 cservice BULLETIN ISSUE DATE September 1, 2000 PRODUCT Orion 7P Manipulator Systems COMPONENT Filter Block, P/N , a component of the Orion 7P Slave Controller SERVICE ISSUE In October of 1998, the Orion 7P slave controller filter block was modified to accept a change to the filter made by the filter manufacturer. We have determined that this change compromises the integrity of the part. Failure of the filter block may result in a high pressure leak from the filter manifold, subsequent damage to the valve cover, and a system hydraulic and compensation circuit leak to the environment.. RESOLUTION Replace the filter block using the hardware in Filter Block Retrofit Kit (P/N ) and the instructions on the following pages. QUESTIONS If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@powerconv.alstom.com PAGE BREAK ABCD Doc. No Page 1 of 6

39 1 Is Replacement Necessary? Only filter blocks of a specific size must be replaced. Follow the steps, below, to determine if replacement is necessary (refer to Figure 2, "Orion 7P SLave Controller, ," on page 5). Numbers in parentheses, below, refer to item numbers on the drawing. Access the Filter Block 1. Turn off and lock out electrical and hydraulic power to the system. Bleed off residual hydraulic pressure to the slave controller. 2. Disconnect compensation and drain the fluid from the slave controller. 3. Remove the lid (2) from the manifold (1). SHCS, 10-24x1and flatwasher, 12x Check Filter Block Dimensions 1. Measure the length of the filter block (3) or filter block/cap assembly (3 and 4). See Figure 1, below. OK, DO NOT REPLACE: Filter block = 4.1-in (104 mm) or filter block + cap = 5.0-in (127 mm) REPLACE FILTER BLOCK: Filter block = 4.0-in (102 mm) or filter block + cap = 4.9-in (124 mm) OK 4.1-in (104 mm) 5.0-in (127 mm) REPLACE! 4.0-in (102 mm) 4.9-in (124 mm) Figure 1 Filter Block Dimensions Page 2 of 6 1 Is Replacement Necessary?

40 2. To replace the filter block, proceed to the next section. 2 Replacing the Filter Block Parts included in the Filter Block Retrofit Kit ( ) are shown in the table below: Remove Old Filter Block Filter Block Retrofit Kit (Orion Slave Controller) Item No. P/N Description Qty O-RING, O-RING, FILTER BLOCK 1 1. Disconnect the blue solenoid coil wires (36), from the base module PCB (14). 2. Remove the base module PCB (14). SHCS, 10-32x5, 3x (40) 3. Remove the filter block assembly from the manifold (1) SHCS 10-24x2, 2x (19). 4. Remove the standoff (37) and solenoid valve/coil (35) (36) from the filter block (3). 5. Remove the filter cap assembly (4) and filter element (33) from the filter block. SHCS10-24x1-1/2, 6x (27) 6. Remove the filter element (33) from the filter block. Install New Filter Block 1. Clean the filter and install with new o-ring (31) into the new filter block. 2. Install the standoff (37). 3. Install the filter cap (4) and o-rings (21). SHCS10-24x1-1/2, 6x (27) Torque = 45 in-lbs 4. Install the solenoid valve and coil into the new filterblock. Solenoid cartidge torque = 15 ft-lb Solenoid nut torque = 30 in-lb 2 Replacing the Filter Block Page 3 of 6

41 5. Install two new o-rings (21) to the bottom of the filter assembly and install it to the Slave Controller manifold (1). SHCS 10-24x2, 2x (19). Torque = 45 in-lbs 6. Connect the blue Solenoid coil wires to the base module PCB and install the PCB to the standoffs. SHCS, 10-32x5, 3x (40) Torque = 45 in-lbs 7. Test slave controller functions and check for leaks. 8. Make sure the o-ring (59) is inplace and install the lid (2). SHCS, 10-24x1and flatwasher, 12x Torque = 45 in-lbs 9. Reconnect compensator, refill slave controller compensation fluid, and bleed off air. Page 4 of 6 2 Replacing the Filter Block

42 This page not used. Page 5 of 6 2 Replacing Figure the 2 Filter Orion Block 7P SLave Controller,

43 This page not used. Page 6 of 6 2 Replacing the Filter Block

44 ctechnical BULLETIN ISSUE DATE: April 27, 2001 PRODUCT Orion 7P Manipulator Systems BULLETIN We have determined that the in-line relief valve fitted on the hydraulic hoses leading to the pitch actuators is not necessary and will not be fitted to future Orion manipulators systems. If you have an Orion with the in-line relief valve fitted, it should be left in place. There is no need to remove it. If it fails, replacement is not necessary. Note that Orion 7P position-controlled manipulators already have overpressure relief valves on the slave controller as standard equipment, and Orion 7R ratecontrolled manipulators should always be operated from a valve pack that is fitted with cross port relief valves. QUESTIONS If you have any questions about this bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@powerconv.alstom.com PAGE BREAK Doc. No Page 1 of 2 ABCD Schilling Robotics

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46 CALSTOM Schilling Robotics SERVICE BULLETIN ISSUE DATE: November13, 2002 PRODUCT Titan III, Orion, Conan, and RigMaster Slave Arms and Manipulator Systems COMPONENT Jaw bolts SERVICE ISSUE Breaking jaw bolts Background: The jaw bolts for Titan III, Orion, Conan, and RigMaster jaws are designed to act like a fuse and protect the rest of the manipulator from damage. They should last indefinitely if they are installed and used correctly. However, if they are not tightened to the correct torque or have been driven into other objects while fully open, they may fatigue and break prematurely. RESOLUTION 1. Install the jaw bolt using anti-sieze compound under the bolt head and on the threads. Torque the bolt to the value specified on the jaw drawing or service instruction in the technical manual (also see the drawings on pages 3 and 4). The correct torque is important to bringing the bolt to the right degree of plastic deformation; otherwise it will not break at the desired force. Remember that it is a good thing when the bolt breaks in operation, as it has prevented more expensive damage from occurring. Always carry spare bolts and t-bar plates. The t-bar plate should not break if the bolt has been tightened correctly, but may get lost when the bolt breaks. 2. Apply two simple actions to help prevent the breaking bolts: Do not fly the vehicle with the arm extended and the jaws open. This is especially true for the RigMaster, where the large moment arm due to the 12" jaws can create huge loads if you fly the vehicle into an object. Of course, sometimes you need to fly with open jaws when trying to grab an object; just don't use the arm as a bumper when you don't need to!

47 SERVICE BULLETIN If you are going to fly with the jaws open, leave them just 3/4 open so there is some hydraulic cushion and the relief valve can dissipate the energy before the jaws reach a hard stop. Note: The Conan and RigMaster jaws use the same parts. The Titan III and the Orion jaws use the same parts. The drawings on the following pages have the individual part numbers in the table at the lower right. Torque values are in the notes at the upper left. QUESTIONS If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@tde.alstom.com Page 2 of

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50 CALSTOM Schilling Robotics SERVICE BULLETIN ISSUE DATE: January 28, 2003 PRODUCT Titan II and Titan III Manipulator Systems COMPONENT Slave Cable NEW SERVICE IINFORMATION A molded, highly flexible slave arm cable ( ) with 79 pin Glenair connectors is currently supplied for Titan 2 and Titan 3 manipulator systems. To get the best performance and longest life from these cables, follow the recommendations below: 1. Clean the cable connectors prior to installation. Remove the flat seal (face seal), clean, inspect, and replace if required. Do not lubricate the flat seal, as this can cause debris to collect and could lead to problems in the future. Clean the connector and locking ring to remove any debris and re-install the flat seal. We recommend a cleaner and connector lubricant such as Pro-Gold G5 (PN ), shown at right, for use on the connector pins and socket. Allow any moisture that may condense on the mating surfaces of the connector from the aerosol spray to evaporate before mating the connector 2. Before installing the cable, remove the o-ring from the mating connector on the slave arm and on the slave controller. Clean the o-ring groove with a cotton bud or Q-tip. Clean and inspect the o-ring and replace if damaged (PN ). Lightly lubricate the o-ring with Dow Corning 55, Dow Corning 4, Moly-kote M55, or petroleum jelly, and install into the 0-ring groove. 3. Pay special attention when mating the connectors to ensure that you are mating male to female. Caution Mating the connectors male to male can damage the cable and/or slave wiring harness beyond repair. 4. Tighten the coupling nut to 6-8 Nm (50-70 in/lb) Page 1 of 2

51 SERVICE BULLETIN Periodically, the flange connectors should be removed from the slave controller and slave arm to clean the o-ring groove and replace the o-ring. The flange o-ring is: O-RING, 2-030, BUNA 70, Note: Corrosion can be a problem on aluminum slave controllers. Therefore apply a film of o-ring grease or Aqualube beneath the flange to retard corrosion. Operating Close to Maximum Rated Depth When operating the slave cable at close to it's maximum rated depth it is advisable to change the cable connector o-ring and flat seal to a harder urethane compound to prevent extrusion of the seals under high hydrostatic pressures. Replace the O-ring with: O-RING, 2-024, URETHANE 70, Replace the blue Glenair supplied flat seal with: SEAL, FLAT, QUESTIONS If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@tde.alstom.com Page 2 of

52 CALSTOM Schilling Robotics SERVICE ADVISORY ISSUE DATE: July 7, 2003 TITLE Preventing Slave Controller Corrosion and Flooding PRODUCT Titan 2 and Titan 3 Manipulator Systems COMPONENTS Slave controller bottles (and other aluminum components with stainless steel caps, plugs, or connectors) ADVISORY Even though the 6061-T6 aluminum slave controller bottle is hard-anodized to provide corrosion resistance in subsea environments, localized galvanic cells between the aluminum cover plate and the stainless steel connectors, plugs, penetrators, and fasteners can cause corrosion and pitting of the aluminum (see photo, below). Without regular inspections and maintenance these cells can cause failure of the o-ring sealing surfaces and flooding of the slave controller bottle. CAUTION! If your connector looks like this, service it at once (arrows point to corrosion, pitting, and potential leak paths). A properly maintained slave controller should operate without any corrosion problems for many months. However, corrosion is a dynamic process that can be hastened by many factors, including water temperature, water speed, oxygen content, organic matter, and the voltage Page 1 of 4

53 SERVICE ADVISORY potential of surrounding equipment. Therefore, the controller bottle should be inspected on a regular basis. Corrosion produces aluminum oxide, which can appear as a white powdery or crusty substance. It is typically found at the interface between stainless steel and aluminum components or where the anodizing has been damaged by physical damage. If corrosion is noted during an inspection, the component should be serviced to the following guidelines (see page 3 for a drawing and part list of cover hardware). 1. Open the slave controller and disconnect the power and telemetry wires to the two conectors. 2. Remove the four 4-40 screws securing the Glenair 79 pinpenetrator. It is not necessary to remove it completely; just enough so all the o-rings can be replaced. 3. Remove all other plugs and caps. Remove and discard all o-rings. Clean all o-ring grooves and install new o-rings lubricated with Dow Corning 55 or equivalent. 4. Clean the aluminum o-ring sealing surfaces and carefully inspect the area for any signs of pitting. If pitting is detected, replace the cover. (Covers can be repaired in most cases, however this requires careful machining and re-anodizing.) 5. Apply a layer of Al-Guard or other waterproof grease such as Aqualube to the mating surfaces which will create a water barrier, preventing seawater from entering the area between the Aluminum and stainless steel. 6. Apply Al-Guard or Aqualube to the threads of the bolts and fittings. 7. Install a new zinc anode to the slave controller if less than 50% of the old one remains. QUESTIONS If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@tde.alstom.com Page 2 of

54 Slave Controller Cover Part List Item No. Part No. Description Qty CABLE ASSY,T3,SCU,SUBSEA SHCS,4-40X.375,SS COVER,SCU,AL O-RING,2-257,N MOUNT,BOTTLE,T O-RING,2-251,BUNA FTG,HYD,PLUG,4HP50N-SS WIRING HARNESS,T3,SCU,PWR/TELEM,BURT O-RING,3-904 BUNA O-RING,2-118 BUNA O-RING,2-030 BUNA O-RING,2-024,URETHANE PLUG,5/8-18,FACE SEAL PLUG,3/4-16,FACE SEAL O-RING,2-116,BUNA ANODE,GALVANIC O-RING,2-143 BUNA 70 1 Page 3 of

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56 CALSTOM Schilling Robotics SERVICE BULLETIN ISSUE DATE: 15 September, 2003 PRODUCT All Conan Rate Slave Arms & Manipulator Systems COMPONENT Linear Actuator, 1.75 x 2.6-in stroke, P/N , found in slave arm pitch and yaw assemblies SERVICE ISSUE The 1/2-20 x 2 1/4-in. fasteners ( ) securing the small actuators ( ) in the pitch and yaw functions may come loose when working at full capacity for extended periods (see Figure 1). Should the fasteners come loose, there is the possibly of a hydraulic fluid leak. Figure 1 Typical pitch/yaw assembly RESOLUTION 1. At the first opportunity, remove and inspect the fasteners. Clean the threads, apply Loctite 242 (mild), install, and torque to 60 ft/lb (81.4 Nm). 2. Establish a monthly maintenance schedule to monitor the 1/2-20 HHCS for correct torque; adjust the maintenancce interval as needed based on the stability of the torque setting Page 1

57 SERVICE BULLETIN QUESTIONS If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) Page

58 Service Bulletin Preventing conductor failure in slave cables Compliance: RECOMMENDED* ISSUE DATE: 14 November, 2003 AFFECTED PRODUCT(S) Titan 2 and Titan 3 Manipulator Systems AFFECTED COMPONENT Slave Cable SERVICE ISSUE A slave cable that is secured too tightly can cause conductor failure. A slave arm cable should not be secured too tightly where it is subjected to any movement. If the inner conductors cannot slide within the outer jacket as the cable flexes, they will fatigue and eventually break. There is often no external signs of damage when this occurs, but the manipulator will exhibit symptoms consistent with the intermittant or complete loss of continuity on one or more conductors. FIELD ACTION Recommendations: 1. Inspect installation of manipulator slave cable for the following: Cable ties or any other devices used to secure the slave arm cable where it is subject to flexing should be loose enough to slide the cable back and forth within them. The first 3 feet (or 1 meter) of the cable extending from the manipulator should not be secured by any means in order to allow unrestricted movement. Cable slack should be sufficient to avoid stress on the connector. Cable is routed and/or secured with a bend radius of 12 inches (30 cm) or more. 2. For reference, place a copy of this bulletin in the Installation chapter of the Titan 2/3 Technical manual. Information in this bulletin has been added to technical manuals for current Titan 3 models. Technical manuals and service bulletins are available on the Schilling Robotics website at QUESTIONS If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Page 1 of 2

59 Fax: (USA) or +44 (0) (UK) *About Bulletin compliance levels: Field action is REQUIRED and critical for personnel safety, equipment functionality, and/ REQUIRED or continuation of warranty coverage. Field action is not REQUIRED but is highly RECOMMENDED and will result in significantly RECOMMENDED increased levels of personnel safety and/or equipment functionality. Field action may be useful under certain circumstances. Compliance is OPTIONAL and left OPTIONAL to the discretion of the owner/operator. Bulletin contains information to assist the owner/operator in more effective operation or INFORMATIONAL service of the product. Compliance is N/A. PAGE BREAK Service Bulletin Page 2 of 2

60 Service Bulletin Remote Systems Products Compensation pressure pops penetrator when cable is disconnected. Compliance: Recommended* ISSUE DATE: February 20, 2004 AFFECTED PRODUCT(S) Quest ROV Systems 1 through 5 AFFECTED COMPONENTS - Valve Pack and Quest Orion 7P Manipulator System Slave Controller Unit SERVICE ISSUE The Seanet penetrator on the valve pack and Orion slave controller unit can be forced out of its shell by compensation pressure when the SeaNet cable is disconnected (see figure, right). Penetrator O-ring This only occurs in the valve pack and Orion slave controller, components that are compensated by a separate circuit. The cause has been traced to the 70 durometer o-ring (grayed item), which is too soft for this application. Current production models of the valve pack and slave controller penetrators are installed with 90 durometer o-ring Shell FIELD ACTION Replace o-ring on valve pack and Orion slave controller penetrators with 90 durometer o-ring O-ring is not included in current spares kits and may be ordered from the factory or procured locally (Disogrin urethane 90). The replacement process is described on the following page. PAGE BREAK *BULLETIN COMPLIANCE LEVELS Field action is REQUIRED and critical for personnel safety, equipment functionality, and/ REQUIRED or continuation of warranty coverage. RECOMMENDED Field action is not REQUIRED but is highly RECOMMENDED and will result in significantly increased levels of personnel safety and/or equipment functionality. OPTIONAL Field action may be useful under certain circumstances. Compliance is OPTIONAL and left to the discretion of the owner/operator. Bulletin contains information to assist the owner/operator in more effective operation or INFORMATIONAL service of the product. Compliance is not rated. If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@tde.alstom.com Service Bulletin Page 1 of 2

61 Required materials: Penetrator O-ring Replacement Note: Steps apply only to the Quest valve pack / and the Quest Orion 7P slave controller (component in photos for illustration only). O-ring, 2-212, urethane 90, O-ring lube (Dow Corning 55 or equivalent) 1. Disconnect compensation line from circuit. Relieve compensation pressure from component. Bleed component as needed. 2. Gently work a small flat-blade screwdriver around the side of the penetrator until a flat spot is felt. Place a second small screwdriver in the flat spot on the opposite side of the penetrator. Use both screwdrivers to lift the penetrator out of the shell as shown in Figure 1. Lift the penetrator only enough to remove the o-ring. Do not stretch or stress the wiring. Penetrator Flat spot Shell O-ring Figure 1 Lifting the penetrator out of the shell 3. Apply o-ring lube to the new o-ring ( ) and all mating surfaces. Install o-ring on the penetrator. 4. Use both thumbs to evenly press the penetrator back into the shell until it is seated flat and flush. If the penetrator becomes cocked in the shell, pull it out a little and start again. NO! Figure 2 Reseating the penetrator -End- Page 2 of 2 Service Bulletin

62 Field Service Instruction Remote Systems Products ISSUE DATE: July 15, 2004 Pitch/Yaw Actuator Torque Adjustment Compliance: Recommended* AFFECTED PRODUCT Titan 3 Manipulator Systems AFFECTED COMPONENTS Pitch/Yaw Actuator , Pitch/Yaw Assembly PURPOSE OF INSTRUCTION This instruction describes the process for reducing the torque to the torque ring setscrews in the pitch and yaw actuators. The purpose is to increase actuator safety margins and greatly reduce the risk of actuator failure. References for This Instruction Attached drawings and part lists: Pitch-Yaw Actuator, , Rev C...page 12 Pitch/Yaw, , Rev C...page 16 Drawings and part lists in your Titan 3 technical manual. Slave Arm, (or equivalent) Forearm, (or equivalent) Acronyms: NAS National Aerospace Standard HHCS hex head cap screw LVDT linear variable differential transformer (position feedback) SHCS socket head cap screw (Allen head) *BULLETIN COMPLIANCE LEVELS REQUIRED Field action is REQUIRED and critical for personnel safety, equipment functionality, and/or continuation of warranty coverage. Field action is not REQUIRED but is highly RECOMMENDED and will result in significantly RECOMMENDED increased levels of personnel safety and/or equipment functionality. OPTIONAL Field action may be useful under certain circumstances. Compliance is OPTIONAL and left to the discretion of the owner/operator. Bulletin contains information to assist the owner/operator in more effective operation or INFORMATIONAL service of the product. Compliance is not rated. If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@tde.alstom.com Field Service Instruction Page 1 of 18

63 1 Before You Start... The following tools and supplies will be needed to complete this instruction. Tools: 7/16 socket and drive 5/32 hex (Allen) drive Torque wrench 0-75 in-lb Torque wrench 0-75 ft-lb Supplies: O-ring lube, Dow Corning 55, or equivalent Grease, Valvoline Val-Plex EP grease, or equivalent Waterproof grease, AcquaShield (AquaLube) ( ), or equivalent Clean shop rags 2 Instructions for Both Actuators Perform the following instructions on the pitch and yaw actuators. 1. Position the slave arm as shown at right. 2. Remove forearm cover (arrow). 3. Remove pitch resolver cover (A). 4. Remove pitch wireway cover (B). A B Page 2 of 18 1 Before You Start

64 5. Remove yaw resolver cover (A). 6. Remove yaw wireway cover (B). 7. In forearm, unplug pitch resolver, yaw resolver, wrist resolver, and tool LVDT. A B 8. Remove SHCS and separate the pitch and yaw resolver metal wire guides from actuator assemblies. (A, arrow). 9. Feed resolver wires back through wireway passages all the way to their origin (B). A B 10. Remove the pitch and yaw wire guides (A, arrow). 11. Remove pitch and yaw retaining rings (B, arrow). A B 12. Remove the SHCS fasteners securing the pitch and yaw resolvers (A, white arrow). 13. Remove pitch and yaw resolvers (A, black arrow). Be careful not to damage wires while handling resolvers. 14. Remove the resolver spacers ((B, arrow) from the pitch and yaw sliprings. A B 3 Resolver Manifold Side, Pitch or Yaw Actuator From this point, select one actuator to complete the service in this section (section 3, "Resolver Manifold Side, Pitch or Yaw Actuator) and the next (section 4, "Output Flange Side of Pitch or Yaw Actuator," on page 8). Perform the service to one side of the actuator, from start to finish, before starting the other side. This will prevent the shims from getting mixed up. This section covers the resolver manifold side of the actuator, and applies to both the pitch and yaw actuators. Page 3 of 18 3 Resolver Manifold Side, Pitch or Yaw Actuator

65 15. Remove retaining ring (A, arrows). 16. Remove thrust race (B, arrow). A B Note: In the next steps, the arm will leak hydraulic fluid. Loosen fasteners slowly as there may be a small amount of pressure present. The slave arm will not move. 17. Remove 6 NAS fasteners from the stator manifold (A). 18. Remove 10 SHCS from stator manifold (B, arrow). Make sure each SHCS retains its o-ring (B-inset, arrow) and no SHCS o-rings are stuck to the manifold. A 6X B 10X 19. Carefully remove stator manifold. Verify all 10 o-rings remain in the rotor (arrow 1). If they stick on the manifold, reinstall them on the rotor. Verify all needle bearings are present. If they fall out while pulling the manifold, clean them and put them back in. There should be a small gap, but not big enough to fit another needle roller (arrow 2). A B While removing stator manifold, clean the bearing, thrust washers, and shims of oil and reinstall them to the manifold using a small amount of EP grease on each piece ti glue them in place. The correct order of installation is critical: a. Shims (35-39, as supplied) b. Thrust washer (17) c. Bearing (16) d. Thrust washer (17)!Caution Installing shims next to the bearings (35-39) will cause severe damage. Page 4 of 18 3 Resolver Manifold Side, Pitch or Yaw Actuator

66 21. Prepared for reassembly, the shims, bearing and thrust washers are carefully stacked and aligned in the manifold (A, arrow). 22. Remove Fluorocarbon seal. Be careful not to scratch seal with finger nails (B, arrow). A B KEY INSTRUCTION 23. Loosen all 16 SHCS (A, arrow). To avoid stripping the socket head, make sure that the hex driver is not worn and is completely bottomed in the socket. 24. Retorque 16 SHCS fasteners to 25 in lb (2.82 Nm), using a cross pattern then run clockwise around all fasteners sequentially 2 times at 25 in lb (2.82 Nm) (B). A B 2X Etc Carefully install fluorocarbon seal (A, arrow). 26. Before reinstalling stator manifold, insure that all 10 of the o-rings are installed into the end of the rotor (arrow). A B 10X 27. Make sure all 11 o-rings are installed into the stator manifold block (A, box). 28. Verify shims, bearing, and thrust washers are installed into stator manifold (A, arrow). 29. Carefully install stator manifold (B). The fluorocarbon seal will hold the manifold out slightly. A B Page 5 of 18 3 Resolver Manifold Side, Pitch or Yaw Actuator

67 30. Verify o-rings are installed on SHCS (A, arrow). Install 2 SHCS opposite each other (B, white arrows). Hand-tighten them down evenly, working the o-rings into their seats. Do not torque at this time. Note: If the stator manifold does not draw down evenly onto the rotor and housing, STOP tightening the SHCS; the shims, thrust washers, and bearing stack may have slipped out of position. Remove the manifold and reinstall shims, thrust washers, and bearing using a small amount of EP grease to hold them in place. A B Once the manifold is snug. Install the remaining 8 SHCS. While installing each SHCS, gently work the o-ring into the o-ring seat as the fastener head bottoms out. Do not torque at this time. 31. Using AquaShield grease, install the 6 NAS HHCS in the A stator manifold (A) and hand-tighten just enough to draw the stator manifold down to the manifold block. Do not torque at this time. 32. Return to the 10 SHCS installed in step 30 and torque them to 76 in-lb (8.59 Nm). Use a cross pattern; then torque them clockwise sequentially 2 times. 33. Torque 6 NAS HHCS to 21 ft-lb (28.47 Nm) (B). B 34. Install thrust washer onto slip ring (A, arrow). 35. Install the retaining ring (B, arrow). A B 36. Install resolver spacer (A, arrow)) 37. Install resolver with wires in the orientation shown (B, white arrow). Turn resolver body slightly until you feel both sets of alignment pins engage. Install the SHCS and clamp finger-tight. (B, black arrow) A B Page 6 of 18 3 Resolver Manifold Side, Pitch or Yaw Actuator

68 38. Install retaining ring to slip ring (A, arrow). 39. Twist wire guide (B, arrow) and install resolver wires. A B 40. Install wire guide into slipring (A). 41. Route resolver cable through back side of metal wire guide (B, arrow). A B 42. Seat wire guide as you gently pull resolver wires through. Be sure there are no wires underneath the guide (A). 43. Install SHCS through resolver lug and wire guide and tighten (B, arrow). Torque to 5 ft-lb (6.78 Nm) A B 44. Tighten top SHCS and resolver hold down clamp (A, arrow). 45. Route resolver wires up to forearm (B). 46. Do not install cover until both actuators are done. A B PAGE BREAK Page 7 of 18 3 Resolver Manifold Side, Pitch or Yaw Actuator

69 4 Output Flange Side of Pitch or Yaw Actuator Perform the service to this side of the actuator, from start to finish, before moving to the next actuator. This will prevent the shims from getting mixed up. This section covers the output flange side of the actuator. 1. Remove 6 NAS HHCS from A B rotor manifold (A). 2. Slowly Loosen the 2 SHCS and remove rotor manifold (B). Caution: There may be some trapped pressure. A little oil will be lost. The arm will not move. 3. Remove 4 NAS HHCS from the output flange (A). 4. Remove 10 SHCS from the output flange (B). A B 5. Carefully remove the oputput flange (A). A 6. Verify all 10 o-rings remain in the slipring (arrow 1). If they stick on the flange, reinstall them on the slipring. Verify all needle bearings are present. If they fall out while pulling the flange, clean them and put them back in. There should be a small gap, but not big enough to fit another needle roller (arrow 2) (B). 7. If the thrust washers, bearing, or shims are separated from the rotor manifold, it is critical to reinstall them in the correct order: a. Shims (35-39, as supplied) b. Thrust washer (17) c. Bearing (16) d. Thrust washer (17)!Caution Do not install shims next to the bearing. This will cause severe damage! B 1 2 Page 8 of 18 4 Output Flange Side of Pitch or Yaw Actuator

70 8. If bearing and thrust washers do not fall out, leave them stacked in flange (A, arrow). 9. Remove fluorocarbon seal. Be careful not to scratch seal with finger nails (B, arrow). A B KEY INSTRUCTION 10. Loosen all 16 SHCS in torque ring (A). To avoid stripping the socket, use a fresh hex driver, completely bottomed in the socket. 11. Using a cross pattern, retorque all set screws to 25 in-lb (2.82 Nm). Then torque them again two times using a clockwise sequential pattern (B). A B 2X Etc, 12. Re-install fluorocarbon seal A (A). 13. Re-install output flange, making sure the shims, thrust washers, and bearing remain in place (B). The fluorocarbon seal will keep the flange from seating on the stator until the 10 SHCS are installed in the next step. 14. Insure o-rings are installed on SHCS (A, arrow). Install 2 SHCS to opposite sides of the flange (B, white arrows). Gently handtighten them down evenly, working the o-rings into their seats. Do not torque at this time. B B Note: If the output flange does not draw A down square onto the stator and housing, STOP tightening the SHCS; the shims, thrust washers, and/or bearing may have slipped out of position. Remove the flange and reinstall shims, thrust washers, and bearing using a small amount of EP grease to hold them in place. Once the flange is seated on the stator, install the remaining 8 SHCS. While installing each SHCS, gently work the o-ring into the o-ring seat as the fastener head bottoms out. Do not final torque. Page 9 of 18 4 Output Flange Side of Pitch or Yaw Actuator

71 15. Install the output flange using AquaShield grease on the 4 NAS HHCS (A). Hand-tighten them just enough to make the flange seat on the manifold block. Do not torque at this time. 16. Return to the 10 SHCS previously installed in step 14 and torque them to 76 in-lb (8.586 Nm) (B). Use a cross pattern; then torque them clockwise sequentially 1 time. 17. Torque 4 NAS SHCS to 21 ft-lb (28.47 Nm) (C). A C B 18. Verify that the 10 o-rings are installed on the end of the slipring (A, arrow). 19. Verify that the 11 o-rings are installed in the wrist base (yaw) or forearm manifold (pitch) (B, box). A B 20. Verify o-ring is in the rotor manifold (A, arrow). 21. Feed resolver wires through rotor manifold (B). A B 22. Mount the rotor manifold and install 2 SHCS finger-tight (A). 23. Install 6 NAS HHCS (B). Handtighten them just enough to make the manifold seat on the manifold block. Do not torque at this time. A B Page 10 of 18 4 Output Flange Side of Pitch or Yaw Actuator

72 24. Torque 2 SHCS to 76 in-lb (8.586 Nm) (A). 25. Torque 6 NAS HHCS to 21 ft-lb (28.47 Nm) (B). 26. Route the resolver wires up toward forearm and reconnect. A B 27. Confirm o-ring is in wireway cover (A, arrow). 28. Using AquaShield grease on the 4 NAS HHCS, install wireway cover (B). Torque 4 NAS HHCS to 21 ft-lb (28.47 Nm). This completes the output flange side of the actuator. A B 5 Service Remaining Actuator 1. Repeat section 3, "Resolver Manifold Side, Pitch or Yaw Actuator," on page 3 and section 4, "Output Flange Side of Pitch or Yaw Actuator," on page 8 for the remaining actuator. 6 Finishing the Instruction Complete the following instructions for both actuators. 1. Make electrical connections in the forearm manifold. 2. Replace the forearm cover and o-ring, making sure no wires are pinched. Install the six HHCS and torque to 21 ft-lb (28.47 Nm). 3. Install o-ring for cover using o-ring lube (A, arrow). 4. Using AquaShield grease on the six NAS HHCS, install resolver cover. Torque to 21 ft lb (28.47 Nm). A B 7 Reference Drawings and Part lists in this section: Pitch-Yaw Actuator, , Rev C... page 12 Pitch/Yaw, , Rev C... page 16 Page 11 of 18 5 Service Remaining Actuator

73 Item No. Pitch-Yaw Actuator, , Rev C P/N Part Description Qty. Unit HOUSING, PITCH VANE, ROTOR, PITCH, T3 1/ DRIVE SHAFT/ROTOR BODY, PITCH, T PL, END, PITCH, T TORQUE RING, PITCH SEAL, END, PITCH, T3 1/ FLANGE, OUTPUT, PITCH VANE, STATOR, PITCH, T3 1/ P SHCS, 10-32X1/2, A286, NYLON PATCH RING, RETAINING, INTERNAL, W/LOCKING TABS, PITCH P NAS 6404U1, NYLON PATCH TORRINGTON, Q BEARING, THRUST, NTA4052, TORRINGTON WASHER, THRUST, TRB4052, TORRINGTON P SCREW, SET, 1/4-28 X.312, FLAT POINT, NYLON PATCH O-RING, X.040, BUNA SEAL, VANE, PITCH, T3 1/ O-RING, BUNA O-RING,.244x.039 BUNA 90 APPLE O-RING, N O-RING,.189 X.039, BUNA BACK-UP, VANE SEAL, PITCH, ROTOR VANE, T3 1/ BACK-UP, VANE SEAL, PITCH, STATOR VANE, T3 1/ SEAL, FLUOROCARBON #AR UC PLUG, CV, CVES A, 316AA, SHORT, CV XTRA SHT MANIFOLD, STATOR, PITCH/YAW BACK-UP RING, TITAN II, PITCH SHIM, PITCH,.001 THK SHIM, PITCH,.003 THK SHIM, PITCH,.005 THK SHIM, PITCH,.007 THK SHIM, PITCH,.008 THK RING, PITCH/YAW BEARING SLEEVE SHCS, X 1/2, ALLOY STEEL(UNBRAKO) ADHESIVE, LOCTITE 609, RETAINING COMPOUND ADHESIVE, #271 RED LOCTITE 50ML TOOL, INSTALLATION, CV PLUG Page 12 of 18 7 Reference Drawings and Part lists

74 Item No. Pitch-Yaw Actuator, , Rev C (cont.) P/N Part Description Qty. Unit TOOL, ENDPLATE INSTALLATION, PITCH, T P SHCS, 10-32X1/2, ALLOY, NYLON PATCH 10 Page 13 of 18 7 Reference Drawings and Part lists

75 Page 14 of 18 7 Reference Drawings and Part lists

76 Page 15 of 18 7 Reference Drawings and Part lists

77 Pitch/Yaw, , Rev C Item No. P/N Part Description Qty. Unit BLOCK, MANIFOLD, PITCH/YAW SLIP RING, MANIFOLD P SHCS, 10-32X1/2, ALLOY, NYLON PATCH P NAS 6404U3, NYLON PATCH O-RING,.189 X.039, N70(APPLE) O-RING, X.039, N70(APPLE) SEAL, SLIP RING SLYD RING O-RING, BUNA O-RING, V ACTUATOR, ROTARY, PITCH, W/FLATS, T MANIFOLD, ROTOR, SLAVE WRIST PITCH YAW RING, RETAINING, SMALLEY #WSM RACE, THRUST, TORRINGTON, TRA P NAS 6404U7, NYLON PATCH O-RING, BUNA WI WORK INSTR 0 g110 Page 16 of 18 7 Reference Drawings and Part lists

78 Page 17 of 18 7 Reference Drawings and Part lists

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80 Service Bulletin Remote Systems Products ISSUE DATE: December 22, 2004 Bleedscrew added to roll actuator sensor cable Compliance: Informational* AFFECTED PRODUCTS All Orion 7P systems AFFECTED COMPONENT Roll actuator sensor cable SERVICE INFORMATION A compensation bleedscrew has been added to the upper fitting on roll actuator sensor cable (see Figure 1). This new cable is installed on all new Orion 7P manipulator systems. Although it is NOT necessary to bleed this cable, the bleedscrew addresses operator service policies that require bleeding all compensated cables. The new roll actuator sensor cable can also be retrofitted to older Orion 7P manipulator systems when bleed capability is needed. Wire Housing Bleed Screw Forearm Roll Sensor Cable Bleed Screw Forearm Wire Housing Forearm Roll Sensor Cable Figure 1 Roll actuator sensor cable and forearm wire housing bleed points REQUIRED RECOMMENDED OPTIONAL INFORMATIONAL *BULLETIN COMPLIANCE LEVELS Field action is REQUIRED and critical for personnel safety, equipment functionality, and/or continuation of warranty coverage. Field action is not REQUIRED but is highly RECOMMENDED and will result in significantly increased levels of personnel safety and/or equipment functionality. Field action may be useful under certain circumstances. Compliance is OPTIONAL and left to the discretion of the owner/operator. Bulletin contains information to assist the owner/operator in more effective operation or service of the product. Compliance is not rated. If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@tde.alstom.com For bulletins & manuals online, go to: Service Bulletin Page 1