Maintenance & Service

Transcription

1 Maintenance & Service In This Chapter: 1 Safety First!...page Maintenance... page Important Service Practices & Procedures... page Junction Box Service... page Master Controller Service & Configuration... page Slave Controller Service & Configuration... page System Adjustments... page Shortening the Hydraulic Hoses... page Service Instructions... page Safety First! These guidelines, warning, and cautions are a reminder of the safety issues present when maintaining or servicing a slave arm or manipulator system. They do not cover every possible safety risk and are not meant to supersede or replace existing vessel/operator safety policies, standards, processes, and practices. Please Note: This slave arm or manipulator system is not an isolated piece of equipment. Be sure to know and use the safety and service guidelines provided in the technical manual for the system or vehicle on which it is used. 1.1 Worksite Safety! WARNING ELECTRICAL, HYDRAULIC, AND MECHANICAL HAZARDS! Before any contact with this equipment: Notify the appropriate personnel of your activities. Be sure you have a safe electrical, hydraulic, and mechanical working environment. Turn off, lock out/tag out, and/or isolate surrounding equipment that could be a safety hazard to you. Observe all safety regulations and procedures in effect at the worksite. Wear personal protective equipment (PPE) appropriate for the task Page 115

2 Maintenance & Service 1.2 Electrical Safety! WARNING SHOCK HAZARD! Lethal voltages can be present in the manipulator system (see the Specification chapter for specific voltages). Before any contact with this equipment, CONFIRM that it is electrically isolated, locked-out and tagged-out as directed by applicable electrical safety regulations and procedures. Wear personal protective equipment (PPE) appropriate for the task. 1.3 Mechanical Safety! WARNING Slave arm components are heavy and can move, drop, shift, or collapse suddenly when hydraulic pressure is removed or relieved. Support the slave arm at the elbow and jaw when relieving hydraulic pressure or opening any hydraulic connection. Wear personal protective equipment (PPE) appropriate for the task. 1.4 Hydraulic Safety! WARNING Slave arm components are heavy and can move, drop, shift, or collapse when hydraulic pressure is removed or relieved. Support the slave arm at the elbow and jaw when relieving hydraulic pressure or opening any hydraulic connection. Wear personal protective equipment (PPE) appropriate for the task.! WARNING Failure to follow safety procedures for working with high-pressure hydraulic equipment can result in serious injury or death. ALWAYS assume that hydraulic equipment is energized until you have CON- FIRMED that it is isolated, locked out, and tagged out as directed by applicable hydraulic safety regulations and procedures, that all pressure gauges indicate zero pressure, and that all stored and residual pressures have been isolated or relieved. Common causes of serious injury and death from high-pressure hydraulic equipment include: Injection of pressurized hydraulic fluid into the body. Blunt force trauma to the body from flailing, pressurized hoses and forcefully ejected fittings. Bodily contact with hot hydraulic fluids and sprays or ignited fluids, sprays, or mists. Falls caused by slipping on spilled fluids. Page 116 Safety First!

3 Maintenance & Service To prevent injury or death while working with high-pressure hydraulic equipment, always follow all applicable hydraulic safety regulations and procedures. The instructions listed below provide general guidelines and are not meant to replace or modify existing safety regulations and procedures. Always lock out and tag out hydraulic equipment before it is serviced so that it cannot be accidentally energized. Provide support for equipment and components that can move, drop, shift, or collapse when hydraulic pressure is removed or relieved. Always wear safety glasses and other required personal protective equipment (PPE). Confirm that equipment pressure gauges indicate zero pressure. Before loosening any fittings, isolate or relieve any stored or residual pressure that remains in components even when the hydraulic system is de-energized. Never use any part of your hand or body to check for hydraulic fluid leaks, even if you are wearing personal protective equipment. High-pressure hydraulic fluid injects easily into any body part, and an injection wound, regardless of size, must be evaluated immediately by a physician as a surgical emergency. Service hydraulic equipment away from sparks or open flame. Immediately clean up spilled hydraulic fluid from floors or other surfaces. Before returning the equipment to service, tighten all fittings and connections as specified by the equipment manufacturer. Move all personnel away from serviced hydraulic equipment before pressurizing it and testing for safe operation. Only qualified and authorized personnel should perform hydraulic work on this equipment. A qualified person is one who has the required skills and knowledge to perform hydraulic work safely, even under adverse environmental conditions, and who knows the hazards associated with hydraulic work and the methods for reducing the risk of accidents from those hazards. 1.5 Deck Testing! WARNING Use extreme caution when testing a slave arm on deck: Move all personnel outside the slave arm's range of motion when hydraulic pressure is applied and functions are tested. Direct the slave arm to point away from personnel and critical or sensitive areas while testing jaw functions. 2 Service Guidelines 2.1 Service Assumption Instructions in this manual assume that service personnel are familiar with the general operating principles, safety guidelines, and service practices associated with the types of equipment described in this manual Service Guidelines Page 117

4 Maintenance & Service 2.2 Guidelines ESD-Sensitive Devices! Caution Electrostatic discharge (ESD) can permanently damage sensitive electrical components like printed circuit boards (PCBs), integrated circuits (ICs), and other ESD-sensitive components. To prevent damage, always handle these components according to ESD prevention guidelines. Microelectronic devices are very susceptible to ESD. Careless handling may cause immediate component failure. It may also make a component more vulnerable to future damage, which can be difficult to detect and often results in faulty performance and intermittent failures. When you handle PCBs, ICs, and other ESD-sensitive components, follow the basic ESD prevention guidelines below. Prepare an ESD workstation by grounding all items in the work area (work surfaces, people, equipment, etc.) to the same electrical ground point (called the common point ground). Keep the work area free of nonessential insulators (such as plastic cups, bags, and envelopes). If possible, disconnect all power sources, signal sources, and loads connected to the component before you begin maintenance or service. Always ground yourself before you touch ESD-sensitive equipment. Discharge any static electricity by touching ground on the workstation each time that you approach and sit at the workbench. Ground all tools that may come into contact with the ESD-sensitive equipment. Before you handle PCBs, ICs, and other ESD-sensitive components, attach a grounding wrist strap and confirm that the strap is connected to the grounding pad. Handle PCBs by the base or edges; always avoid contact with pins. Do not unnecessarily pick up, hold, or carry ESD-sensitive devices that are not in shielded packaging. Always store and seal ESD-sensitive components in the anti-static packaging in which they were shipped, or in equivalent storage material Torque Specifications See the Maintenance & Service section, service or work instructions, and/or drawings in the Drawings & Part Lists sections for torque specifications. When a torque specification differs between manual text and engineering drawing, use the specification on the drawing. When no torque specification is present, use prevailing industry standards and common sense. Page 118 Service Guidelines

5 Maintenance & Service Nylock ( Patch ) Fasteners Under ideal conditions, Nylock ( patch ) fasteners can be reused up to 5 times. Because tracking their use is difficult and operating conditions are always less than ideal, Nylock fasteners should be replaced whenever they are removed.! Caution DO NOT replace Nylock fasteners with standard fasteners. Standard fasteners may loosen and cause component failure or loss Fastener Lubrication Stainless steel to stainless steel or titanium: Apply nickel or molybdenum-based anti-seize compound (Bostik Never-Seez, or equivalent) when assembling stainless steel fasteners or threading them into stainless steel or titanium components (including nylon-patch/nylock fasteners). Stainless steel to aluminum: Apply waterproof grease (Aqua Lube, or equivalent) when assembling stainless steel fasteners to aluminum IF they are exposed to seawater. Do NOT use Aqua Lube on fasteners penetrating hydraulic or compensated areas, unless directed otherwise in a service instruction or engineering drawing O-rings Inspect o-rings for damage during routine maintenance. Replace o-rings that are broken, damaged, or hardened. Lubricate o-rings prior to installation (Dow Corning 55 O-ring lube, petroleum jelly, or equivalent) Connection Identification Before disconnecting any hose, cable, or conductor, make sure the item and its matching fitting, connector, or terminal are adequately labeled for correct re-assembly Drawings & Part Lists Engineering drawings and part lists are supplied to assist in servicing and maintaining the equipment. They can be a valuable source for determining torque values and the part numbers for serviceable components. Most are located in the Drawings & Part Lists section. 3 Maintenance 3.1 Daily Maintenance Perform the following steps daily, or after every duty cycle: Submersible Models 1. Thoroughly rinse the slave arm and slave controller with clean, fresh water. 2. Apply a spray lubricant to the slave arm jaw assembly and actuator rods to displace any water Maintenance Page 119

6 Maintenance & Service All Models Inspect slave arm for: 1. Damage: If the slave arm has had severe service or a collision, inspect slave arm components, inspect all joints, actuator shaft pivot pins, and joint pivot pins. inspect the linear actuator body and shaft for dents, bends, or damaged components. check all hoses, fittings, and electrical cables. repair or replace damaged components. 2. Loose or missing fasteners Replace or retighten fasteners, as needed. Vibration and temperature cycles may cause fasteners to loosen. 3. Loose or dirty electrical connectors. Re-tighten as needed. Clean and lubricate o-rings prior to mating. Vibration and temperature cycles may cause electrical connectors to loosen. 4. Trapped debris Remove debris and inspect for damage. 5. Hydraulic leaks Repair any leaks, replace lost fluid, and bleed air, as needed. 6. Damaged hydraulic hoses Repair or replace hoses, as necessary. If possible, install protection or reroute hoses to prevent future damage. 7. Anode consumption Inspect all anodes (if present) and replace when 1/3 or less remains. 3.2 Long Term Periodic Maintenance Efficient and reliable long-term operation depends on the following three steps: 1. Inspect components and observe performance frequently. Do this starting with the first use. You will then be able to develop a schedule of inspection, maintenance, and service for hydraulic and mechanical components that meet the needs of the slave arm s operating environment and duty cycles. 2. Perform the inspections, maintenance, or service as scheduled. Staying with the schedule below will help keep the slave arm in good working condition. 3. Keep a log of all inspection, maintenance, and service actions. Page 120 Maintenance

7 Maintenance & Service Keeping a log will help you understand when and why problems are occurring. Then you can modify your schedule based on this knowledge. Table 1 contains a minimum schedule for performing regular long-term maintenance. Table 1 Recommended minimum maintenance schedule Schedule Period Every 100 operating hours Maintenance Task Tighten all external slave arm fasteners to the specified torque. Check a sample of hydraulic fluid for water and particulates. Replace if contaminated. Apply anti-corrosion paint wherever an anodized surface is damaged and aluminum is exposed. Submersible: Recoat pivot pins and pivot pin bores with silicone grease such as DC-5. Every 2000 operating hours Every 2000 operating hours or every 3 years (whichever comes first) Replace worn or damaged actuator pins and bushings. Replace all actuator o-rings and seals. Lubricate with Dow Corning DC-4. Clean all o-ring grooves and surfaces. 4 Important Service Practices & Procedures Key practices and procedures for successful manipulator system service: Clean, degrease, and inspect disassembled parts before reassembling. Replace o-rings that are broken, damaged, or shows signs of wear. Lubricate all o-rings with o-ring lubricant (Dow Corning 55 or petroleum jelly). NOTE: Do not use lubricants that contain suspended particles such as molybdenum or graphite the particles can be drawn into the hydraulic system and clog filters. Apply Aqua Lube (or equivalent) to all fastener threads, EXCEPT: when threads are exposed to the hydraulic system. when you are directed otherwise by the work instruction or engineering drawing. Torque all fasteners as specified. Torque specifications on engineering drawings take precedence over all other text references. 4.1 Protecting PC Boards! Caution Electrostatic discharge (ESD) can permanently damage sensitive electrical components like printed circuit boards (PCBs), integrated circuits (ICs), and other ESD-sensitive components. To prevent damage, always handle these components according to ESD prevention guidelines Important Service Practices & Procedures Page 121

8 Maintenance & Service Microelectronic devices are very susceptible to ESD. Careless handling may cause immediate component failure. It may also make a component more vulnerable to future damage, which can be difficult to detect and often results in faulty performance and intermittent failures. When you handle PCBs, ICs, and other ESD-sensitive components, follow the basic ESD prevention guidelines below. Prepare an ESD workstation by grounding all items in the work area (work surfaces, people, equipment, etc.) to the same electrical ground point (called the common point ground). Keep the work area free of nonessential insulators (such as plastic cups, bags, and envelopes). If possible, disconnect all power sources, signal sources, and loads connected to the component before you begin maintenance or service. Always ground yourself before you touch ESD-sensitive equipment. Discharge any static electricity by touching ground on the workstation each time that you approach and sit at the workbench. Ground all tools that may come into contact with the ESD-sensitive equipment. Before you handle PCBs, ICs, and other ESD-sensitive components, attach a grounding wrist strap and confirm that the strap is connected to the grounding pad. Handle PCBs by the base or edges; always avoid contact with pins. Do not unnecessarily pick up, hold, or carry ESD-sensitive devices that are not in shielded packaging. Always store and seal ESD-sensitive components in the anti-static packaging in which they were shipped, or in equivalent storage material. 4.2 Startup After Maintenance or Service After Minor Maintenance or Service 1. Follow steps in the Pre-Start Check and Startup sections of the Operation chapter. 2. Be sure to replace hydraulic and compensation fluids lost during maintenance or service After Major Service 1. Follow the procedures in Completing the Installation in the Installation chapter before resuming normal operation. 2. If the hydraulic or compensation fluid has been contaminated, flush the system and refill with fresh fluid. 5 Junction Box Service This section contains special maintenance and service procedures not covered in the Work Instructions. For additional details, refer to the junction box drawing and part list in the Drawings & Part Lists chapter. Fuse Replacement Littlefuse T 6.3AL 250V (SRS P/N ) The fuse is located under the fuse symbol, between the power switch and the power-in socket. Use the tab on the fuse cover to pry out the fuse for replacement or inspection. Page 122 Junction Box Service

9 6 Master Controller Service & Configuration Maintenance & Service This section contains special maintenance and service procedures not covered in the Work Instructions. For additional details, refer to Master Controller, in the Drawings & Part Lists chapter. PCB Features and Functions... page 123 Accessing Internal Components... page 124 Adjusting the LCD Screen Viewing Angle... page 125 Master Controller Software Selection... page 125 Incompatibility Alert Screens... page PCB Features and Functions The master processor board performs the following functions: Communicates with the slave controller. Reads master arm potentiometer positions for use by the control algorithm. Detects front panel switch inputs for use by the control algorithm. Displays operation information on the LCD display. Contains the program information for each system. Stores system parameters in non-volatile memory for use by the control algorithm. Illuminates status LED's to assist troubleshooting and diagnostics. The master processor board operates on VAC (standard) or 18-36VDC (optional). Power is supplied by either the supplied AC junction box, or by a user installed CPC connector mounted near the operating station. A 4 pin power connector (P7) plugs into the board. An adjacent 4 pin plug (P2) connects to a SPST on/off switch mounted in the controller faceplate. An in-line fuse (F1) provides over-current protection to the PCB. Communication between the master processor board and the slave controller board is via RS- 232 or RS-485. A 9 pin connector is plugged into the appropriate receptacle (Either P1A or P1B) depending on system requirements. An auxiliary RS-232 connection is also present on both connectors for applications that require an additional serial port connection. (The auxiliary RS-232 is not used for connection to the slave controller board) A telemetry daughter (inductive isolation) board is plugged into connectors J1 and J2. The purpose of the telemetry board is to provide electrical isolation and protection from over-voltage or voltage spikes between the telemetry conductors and the PCB electronics. Two hex switches marked Mode H (high bit) and Mode L (low bit)' are used to select which program to load during startup. This allows the PCB to be pre-loaded with all standard product program software and allows the user to reconfigure the PCB for other systems without the need for additional ICs or programming. A table provides the switch position options. The master arm connects to 12-pin circular connector P4 (Standard). In a dual arm system, the additional master arm connects to P5. The master processor board sends a 4VDC reference voltage to each of the potentiometers in the master arm. An analog to digital converter interprets the voltage as a numerical value that is used by the control algorithm Master Controller Service & Configuration Page 123

10 Maintenance & Service The USB port (J6) can be used in place of the auxiliary RS-232 connector for applications that require serial port connection. (The USB port cannot be used for connection to the slave controller board) The 20 pin DIP connector (J7) can be used to run legacy LCD displays that have a ribbon cable interconnection. Current displays connect via spring loaded pins onto contacts (J4) on the back side of the PCB. Two additional SIP receptacles marked LCD backlight are also used with legacy LCD displays and provide ~80VAC to power the backlight via two wires coming from the legacy display. Two spring loaded pins are used on current displays Adjusting the LCD A potentiometer (VR1) is used to set the optimal contrast between the black text and the bluegray background at the desired viewing angle. Once the potentiometer is adjusted, it will automatically compensate for changes in temperature so the display remains viewable throughout the operating temperature range. See Adjusting the LCD Screen Viewing Angle section on page Changing the Software Image Changing software image (Titan to Conan, Orion to Titan, etc.) is accomplished by selecting the appropriate hex switch settings on the PCB and then cycling power to the master processor. See Selecting Pre-Loaded Software Images section on page 126. The master processor can also be run from a legacy EPROM installed in the 28 pin DIP socket (U11). This connector was installed to ensure the master processor board is fully backwards compatible with existing master controllers. See Installing an EPROM section on page 127. The Secure Digital card slot (J5) allows new software, when available, to be loaded into memory on the PCB. See Installing Images from an SD Card section on page 127. For more information on changing the software image, see Master Controller Software Selection section on page Troubleshooting the PCB Communications The master controller PCB has seven LEDS to indicate the status of PCB power, master arm reference voltage, image loading, processor function, and communication with the slave controller (TX and RX). See the Troubleshooting chapter for details. Power There are test-points on the master controller PCB for -16V, +12V, +5V, +3.3V, +2.5V, +1.2V, and ground. See the Troubleshooting chapter for details. NOTE: There are no user-serviceable parts on the master controller PCB. If the board fails to function, replace it with a spare. 6.2 Accessing Internal Components Removing the Faceplate 1. Turn off the master controller and disconnect the whip from its power source. Page 124 Master Controller Service & Configuration

11 Maintenance & Service 2. Remove the four screws holding the master controller faceplate to the enclosure (Figure, right). 3. Lift the faceplate assembly out of the enclosure. Turn it over to expose the face of the PC board. Take care to immobilize the master arm(s) and avoid stressing the cables connected to the boards in the enclosure. Remove screws Installing the Faceplate 4. Carefully swing the faceplate assembly back over and seat it on the enclosure. Reinstall the four mounting screws. Check that no wires or cables are pinched between the faceplate and the enclosure. 6.3 Adjusting the LCD Screen Viewing Angle The LCD screen comes with a temperature sensor and compensation circuit that keeps the viewing angle stable over a broad temperature range. If you find the viewing angle is not acceptable for your work environment, adjust it as follows:! WARNING SHOCK HAZARD! Be aware that potentially lethal voltages are present while adjusting the LCD viewing angle potentiometer. Always observe appropriate safety procedures. 1. While keeping power supplied to the master controller, open the assembly as described in Removing the Faceplate section on page Identify the LCD adjustment potentiometer (labeled VR1 on the PC board), located at the bottom right of the board (Figure 1). Figure 1 LCD Adjustment potentiometer 3. Using a small flat blade screwdriver, adjust this potentiometer for the desired viewing angle. 4. Close the master controller as described in Installing the Faceplate section on page Master Controller Software Selection The master processor board is shipped with several pre-loaded software images, allowing the master controller to be used with different slave arms. The software is user-selectable by configuring two Mode switches located on the main PC board Master Controller Service & Configuration Page 125

12 Maintenance & Service Software can also be loaded from: an existing EPROM using the 28-pin connector on the PC board a Secure Digital card using slot (J5). The three methods are described in the following sections. NOTE: The jaw mode POS (position) option is lost when the software image is changed. To re-enable it after a software change, see section 6.4, Master Controller Software Selection, on page Preparation 1. Turn off the master controller and disconnect the whip from its power source. 2. Open the master controller as described in Removing the Faceplate on page 124.! Caution PC board components can be damaged by static electricity. Wear a grounded anti-static wrist band handling PC boards or chips Selecting Pre-Loaded Software Images The two hexadecimal Mode switches (H and L) are located at the top center of the processor board (Figure 3, left). The available software is listed in a table at the right of Figure 3, and the switch settings for the H and L switches are shown as well. Figure 3 H L Description 0 0 Titan 4, Titan 3, Titan Orion 7P 0 2 Conan 7P 0 3 Dual T3 0 4 Dual Orion 0 5 Dual Conan 0 6 T3 Spaceball FLX 0 7 T3 Robotics 0 8 Titan 4, Enhanced 0 9 Titan 4 Dual Hexadecimal switch orientation and software values 1. Using a small, flat head screwdriver, adjust each switch so the H and L values match those shown for the software you want to use. 2. Close the master controller as described in Installing the Faceplate on page 125 and reconnect the whip. 3. Power up the master controller and view the LCD display. If a compatibility issue occurs between the new system parameters and the old software image, a message will appear on the screen asking you to Ignore, Overwrite, or Update the version number only. If in doubt, overwrite; there are no irreparable consequences due to overwriting the image. Page 126 Master Controller Service & Configuration

13 Maintenance & Service (Overwriting loads the factory default values for system parameters, gains, limits, and stow positions.) Installing an EPROM To install an EPROM chip on the master controller processor board, perform the following steps (also refer to the master controller drawing in the Drawings & Part Lists chapter). The 28-pin connector is located at the lower left corner of the processor board (see Figure 4). 1. Confirm that all pins on the EPROM are aligned and straight. Orient the EPROM with its notch towards the edge of the PCB and press it gently into the socket until the locking clips snap into place. Figure 4 EPROM notch to this end EPROM 28-pin connector! Caution Installing the chip backwards will damage system electronic assemblies. Locate the notch on the chip to the edge of master processor board. 2. Set each hexadecimal switch to F (see Figure 3 on page 126 for an example of the hexadecimal switches and the EPROM switch settings). 3. Close the master controller as described in Installing the Faceplate on page Power on the master controller to load the new software. NOTE: You can also load the EPROM image into the master processor board memory by moving the hex switch to F 0, and then switch to 0 F while the processor board is powered. The EPROM can then be removed from the board and the EPROM image will be available for loading by selecting the hex switch position 0 F. A different EPROM can be installed and the image loaded by selecting hex switch position F F, however if you overwrite the image by selecting F 0 then 0 F, the image from the first EPROM is lost Installing Images from an SD Card The Secure Digital card slot (J5) allows new software, when available, to be loaded into memory on the PCB. Binary images containing the manipulator programs can be loaded onto the SD cards root directory. When the card in inserted into the slot, changing the hex switch settings from F 0 then to 0 F while the processor is running loads the images into memory. The program Master Controller Service & Configuration Page 127

14 Maintenance & Service can then be loaded by selecting the appropriate hex switch positions. After loading into memory, the SD card can be removed Re-enabling POS (Position) Jaw Control The jaw mode POS (position) option is lost when the master controller software image is changed by: adjusting the PCB mode switches. replacing the EPROM (if used). loading a new image from an SD card. To re-enable position jaw control when one of these events has occurred, edit the MEMORY menu as described below. 1. Reconnect the master controller to the manipulator system. Do not provide hydraulic power to the slave controller. 2. Turn on electrical power at the junction box and/or master controller, and the base module. 3. Cycle through the startup menus to the MAIN MENU. Press the 3>SETUP key. Press the SECURITY <6 menu and set the security level to 1 or higher. 4. Press the MEMORY <5 key to enter the MEMORY menu. Use the RT and LF control keys to move the cursor (^) along the address line. Using the UP and DN control keys to select numerals and letters, change the address line from [0:0000-FFFF] to [5:00F0-0000] (FFFF changes to 0000 automatically) as shown in Figure 5. MEMORY EDIT LOCK > Edit:OFF 2> View:OFF LF & RT keys control the cursor. UP & DN keys control the numeral. [5:00F0-0000] ^ EXIT < <CAUTION>-CONSULT MANUAL BEFORE USING THIS MENU Figure 5 MEMORY EDIT menu with new address 5. Press the 1> Edit key to display 1> Edit:0000 (+0000). Use the control keys to change the fourth zero (0) to 1, and the line reads 1> Edit: 0001 (+0001). 6. Press the 1> Edit key to turn the edit function to OFF. The address line now reflects your editing as shown in Figure 6. Page 128 Master Controller Service & Configuration

15 Maintenance & Service MEMORY EDIT LOCK > Edit:OFF 2> View:OFF LF & RT keys control the cursor. UP & DN keys control the numeral. [5:00F0-0001] ^ EXIT < <CAUTION>-CONSULT MANUAL BEFORE USING THIS MENU Figure 6 Address line after editing 7. Press the EXIT <8 key to return to the SETUP menu. Exit the SETUP menu and shut down the system. The editing changes will not take affect until the master controller has been turned off and restarted. 6.5 Incompatibility Alert Screens Incompatibility alert screens may occur during startup when (1) a master controller is used as-is to operate a slave arm other than the one it was supplied with, or (2) when the master controller software configuration has been changed to operate a slave arm other than the one it was supplied with, and (3) the software encounters a setting, ID code, or other condition that differs from what it is expecting. This difference may range from unimportant to critical. The alert screen typically offers an option and the user may have other options for proceeding. These are described in the following sections. No matter which option is chosen, proceed with extreme caution during the startup and operation of the slave arm.! Caution When an incompatibility alert screen appears, use extreme caution if you continue operation. Be prepared to quickly disable hydraulics if the slave arm behaves erratically. NOTE: A Fatal Telemetry Error message at startup is NOT an incompatibility alert screen. It indicates a communications failure caused by component or connection problems, or that the master controller and slave controller/slave arm are completely different models (that is, a master controller configured with Conan software has been connected to an Orion slave controller/slave arm, etc.) Incompatible User-Configurable Settings The user-configurable settings (such as joint travel limits, stow sequence, etc.) remain in nonvolatile memory even after the master controller has been configured with new software. If they are not compatible with the software currently loaded, the alert screen in Figure 7 will be displayed. You have three options Master Controller Service & Configuration Page 129

16 Maintenance & Service a. Press the 4> Overwrite EEPROM button to install the default system non-volatile user-settings. b. Press 3> Ignore to operate the slave arm with the current user-settings. Use extreme caution when testing the slave arm for safe and successful operation. Note that the alert screen will reappear each time the master controller is turned on. c. Press the <7 Update EEPROM Version # only button to operate the slave arm with the current user-settings on a continuing basis the version number is updated to prevent the alert screen from appearing each time the master controller is turned on. Use this option only if you have successfully tried option b. SCHILLING ROBOTICS, INC XXXXX MANIPULATOR SYSTEM Non-volatile memory (EEPROM) is not compatible with this ROM version. Danger exists if the system is operated without the correct memory value. 3> Ignore Update EEPROM <7 Version # only 4> Overwrite EEPROM Figure 7 Non-volatile memory (EEPROM)... warning screen Incompatible Slave Arms/Controllers If the master controller is configured for a standard manipulator system and is connected to an incompatible or custom slave arm and slave controller, you may see the alert screen shown in Figure 8. SCHILLING ROBOTICS, LLC XXXXX MANIPULATOR SYSTEM The Master Controller software is not compatible with the slave arm. Further operation may risk damage to equipment. Select [Yes] only if you would like to proceed anyway. 4> Yes Figure 8 Incompatibility screen You have three options. a. Recommended: Do not use the master controller with this slave arm. Connect a compatible model instead. Page 130 Master Controller Service & Configuration

17 Maintenance & Service b. Operate the slave arm with the software on its original EPROM: if the original EPROM ( PROM ) used with the slave arm is available, install it in the master controller as described in section 6.4.3, Installing an EPROM, on page 127. c. Pressing the 4> Yes key updates the user-configurable memory with the factory default settings for the currently loaded software. Use extreme caution when testing the slave arm for safe and successful operation Incompatible Systems A master controller configured for use with one type of manipulator system (Titan, Conan, or Orion) cannot communicate with a slave arm of a different type system, and if connected, will display a Fatal Telemetry Error screen at startup. 7 Slave Controller Service & Configuration This section contains special maintenance and service procedures not covered in the Work Instructions. For additional details, refer to the Slave Controller drawing and part list in the Drawings & Part Lists chapter. 7.1 Fuse Replacement Slave controller circuits are protected by self-resetting, non-replaceable fuses. 7.2 Internal Access Opening the Slave Controller To access internal slave controller components, perform the following steps: 1. Disable electrical power and hydraulic power to the slave controller. 2. Isolate the compensation system and drain the slave controller cavity. 3. Remove 12 SHCS and washers securing the slave controller lid (Figure 9). Remove the lid. Remove Screw & Washer (12X) Figure 9 Slave controller lid screws With the lid removed the following special service procedures can be performed: Replacing the Solenoid Filter section on page Slave Controller Service & Configuration Page 131

18 Maintenance & Service Replacing an Actuator Controller Board section on page 133 Changing Jumpers in the Slave Controller section on page 139 With the lid removed and the motherboard swung aside, the following special service procedures can be performed ( Accessing the Servo Valves, Jaw Bypass Valve, & Filter section on page 135): Replacing a Servo Valve section on page 136 Removing the Jaw Bypass Valve section on page Closing the Slave Controller 1. Replace the slave controller lid o-ring ( ). Make sure it is completely seated before installing lid. Install the x 1-in screws and washers, and torque to 45-in./ lbs (Figure 9). 7.3 Replacing the Solenoid Filter The solenoid valve assembly contains a tubular, mesh-screen hydraulic filter which can be removed for cleaning. The most common symptom of a clogged filter is sluggish operation of all slave arm functions despite adequate hydraulic pressure and flow from the HPU. This procedure assumes the lid has been removed from the slave controller. The solenoid filter assembly is shown in Figure Remove the six x 1-1/2 screws from the filter block and lift off the filter cap/filter assembly (Figure 10). Filter Block Filter Cap Figure Screw (6x) Solenoid filter access 2. Remove the filter from the cap. Use compressed air to blow out passages in cap. 3. Install a new filter into cap (check that o-ring is present) or replace original filter after cleaning with ultrasound (Figure 11). Page 132 Slave Controller Service & Configuration

19 Maintenance & Service O-ring Filter and O-ring O-ring Filter Cap Figure 11 Filter, filter cap, and o-rings 4. Install new o-rings and to cap (Figure 11). 5. Replace the filter cap and secure with the six x 1-1/2-in screws. Torque the screws to 45-in./lbs. 6. Replace the slave controller lid as described in Closing the Slave Controller on page Replacing an Actuator Controller Board! Caution When any actuator controller board is replaced, the new board s DIP switch must be set with the address of the actuator it will control. If the controller board has the wrong address, the actuator may not respond to commands or may respond to commands intended for a different actuator. When any controller board is replaced on the motherboard, its DIP switch must be set with the address of the actuator it will control. If the controller board has the wrong address, the actuator may not respond to commands or may respond to commands intended for a different actuator.! Caution When handling PC boards or other electronic components, wear an anti-static wrist band attached to earth ground or large metal object. The actuator/joint designation and DIP switch settings are printed on the motherboard beneath each of the actuator controller boards. 1. Complete the steps in Internal Access on page Locate the controller board to replace. 3. Remove the harness at J5 (Figure 12). Press all five tabs on connector J4 to remove the ribbon cable. 4. Squeeze the three tabs and lift the board straight up off the standoffs Slave Controller Service & Configuration Page 133

20 Maintenance & Service Harness to J5 Connector J4 Tabs (3x) Figure 12 Removing harness, ribbon cable and controller board 5. Set DIP switches on the replacement controller board as outlined below: The DIP switch unit is shown in Figure 13. Individual switches are labeled, left to right, with numbers 1 through 8 across the bottom of the switch unit. Each switch contains a sliding tab. The switch is on when the sliding tab is toward the on label. It is in the off position when the sliding tab is moved closest to its number. Figure 13 Setting controller board address switches The actuator/joint designation and DIP switch settings are printed on the motherboard beneath each of the actuator controller boards. Switch settings for each joint are also shown in Table 2 and Table 3. Use a non-conducting tool for moving switches. Table 2 Joint No. Joint Name Sw 1 Sw 2 Sw 3 Sw 4 Sw 5 Sw 6 Sw 7 Sw 8 0 Azimuth On On On On On On On On 1 Shoulder Off On On On On On On On 2 Elbow On Off On On On On On On 3 Forearm roll Off Off On On On On On On 4 Pitch On On Off On On On On On 5 Wrist Off On Off On On On On On 6 Jaw On Off Off On On On On Off Page 134 Slave Controller Service & Configuration

21 Maintenance & Service Joint No. Joint Name Table 3 Sw 1 Sw 2 Sw 3 Sw 4 Sw 5 Sw 6 Sw 7 Sw 8 0 Azimuth On On On Off On On On On 1 Shoulder Off On On Off On On On On 2 Elbow On Off On Off On On On On 3 Forearm roll Off Off On Off On On On On 4 Pitch On On Off Off On On On On 5 Wrist Off On Off Off On On On On 6 Jaw On Off Off Off On On On Off 6. Install the new controller board. While installing the board, be careful not to damage the pins that the board seats on. 7. Install the ribbon cable and wire harness (Figure 12). 8. Replace the slave controller lid as described in Closing the Slave Controller on page Accessing the Servo Valves, Jaw Bypass Valve, & Filter The following steps assume the slave controller lid has been removed ( Internal Access on page 131): 1. On the slave controller board, press all five tabs on connector J2 to remove the ribbon cable (Figure 14). Ribbon Cable Motherboard Connector J2 Slave Controller Board Figure 14 Removing slave controller board ribbon cable 2. Remove the wire harness from J5 on the jaw, wrist, and pitch controller boards (Figure 15). Feed the wires down through the holes in the motherboard Slave Controller Service & Configuration Page 135

22 Maintenance & Service Wire Harness J5(3x) Motherboard Retaining Screw Jaw Bypass Valve Figure 15 Removing wire harness at J5 (3x) 3. Remove the three 6-32 screws that hold the motherboard in place (Figure 15). Carefully swing the motherboard up and to the side. With the motherboard swung aside, the following service procedures are possible: Replacing a Servo Valve section on page 136 Removing the Jaw Bypass Valve section on page Replacing a Servo Valve This procedure assumes the motherboard is swung aside and the servo valves are accessible ( Accessing the Servo Valves, Jaw Bypass Valve, & Filter section on page 135). Lockvalves and associated assemblies for other servo valves vary with function. To replace a servo valve follow the steps below: 1. Remove four 6-32 screws that hold the servo valve in place (Figure 16, Removing servo valve on page 137). Remove the servo valve and the o-ring that lies under it. Page 136 Slave Controller Service & Configuration

23 Maintenance & Service Servo Valve 6-32 Screw (4x) Screw (4x Bypass Valve Lockvalve Figure 16 Removing servo valve 2. Lubricate a new o-ring with o-ring lube and install. Install the new servo valve and torque 6-32 screws to 5-in./lbs. 3. Swing the motherboard back into position. Secure it with the three 6-32 screws and torque them to 5-in./lbs. Feed the wire harnesses up through the motherboard and connect to the J5 connector on the controller boards ( Removing wire harness at J5 (3x) section on page 136). Connect the ribbon cable to the slave controller board ( Removing slave controller board ribbon cable section on page 135). 4. Replace the slave controller lid as described in Closing the Slave Controller on page Removing the Jaw Bypass Valve Manifold When hydraulics are disabled, whether through operator control or hydraulic failure, a bypass valve in the slave controller causes the jaw to relax its grip. Objects held by the jaw may be released or dropped. If you prefer that the jaw lock when hydraulic power is disabled, the bypass valve must be removed. NOTE: This procedure requires four new SHCS, x 1-1/2-in. (P/N ), and cannot be completed without them (see Orion Spares Kit or Slave Controller Spares Kit ). This procedure assumes the motherboard is swung aside and the servo valves are accessible ( Accessing the Servo Valves, Jaw Bypass Valve, & Filter section on page 135). NOTE: It is not necessary to remove or separate the servo valve from the lockvalve for this procedure. 1. Locate the jaw servo valve (Figure 16). 2. Remove the four screws that secure the servo valve/lockvalve assembly and the jaw bypass valve to the slave controller manifold. 3. Carefully move the servo valve/lockvalve assembly aside and remove the bypass valve block and the bottom four o-rings Slave Controller Service & Configuration Page 137

24 Maintenance & Service 4. Add four new o-rings to the bottom of the servo valve/lockvalve assembly. Place the servo valve/lockvalve assembly onto the slave controller manifold and align the mounting holes. 5. Install four new SHCS x 1-1/2-in. (P/N ) and torque to 45-in./lbs. 6. Swing the motherboard back into position. Secure with the three 6-32 screws and torque to 5-in./lbs. Feed the wire harnesses up through the motherboard and connect to connector J5 on the controller boards (Figure 15). Connect the ribbon cable to the slave controller board (Figure 14). 7. Replace the slave controller lid as described in Closing the Slave Controller on page System Adjustments 8.1 Changing the Communications Protocol This manipulator system can be operated using RS-232 or RS-485 telemetry protocol. RS-232 is the factory default. To alter the telemetry protocol you must: move the connector on the master controller board (see section 8.1.1) change the jumpers in the base module PC board in the slave controller (see section 8.1.2) Configuring the Master Processor Board 1. Open the master controller as described in the Master Controller Service section. The P1A connectors for RS-232 communications (Default) and P1B for RS-485 communications are located at the upper right side of the processor board. In Figure 17 below, the J1 connector terminating the power/telemetry bundle is connected to P1A (RS-232). Figure 17 RS-232 / RS-485 connection points 2. To relocate the J1 connector, grasp the connector with needle-nosed pliers, pull it straight out of the P1A plug, and carefully reinstall it into the P1B plug. 3. Verify that the protocol selected on the forearm harness connection and the master processor board are the same (RS-232 or RS-485). 4. Swing the faceplate assembly back over and seat it on the enclosure. Make sure that no wires or cables are pinched between the faceplate and the enclosure. 5. Loosely install the four cover mounting screws - do not tighten at this time. Page 138 System Adjustments

25 Maintenance & Service Changing Jumpers in the Slave Controller Perform the following steps to access base module PC board (the small board located above the solenoid and filter): 1. Disable electrical power and hydraulic power to the slave controller. 2. Isolate the compensation system and drain the slave controller. 3. Remove 12 SHCS and washers securing the slave controller lid (Figure 9). Remove the lid Screw & Washer (12X) Figure 18 Slave controller lid screws 4. Set the jumpers on the base module PC board for the desired telemetry option using the table and illustration shown in Figure 19. Jumper settings that are the same for RS-232 and RS-485 are shown in gray System Adjustments Page 139

26 Maintenance & Service JP1 1 2 = Jumper setting the same for RS-232 & RS JP2 JP3 JP4 JP5 JP6 JP JP8 JP9 Base Module PCB (RS-485 configuration shown) TABLE FROM DRAWING Figure 19 Base module/scu PCB and jumper locations & settings 5. Do not close up the slave controller. Proceed to the sext section Testing the Protocol Configuration 1. Before closing up the master and slave controllers, connect all manipulator system components and confirm system operation. If the system starts and operates correctly, proceed to the next step. If the system fails to start or the message FATAL TELEMETRY ERROR appears on the display, check for the following problems and correct them before proceeding: a. Are the settings in the master controller and slave controller for the same protocol? b. Has a jumper or pin been damaged or bent? c. Does the manipulator system operate correctly when connected for deck-testing (long lines bypassed)? Page 140 System Adjustments

27 Maintenance & Service d. Are the connections to multiplexed long lines consistent, end to end, for slave>master/master>slave or RS-485/RS-232 communications. 2. (System is operating correctly) Make sure that no wires or cables are pinched between the faceplate and the master controller enclosure. Tighten the four mounting screws. 3. Replace slave controller lid o-ring ( ). Ensure it is completely seated before installing lid. Install the twelve x 1-in screws and washers and torque to 5.08 Nm (45-in./lb). 4. Charge and bleed the slave controller compensation system (see the Installation chapter for details). 8.2 Setting Servo Valve Offsets The servo offset adjustment balances servo valve response to control input so the actuator movement speed is consistent in both directions of travel. Correct adjustment also keeps actuators without lockvalves (wrist pitch/yaw, wrist, jaw) immobile when the servo valve is inactive (no control input pending) and reduces sag and/or drift when hydraulics are disabled. Key physical symptoms pointing to need for adjustment are: A joint that moves faster in one direction than the other (given similar control inputs). This is most noticeable following a high speed movement of the master arm, when the servo valve is fully driven Spontaneous joint drift in the wrist pitch/yaw, wrist, or jaw functions An increase in the sag or drift of the wrist pitch/yaw, wrist, or jaw functions when hydraulics are disabled The servo valve offset for each function is set at the factory but should be checked and adjusted when a servo valve, control module, actuator, or other control software or hardware within the master controller, slave controller, or control module has been serviced or replaced. Component wear, temperature, and other environmental factors may also affect the servo valve response and initiate the need for offset adjustment. The servo offset for each joint (including the wrist and jaw) is set independently, and does not affect the offset for any other joint. The goal is to equalize the servo valve's null position so that when it is activated the servo can provide an equivalent hydraulic flow to either port of the actuator. This will ensure balanced travel rates and minimize sagging and drift in the functions without lockvalves.! Caution Changes to the servo offsets can change the positioning response of the slave arm joint. If the slave arm movement limits and/or stow sequence are critical to prevent damage to the slave arm or work area, you should immediately reset them (see the Operation chapter for details). To set the slave arm servo offsets, follow these steps: 1. Set the current privilege level to 1 or higher. (If you aren't sure what the current level is, display the SET LEVEL menu, as described in the Operation chapter, and note the level System Adjustments Page 141

28 Maintenance & Service displayed on the screen). Enter the password and change to a higher privilege level if necessary. 2. From the OPERATE menu toggle the jaw mode to POS. Make sure hydraulics are enabled (ON). 3. From the MAIN menu, select 3> SETUP. From the SETUP menu, select SET SV OFFSET <7 (Figure 20). SET SV OFFSET FRZ > Joint:Azimuth Inc Offset <5 Pos Error:+0004 Dec Offset <6 SV Offset:-050 EXIT < Figure 20 Setting servo offsets 4. The slave arm should be positioned so that all joints are near the centers of their ranges of motion. If any of the joints are at or near their limits, unfreeze the arm and reposition it, then freeze it again. 5. The joint for which servo offset is being set will appear in the 1> Joint: field. You can cycle through the joints by pressing 1> Joint. 6. For each joint, a value appears in the Pos Error: field. The goal is to get this value as close to zero as possible. (In practice, the lowest absolute value between and is acceptable.) If displayed value is not near-zero, press 5> Inc Offset and 6> Dec Offset keys to adjust the value in the SV Offset: field until the Pos Error: field value is lowest. NOTE: The slave arm will move slightly after each increment or decrement of the servo offset. You should wait a few seconds after each change for the arm, and the values, to stabilize. 7. Press 1> Joint: to move to the next joint. Repeat step 6 until the servo offsets for all joints except the jaw (azimuth, shoulder, elbow, pitch, yaw, and wrist) have been nulled. 8. Jaw offset adjustment: If necessary, reposition the arm so that you can see the jaw, and freeze the arm again. The jaw mode must be set, in the OPERATE menu, to POS for this step. The jaw lacks position feedback, so its servo offset adjustment is less precise. Normally, you must adjust the jaw servo offset only if the servo valve has been serviced, or the jaw slowly opens or closes spontaneously. To null the jaw servo offset, perform the following adjustment procedure: a. Press 1> Joint until the adjacent field reads JAW. b. Press 5> Inc Offset until the jaw begins closing slowly. Note the SV Offset value (it may be relatively large). (Allow the jaw to close all or most of the way.) Page 142 System Adjustments

29 Maintenance & Service c. Press 6> Dec Offset until the jaw begins opening slowly. Again note the SV Offset value. d. Add the two offset values algebraically (include plus or minus signs). If, for example, the positive offset value was +500 and the negative offset value was -240, their algebraic sum is Divide this value by 2. Increment or decrement the SV offset to match this result (+130, in the example). 9. Press 8> EXIT to exit the SET SV OFFSET menu and save the new settings.! Caution Changes to the servo offsets can change the positioning response of the slave arm joints. Reset the slave arm movement limits and/or stow sequence immediately if the settings are needed to prevent damage to the slave arm or work area (see the Operation chapter for details). 9 Shortening the Hydraulic Hoses The following instructions describes how to shorten and reterminate a hydraulic hose with reusable fitting (OEM Aeroquip ). 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 21). 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. 3. Trim the hose jacket back about 1-1/2 in. from the end, exposing the braid, as shown in Figure /2 Figure 21 4.Match and install new hose code tags to the appropriate hoses, at least 2-in. from the hose ends. Hose code/functions designations are shown in the table above. 5. Install the socket onto the hose end (Figure 22, arrow). Push the new sleeve over the end of the tube and under the wire braid by hand as shown in Figure 22. 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 endface of the sleeve). Visually confirm this orientation. Figure Shortening the Hydraulic Hoses Page 143

30 Maintenance & Service 6. Clamp the hex of the nipple in a vise (male fitting shown). Push the hose and sleeve over nipple as shown in Figure 23. Work the hose with twisting motion until it is seated against the nipple chamfer (at the base of the nipple). Figure 23 7.As shown in Figure 24A below, push the socket forward on the hose and thread onto the nipple. 8. As shown in Figure 24B 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. A B Figure Clean interior of hose assembly with compressed air or flush with mineral spirits or hot water (65 C/150 F max.). If the hose will not be reconnected immediately, cap or plug end fittings. 10.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. 11. Proof testing:! Caution Conduct hose tests with adequate safeguards to protect the operator. Test the hose assembly at 6000 psi (twice the recommended working pressure of the hose). Hold the test pressure 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 the hose in relation to the hose fitting. Correct any defects before placing the hose into service. 12. Install the hoses between the slave arm and slave controller, matching the hose and fitting codes. 10 Service Instructions This section includes detailed service instructions, information on how to use them, and steps for restarting your slave arm after service. Page 144 Service Instructions

31 10.1 Using the Service Instructions Preliminary Information & Requirements Maintenance & Service The first section of each Service Instruction provides information about the specific component or assembly to which it applies, and estimated time to complete the instruction. Following are sections listing materials, chemicals, standard and custom tools you must provide, and preparations you must complete before starting service. Acronyms and other potentially ambiguous terminology within the text are defined. Part Identification Within the instruction steps, individual parts are identified by a number in parentheses. This number corresponds to the part number of the part on the part list (see Drawings & Part Lists chapter). On the related drawing, this number is placed in a box, with a line drawn to the specific part. Alert Symbols Contained in the service instructions are special paragraphs that will help you perform the procedures more efficiently or safely: A Note paragraph contains added information that you will need to consider while performing a specific procedure. A Tip paragraph contains information that will help you perform a procedure quicker or easier. A Caution paragraph may indicate a critical process, an unexpected result, or other action where equipment is at risk. A Warning paragraph indicates a risk of personal safety or severe damage to equipment. Pay close attention to warnings. Before beginning any service, review the required maintenance and service practices and safety alerts outlined at the start of the chapter Start-up Following Service After Minor Service: Follow the Startup Process in the Installation chapter. Be sure to replace any hydraulic fluid lost during maintenance or service and bleed air from the system. After Major Service: Follow the procedures in the First Startup section of the Installation chapter before operation. If it is likely that fluid has been contaminated, flush the hydraulic system, replace with fresh, filtered fluid, and bleed air from the system Service Instructions Service instructions are provided in this section. See the list of instructions on the following page Service Instructions Page 145

32 Maintenance & Service This page not used. Page 146 Service Instructions

33 Service Instructions List Service Instructions List Service and work instructions are listed below. Only one of the jaw service instructions will apply to your manipulator system. Azimuth page 149 Upper Arm, Standard, page 157 Upper Arm, Extended, & page 171 Forearm Rotary Actuator, page 185 Forearm, page 215 Wrist, page 235 Jaw Piston/Nose Block, page 257 Jaw Piston/Nose Block for P-A Jaw, page 267 Wrist/Jaw Adapter for P-A Jaw, page 277 Parallel-Acting Jaw page in Intermeshing Jaw, & page 293 Intermeshing Jaw, 11.5-in, page 299 Linear Actuators, , -3939, 4328, & page 307 Change Forearm Rotary Index Setting page Liter Compensator Diaphragm: Remove & Install page Liter Compensator Oil-Side Housing: Remove & Install page Page 147

34 Service Instructions List This page not used. Page

35 Service Instruction Azimuth Estimated Time to Complete 2 hours Preparation for Service Below is a list of required tools and materials for this Service Instruction. Look over the list and make sure you have all the materials before you get started. Read through the entire procedure to make sure you understand, and are capable of performing, the service. Take special notice of all notes, warnings, and the terminology section. Tools Needed 7/16-in. socket Materials Needed Valvoline Val-Plex EP Grease 1/2-in. socket Aqua Lube ( ) 0-25mm (0-1-in.) micrometer Dow Corning 55 O-ring lube or petroleum jelly Dow Corning 5 Silicone Grease Custom Tools Needed none needed Terminology HHCS = Hex Head Cap Screw HPU = Hydraulic Power Unit SHCS = Socket Head Cap Screw! Caution Some components have protective coatings such as anodizing. Take care not to scratch any protective coatings. Corrosion damage will result. Note: To remove the azimuth assembly you must remove the slave arm from the azimuth. You will need an adequate means of supporting the arm when it is removed. SERVICE INSTRUCTION Page 149

36 Perform all assembly work in a clean, dry environment if possible. Although assembly of major slave arm components must often be performed under field conditions, the intermeshing jaw should be disassembled and reassembled under clean service conditions to prevent contamination and damage to bearing surfaces. Prepare a clear area on the work surface in which to arrange the components as the intermeshing jaw is disassembled. We recommend that you make a photocopy of this Service Instruction for workbench use. Disable the Slave Arm! WARNING Before you can service the arm safely, you need to disable the electrical and hydraulic functions of the arm. Follow the steps below before you continue. 1. Raise the arm to a comfortable working position. 2. Turn off the power switches located on the master controller and the junction box. 3. Turn off the power to the hydraulic power unit (HPU). 4. If power is supplied from a local, independent source, turn off power to the slave controller. 5. If your arm is equipped with a hydraulic compensation unit, isolate the unit from the arm. Remove the Azimuth Disassembly of the intermeshing jaw assumes that all preparations, previously described in this Service Instruction, have been met. Numbers in parentheses refer to the part number of the item. See Figure 1 for basic identification of intermeshing jaw parts. Page SERVICE INSTRUCTION

37 Hose Guard Bearing (4x) Base HHCS (4x) Retainer (2x) Pin (2x) HHCS and Washer (3x) and Anode Hose Guard Bumper (2x) HHCS (4x) Bumper (2x) Azimuth Linear Actuator Connector Spacer (2x) Bearing (2x) Azimuth Pin HHCS (2x) Figure 1 Azimuth basic parts identification Remove Slave Arm from Azimuth Assembly Refer to Figure 1 and Figure 2 for this procedure. SERVICE INSTRUCTION Page 151

38 HHCS (2x) Retainer (2x) Pin Shoulder Linear Actuator Actuator Guard Upper Arm Anode Base Azimuth Pin HHCS and Washers (2x) and Spacer (2x) Figure 2 Removing the slave arm 1. Remove the two anodes ( ) from the base ( ) and the azimuth ( ) (see Figure 1 and Figure 2). 2. Remove the three HHCS and washers ( and ) and remove the hose guard ( ) (see Figure 1). 3. Remove the four HHCS ( ) and remove the hose guard ( ) and two bumpers ( ) (see Figure 1).! WARNING After the next step, the slave arm will not be supported. Properly support the slave arm to avoid personal injury and damage to the slave arm and attached hydraulic hoses. 4. At the shoulder linear actuator ( ), remove the two HHCS ( ), washers ( ), and actuator guard ( ) from the upper arm (see Figure 2). Slide the pin ( ) out of the upper arm (see Figure 2). 5. Remove the two HHCS ( ) and retainer pin ( ) from the upper arm (see Figure 2). Slide the pin ( ) out of the upper arm (see Figure 2). As you remove the slave arm from the azimuth ( ), carefully move the slave arm to the side. Remove Azimuth from Base Assembly Refer to Figure 3 and Figure 4 for this procedure. Page SERVICE INSTRUCTION

39 Base Retainer HHCS (4x) (2x) Pin Connector Azimuth Spacer (2x) SHCS and Washers (4x) and HHCS (2x) Pin Hydraulic Hose (2x) Azimuth Linear Actuator Figure 3 Removing azimuth linear actuator from base assembly 1. At the azimuth linear actuator ( ), remove two HHCS ( ) and retainer pin ( ) from base ( ) (Figure 3). Slide pin ( ) out of the base (Figure 3). 2. If you do not need to service the azimuth linear actuator, skip to step 3. Remove the four SHCS ( ) and washers ( ) from the connector ( ) (see Figure 3) and the actuator. Remove the connector. 3. Remove two HHCS ( ) and retainer pin ( ) from the base (Figure 4). Remove pin ( ) and slide the azimuth out of the base enough to perform step 4 (Figure 4). Azimuth Pin HHCS (2x) Retainer Pin Bumper (2x) Base Bearing (6x) Figure 4 Removing azimuth from base assembly 4. Remove the two HHCS ( ), slide the pin ( ) out, and remove the two spacers ( ) (see Figure 3). Remove the actuator from the base. Note: Do not allow the actuator to hang from the hydraulic hoses. SERVICE INSTRUCTION Page 153

40 5. If you do not need to service the azimuth linear actuator, skip to step 6. If you need to service the azimuth linear actuator, remove the hydraulic hoses from the actuator (see Figure 3). To service the actuator, see Orion P Service Instructions for Linear Actuators, , -3939, 4328, & Remove the two bumpers ( ) from the azimuth (see Figure 4). Inspect Azimuth Components Refer to Figure 1 and Figure 6 for this procedure. 1. Inspect the bearings ( ) for signs of excessive wear or damage (see Figure 1 and Figure 6). Replace any damaged bearing. 2. Inspect the pins ( and ) for signs of excessive wear, galling, or other damage (see Figure 1). Use a micrometer to measure the pins. Replace any damaged pin, or any pin with a diameter of 25.3 mm or less (0.997-in. or less). 3. Inspect the bumpers ( and ) (see Figure 1). Replace if damaged or excessively compressed. 4. Inspect the azimuth ( ) and base ( ) for signs of twisting, cracking, or other damage (see Figure 1). Replace if damage is found. Install Azimuth into Base Assembly Refer to Figure 5 and Figure 6 for this procedure. Base Pin HHCS (4x) (2x) Pin Connector Azimuth Spacer (2x) HHCS (2x) Pin SHCS and Washers (4x) and Azimuth Linear Actuator Figure 5 Installing azimuth linear actuator into base assembly 1. If you did not service the azimuth linear actuator, skip to step 2. If you serviced the azimuth linear actuator, lightly lube hydraulic fitting sealing surfaces with EP grease. Install hydraulic hoses to the azimuth linear actuator (Figure 5). Tighten the hose fittings finger tight, then one-sixth of a turn to tighten the hose fitting. Page SERVICE INSTRUCTION

41 2. Lubricate the two HHCS ( ) with Aqua Lube (see Figure 5). Lubricate the pin ( ) with EP grease (see Figure 5). Install the spacers ( ) and azimuth linear actuator ( ) into the azimuth ( ) (see Figure 5). Slide the pin into place. Install two HHCS and torque to 11 Nm (8 ft/lbs). 3. Install the two bumpers ( ) onto the azimuth ( ) (see Figure 6). Azimuth Pin HHCS (2x) Retainer Pin Bumper (2x) Base Bearing (6x) Figure 6 Installing azimuth into base assembly 4. Lubricate the two bearings ( ) with EP grease (see Figure 6). Place the azimuth into position in the base (see Figure 6). Lubricate the pin ( ) with EP grease and install into the base and azimuth (see Figure 6). 5. Apply Aqua Lube to threads of the two HHCS ( ) (Figure 6). Install two HHCS and the retainer pin ( ) onto base (Figure 6). Torque to 11 Nm (8 ft/lbs). 6. If you did not service the azimuth linear actuator, skip to step 7. Apply Aqua Lube to the threads of the four SHCS ( ) (see Figure 5). Fill the cavity of the connector ( ) with DC5 grease. Using four SHCS and washers ( ), install the connector to the shoulder linear actuator ( ) (see Figure 5). Torque to 1.1 Nm (10-in./lbs). Wipe away excess DC5 grease. 7. Apply Aqua Lube to the threads of the two HHCS ( ) (see Figure 5). Lubricate the retainer pin ( ) with EP grease (see Figure 5). Align the shoulder linear actuator with the base and insert the pin ( ) (see Figure 5). Install two HHCS and retainer pin ( ) (see Figure 5). Torque to 11 Nm (8 ft/lbs). SERVICE INSTRUCTION Page 155

42 Install Slave Arm onto Azimuth Assembly Refer to Figure 1 and Figure 7 for this procedure. HHCS (2x) Pin (2x) Pin Shoulder Linear Actuator Actuator Guard Upper Arm Anode Base Azimuth Pin HHCS and Washers (2x) and Spacer (2x) Figure 7 Installing the slave arm 1. Apply Aqua Lube to threads of the four HHCS ( ) (Figure 7). Lubricate the two pins ( ) with EP grease. Place the upper arm into position on the base (Figure 7). Slide the pins ( ) through the upper arm and into the base (Figure 7). 2. Apply Aqua Lube to threads of the two HHCS ( ) (Figure 7). Install two HHCS and the retainer pin ( ) onto upper arm (Figure 7). Torque to 11 Nm (8 ft/lbs). 3. Position shoulder linear actuator ( ) into azimuth ( ) (Figure 7). Lubricate pin ( ) with EP grease. With two spacers ( ), slide into place (Figure 7). 4. Apply Aqua Lube to the threads of the two HHCS ( ). Install the washers ( ) to the two HHCS and attach the linear actuator guard ( ) to the shoulder linear actuator (see Figure 7). Torque to 11 Nm (8 ft/lbs). 5. Apply Aqua Lube to threads of the four HHCS ( ). Install hose guard ( ) and two bumpers ( ) onto the base (Figure 1). Torque to 2.7 Nm (24-in./lbs). 6. Apply Aqua Lube to the threads of the two HHCS. Install the hose guard ( ) with HHCS and washers ( and ) (see Figure 1). Torque to 11 Nm (8 ft/lbs). 7. Apply Aqua Lube to the threads of the two anodes ( ). Install them to the base and the azimuth (see Figure 1 and Figure 7). END OF SERVICE INSTRUCTION Page SERVICE INSTRUCTION

43 Service Instruction Upper Arm, Standard, Estimated Time to Complete 3 hours Preparation for Service Below is a list of required tools and materials for this Service Instruction. Look over the list and make sure you have all the materials before you get started. Read through the entire procedure to make sure you understand, and are capable of performing, the service. Take special notice of all notes, warnings, and the terminology section. Tools Needed Materials Needed 9/64-in. allen wrench Valvoline Val-Plex EP Grease 3-32-in. allen wrench Aqua Lube ( ) 7/16-in. socket Dow Corning 55 O-ring lube or petroleum jelly 9/16-in. socket Dow Corning 5 Silicone Grease 9/16-in. open-end wrench 3/32-in. flat-blade screwdriver Custom Tools Needed none needed Terminology HHCS = Hex Head Cap Screw SHCS = Socket Head Cap Screw HPU = Hydraulic Power Unit! Caution Some components have protective coatings such as anodizing. Take care not to scratch any protective coatings. Corrosion damage will result. SERVICE INSTRUCTION Page 157

44 ! Caution Replace hydraulic hoses only with the designated PDH (Pressure Diagnostic Hose) spares: Orion 7 PE Standard Orion QUEST 7PE -4 Hose, 1B Hose, 1A Hose, 2A Hose, 2B Replacement with hoses of other jacket types (steel, etc.) will result in premature hose failure. The procedures in this Service Instruction assume that the intermeshing jaw will be removed from, and then reattached to, the azimuth. The roll (elbow) joint will need to be detached from and reattached to the upper arm assembly as part of the servicing. Perform all assembly work in a clean, dry environment if possible. Although assembly of major slave arm components must often be performed under field conditions, the intermeshing jaw should be disassembled and reassembled under clean service conditions to prevent contamination and damage to bearing surfaces. Prepare a clear area on the work surface in which to arrange the components as the intermeshing jaw is disassembled. We recommend that you make a photocopy of this Service Instruction for workbench use. Disable the Slave Arm! WARNING Before you can service the arm safely, you need to disable the electrical and hydraulic functions of the arm. Follow the steps below before you continue. 1. Raise the arm to a comfortable working position. 2. Turn off the power switches located on the master controller and the junction box. 3. Turn off the power to the hydraulic power unit (HPU). 4. If power is supplied from a local, independent, source turn off power to the slave controller. 5. If your arm is equipped with a hydraulic compensation unit, isolate the unit from the arm. Introduction The serviceable areas of the intermeshing jaw assembly are the: Hydraulic hoses Elbow linear actuator with its pivot pins and bearings Shoulder linear actuator with its pivot pins and bearings Page SERVICE INSTRUCTION

45 Shoulder joint pivot pin and bearing Roll (elbow) joint pivot pin and bearings Remove the Upper Arm Disassembly of the intermeshing jaw assumes that all preparations, previously described in this Service Instruction, have been met. Numbers in parentheses refer to the part number of the item. See Figure 1 for basic identification of intermeshing jaw parts. Upper Arm HHCS and Washers (8x) and Manifold Cover Roll Base Shoulder Linear Actuator Elbow Linear Actuator Figure 1 Upper arm parts identification Remove Elbow Parts Refer to Figure 2, Figure 3, Figure 4, and Figure 5 for this procedure. HHCS and Washers (8x) and Manifold Cover Upper Arm Forearm Rotary Actuator Forearm Figure 2 Manifold cover and forearm rotary actuator 1. Remove the eight HHCS ( ) and washers ( ) securing the manifold cover ( ) to the top of the forearm rotary actuator ( ) (see Figure 2). Remove the manifold cover to expose the wire housing cover ( ) (see Figure 3). SERVICE INSTRUCTION Page 159

46 2. Remove five SHCS ( ) holding wire housing cover ( ) to the top of the wire housing (Figure 3). Remove wire cover housing cover and remove large o-ring ( ) and four smaller o-rings ( ) from the wire housing cover (Figure 3). O-ring O-ring (4x) Wire Housing Cover Wire Housing SHCS (5x) Figure 3 Wire housing cover and o-ring location 3. Using a 3/32-in flat-blade screwdriver, remove the position sensor wires from the PCB assembly ( ) (see Figure 4). Note: Note that the wires are connected across from wires of the same color and striping. Position Sensor Wires Wire Housing O-ring (2x) SHCS (4x) PCB Assembly Position Sensor Rotary Actuator Adapter Plate Figure 4 Removing position sensor wires and position sensor 4. Remove the four SHCS ( ) securing the wire housing ( ) to the rotary actuator ( ) (see Figure 4). Lift the wire housing off and remove the o-ring ( ) from the bottom of the wire housing. Page SERVICE INSTRUCTION

47 5. Carefully lift the position sensor ( ) straight up and off the rotary actuator (see Figure 4). Try not to rotate the sensor as you lift it from the actuator. Set the sensor aside. 6. Remove the o-ring ( ) from the bottom of the position sensor (see Figure 4). Note: Before continuing to step 7, make sure the hydraulic hose ends at the manifold are clearly labeled. Use a permanent marker and tape to label unmarked hoses.! Caution Hydraulic fluid will spill out of the hydraulic hoses when you remove them during step 7. Have a drain pan ready to catch the fluid. 7. Remove all the hydraulic hoses (8x) from the slipring manifold ( ) (see Figure 5). Hydraulic Hoses (6x) Slipring Manifold Hydraulic Hoses (2x) Figure 5 Removing the hydraulic hoses from the slipring manifold Remove Roll Base/Forearm Refer to Figure 6 for this procedure.! WARNING After step 8, the elbow/forearm of the slave arm will not be supported. Properly support the slave arm to avoid personal injury and damage to the forearm. 8. Support the forearm. Remove the two HHCS ( ) and slide the pin ( ) out of the roll base and elbow linear actuator ( ). 9. Support the forearm. Remove four HHCS ( ) and two pins ( ) from the roll base. Remove pins ( ) from roll base and upper arm. Set the forearm aside. 1. Remove the two cap plugs ( ) from each side of the roll base ( ). SERVICE INSTRUCTION Page 161

48 Roll Base Elbow Linear Actuator HHCS (2x) Pin Pin Pin Retainer2x) HHCS (4x) Cap Plug (2x) Bearing Figure 6 Removing roll base/forearm Remove Linear Actuators from Upper Arm Refer to Figure 7 and Figure 8 for this procedure. Anode (opposite side) Upper Arm Azimuth Pin Elbow Linear Actuator HHCS and Washers (2x) and Shoulder Linear Actuator Spacer (2x) Actuator Guard Pin Pin Retainer HHCS Figure 7 Removing actuators from upper arm 1. Remove the anode ( ) from the upper arm ( ) (see Figure 7). 2. At elbow linear actuator ( ), remove two HHCS ( ) and pin ( ) from the upper arm (Figure 7). Slide pin ( ) out of the upper arm (Figure 7). Note: Do not allow the actuator to hang from the hydraulic hoses. Page SERVICE INSTRUCTION

49 3. Remove the four SHCS ( ) and washers ( ) from the connector ( ) (see Figure 8) and the actuator. Push the connector up, and through, the cutout in the upper arm (see Figure 8). To the service linear actuator, see Orion P Linear Actuators, , -3939, 4328, & Service Instruction. Shoulder Linear Actuator Cutout (2x) Elbow Linear Actuator Connector SHCS and Washers (8x) and Connector Bearing (2x) Figure 8 Removing connectors from linear actuators 4. At shoulder linear actuator ( ), remove two HHCS ( ) and pin ( ) from the upper arm (Figure 7). Slide pin ( ) out of upper arm (Figure 7). Note: Do not allow the actuator to hang from the hydraulic hoses. 5. Remove two HHCS ( ), washers ( ), and linear actuator guard ( ) from shoulder linear actuator ( ) (Figure 7). Slide pin ( ) out and remove two spacers ( ) (Figure 7). 6. Remove four SHCS ( ) and washers ( ) from connector ( ) (Figure 8) and the actuator. Push the connector up, and through, the cutout in the upper arm (Figure 8, on page 163). To the service linear actuator, see Orion P Linear Actuators, , -3939, 4328, & Service Instruction. Remove the Upper Arm from the Azimuth Refer to Figure 9 for this procedure. 1. Remove the two HHCS ( ) and pin ( ) from the upper arm. Slide the pin ( ) out of the upper arm. As you remove the upper arm ( ) from the azimuth ( ), carefully feed all the hoses out of the upper arm. Inspect Upper Arm Parts Refer to Figure 6, Figure 7, Figure 8, and Figure 9 for this procedure. 1. Inspect the bearings ( ) for cracks, excessive wear, or other damage (see Figure 6, Figure 7, Figure 8, and Figure 9). Replace any damaged bearing. SERVICE INSTRUCTION Page 163

50 2. Inspect the pins ( , , and ) for signs of excessive wear, galling, or other damage (see Figure 6, Figure 7, and Figure 9). Replace any damaged pin. 3. Inspect the upper arm ( ) for signs of cracking, twisting, deformation, or other damage. Replace if damaged. Azimuth Pin Retainer Pin (2x) HHCS (2x) Upper Arm Figure 9 Upper arm hardware Install the Upper Arm onto the Azimuth Refer to Figure 9 for this procedure. 1. Carefully feed all the hoses into the upper arm ( ). The hoses should follow a straight path through the upper arm, with no twists or sharp bends. 2. Apply EP grease to pin ( ). Align the upper arm to azimuth ( ) and insert the pin. 3. Apply Aqua Lube to the threads of the two HHCS ( ). Install two HHCS and the pin ( ) onto the upperarm. Torque to 11 Nm (8 ft/lbs). Install Linear Actuators into Upper Arm Refer to Figure 8, Figure 10, Figure 11, and Figure 12 for this procedure. 1. Lubricate the o-ring and back-up ring ( and ) on the deep transducer ( ) of each linear actuator ( ) with o-ring lube (see Figure 10). O-ring Deep Transducer Backup Ring Figure 10 Lubricating deep transducer o-rings Page SERVICE INSTRUCTION

51 2. If linear actuators ( ) were serviced, reattach hydraulic hoses. Attach hoses 1A and 1B to the shoulder actuator (Figure 11). Hoses 2A and 2B attach to the elbow actuator (Figure 11). Apply a thin coat of EP grease to each hose fitting sealing surface. Tighten each hose fitting finger tight, then one-sixth of a turn to tighten the hose fitting. Hose 1B Hose 1A Hose 2A Hose 2B Figure 11 Routing hydraulic hoses 3. Feed both connectors ( and ) through the cutouts in the upper arm (see Figure 8). Be sure you have the correct connector in the correct cutout and the hoses follow a straight path through the upper arm, with no twists or sharp bends. 4. Lubricate the four SHCS ( ) with Aqua Lube (see Figure 8). Fill the cavity of the connector ( ) with DC5 grease. Using four SHCS and washers ( ), install the connector to the shoulder linear actuator (see Figure 8). Torque to 1.1 Nm (28-in./lbs). Wipe away excess DC5 grease. 5. Attach shoulder linear actuator to azimuth ( ) (Figure 12). Lubricate pin ( ) with EP grease and, with two spacers ( ), slide into place (Figure 12). 6. Lubricate two HHCS ( ) with Aqua Lube. Install washers ( ) to the two HHCS and attach linear actuator guard ( ) to the shoulder linear actuator (Figure 12). Torque to 11 Nm (8 ft/lbs). 7. Apply EP grease to pin ( ). Align shoulder linear actuator with the upper arm and insert the pin (Figure 12). Apply Aqua Lube to threads of two HHCS ( ). Install two HHCS and pin ( ) onto the upper arm (Figure 12). Torque to 11 Nm (8 ft/lbs ). 8. Lubricate four SHCS ( ) with Aqua Lube (Figure 8). Fill the cavity of connector ( ) with DC5 grease. Using four SHCS and washers ( ), install connector to elbow linear actuator ( ) (Figure 8). Torque to 1.1 Nm (28-in./lbs). Wipe away excess DC5 grease. 9. Apply EP grease to pin ( ). Align elbow linear actuator with the upper arm and insert the pin (Figure 12). Apply Aqua Lube to threads of the two HHCS ( ). Install two HHCS and pin ( ) onto the upper arm (Figure 12). Torque to 11 Nm (8 ft/lbs). SERVICE INSTRUCTION Page 165

52 Anode (opposite side) Upper Arm Azimuth Pin Elbow Linear Actuator HHCS and Washers (2x) and Pin Pin Retainer Shoulder Linear Actuator Spacer (2x) Actuator Guard HHCS Figure 12 Installing actuators into upper arm 10. Lubricate anode threads ( ) with Aqua Lube and install onto upperarm (Figure 12). Install Roll Base/Forearm Refer to Figure 13 for this procedure. Roll Base Elbow Linear Actuator HHCS (2x) Pin Pin (2x) Pin (2x) HHCS (4x) Cap Plug (2x) Bearing (2x) Figure 13 Installing roll base/forearm 1. Support the forearm. Apply EP grease to the pin ( ) and install into the roll base ( ) and upper arm. Apply Aqua Lube to the four HHCS ( ) and install with the two pins ( ) onto the roll base. Page SERVICE INSTRUCTION

53 2. Support the forearm. Apply EP grease to the two bearings ( ). Apply EP grease to the pin ( ) and install into the roll base and elbow linear actuator ( ). Apply Aqua Lube to the two HHCS ( ) and install into the elbow linear actuator. 3. Install the two cap plugs ( ) onto each side of the roll base. Install the Position Sensor and Position Sensor Wires Refer to Figure 14, Figure 15, and Figure 16 for this procedure.! Caution In this procedure you will set the center position of the rotary actuator position sensor. To do this you will need have the power to the master controller turned on. Do not turn on the hydraulics at this time. Hydraulic Hoses (6x) Slipring Manifold Hydraulic Hoses (2x) Figure 14 Installing hydraulic hoses onto slipring manifold 1. Lubricate hydraulic hose fitting threads with EP grease. Loosely install hydraulic hoses to the appropriate fittings on slipring manifold ( ) (Figure 14). Ensure that hoses exit cleanly into the upper arm and will clear the manifold cover ( ) and position sensor ( ) (Figure 15). Tighten each hose fitting finger tight, then one-sixth of a turn to tighten the hose fitting. 2. Lubricate a new o-ring ( ) with o-ring lube and install onto the top of the adapter plate ( ) (see Figure 15). 3. Carefully install the position sensor straight down over the sensor driveshaft (not shown) and onto the adaptor plate (see Figure 15). Turn on the power to the master controller. Go to the diagnostics menu: Press DOWN TO EXIT > 4 DIAGNOSE > 2 SLAVE. Locate the ROL column and read the "FEED BACK" readout. Check that the "FEED BACK" readout is 0 (± 100). If the readout is not 0 (± 100), go to step 4. If the readout is 0 (± 100), skip to step 10. SERVICE INSTRUCTION Page 167

54 Position Sensor Wires Wire Housing O-ring (2x) SHCS (4x) PCB Assembly Position Sensor Rotary Actuator Adapter Plate Figure 15 Installing position sensor and wire housing 4. Lift the position sensor off the adapter plate and set aside. Using a flat-blade screw driver, gently pry sensor driveshaft ( ) up and out of the adapter plate (Figure 16). Gently Pry Up Here Sensor Driveshaft Bearing Adapter Plate Figure 16 Removing the sensor driveshaft 5. Grasp the forearm and turn the rotary actuator all the way to one hard stop. Note position of the rotary actuator. Turn rotary actuator the opposite direction to the other hard stop. Note position of rotary actuator. Turn rotary actuator back to the center of rotation. Do not rotate the arm away from the centered position. 6. Place the sensor driveshaft ( ) into the position sensor ( ) as shown in Figure 17. Look at the readout and slowly rotate the driveshaft until it reads 0 (± 100). Pull the drive shaft straight out of the sensor. 7. Lubricate the bearing ( ) with EP grease (see Figure 16). Align the flat on the sensor driveshaft with the flat on the coupler inside the actuator and install the sensor driveshaft into the rotary actuator 8. Lubricate the o-ring ( ) on the top of the adapter plate ( ) with o-ring lube (see Figure 15). 9. Install the position sensor onto the adapter plate (see Figure 15). Page SERVICE INSTRUCTION

55 Note: Check that the "FEED BACK" readout is still at 0 (± 100). If not, repeat steps 5-9 until the desired readout is maintained. Position Sensor Sensor Driveshaft Figure 17 Centering the position sensor 10. Turn off the power to the master controller. 11. Lubricate a new o-ring ( ) with o-ring lube and install it into the wire housing ( ) (see Figure 15). 12. Lubricate four SHCS ( ) with Aqua Lube and install the wire housing onto the rotary actuator (see Figure 15). Torque to 3.2 Nm (28-in./lbs). 13. Install the position sensor wires to the PCB assembly ( ) (see Figure 15). To connect wires properly, match the wire colors across the connector. Install the Wire Housing Cover and Manifold Cover Refer to Figure 2 and Figure 18 for this procedure. 1. Lubricate a new large o-ring ( ) and four new smaller o-rings ( ) with Desitin ( ) and install into the wire housing cover ( ) (see Figure 18). O-ring O-ring (4x) Wire Housing Cover Wire Housing SHCS (5x) Figure 18 Wire housing cover and o-ring location SERVICE INSTRUCTION Page 169

56 2. Lubricate five SHCS ( ) with Aqua Lube and install the wire housing cover ( ) (see Figure 18). Torque to 3.2 Nm (28-in./lbs). 3. Lubricate eight HHCS ( ) with Aqua Lube, add washers ( ), and install manifold cover ( ) onto the rotary actuator (Figure 2). Torque to 47.5 Nm (35 ft/lbs). END OF SERVICE INSTRUCTION Page SERVICE INSTRUCTION

57 Service Instruction Upper Arm, Extended, & Estimated Time to Complete 3 hours Preparation for Service Below is a list of required tools and materials for this Service Instruction. Look over the list and make sure you have all the materials before you get started. Read through the entire procedure to make sure you understand, and are capable of performing, the service. Take special notice of all notes, warnings, and the terminology section. Tools Needed Materials Needed 9/64-in. allen wrench Valvoline Val-Plex EP Grease 3-32-in. allen wrench Aqua Lube ( ) 7/16-in. socket Dow Corning 55 O-ring lube or petroleum jelly 9/16-in. socket Dow Corning 5 Silicone Grease 9/16-in. open-end wrench 3/32-in. flat-blade screwdriver Custom Tools Needed none needed Terminology HHCS = Hex Head Cap Screw SHCS = Socket Head Cap Screw HPU = Hydraulic Power Unit! Caution Some components have protective coatings such as anodizing. Take care not to scratch any protective coatings. Corrosion damage will result. SERVICE INSTRUCTION Page 171

58 ! Caution Replace the following hydraulic hoses only with the designated pressure diagnostic hose (PDH) spares: Orion 7 PE Standard Orion 7PE -4 Hose, 1B Hose, 1A Hose, 2A Hose, 2B Replacement with hoses of other jacket types (steel, etc.) will result in premature hose failure. Procedures in this Service Instruction assume that the intermeshing jaw will be removed from, and then reattached to, the azimuth. The roll (elbow) joint must be detached from and reattached to the intermeshing jaw assembly as part of the servicing. Perform all assembly work in a clean, dry environment if possible. Although assembly of major slave arm components must often be performed under field conditions, the intermeshing jaw should be disassembled and reassembled under clean service conditions to prevent contamination and damage to bearing surfaces. Prepare a clear area on the work surface in which to arrange the components as the intermeshing jaw is disassembled. We recommend that you make a photocopy of this Service Instruction for workbench use. Disable the Slave Arm! WARNING Before you can service the arm safely, must disable electrical and hydraulic functions of the arm. Follow steps below before you continue. 1. Raise the arm to a comfortable working position. 2. Turn off the power switches located on the master controller and the junction box. 3. Turn off the power to the hydraulic power unit (HPU). 4. If power is supplied from a local, independent, source turn off power to the slave controller. 5. If your arm is equipped with a hydraulic compensation unit, isolate the unit from the arm. Introduction The serviceable areas of the intermeshing jaw assembly are the: Hydraulic hoses Elbow linear actuator with its pivot pins and bearings Shoulder linear actuator with its pivot pins and bearings Page SERVICE INSTRUCTION

59 Shoulder joint pivot pin and bearings Roll (elbow) joint pivot pin and bearings Remove the Upper Arm Disassembly of the intermeshing jaw assumes that all preparations, previously described in this Service Instruction, have been met. Numbers in parentheses refer to the part number of the item. See Figure 1 for basic identification of intermeshing jaw parts. Upper Arm HHCS and Washers (8x) and Manifold Cover Roll Base Shoulder Linear Actuator Elbow Linear Actuator Figure 1 Upper arm parts identification Remove Elbow Parts Refer to Figure 2, Figure 3, Figure 4, and Figure 5 for this procedure. HHCS and Washers (8x) and Manifold Cover Upper Arm Forearm Rotary Actuator Forearm Figure 2 Manifold cover and forearm rotary actuator 1. Remove the eight HHCS ( ) and washers ( ) securing the manifold cover ( ) to the top of the forearm rotary actuator ( ) (see Figure 2). Remove the manifold cover to expose the wire housing cover ( ) (see Figure 3). SERVICE INSTRUCTION Page 173

60 2. Remove five SHCS ( ) holding wire housing cover ( ) to the top of the wire housing (Figure 3). Remove the wire cover housing cover and remove large o-ring ( ) and four smaller o-rings ( ) from the wire housing cover (Figure 3). O-ring O-ring (4x) Wire Housing Cover Wire Housing SHCS (5x) Figure 3 Wire housing cover and O-ring location 3. Using a 3/32-in. flat-blade screwdriver, remove the position sensor wires from the PCB assembly ( ) (see Figure 4). Note: Note that the wires are connected across from wires of the same color and striping. Position Sensor Wires Wire Housing O-ring (2x) SHCS (4x) PCB Assembly Position Sensor Rotary Actuator Adapter Plate Figure 4 Removing position sensor wires and position sensor 4. Remove the four SHCS ( ) securing the wire housing ( ) to the rotary actuator ( ) (see Figure 4). Lift the wire housing off and remove the o-ring ( ) from the bottom of the wire housing. Page SERVICE INSTRUCTION

61 5. Carefully lift the position sensor ( ) straight up and off the rotary actuator (see Figure 4). Try not to rotate the sensor as you lift it from the actuator. Set the sensor aside. 6. Remove the o-ring ( ) from the bottom of the position sensor (see Figure 4). Note: Before continuing to step 7, make sure the hydraulic hose ends at the manifold are clearly labeled. Use a permanent marker and tape to label unmarked hoses.! Caution Hydraulic fluid will spill out of the hydraulic hoses when you remove them during the next step. Have a drain pan ready to catch the fluid. 7. Remove all hydraulic hoses (8x) from the slipring manifold ( ) (see Figure 5). Hydraulic Hoses (6x) Slipring Manifold Hydraulic Hoses (2x) Figure 5 Removing the hydraulic hoses from the slipring manifold Remove Roll Base/Forearm Refer to Figure 6 for this procedure. 1. Remove the two cap plugs ( ) from each side of the roll base ( ).! WARNING After the next step, the elbow/forearm of the slave arm will not be supported. Properly support the slave arm to avoid personal injury and damage to the forearm. 2. Support the forearm. Remove the two HHCS ( ) and slide the pin ( ) out of the roll base and elbow linear actuator ( ). 3. Support the forearm. Remove the four HHCS ( ) and two pins ( ) from the roll base. Remove the two pins ( ) from the roll base and upper arm. Set the forearm aside. SERVICE INSTRUCTION Page 175

62 Roll Base Elbow Linear Actuator HHCS (2x) Pin Pin (2x) Retainer (2x) HHCS (4x) Cap Plug (2x) Bearing Figure 6 Removing roll base/forearm Remove Linear Actuators from Upper Arm Refer to Figure 7 and Figure 8 for this procedure. Anode (opposite side) Shoulder Linear Actuator Upper Arm Azimuth Pin Elbow Linear Actuator Pin (2x) HHCS and Washers (2x) and Spacer (2x) Actuator Guard Retainer (2x) HHCS (4x) Figure 7 Removing actuators from upper arm 1. Remove the anode ( ) from the upper arm ( ) (see Figure 7). 2. At elbow linear actuator ( ), remove two HHCS ( ) and pin ( ) from the upper arm (Figure 7). Slide pin ( ) out of the upper arm (Figure 7). Page SERVICE INSTRUCTION

63 Note: Do not allow the actuator to hang from the hydraulic hoses. 3. Remove the four SHCS ( ) and washers ( ) from the elbow actuator connector (see Figure 8) and the actuator. Remove the connector and push it up, and through, the cutout in the upper arm (see Figure 8). To service the actuator, see Orion P "Linear Actuators, , -3939, -4328" Service Instruction. Shoulder Linear Actuator Cutout (2x) Connector (varies w. model) Elbow Linear Actuator Connector ( ) SHCS and Washers (8x) and Bearing (2x) Figure 8 Removing connectors from linear actuators 4. At shoulder linear actuator ( ), remove two HHCS ( ) and pin ( ) from the upper arm (Figure 7). Slide pin ( ) out of the upper arm (Figure 7). Note: Do not allow the actuator to hang from the hydraulic hoses. 5. Remove the two HHCS ( ), washers ( ), and the linear actuator guard ( ) from the shoulder linear actuator (see Figure 7). Slide the pin ( ) out and remove the two spacers ( ) (see Figure 7). 6. Remove four SHCS ( ) and washers ( ) from the shoulder actuator connector (Figure 8) and the actuator. Push the connector up, and through, the cutout in the upper arm (Figure 8). To service the actuator, see Orion P "Linear Actuators, , -3939, -4328" Service Instruction. Remove the Upper Arm from the Azimuth Refer to Figure 9 for this procedure. 1. Remove the two HHCS ( ) and pin ( ) from the upper arm. Slide the pin ( ) out of the upper arm. As you remove the upper arm ( ) from the azimuth, carefully feed all the hoses out of the upper arm. Inspect Upper Arm Parts Refer to Figure 6, Figure 7, Figure 8, and Figure 9 for this procedure. SERVICE INSTRUCTION Page 177

64 1. Inspect the bearings ( ) for cracks, excessive wear, or other damage (see Figure 6 and Figure 8). Replace any damaged bearing. 2. Inspect the pins ( , , and ) for signs of excessive wear, galling, or other damage (see Figure 6, Figure 7, and Figure 9). Replace any damaged pin. 3. Inspect the upper arm ( ) for signs of cracking, twisting, deformation, or other damage. Replace if damaged. Azimuth Pin (2x) Retainer (2x) HHCS (2x) Upper Arm Figure 9 Removing upper arm from azimuth Install the Upper Arm onto the Azimuth Refer to Figure 9 for this procedure. 1. Carefully feed all the hoses into the upper arm ( ). The hoses should follow a straight path through the upper arm, with no twists or sharp bends. 2. Apply EP grease to pin ( ). Align the upper arm to the azimuth and insert the pin. 3. Apply Aqua Lube to the threads of the two HHCS ( ). Install two HHCS and the pin ( ) onto the upper arm. Torque to 11 Nm (8 ft/lbs). Install Linear Actuators into Upper Arm Refer to Figure 8, Figure 10, and Figure 12 for this procedure. 1. Lubricate the o-ring and back-up ring ( and ) on the deep transducer of each linear actuator ( ) with o-ring lube (see Figure 10). Deep Transducer O-ring Backup Ring Figure 10 Lubricating deep transducer o-rings Page SERVICE INSTRUCTION

65 2. If linear actuators ( ) were serviced, reattach hydraulic hoses. Attach hoses 1A and 1B to the shoulder actuator (Figure 11). Attach hoses 2A and 2B to the elbow actuator (Figure 11). Apply a thin coat of EP grease to each hose fitting sealing surface. Tighten each hose fitting finger tight, then one-sixth of a turn to tighten the hose fitting. Hose 1B Hose 1A Hose 2A Hose 2B Figure 11 Routing hydraulic hoses 3. Feed both connectors through the cutouts in the upper arm (see Figure 8). Be sure you have the correct connector in the correct cutout and the hoses follow a straight path through the upper arm, with no twists or sharp bends. 4. Lubricate the four SHCS ( ) with Aqua Lube (see Figure 8). Fill the cavity of the shoulder actuator connector with DC5 grease. Using four SHCS and washers ( ), install the connector to the shoulder linear actuator ( ) (see Figure 8). Torque to 1.1 Nm (28-in./lbs). Wipe away excess DC5 grease. 5. Position the shoulder linear actuator into the azimuth (see Figure 12). Lubricate the pin ( ) with EP grease and, with the two spacers ( ), slide into place. 6. Lubricate the two HHCS ( ) with Aqua Lube. Install the washers ( ) to the two HHCS and attach the linear actuator guard ( ) to the shoulder linear actuator (see Figure 12). Torque to 11 Nm (8 ft/lbs). 7. Apply EP grease to the pin ( ). Align the shoulder linear actuator with the upper arm and insert the pin (see Figure 12). Apply Aqua Lube to the threads of the two HHCS ( ). Install two HHCS and the pin ( ) onto the upper arm (see Figure 12). Torque to 11 Nm (8 ft/lbs). 8. Lubricate four SHCS ( ) with Aqua Lube (Figure 8). Fill the cavity of the elbow actuator connector with DC5 grease. Using four SHCS and washers ( ), install the connector to elbow linear actuator ( ) (Figure 8). Torque to 1.1 Nm (28-in./lbs). Wipe away excess DC5 grease. 9. Apply EP grease to pin ( ). Align the elbow linear actuator with the upper arm and insert pin (Figure 12). Apply Aqua Lube to threads of two HHCS ( ). Install two HHCS and pin ( ) onto the upper arm (Figure 12). Torque to 11 Nm (8 ft/lbs). SERVICE INSTRUCTION Page 179

66 Anode (opposite side) Shoulder Linear Actuator Upper Arm Azimuth Pin Elbow Linear Actuator Pin (2x) HHCS and Washers (2x) and Spacer (2x) Actuator Guard Pin (2x) HHCS (4x) Figure 12 Installing actuators from upper arm 10. Lubricate the anode threads ( ) with Aqua Lube and install onto upper arm (see Figure 12). Install Roll Base/Forearm Refer to Figure 13 for this procedure. Roll Base Elbow Linear Actuator HHCS (2x) Pin Pin Pin Retainer2x) HHCS (4x) Cap Plug (2x) Bearing Figure 13 Installing roll base/forearm Page SERVICE INSTRUCTION

67 1. Support the forearm. Apply EP grease to the pin ( ) and install into the roll base ( ) and upper arm. Apply Aqua Lube to the four HHCS ( ) and install with the two pins ( ) onto the roll base. 2. Support the forearm. Apply EP grease to the two bearings ( ). Apply EP grease to the pin ( ) and install into the roll base and elbow linear actuator ( ). Apply Aqua Lube to the two HHCS ( ) and install into the elbow linear actuator. 3. Install the two cap plugs ( ) onto each side of the roll base. Install the Position Sensor and Position Sensor Wires Refer to Figure 14, Figure 15 and Figure 16 for this procedure.! Caution In this procedure you will set the center position of the rotary actuator position sensor. To do this you will need have the power to the master controller turned on. Do not turn on the hydraulics at this time. Hydraulic Hoses (6x) Slipring Manifold Hydraulic Hoses (2x) Figure 14 Installing hydraulic hoses onto slipring manifold 1. Lubricate the threads of the hydraulic hose fittings with EP grease. Loosely install the hydraulic hoses to the appropriate fittings on the slipring manifold ( ) (see Figure 14). Ensure that the hoses exit cleanly into the upper arm and will clear the manifold cover ( ) and position sensor ( ) (see Figure 15). Tighten each hose fitting finger tight, then one-sixth of a turn to tighten the hose fitting. 2. Lubricate a new o-ring ( ) with o-ring lube and install onto the top of adapter plate ( ) (Figure 15). 3. Carefully install the position sensor straight down over the sensor drive shaft (not shown) and onto the adaptor plate (see Figure 15). Turn on the power to the master controller. Go to the diagnostics menu: Press DOWN TO EXIT > 4 DIAGNOSE > 2 SLAVE. Locate the ROL column and read the FEED BACK readout. Check that the FEED BACK readout is 0 (± 100). If the readout is not 0 (± 100), go to step 4. SERVICE INSTRUCTION Page 181

68 If the readout is 0 (± 100), skip to step 10. Position Sensor Wires Wire Housing O-ring (2x) SHCS (4x) PCB Assembly Position Sensor Rotary Actuator Adapter Plate Figure 15 Installing position sensor and wire housing 4. Lift the position sensor off the adapter plate and set aside. Using a flat-blade screw driver, gently pry sensor drive shaft ( ) up and out of the adapter plate (Figure 16). Gently Pry Up Here Sensor Driveshaft Bearing Adapter Plate Figure 16 Removing the sensor driveshaft 5. Grasp the forearm and turn the rotary actuator all the way to one hard stop. Note the position of the rotary actuator. Turn the rotary actuator the opposite direction to the other hard stop. Note the position of the rotary actuator. Turn the rotary actuator back to the center of the rotation. Do not rotate the arm away from the centered position. 6. Place the sensor driveshaft ( ) into the position sensor ( ) as shown in Figure 17. Look at the readout and slowly rotate the driveshaft until it reads 0 (± 100). Pull the drive shaft straight out of the sensor. 7. Lubricate the bearing ( ) with EP grease (see Figure 16). Align the flat on the sensor driveshaft with the flat on the coupler inside the actuator and install the sensor driveshaft into the rotary actuator. 8. Lubricate o-ring ( ) (top of adapter plate ) with o-ring lube (Figure 15). Page SERVICE INSTRUCTION

69 9. Install the position sensor onto the adapter plate (see Figure 15). Note: Check that the FEED BACK readout is still at 0 (± 100). If not, repeat steps 5-9 until the desired readout is maintained. Position Sensor Sensor Driveshaft Figure 17 Centering the Position Sensor 10. Turn off the power to the master controller. 11. Lubricate a new o-ring ( ) with o-ring lube and install it into the wire housing ( ) (see Figure 15). 12. Lubricate four SHCS ( ) with Aqua Lube and install the wire housing onto the rotary actuator (see Figure 15). Torque to 3.2 Nm (28-in./lbs). 13. Install the position sensor wires to the PCB assembly ( ) (see Figure 15). To connect wires properly, match the wire colors across the connector. Install the Wire Housing Cover and Manifold Cover Refer to Figure 2 and Figure 18 for this procedure. 1. Lubricate a new large o-ring ( ) and four new smaller o-rings ( ) with Desitin ( ) and install into the wire housing cover ( ) (see Figure 18). O-ring O-ring (4x) Wire Housing Cover Wire Housing SHCS (5x) Figure 18 Wire housing cover and o-ring location SERVICE INSTRUCTION Page 183

70 2. Lubricate five SHCS ( ) with Aqua Lube and install the wire housing cover ( ) (see Figure 18). Torque to 3.2 Nm (28-in./lbs). 3. Lubricate eight HHCS ( ) with Aqua Lube, add washers ( ), and install manifold cover ( ) onto the rotary actuator (Figure 2). Torque to 47.5 Nm (35 ft/lbs). END OF SERVICE INSTRUCTION Page SERVICE INSTRUCTION

71 Service Instruction Forearm Rotary Actuator, Description Complete service instructions for the Orion P intermeshing jaw. Estimated Time to Complete 4 hours Preparation for Service Below is a list of required tools and materials for this Service Instruction. Look over the list and make sure you have all the materials before you get started. Read through the entire procedure to make sure you understand, and are capable of performing, the service. Take special notice of all notes, warnings, and the terminology section. Tools Needed Materials Needed 7/16-in. sockets Valvoline Val-Plex EP Grease 9/16-in. socket Aqua Lube ( ) 3/8-in. socket Dow Corning 55 O-ring lube or petroleum jelly 3/16-in. hex key Loctite 271 ( ) 3/32-in. flat-blade screwdriver Loctite 222 ( ) flat blade screwdriver rubber hammer new razor blade or X-acto style knife Custom Tools Needed Spares Kit(s) From Orion Tool Kit Seals and o-rings for rotary actuator torquing tool are available as a part of the Orion Spares Kit (P/N ) and in two spares kits specifically for the rotary actuator: the Seal Kit (P/N slip ring seal installation tool roll slip ring seal resizing tool slip ring seal resizing tool ) and the Slip Ring Spares Kit (P/N ) Terminology slip ring pusher tool HHCS = Hex Head Cap Screw endplate adjuster SHCS = Socket Head Cap Screw HPU = Hydraulic Power Unit SERVICE INSTRUCTION Page 185

72 ! Caution Some components have protective coatings such as anodizing. Take care not to scratch any protective coatings. Corrosion damage will result.! Caution If you are planning to replace slip ring seals ( ), you must have replacements on-hand. You must destroy the old seals to remove them. Perform all assembly work in a clean, dry environment if possible. Although assembly of major slave arm components must often be performed under field conditions, the intermeshing jaw should be disassembled and reassembled under clean service conditions to prevent contamination and damage to bearings and seals. Provide a clear workbench surface on which to arrange components as the intermeshing jaw is disassembled.we recommend you make a photocopy of this Service Instruction for workbench use. Special Instructions It is recommended that all rotary actuator seals and o-rings be replaced when the rotary actuator is serviced. Seals and o-rings are available as a part of the general Orion Spares Kit ( ) and in two spares kits specifically for the rotary actuator: the Seal Kit ( ) and the Slip Ring Spares Kit ( ).! Caution If seals and o-rings must be reused, set them aside during disassembly and carefully inspect them for damage before re-installation. All damaged seals and o-rings must be replaced. Disable the Slave Arm! WARNING Before you can service the arm safely, you need to disable the electrical and hydraulic functions of the arm. Follow the steps below before you continue. 1. Raise the arm to a comfortable working position. 2. Turn off the power switches located on the master controller and the junction box. 3. Turn off the power to the hydraulic power unit (HPU). 4. If power is supplied from a local, independent source, turn off power to the slave controller. Page SERVICE INSTRUCTION

73 5. If your arm is equipped with a hydraulic compensation unit, isolate the unit from the arm. Detach Rotary Actuator This procedure assumes hydraulic power is OFF. Loosen the appropriate hose fittings to allow actuators to leak down and permit positioning the slave arm joints as needed to simplify disassembly. Numbers in parentheses refer to the part number of the item. Detach Forearm Assembly From Forearm Rotary Actuator Refer to Figure 1, Figure 2, Figure 3, and Figure 4 for this procedure. 1. Remove the eight HHCS ( ) and washers ( ) securing the manifold cover ( ) to the rotary actuator ( ) (see Figure 1). Remove the manifold cover to expose the wire housing cover ( ) (see Figure 2). HHCS and Washers (8x) and Manifold Cover Rotary Actuator Forearm HHCS and Washers (10x) and Figure 1 Manifold cover and rotary actuator 2. Remove the wire housing cover by removing the five SHCS ( ) that hold the cover to the rotary actuator (see Figure 2). Remove the large o-ring ( ) and the four smaller o-rings ( ) from the wire housing cover (see Figure 2). SERVICE INSTRUCTION Page 187

74 O-ring O-ring (4x) Wire Housing Cover SHCS (5x) Figure 2 Wire housing cover and o-ring location 3. Using a 3/32-in. flat blade screwdriver, loosen the terminal screws and remove the forearm sensor wires from the PCB assembly ( ) (see Figure 3). Note: Note that the wires are connected across from wires of the same color and striping. PCB Assembly Forearm Sensor Wires! Figure 3 Removing position sensor wires from pcb assembly WARNING When you remove the ten HHCS in step 4, the forearm will be loose. The forearm assembly, including wrist and jaw, weighs about 40 pounds (18 kg) and must be supported during removal. Read the entire step before continuing. Be prepared by properly supporting the forearm. 4. Remove the 10 HHCS ( ) and washers ( ) from the bottom of the rotary actuator (see Figure 1). Separate the forearm from the rotary actuator and extract the position sensor wires from the rotary actuator. Page SERVICE INSTRUCTION

75 5. Remove the nine o-rings ( ) from the bottom of the rotary actuator ( ) (see Figure 4). O-rings (9x) Figure 4 Bottom of rotary actuator Remove Position Sensor & Manifold From Rotary Actuator Refer to Figure 5, Figure 6, Figure 8, and Figure 9 for this procedure. HHCS and Washer (2x) and O-ring Position Sensor Wire Housing Hydraulic Hoses (6x) Hydraulic Hoses (2x) Adapter Plate Rotary Actuator Manifold Slip Ring HHCS and Washer (4x) and Sensor Driveshaft Figure 5 Rotary actuator area parts 1. Remove the four SHCS ( ) securing the wire housing ( ) to the adapter plate ( ) and lay it to the side (see Figure 5 and Figure 6). Remove the o-ring ( ) from the bottom of the wire housing (see Figure 5). SERVICE INSTRUCTION Page 189

76 SHCS (4x) Wire Housing Figure 6 Removing wire housing from rotary actuator 2. Lift position sensor ( ) off adapter plate ( ) and lay it aside (Figure 5). 3. Using a flat-blade screw driver, gently pry the sensor driveshaft ( ) up and out of the adapter plate (see Figure 7). Gently Pry Up Here Sensor Driveshaft Adapter Plate Figure 7 Removing the sensor driveshaft Note: Before continuing to step 4, make sure the hydraulic hose ends at the manifold are clearly labeled. Use a permanent marker and tape to label unmarked hoses. 4. Remove all the hydraulic hoses (8x) from the manifold (see Figure 5, on page 189). 5. Remove two HHCS and washers ( and ) from the manifold (Figure 5, on page 189). 6. Using a rubber hammer, remove the manifold by tapping upward on the edges of the manifold. Do not pry the manifold off of the actuator. 7. Remove o-ring ( ) from the bottom of the manifold (Figure 8). Note the rotary index setting for correct reassembly. The index setting number is located on the flange of slip ring ( ) (Figure 8). Set manifold aside for later disassembly. Page SERVICE INSTRUCTION

77 Note Rotary Index Setting Here: 0-ring Slip Ring Manifold Rotary Index Setting Figure 8 Noting rotary index setting 8. Remove the two o-rings ( ) from the end plate ( ) (see Figure 8). End Plate O-ring (2x) Figure 9 Removing o-rings Remove Rotary Actuator From the Roll Base Refer to Figure 10, Figure 11, and Figure 12 for this procedure. 1. Before removing the rotary actuator ( ) from the roll base ( ), position the arm as shown in Figure 10. Rotary Actuator Roll Base Figure 10 Positioning the arm for removal of the rotary actuator SERVICE INSTRUCTION Page 191

78 2. Remove plugs ( ) from the roll base (Figure 11). Remove two HHCS ( ) and washers ( ) securing pitch pin ( ) to the elbow linear actuator (Figure 11). Support the rotary actuator and remover the pitch pin. Remove elbow spacers ( ). Elbow Spacer(2x) Manifold Plug (2x) Pitch Pin Roll Base Elbow Linear Actuator HHCS (2x) Figure 11 Removing the elbow linear actuator from the roll base! Caution When you remove the four HHCS in step 3, the rotary actuator will be loose. Read the entire step before continuing. Be prepared by properly supporting the rotary actuator. 3. Remove the four HHCS ( ) and washers ( ) securing the rotary actuator to the roll base. Remove the rotary actuator from the roll base (see Figure 11). HHCS and Washers (4x) and Figure 12 Removing the rotary actuator Remove Mounting Flange & Rotor Nut From Rotary Actuator Refer to Figure 13 for this procedure. Page SERVICE INSTRUCTION

79 Rotor Nut Rotor Lock Washer End Plate Housing End Plate Seal O-ring HHCS and Washers (8x) and Mounting Flange O-ring O-ring (8x) Figure 13 Mounting flange and rotor parts 1. Stand the rotary actuator up on the mounting flange ( ). Hold the housing ( ) in place and turn the rotor ( ) clockwise inside its housing until it hits at the hard stop.set the actuator on its mounting legs.! Caution Do not turn the rotor after the HHCS have been removed in step 2. Damage to the end plates ( and ) could result. 2. Remove the eight HHCS and washers ( and ) from the rotary actuator. 3. Use a rubber hammer to gently tap the mounting flange ( ) off the rotor ( ). 4. Remove the o-rings ( and ) and the seal ( ) from the mounting flange. 5. Remove the eight o-rings ( ) from the rotor. SERVICE INSTRUCTION Page 193

80 6. Pry the lock tab on washer ( ) from the slot in rotor nut ( ). Using the torquing tool ( ), remove the rotor nut ( ) and lock washer ( ). Disassemble the Rotary Actuator Refer to Figure 14, Figure 15, and Figure 16 for this procedure. SHCS and Nut (16x) and Washer (32x) Rotor End Plate O-ring (2x) Housing O-ring (2x) End Seal (2x) Bearing End Plate Figure 14 Rotary actuator parts 1. Remove both bearings ( ) (Figure 14). They should drop straight out of their bores if the edges of endplates ( or ) are gently struck on a plastic or wooden work surface. If a bearing becomes cocked in its bore, gently tap it back into place and try again. 2. Remove 14 of 16 SHCS ( ), washers ( ), and nuts ( ) from the rotary actuator assembly (see Figure 14). While removing the last two SHCS, use care to ensure that the end plates ( and ) do not loosen and become cocked on the housing ( ). 3. Stand the rotary actuator on end, with spacers under the rotary actuator so that rotor ( ) is not touching the work surface (see Figure 15). Remove the end plate ( ). Page SERVICE INSTRUCTION

81 Note: If the end plate is difficult to remove by hand, it may be pushed off using the four threaded through-holes present in both end plates. Install an endplate pusher ( ) into each through-hole, followed by a 3/8 x 3-in. HHCS ( ). The pusher prevents scoring of the housing or the end plate by the bolt. Evenly thread in the four HHCS until the end plate and housing are separated. Support both assemblies so they are not damaged after separation.! Caution Do not damage the sharp edges of the housing ( ) as shown in Figure 15. Damage will cause reduced performance and leakage. Rotor O-ring (2x) End Seal (2x) Housing O-ring (2x) End Plate Spacer End Plate Do Not Damage Housing Edges Figure 15 Removing the end plate ( ) 4. Remove seal ( ) and o-ring ( ) from rotor ( ) (Figure 15). 5. Remove the housing ( ) from the rotor (see Figure 15). 6. Carefully remove the rotor ( ) from the endplate ( ) (see Figure 15). 7. Remove the remaining seal ( ) and o-ring ( ) from rotor ( ) (Figure 15). 8. Remove the seal, o-ring, filler plate, and back-up plates ( , , , and ) from the vanes ( ) on the rotor, and the housing vane mount (see Figure 16). De-grease all vane parts. Set the rotor aside for later service. SERVICE INSTRUCTION Page 195

82 ! Caution Do not damage the sharp edges of the housing as shown in Figure 16. Seal (2x) Back-up Plate (2x) O-ring (2x) Vane (2x) Filler Plate Housing Vane Mount Rotor Housing Do Not Damage Housing Edges Figure 16 Removing vanes parts from the rotor and the housing Inspect Rotary Actuator Components It is recommended that you replace all rotary actuator seals and o-rings. Seals and o-rings are available as a part of the Orion spares kit ( ) and in two spares kits for the rotary actuator: the seal kit ( ) and the slip ring spares kit ( ). Inspect other components as outlined below: 1. Inspect the roller bearings ( ) and endplate races ( and ) (see Figure 14). Replace if damage is present. 2. Inspect the sharp edge of the housing ( ) (see Figure 15). This edge is critical to actuator performance and must be sharp. If any damage is noted, replace the housing. 3. Inspect all other rotary actuator components. Replace damaged components. Disassemble the Manifold Refer to Figure 17 for this procedure. Page SERVICE INSTRUCTION

83 O-ring (2x) Bearing HHCS (4x) Adapter Plate O-ring (8x) O-ring (8x) Manifold O-ring Slip Ring Seal (9x) Slip Ring Bearing (2x) O-ring (9x) Figure 17 Manifold parts identification 1. Remove the HHCS ( ) from the adaptor plate ( ) and remove the adaptor plate and slip ring ( ) from the manifold ( ). 2. Remove o-rings and bearing ( , , and ) from the adaptor plate. 3. Remove the bearings ( ) from the slip ring.! Caution If you are planning to replace slip ring seals ( ) in step 4, you must have replacements on-hand. You will need to destroy the old seals to remove them. 4. Remove slip ring seals ( ), from the slip ring. Carefully cut across them with a new razor blade or X-acto style knife. Using a small pick tool, remove o- ring ( ). Note: Be very careful not to damage the finish on the slip ring 5. Inspect the manifold, slip ring, and bearings ( ) for damage. Replace damaged components. Replace Slip Ring Bearings & O-rings Refer to Figure 17 for this procedure. SERVICE INSTRUCTION Page 197

84 1. Lubricate a bearing ( ) with EP grease and install into the bearing groove at the flanged end of the slip ring ( ). 2. Lubricate nine new o-rings ( ) with o-ring lube and install onto the slip ring. 3. Install the slip ring seal installation tool ( ) onto the end of the slip ring. Lubricate the tool with o-ring lube. 4. Lubricate a new slip ring seal ( ) with o-ring lube and seal the bearing onto the tool. Slide the seal along the tool and into the groove closest to the flange. Repeat with all remaining seals. Remove the slip ring seal installation tool. 5. Lubricate the remaining bearing ( ) with EP grease and install it into the remaining bearing groove. 6. Lubricate the inner surface of slip ring seal resizing tool ( ) with o-ring lube. Slowly slide the tool onto the slip ring until it touches the flange. Be sure that slip ring bearings properly seat into their grooves. Allow the tool to remain in place at least one hour. Assemble the Slip Ring to Manifold Refer to Figure 18, Figure 19, and Figure 20 for this procedure. O-ring (2x) Bearing HHCS (4x) Adapter Plate O-ring (8x) O-ring (4x) Manifold O-ring Slip Ring Figure 18 Assembling the slip ring and manifold 1. Lubricate eight new o-rings ( ) with o-ring lube and install into the slip ring flange (Figure 18). 2. Lubricate new o-ring ( ) with o-ring lube and install into slip ring flange (Figure 18). 3. Lubricate two new o-rings ( ) with o-ring lube and install into adapter plate ( ) (Figure 18). Page SERVICE INSTRUCTION

85 4. Lubricate bearing ( ) with EP grease and install into adapter plate (Figure 18).! Caution Do not perform step 5 unless the resizing tool ( ) has been on the slip ring for at least one hour. 5. Place the flanged end of the slip ring ( ) into the resizing tool stripper ( ) so that the resizing tool ( ) is seated in the counterbore (Figure 19). Install the shaft of pusher tool ( ) into the opposite end of the slip ring. Place a socket extension, or a suitable rod, into the recessed end of the pusher tool and drive the slip ring out of the resizing tool. Figure 19 Removing the resizing tool from the slip ring 6. Lubricate four HHCS ( ) with EP grease and install into the adapter plate (Figure 18). Lubricate four new o-rings ( ) with o-ring lube and install onto four HHCS (Figure 18). Install the adapter plate onto manifold ( ) (Figure 18). Align the slip ring to the correct rotary index setting (Figure 20 and refer to Figure 8 for your rotary index setting). Torque to 2.7 Nm (24-in./ lbs). O-ring Slip Ring Manifold Rotary Index Setting Figure 20 Setting the rotary index setting 7. Lubricate a new o-ring ( ) with o-ring lube and install onto the manifold (see Figure 20). Set the manifold/slip ring assembly aside for later installation. Assemble the Rotor Refer to Figure 21 and Figure 22 for this procedure. SERVICE INSTRUCTION Page 199

86 1. Thread an 8/32 screw into the plug and pull the plug ( ) out of the rotor (see Figure 21). Leave the 8/32 screw installed in the plug. Rotor Plug O-ring /32 Screw Figure 21 Removing the plug from the rotor 2. Remove the o-ring ( ) from the plug (see Figure 22). Lubricate a new o- ring with o-ring lube and install it onto the plug. Rotor O-ring Plug End Seal /32 Screw O-ring O-ring (8x) Figure 22 Assembling the rotor 3. Lubricate the plug with o-ring lube and install it into the rotor ( ) (see Figure 22). Remove the screw. 4. Lubricate new o-ring ( ) with o-ring lube and install onto the rotor (Figure 22). 5. Lubricate new end seal ( ) with o-ring lube and install onto the rotor (Figure 22). Page SERVICE INSTRUCTION

87 6. Lubricate eight new o-rings ( ) with o-ring lube and install them into the rotor (see Figure 22). Set the rotor aside for later installation. Assemble the Mounting Flange Refer to Figure 23 for this procedure Seal O-ring O-ring Mounting Flange Figure 23 Assembling the mounting flange 1. Lubricate two o-rings ( and ) with o-ring lube and install onto the mounting flange ( ). 2. Lubricate seal ( ) with o-ring lube and install onto the mounting flange. Assemble the End Plates & Rotor Refer to Figure 24, Figure 25, Figure 26, Figure 27, Figure 28, and Figure 29 for this procedure. SERVICE INSTRUCTION Page 201

88 Seal (2x) Back-up Plate (2x) O-ring (2x) Vane (2x) Filler Plate Housing Vane Mount Rotor Housing Do Not Damage Housing Edges Figure 24 Installing vanes parts into the rotor and the housing 1. Reassemble the seal, o-ring, filler plate, and back-up plate assemblies ( , , , and ) (see Figure 24). Lubricate the assemblies with o-ring lube after they are assembled. 2. Install the assembly between vanes ( ) on rotor ( ) (Figure 24). Repeat step 1 for housing ( ) (Figure 24). Ensure the vane seals are installed square.! Caution When performing steps 3-7, use extreme care not to damage the sharp edges of the end seals, the housing, and the end plates. 3. Lubricate a new o-ring ( ) with o-ring lube and install into the end plate ( ) (see Figure 25). Support the end plate on spacers as shown in Figure 25. Lubricate the end plate with EP grease as shown in Figure 25. Page SERVICE INSTRUCTION

89 Lubricate Along These Surfaces End Plate O-ring Spacer Figure 25 Supporting and lubricating the end plate for assembly 4. Lubricate the end seal ( ) and outer surfaces of the rotor ( ) with EP grease. Carefully install the rotor into the end plate (see Figure 26). Rotor End Plate End Seal Figure 26 Installing the rotor into the end plate 5. Lubricate the inner surfaces of the housing as shown in Figure 27. Carefully install the housing onto the end plate (see Figure 27). Orient the rotor as shown in Figure 27. SERVICE INSTRUCTION Page 203

90 View Looking Down From Above Lubricate Along These Surfaces Housing Figure 27 Lubricating and installing the housing onto the rotor and end plate 6. Lubricate the o-ring ( ) and end seal ( ) with o-ring lube and install them onto the rotor (see Figure 28). Page SERVICE INSTRUCTION

91 End Seal O-ring Figure 28 Installing o-ring and end seal 7. Lubricate the end plate with o-ring lube as shown in Figure 29. Carefully install the end plate ( ) onto the rotor (see Figure 29). SHCS and Nut (16x) and Washer (32x) End Plate Lubricate Along These Surfaces Rounded Edge of Washer Figure 29 Installing the end plate! Caution During step 8, you must place the rounded side of the washers ( ) against end plate surfaces (see Figure 29). Damage will result to end plates if the sharp edge of the washers are placed against the end plates. SERVICE INSTRUCTION Page 205

92 8. Heavily lubricate two SHCS ( ) with Aqua Lube (Figure 29). Install on opposite sides of the end plates with four washers and two new locknuts ( and ). Place the assembly mounting legs on a flat surface. Slowly and carefully draw the end plates together. Damage will result to end seals if the plates are drawn together unevenly. Heavily lubricate the remaining fourteen SHCS with Aqua Lube and install with washers and new locknuts. Lightly tighten all locknuts. 9. Place the actuator on its mounting legs on a known flat surface or attach it to the roll base ( ). Adjust the endplates so that all four mounting legs are in complete contact with the surface. Torque all locknuts to 16.3 Nm (12 ft/lbs). Install Bearings and Mounting Flange to Rotary Actuator Refer to Figure 30, Figure 31, Figure 32, and Figure 33 for this procedure. Note: In step 1 you will install the bearings ( ) into the rotary actuator. The bearings need to be reassembled into the proper end of the rotary actuator. 1. Pack bearings ( ) with EP grease, and install onto rotor ( ) (Figure 30). Rotor Bearing (2x) Figure 30 Installing bearings 2. Lubricate the sealing surfaces of the mounting flange ( ) with o-ring lube. Place the mounting flange onto the rotor (see Figure 31). Page SERVICE INSTRUCTION

93 HHCS and Washers (8x) and Mounting Flange End Plate Seal Figure 31 Installing the mounting flange 3. Align the rotary index number on the mounting flange to the two alignment marks on the rotor (see Figure 32) Note: The mounting flange/rotor interface must match the rotary index setting at the manifold/slip ring interface that you recorded in Figure 8. HHCS and Washers (8x) and Rotor Alignment Marks Rotor Mounting Flange Rotary Index Setting Figure 32 Aligning the mounting flange and rotor Tip: The flat inside the coupler ( ) should be perpendicular with the rotary index setting on the mounting flange (see Figure 33). SERVICE INSTRUCTION Page 207

94 Rotary Index Setting Coupler Figure 33 Noting coupler position 4. Lubricate eight HHCS ( ) with Aqua Lube and install, with washers ( ) through the mounting flange and into the rotor (Figure 32). Tighten in an opposing pattern to evenly draw the mounting flange to the rotor. Ensure seal ( ) seats to the inner bore of the end plate and is not folded back between the outer face of the end plate ( ) and mounting flange (Figure 31). Do not torque the HHCS until the next step. 5. Lubricate the rotor nut ( ) with Aqua Lube and install, with lock washer ( ), onto the rotor (see Figure 13). Use the torquing tool ( ) and a 1/2-in. drive socket wrench to hold the rotor vane on the housing vane hardstop as shown in Figure 27. Torque the HHCS, installed in step 4, to 33.9 Nm (25 ft/ lbs). 6. Using the torquing tool, torque the rotor nut to a minimum of 135 Nm (100 ft/ lbs), and until one of the tabs on the washer lines up with a notch in the rotor nut. Bend a tab into a notch. Testing Operation (optional) If test equipment is available, check that the rotary actuator meets port to port leakage and break-away pressure specifications before it is reinstalled on the slave arm. If no equipment is available, skip to Reattach Forearm Rotary Actuator to Roll Base. 1. Test 1: Perform this test in both directions. Connect a directional-controlled hydraulic power source to the 3A and 3B hose ports. At a pressure of 300 psig (± 50 psig), slowly rotate the rotary actuator back-and-forth to expel any trapped air. Drive the rotor in either direction to the hard stop. Set the test pressure to 0 psig. Set one directional control valve to be fully open. Slowly increase the test pressure until the forearm starts to rotate (break-away). Record the break-away pressure: (250 psi or less is acceptable). Break-away pressures above 250 psi may indicate misaligned or incorrectly installed seals/bearings, a foreign object inside the actuator, or other assembly error. 2. Test 2: Page SERVICE INSTRUCTION

95 Disconnect the 3B hose and case drain hose, and route into a suitable container. Pressurize port 3A to 300 psig (± 50 psig) to test for port to port leakage. Record the amount of fluid coming from port B (Return) and/or the case drain: (57 drops/min or less from either hose is acceptable). An unacceptable leakage rate to the case drain indicates an end seal problem. An unacceptable leakage rate from port 3B may indicate a vane seal or end seal problem, or damage to the edges between the face and bore of the housing ( ). Reattach Forearm Rotary Actuator to Roll Base Refer to Figure 34 and Figure 35 for this procedure. Rotary Actuator HHCS and Washers (4x) and Roll Base Figure 34 Installing rotary actuator to roll base 1. Place the rotary actuator ( ) onto the roll base ( ) (see Figure 34). 2. Apply a coating of Loctite 271 to the threads of four HHCS ( ) and install, with washers ( ), through the roll base ( ) and into the rotary actuator (see Figure 34). Torque to 48 Nm (35 ft/lbs). 3. Lubricate pitch pin ( ) and elbow spacers ( ) with EP grease and install into place as shown in Figure 35. Install two HHCS ( ) to secure pitch pin ( ) to elbow linear actuator ( ) (Figure 35). Torque to 10.8 Nm (8 ft/lbs). SERVICE INSTRUCTION Page 209

96 Elbow Spacer(2x) Manifold Plug (2x) Pitch Pin Roll Base Elbow Linear Actuator HHCS (2x) Figure 35 Installing the elbow linear actuator to the roll base 4. Install the plugs ( ) into the roll base (see Figure 35). 5. Run a 3 foot-long, 24 gauge wire (or equivalent string) through the center of the rotary actuator. This pull-wire will help you get the sensor wires through the rotary actuator when the forearm is reattached. Install Slip Ring/Manifold to Rotary Actuator Refer to Figure 1, Figure 5, Figure 36, and Figure 37 for this procedure. 1. Lubricate two new o-rings ( ) with o-ring lube and install onto end plate ( ) (see Figure 36). End Plate O-ring (2x) Figure 36 Installing o-rings 2. Loosely install hydraulic hoses to the appropriate fittings on manifold ( ) (Figure 5). 3. Feed the pull-wire through the slip ring ( ) and manifold (see Figure 37). Page SERVICE INSTRUCTION

97 Manifold Pull-Wire Slip Ring Figure 37 Installing slip ring/manifold 4. Lubricate the slip ring with o-ring lube and install into the rotary actuator (see Figure 37). 5. Lubricate two HHCS ( ) with Aqua Lube and install, with washers ( ), through the manifold and into the rotor (Figure 5). Center the manifold on the rotary actuator by loosely installing the remaining eight HHCS ( ) (Figure 1). Torque the two HHCS ( ) to 47 Nm (35 ft/lbs). Remove the eight HHCS ( ). Center the Position Sensor Refer to Figure 1, Figure 5, Figure 18, Figure 38, and Figure 39 for this procedure.! Caution In this procedure you will set the center position of the rotary actuator position sensor. To do this you will need have the power to the master controller turned on. Do not turn on the hydraulics at this time. 1. Place two opposing HHCS ( ) (Figure 1) into the bottom of rotary actuator assembly ( ). Use a crossbar between these screws to turn the rotary actuator all the way to one hard stop. Note position of rotary actuator. Turn the rotary actuator the opposite direction to the other hard stop. Note position of rotary actuator. Turn rotary actuator back to the center of the rotation. Do not rotate the arm away from the centered position. 2. Turn on the power to the master controller. Go to the diagnostics menu: Press DOWN TO EXIT > 4 DIAGNOSE > 2 SLAVE. Locate the ROL column and read the FEED BACK readout. Place the sensor driveshaft ( ) into the position sensor ( ) as shown in Figure 38. Look at the readout and slowly rotate the driveshaft until it reads 0 (± 100). Pull the drive shaft straight out of the sensor. SERVICE INSTRUCTION Page 211

98 Position Sensor Sensor Driveshaft Figure 38 Centering the position sensor 3. Lubricate the bearing ( ) with EP grease (see Figure 18). Align the flat on the sensor driveshaft with the flat on the coupler (see Figure 33) and install the sensor driveshaft into the rotary actuator (see Figure 5). 4. Lubricate o-ring ( ) on the top of the adapter plate ( ) with o- ring lube (Figure 17). 5. Install the position sensor onto the adapter plate (see Figure 5). 6. Lubricate new o-ring ( ) with o-ring lube and install into wire housing ( ) (Figure 5). 7. Feed the pull-wire through the wire housing as shown in Figure 39. Lubricate four SHCS ( ) with Aqua Lube and install the wire housing onto the rotary actuator (see Figure 39). Torque to 28-in./lbs (3.2 Nm). SHCS (4x) Pull-Wire Wire Housing Figure 39 Installing the wire housing Note: Check that the FEED BACK readout is still at 0 (± 100). If not, repeat steps 1-7 until the desired readout is maintained. 8. Remove the two screws from step 1. Turn off the master controller. Page SERVICE INSTRUCTION

99 Reattach Forearm to Rotary Actuator Refer to Figure 1, Figure 2, Figure 40, and Figure 41 for this procedure. 1. Lubricate nine o-rings ( ) with o-ring lube and install on the bottom of the mounting flange ( ) (see Figure 40). O-rings (9x) Pull-Wire Mounting Flange Figure 40 Installing o-rings to bottom of the rotary actuator 2. Lubricate ten HHCS ( ) with Aqua Lube (see Figure 1). 3. Tie the pull-wire to the six sensor wires coming out the top of the forearm. Pull the pull-wire through the rotary actuator as you align the mounting flange of the forearm with the pin on the face of the mounting flange ( ). 4. Install HHCS from step 2, with washers ( ), to secure the forearm (see Figure 1, on page 187). Torque to 10.7 Nm (8 ft/lbs). 5. Align the all hydraulic hose fittings. Ensure that the hoses exit cleanly into the upper arm and will clear the manifold cover ( ) (see Figure 1). Tighten the hose fittings finger tight, then one-sixth of a turn to tighten the hose fittings. 6. Lubricate five new o-rings ( and ) with o-ring lube and install them into the wire housing cover ( ) (see Figure 2). 7. Install the position sensor wires to the PCB assembly (see Figure 41). To connect wires properly, match the wire colors across the connector. PCB Assembly Position Sensor Wires From Forearm Area Figure 41 Connecting sensor wires 8. Lubricate five SHCS ( ) with Aqua Lube and install the wire housing cover ( ) (see Figure 2). Torque to 3.2 Nm (28-in./lbs). SERVICE INSTRUCTION Page 213

100 9. Lubricate eight HHCS ( ) with Aqua Lube, add washers ( ), and install manifold cover ( ) onto the rotary actuator (Figure 1). Torque to 47.5 Nm (35 ft/lbs). END OF SERVICE INSTRUCTION Page SERVICE INSTRUCTION

101 Service Instruction Forearm, Description Complete service instructions for the Orion P intermeshing jaw Estimated Time to Complete 3 hours Preparation for Service Below is a list of required tools and materials for this Service Instruction. Look over the list and make sure you have all the materials before you get started. Read through the entire procedure to make sure you understand, and are capable of performing, the service. Take special notice of all notes, warnings, and the terminology section. Tools Needed Materials Needed 7/16-in. socket Aqua Lube ( ) 9/16-in. socket Dow Corning 55 O-ring lube or petroleum jelly 9/64 allen wrench Loctite 271 ( ) 1/4-in. flat blade screwdriver 3/32-in. flat blade screwdriver 7/16-in. wrench 9/16-in. wrench ft 24 gauge wire or equivalent string Valvoline Val-Plex EP Grease Dow Corning 5 Silicone Grease Custom Tools Needed none needed Terminology HHCS = Hex Head Cap Screw PHMS = Pan Head Machine Screw! Caution Some components have protective coatings such as anodizing. Take care not to scratch any protective coatings. Corrosion damage will result. SERVICE INSTRUCTION Page 215

102 ! Caution Replace hydraulic hoses only with the designated PDH (Pressure Diagnostic Hose) spares (P/N: , -3836, -3837, -3838, -3839, -3840, -3841). Replacement with hoses of other jacket types (steel, etc.) will result in premature hose failure. Procedures in this Service Instruction assume that the forearm assembly will be removed from and then reattached to the slave arm. Wrist and jaw assemblies must be detached from and reattached to the forearm as part of the service. Refer to the wrist Service Instruction for wrist removal instructions. You must remove the wrist assembly before you can perform service on the intermeshing jaw assembly. See the service instructions for the Orion Wrist Assembly. Perform all assembly work in a clean, dry environment if possible. Although assembly of major slave arm components must often be performed under field conditions, the intermeshing jaw should be disassembled and reassembled under clean service conditions to prevent contamination and damage to bearing surfaces. Prepare a clear area on the work surface in which to arrange the components as the intermeshing jaw is disassembled. We recommend that you make a photocopy of this Service Instruction for workbench use. Introduction The serviceable areas of the forearm assembly are the: O-rings Hydraulic hoses Wrist pitch linear actuator with its pivot pins and bearings Wrist pitch joint pivot pin and bearings Wrist rotary position sensor Note: Under most circumstances, the forearm should not be completely disassembled. The routing and connection of the hydraulic hoses is complex and should not be disturbed unless absolutely necessary for servicing. If you decide, or need, to completely disassemble the forearm, pay special attention to the hydraulic hose routing during reassembly. Disable the Slave Arm! WARNING Before you can service the arm safely, you need to disable the electrical and hydraulic functions of the arm. Follow the steps below before you continue. 1. Raise the arm to a comfortable working position. 2. Turn off the power switches located on the master controller and the junction box. Page SERVICE INSTRUCTION

103 3. Turn off the power to the Hydraulic Power Unit (HPU). 4. If power is supplied from a local, independent source, turn off the power to the slave controller. 5. If your arm is equipped with a hydraulic compensation unit, isolate the unit from the arm. Remove the Forearm Disassembly of the intermeshing jaw assumes that all preparations, previously described in this Service Instruction, have been met. Numbers in parentheses refer to the part number of the item. See Figure 1 for basic identification of intermeshing jaw parts. SERVICE INSTRUCTION Page 217

104 HHCS and Washers and Manifold Cover Anode Forearm Rotary Actuator Pin Pin HHCS (2x) Forearm Wrist Pitch Linear Actuator Bearing Pin (2x) Pin (2x) HHCS (2x) Rotary Position Sensor Linear Actuator Guard HHCS and Washers and Cap Plug (2x) Wrist Base Figure 1 Basic forearm parts identification Remove the Forearm From the Forearm Rotary Actuator Refer to Figure 2, Figure 3, Figure 4, and Figure 5 for this procedure.! Caution When you remove the ten HHCS in step 6, the forearm will be free. Read the entire step before continuing. Be prepared by properly supporting the forearm. 1. Remove the anode ( ) from the forearm ( ) (see Figure 2). Page SERVICE INSTRUCTION

105 2. Remove the eight HHCS ( ) and washers ( ) securing the manifold cover ( ) to the top of the forearm rotary actuator ( ) (see Figure 2). Remove the manifold cover to expose the wire housing cover ( ) (see Figure 3). HHCS and Washers (8x) and Manifold Cover Anode Forearm Rotary Actuator HHCS and Washers (10x) and Forearm Figure 2 Manifold cover and forearm rotary actuator 3. Remove the five SHCS ( ) that hold the wire housing cover to the top of the wire housing ( ) (see Figure 3). Remove the wire cover housing cover and remove the large o-ring ( ) and the four smaller o-rings ( ) from the wire housing cover (see Figure 3). O-ring O-ring (4x) Wire Housing Cover Wire Housing SHCS (5x) Figure 3 Wire housing cover and o-ring location 4. Using a 3/32-in. flat blade screwdriver, remove the forearm sensor wires from the PCB assembly ( ) (see Figure 4). Note: Note that the wires are connected across from wires of the same color and striping. SERVICE INSTRUCTION Page 219

106 PCB Assembly Forearm Sensor Wires Figure 4 Removing position sensor wires from pcb assembly 5. Tightly tie one end of a 3 foot-long, 24 gauge wire (or equivalent string) around all wires just removed in step 4. Tie the other end of the wire to a hydraulic fitting on the top of the forearm rotary actuator. The pull-wire will trail behind when the forearm is removed and help you get the wires back through the forearm rotary actuator when the forearm is reattached.! Caution When you remove the ten HHCS in step 6, the forearm will be free. Read the entire step before continuing. Be prepared by properly supporting the forearm. 6. While supporting the arm, remove ten HHCS ( ) and washers ( ) from the bottom of forearm rotary actuator (Figure 2). Separate the forearm from the forearm rotary actuator and extract the position sensor wires from the forearm rotary actuator. Untie the pull-wire from position sensor wires and set the forearm on a stable work surface. 7. Remove nine o-rings ( ) from the bottom of forearm rotary actuator ( ) (Figure 5). O-rings (9x) Figure 5 Bottom of forearm rotary actuator Remove Wrist from Forearm Refer to Figure 6, Figure 7, Figure 8, and Figure 9 for this procedure. Page SERVICE INSTRUCTION

107 1. Remove the two HHCS ( ) that hold the hose guard ( ) in place and remove the hose guard from the wrist base ( ) (see Figure 6). HHCS (2x)_ Hose Guard Cap Plug (2x) Anode Wrist Base Figure 6 HHCS, hose guard, cap plug, and anode location 2. Remove the anode ( ) from the wrist base ( ) (see Figure 6). 3. Remove the two cap plugs ( ) from the wrist base by placing a finger on the backside of the plug and pushing it out of the hole (see Figure 6). 4. Remove the two HHCS ( ), washers ( ), and the linear actuator guard ( ) from the linear actuator ( ) (see Figure 7). Slide the pin ( ) out and remove the two spacers ( ) (see Figure 7). Linear Actuator Linear Actuator Guard Wrist Base HHCS and Washers and Pin Spacer (2x) Linear Actuator Figure 7 Removing the linear actuator from the wrist base 5. Remove the four HHCS ( ) and washers ( ) and separate the wrist motor ( ) from the wrist adapter ( ) and wrist base (see Figure 8). SERVICE INSTRUCTION Page 221

108 HHCS and Washers (4x) and Wrist Adapter Wrist Base Wrist Motor Figure 8 Removing the wrist motor from the wrist base 6. Remove four small o-rings ( ) and one large o-ring ( ) from the wrist base (Figure 9). Wrist Base O-rings (4x) O-ring Figure 9 Wrist base o-rings Remove Wrist Base and Wrist Position Sensor from Forearm Refer to Figure 10 for this procedure. Wrist Pitch Linear Actuator Wrist Base Wrist Position Sensor PHMS (4x) Bearing (2x) Pin Pin (2x) HHCS (4x) Figure 10 Wrist base parts identification Page SERVICE INSTRUCTION

109 1. Tightly tie one end of a 3 foot-long, 24 gauge wire (or equivalent string) around the three wrist position sensor wires (brown, red, and black) emerging from the top of the forearm. Tie the other end of the pull-wire to a bolt hole in the top of the forearm. When you remove the wrist position sensor ( ) (step 2), the pull-wire will trail behind and help you get the wires back through the wrist sensor hose assembly ( ) when the sensor is reattached. 2. Remove four PHMS ( ) from the wrist position sensor ( ) and remove sensor from the wrist base. Slowly pull wires out of the wrist sensor hose assembly ( ). Untie the pull-wire from the sensor wires. Set the sensor aside for later service. Note: Before continuing to step 3, make sure the hydraulic hose ends at the wrist base are clearly labeled. Use a permanent marker and tape to label unmarked hoses. 3. Disconnect the five hydraulic hoses ( , , , , and ) and the wrist sensor hose assembly ( ) from the wrist base ( ). 4. Remove four HHCS ( ) and pin ( ) from both sides of the forearm. Support the wrist base and slide both pins out of the wrist base to separate the wrist base from forearm. Remove Wrist Pitch Linear Actuator From Forearm Refer to Figure 11 and Figure 12 for this procedure. HHCS and Washer(2x) and Pin Mounting Flange HHCS (2x) Pin Figure 11 Removing pitch linear actuator from forearm 1. Remove the two HHCS ( ) and pin ( ) from the forearm ( ) (see Figure 11). Slide the pin ( ) out of the forearm. 2. Remove the two HHCS ( ) and washers ( ) securing the mounting flange ( ) to the forearm (see Figure 11). 3. Slide the forearm off the mounting flange and wrist pitch linear actuator ( ). Set the forearm aside for later inspection. SERVICE INSTRUCTION Page 223

110 Note: It is recommended that you do not perform steps 4-5 unless you have specific reasons for servicing: the wrist pitch linear actuator ( ), one or more hydraulic hoses, or the mounting flange ( ). If you do not need to service any of the above parts, go to Inspect Forearm Parts on page 224.! Caution Hydraulic fluid will spill from the wrist pitch linear actuator when you remove hydraulic hoses, 4A and 4B ( and ), during step 4. Have a drain pan ready to catch the fluid. 4. Disconnect hydraulic hoses 4A and 4B ( and ) from the wrist pitch linear actuator (see Figure 12). SHCS and Washer(4x) and Sensor Housing Hydraulic Hose 4A Hydraulic Hose 4B Figure 12 Wrist pitch linear actuator 5. Remove the four SHCS and washers ( and ) from the sensor housing ( ). Remove the sensor housing from the wrist pitch linear actuator (see Figure 12). If you need to service the wrist pitch linear actuator, see Orion "Linear Actuators, , -3939, -4328" Service Instruction. Inspect Forearm Parts Refer to Figure 1 for this procedure. 1. Inspect the hydraulic hoses and the connector assembly for signs of chafing, wear, kinking, leakage, or other damage. Replace any damaged hose.! Caution Replace hydraulic hoses only with the designated PDH (Pressure Diagnostic Hose) spares (P/N: , -3836, -3837, -3838, -3839, -3840, -3841). Replacing hoses of other jacket types (steel, etc.) will result in premature hose failure. 2. Inspect the four bearings ( ) for cracks, excessive wear, or other damage (see Figure 1). Replace any damaged bearing. Page SERVICE INSTRUCTION

111 3. Inspect the pins ( , , and ) for signs of excessive wear, galling, or other damage. Replace any damaged pin. 4. Inspect forearm ( ), wrist base ( ), and mounting flange ( ) for signs of cracking, twisting, deformation, or other damage. Replace any damaged parts. Service the Wrist Rotary Position Sensor See Figure 13 and Figure 14 for reference. 1. Remove the two PHMS ( ) from the rotary position connector ( ). Separate the connector from the rotary position sensor ( ) (see Figure 13). Rotary Position Connector PHMS Rotary Position Sensor Figure 13 Rotary position connector and rotary position sensor 2. Remove o-ring ( ) and the back-up ring ( ) from the sensor (Figure 14). Lubricate new o-ring and back-up ring with o-ring lube and install onto the sensor (Figure 14). O-ring Back-up Ring Figure 14 Rotary position sensor o-ring orientation 3. Fill the connector cavity of the rotary position connector with DC 5 grease. Lubricate the two PHMS with Aqua Lube and install the connector onto the sensor. Tighten the PHMS. Set the rotary position sensor aside for later installation onto the forearm. SERVICE INSTRUCTION Page 225

112 Reassemble Forearm Refer to Figure 15, Figure 16, Figure 17, Figure 18, and Figure 19 for this procedure. If you did not disconnect hydraulic hoses from the mounting flange or remove the wrist pitch linear actuator, skip steps that do not apply to you. If wrist pitch linear actuator ( ) was not serviced, skip to step Apply a thin film of EP grease to sealing surfaces of the -4 hydraulic fittings ( ) (see Figure 15). Attach hose 4A and 4B ( and ) (Figure 15). Tighten the hose fittings finger tight, then one-sixth of a turn to tighten the hose fitting. Lubricate the four SHCS ( ) with Aqua Lube (see Figure 15). Fill the connector cavity of the connector housing with DC5 grease. Using four SHCS and washers ( ), install the sensor housing ( ) to the wrist pitch linear actuator (see Figure 15). Torque to 1.1 Nm (10-in./lbs). Wipe away excess DC5 grease.! Caution All hoses must be routed as shown in Figure 15, or premature hose failure will result. SHCS and Washer(4x) and Sensor Housing Hydraulic Hose 4A Hydraulic Hose 4B Figure 15 Hose orientation for wrist pitch linear actuator 2. Apply a thin coat of EP grease to the sealing surface of each -4 hydraulic fitting on the mounting flange ( ). Verify that the three -4 angle fittings ( ) are oriented as shown in Figure 16. Page SERVICE INSTRUCTION

113 -4 Hydraulic Fittings (3x) Figure 16-4 Angle fitting orientation 3. Connect the -4 hydraulic hoses to the appropriate fittings. See Figure 17 for hose orientation. Tighten each hose fitting finger tight, then one-sixth of a turn to tighten the hose fitting. Figure 17-4 Hydraulic hose orientation 4. Connect the two -4 hydraulic hoses from the wrist pitch linear actuator to the mounting flange. See Figure 18 for orientation of wrist pitch linear actuator -4 hydraulic hoses. Drawing not to scale Figure 18 Connecting -4 hydraulic hoses from wrist pitch linear actuator SERVICE INSTRUCTION Page 227

114 5. Pass sensor wires from the wrist pitch position sensor through the fitting marked "P" on the mounting flange ( ). Connect the hydraulic fitting to the fitting marked "P." Tighten the hose fitting finger tight, then one-sixth of a turn to tighten the hose fitting. 6. Carefully pass hoses and the wrist pitch linear actuator through the forearm ( ). Apply Aqua Lube to threads of the two HHCS ( ) and install, with washers ( ), into the mounting flange ( ) (see Figure 19). Torque to 11 Nm (8 ft/lbs). HHCS and Washer(2x) and Mounting Flange Figure 19 Installing the mounting flange Attach Wrist Pitch Linear Actuator to Forearm Refer to Figure 20 for this procedure. 1. Apply EP grease to the pin ( ). Align the wrist pitch linear actuator ( ) with the forearm and insert the pin. Pin HHCS (2x) Pin Figure 20 Installing body end of wrist pitch linear actuator into forearm 2. Apply Aqua Lube to the threads of the two HHCS ( ). Install two HHCS and the pin ( ) onto the forearm. Torque to 11 Nm (8 ft/lbs). Attach -4 Hydraulic Hoses to Wrist Base Refer to Figure 21 for this procedure.! Caution All hoses must be routed as shown in Figure 21, or hose failure will result. Page SERVICE INSTRUCTION

115 1. Apply a thin coat of EP grease to the sealing surface of each hydraulic fitting on the wrist base ( ). 2. Attach hoses 5A and 6B to the wrist base fittings. Tighten each hose fitting finger tight, then one-sixth of a turn to tighten the hose fitting. Linear actuator not shown in this view for clarity Figure 21 Wrist base and hose orientation 3. Attach hoses 6A, 5B, and C to the wrist base fittings. Tighten each hose fitting finger tight, then one-sixth of a turn to tighten the hose fitting. 4. Pass the pull-wire for the wrist position sensor wires through the wrist base at the fitting marked W. Attach wrist position sensor hose to the wrist base at the fitting marked W. Tighten the hose fitting finger tight, then one-sixth of a turn to tighten the hose fitting. Install Wrist Base and Wrist Position Sensor to Forearm Refer to Figure 22 for this procedure. Wrist Base Wrist Position Sensor PHMS (4x) Bearing Pin Pin HHCS (2x) Figure 22 Installing wrist base and wrist position sensor to forearm SERVICE INSTRUCTION Page 229

116 1. Apply EP grease to the bearings ( ) and pivot pins ( ). Align the forearm and wrist base and insert the two pivot pins. 2. Apply Aqua Lube to the threads of the four HHCS ( ) and use them to install the two pins ( ). Torque to 11 Nm (8 ft/lbs). 3. Tie the pull-wire from the wrist position sensor tube to the three wires of the wrist position sensor ( ). Slowly pull the wires up into the wrist position sensor tube and out of the top of the forearm. 4. Lubricate four PHMS ( ) with Aqua Lube and install wrist position sensor ( ) to wrist base ( ). Tighten the PHMS. Untie the pull-wire from the position sensor wires. Install Wrist to Forearm Refer to Figure 23, Figure 24, Figure 25, and Figure 26 for this procedure. 1. Use liberal quantities of o-ring lube to position the four small o-rings ( ) and one large o-ring ( ) to the wrist base ( ) (see Figure 23). Wrist Base O-rings (4x) O-ring Figure 23 Wrist base O-rings 2. Lubricate four HHCS ( ) with Aqua Lube. Add washers ( ) to the HHCS and attach wrist motor/wrist adapter to wrist base ( ). Torque to 34 Nm (25 ft/lbs) (Figure 24).! Caution Be careful to line up all the oil passages correctly. The wrist and jaw will fail to operate if the oil passages are not aligned correctly. Page SERVICE INSTRUCTION

117 HHCS and Washers (4x) and Wrist Adapter Wrist Base Wrist Motor Figure 24 Installing the wrist motor from the wrist base 3. Attach the linear actuator ( ) to the wrist base. Slide the pin ( ) and the two spacers ( ) in place (see Figure 25). Linear Actuator Linear Actuator Guard Wrist Base HHCS and Washers and Pin Spacers Linear Actuator Figure 25 Installing the linear actuator to the wrist base 4. Lubricate two HHCS ( ) with Aqua Lube. Install washers ( ) to the two HHCS and attach linear actuator guard ( ) to linear actuator (Figure 25). Torque to 11 Nm (8 ft/lbs). Install two cap plugs ( ) onto the wrist base (Figure 26). SERVICE INSTRUCTION Page 231

118 HHCS (2x)_ Hose Guard Cap Plug (2x) Anode Wrist Base Figure 26 HHCS, hose guard, cap plug, and anode location 5. Lubricate threads of a new anode ( ) with Aqua Lube and install onto the wrist base (Figure 26). 6. Lubricate the two HHCS ( ) with Aqua Lube and install the hose guard onto the wrist base ( ) (see Figure 26). Torque to 11 Nm (8 ft/lbs). Install Wrist Pitch Actuator to Forearm Refer to Figure 27 for this procedure. 1. Apply EP grease to the bearings ( ) and the pin ( ). Align the rod end of the wrist pitch linear actuator ( ), wrist base ( ), and spacers ( ). Insert the pivot pin so that the bolt holes are aligned with the rod end holes. Linear Actuator Guard HHCS and Washers (2x) and Cap Plug (2x) Wrist Pitch Linear Actuator Bearing Wrist Base Figure 27 Installing rod end of wrist pitch linear actuator into wrist base 2. Apply Aqua Lube to threads of the two HHCS ( ). Attach actuator guard ( ) using the two HHCS ( ) and washers ( ). Torque to 11 Nm (8 ft/lbs). 3. Install the cap plugs ( ) to the wrist base. Page SERVICE INSTRUCTION

119 Attach Forearm to Forearm Rotary Actuator Refer to Figure 2, Figure 3, Figure 28 and Figure 29 for this procedure. 1. Lubricate nine o-rings ( ) with o-ring lube and install on the bottom of the mounting flange ( ) (see Figure 28). Pin O-rings (9x) Pull-Wire Mounting Flange Figure 28 Installing o-rings to bottom of the rotary actuator 2. Lubricate ten HHCS ( ) with Aqua Lube (see Figure 2). 3. Tie the pull-wire to the six sensor wires coming out the top of the forearm. Pull the pull-wire through the rotary actuator as you align the mounting flange of the forearm with the pin on the face of the mounting flange. 4. Install HHCS from step 2, with washers ( ), to secure the forearm (see Figure 2). Torque to 10.7 Nm (8 ft/lbs). 5. Lubricate five new o-rings ( and ) with o-ring lube and install them into the wire housing cover ( ) (see Figure 3). 6. Install the position sensor wires to the PCB assembly (see Figure 29). To connect wires properly, match the wire colors across the connector. PCB Assembly Position Sensor Wires From Forearm Area Figure 29 Connecting sensor wires 7. Lubricate five SHCS ( ) with Aqua Lube and install the wire housing cover ( ) (see Figure 3). Torque to 3.2 Nm (28-in./lbs). 8. Lubricate eight HHCS ( ) with Aqua Lube, add washers ( ), and install the manifold cover ( ) onto the rotary actuator (see Figure 2). Torque to 47.5 Nm (35 ft/lbs). SERVICE INSTRUCTION Page 233

120 9. Lubricate anode threads ( ) with Aqua Lube and install onto forearm (Figure 2). END OF SERVICE INSTRUCTION Page SERVICE INSTRUCTION

121 Service Instruction Wrist, Description Complete service instructions for the Orion P intermeshing jaw. Estimated Time to Complete 3 hours Preparation for Service Below is a list of required tools and materials for this Service Instruction. Look over the list and make sure you have all the materials before you get started. Read through the entire procedure to make sure you understand, and are capable of performing, the service. Take special notice of all notes, warnings, and the terminology section. Tools Needed 7/16-in. socket Materials Needed Valvoline Val-Plex EP Grease 9/16-in. socket Loctite 271 ( ) 1-1/2-in. socket Loctite 242 1/4-in. socket Aqua Lube ( ) 5/32-in. allen wrench Dow Corning 55 o-ring lube or petroleum jelly 0-1-in. (0-25mm) micrometer 6-in. vernier calipers flat blade screwdriver torque wrench capable of Nm (5-75 ft/lbs) torque wrench capable of Nm (0-75- in./lbs) new razor blade or X-acto style knife Custom Tools Needed Terminology jaw rod sleeve installation tool HHCS = Hex Head Cap Screw clamp nut tool SHCS = Socket Head Cap Screw bearing installation tool FHMS = Flat Head Machine Screw piston clamp tool PA = Parallel-Acting lip seal installation tool SERVICE INSTRUCTION Page 235

122 ! Caution Some components have protective coatings such as anodizing. Take care not to scratch any protective coatings. Corrosion damage will result.! Caution If you are planning to replace the three seals ( ) located in the slip ring wrist housing ( ), you must have replacements on-hand.the old seals are destroyed during removal.! Caution The wrist motor cannot be reassembled without new crush washers ( ). These components are one installation only items. Be sure that you have eight of these washers on-hand before starting this procedure. To perform procedures in this Service Instruction, you will remove the wrist assembly from the slave arm. The jaw must be detached from the wrist assembly as a step in the wrist assembly service. Refer to the appropriate jaw Service Instruction to remove the jaw installed on your slave arm. Disable the Slave Arm! WARNING Before you can service the arm safely, you must disable the electrical and hydraulic functions of the arm. Follow the steps below before you continue. 1. Raise the arm to a comfortable working position. Tip: Extend the pitch actuator to full extension. This will help you gain access to the wrist mounting bolts. 2. Turn off the power switches located on the master controller and the junction box. 3. Turn off the power to the hydraulic power unit (HPU). 4. If power is supplied from a local, independent source, remove power to the slave controller. 5. If your arm is equipped with a hydraulic compensation unit, isolate the unit from the arm. Remove the Wrist Disassembly of the intermeshing jaw assumes that all preparations, previously described in this Service Instruction, have been met. Page SERVICE INSTRUCTION

123 Numbers in parentheses refer to the part number of the item. Remove the Jaw Assembly Refer to the appropriate jaw Service Instruction to remove the jaw installed on your slave arm. Read and be familiar with all the steps and requirements before you get started. Return to this point when you have removed your jaw assembly. Remove the Jaw Nose Block/Jaw Piston Assembly Refer to the appropriate nose block/jaw piston Service Instruction to remove the nose block/jaw piston installed on your slave arm. If you have a PA jaw, refer to the appropriate wrist/jaw adaptor Service Instruction to remove the wrist/jaw adaptor installed on your slave arm. Read and be familiar with all the steps and requirements before you get started. Return to this point when you have removed your nose block/jaw piston assembly. Go to Remove Wrist from Forearm. Remove Wrist from Forearm Refer to Figure 1, Figure 2, Figure 3, and Figure 4 for this procedure. 1. Remove the two HHCS ( ) that hold the hose guard ( ) in place and remove the hose guard from the wrist base ( ) (see Figure 1). HHCS (2x)_ Hose Guard Cap Plug (2x) Anode Wrist Base Figure 1 HHCS, hose guard, cap plug, and anode location 2. Remove the anode ( ) from the wrist base (see Figure 1). 3. Remove the two cap plugs ( ) from the wrist base by placing a finger on the backside of the plug and pushing it out of the hole (see Figure 1). 4. Remove the two HHCS ( ), washers ( ), and the linear actuator guard ( ) from the linear actuator ( ) (see Figure 2). Slide the pin ( ) out and remove the two spacers ( ) (see Figure 2). SERVICE INSTRUCTION Page 237

124 Linear Actuator Wrist Base Linear Actuator Guard HHCS and Washers and Pin Spacer (2x) Linear Actuator Figure 2 Removing the linear actuator from the wrist base 5. Support the Wrist. Remove four HHCS ( ) and washers ( ) and separate the wrist motor ( ) from wrist adapter ( ) and wrist base (Figure 3). HHCS and Washers (4x) and Wrist Adapter Wrist Base Wrist Motor Figure 3 Removing the wrist motor from the wrist base 6. Remove the four small o-rings ( ) and one large o-ring ( ) from the bottom of the wrist base (see Figure 4). 7. Remove five small o-rings ( ) from the bottom of the wrist adaptor (Figure 4). Page SERVICE INSTRUCTION

125 Wrist Base Wrist Adapter O-rings (5x) O-rings (4x) O-ring Figure 4 Removing wrist base O-rings Remove the Wrist Manifold From the Slip Ring Housing Refer to Figure 5, Figure 6, and Figure 7 for this procedure.! Caution The wrist motor cannot be reassembled without new crush washers ( ). These components are one installation only items. Be sure that you have eight new washers on-hand before starting this procedure. HHCS (5x) , (2x) , & (1x) Valve Plate Gerotor Drive Shaft O-ring FHMS (3x) Clamping Nut Sensor Shaft HHCS Thrust Washer (2x) Thrust Bearing Wrist Manifold Wrist Housing Figure 5 Basic wrist motor parts identification SERVICE INSTRUCTION Page 239

126 1. Remove the o-ring ( ) from the wrist manifold ( ) (see Figure 5). 2. Remove three FHMS ( ) from the position sensor shaft ( ) and remove the shaft. 3. Using a 5/32-in. allen wrench, loosen, but do not remove SHCS ( ) on clamping nut (Figure 5). Using a 1-1/2-in. socket, or clamping nut torque tool ( ), remove the clamping nut ( ) from drive shaft ( ) (Figure 5). 4. Remove two thrust washers ( ) and thrust bearing ( ) from the drive shaft ( ). 5. Using a 1/4-in. allen wrench, remove the eight SHCS ( , , and ) from the wrist manifold. You will find that two SHCS ( ) may not come out. You may leave them in, for now. They will come out when you remove the wrist manifold ( ) in step 6. Remove the crush washer ( ) from each SCHS. Note: The three different SHCS types must be reinstalled according to the assembly drawing. The SHCS are not interchangeable. 6. Remove the wrist manifold from the wrist housing ( ) (See the "Tip" below). Tip: Removing the wrist manifold may be difficult, but DO NOT use any tools to pry the wrist manifold out of the wrist housing. Use the following technique to remove the wrist manifold from the wrist slip ring housing: Using two HHCS ( ) that hold the nose block to the wrist motor, hold the wrist motor in a soft-jaw vise (Figure 6). Screw two HHCS ( ) that held the jaw motor to the wrist base into the wrist manifold (Figure 6). Squeeze the screws together and evenly pull up to remove the wrist manifold (Figure 6). HHCS (2x) Wrist Manifold Wrist Housing HHCS Figure 6 Removing the wrist manifold from the wrist housing Page SERVICE INSTRUCTION

127 7. Remove o-rings ( and ) and bushing ( ) from both of the SHCS ( ) that remained in the wrist manifold during step 5 (Figure 7). Remove both SHCS from wrist manifold. Remove crush washers ( ) from each SCHS (Figure 7). O-ring (2x) Washer (8x) Wrist Manifold O-ring Bushing SHCS (2x) Bearing O-ring Figure 7 Disassembling the wrist manifold 8. Remove the o-ring ( ) from the wrist manifold (see Figure 7). 9. If the bearing ( )is damaged, remove it from the wrist manifold by evenly tapping it out using a small brass drift or pressing it out using a suitable tool (see Figure 7). If not damaged, the bearing may remain in the wrist manifold. Final Wrist Motor Disassembly Refer to Figure 8, Figure 9, Figure 10, and Figure 11 for this procedure. 1. Remove the o-rings ( , , and ) from the valve plate ( ) (see Figure 8). O-ring Valve Plate O-ring O-ring Figure 8 Removing valve plate O-rings 2. Using the two HHCS ( ) that you used to remove the wrist manifold ( ), remove the valve plate by lifting it up as shown in Figure 9. SERVICE INSTRUCTION Page 241

128 HHCS (2x) Seal Driveshaft Valve Plate Wrist Housing Figure 9 Removing the valve plate 3. Remove the seal ( ) from the valve plate ( ), or the drive shaft ( ), depending on where the seal is when you remove the valve plate (see Figure 9). 4. Turn the slip ring wrist housing face down over a flat surface and allow the gerotor assembly ( ) and wear plate ( ) to fall out of the wrist housing. Set the gerotor assembly aside for later inspection (see Inspect the Gerotor Assembly on page 243). 5. Press down to push the drive shaft up out of the wrist housing. If necessary, tap the housing gently against a plastic or wood work surface to dislodge these parts.! Caution The gerotor assembly ( ) is made up of precision parts. Handle these parts carefully. Do not damage the edges of any of the parts. 6. Remove the seal ( ), backup ring ( ), thrust washer ( ), and roller bearing ( ) from the wrist housing (see Figure 10). Driveshaft Back-up Ring Thrust Washer Seal Figure 10 Removing parts from wrist housing Page SERVICE INSTRUCTION

129 7. Using a small pick tool, remove the bearing ( ) from the wrist housing ( ) (see Figure 11). Set aside bearing to inspect later. Seal (3x) Bearing Needle Bearing Wrist Housing Figure 11 Removing seals, bearing, and needle bearing from wrist housing! Caution To remove three seals ( ), in step 8, you must destroy the seals. If you don t have replacements, do not remove the seals at this time. 8. Remove three seals ( ) (Figure 11) by carefully cutting across them with a new razor blade or X-acto style knife. Using a small pick tool, remove the o-ring that sits under each seal. Note: Be very careful not to damage the finish on the slip ring wrist housing. 9. If the needle bearing ( ) is damaged, remove it from the wrist housing by evenly tapping it out using a small brass drift (see Figure 11). If not damaged, the bearing may remain in the wrist housing. Inspect the Gerotor Assembly In the following steps you will clean, and then check, all parts for corrosion, chipping, scuffing, and wear. The gerotor is assembled with matched parts. If there are damaged parts, replace the entire assembly. Refer to Figure 12, for this procedure. See Figure 12 for basic identification of gerotor parts ( ). SERVICE INSTRUCTION Page 243

130 Figure 12 Gerotor components! Caution The gerotor assembly ( ) is made up of precision matched parts. Handle these parts carefully. Do not damage the edges of any of the parts. Damaging the edges of the parts will cause a lack of torque and power in the wrist assembly. 1. Clean, degrease, and dry all parts. 2. Carefully check all surfaces for wears, nicks, or other damage. Any obvious high spots caused by nicks, or other damage, may be carefully lapped down. If a lapping machine is not available you will have to replace the gerotor assembly as a whole unit. All parts of the gerotor assembly carefully are matched together at the factory and cannot be interchanged with another gerotor assembly. 3. Inspect the inner rotor for wear. The coating on the inner rotor will flake off under extreme conditions. This will show itself as jittery low speed performance and a loss of wrist torque. Replace the gerotor assembly if all, or most of, the coating is gone. Inspect Wrist Components Refer to Figure 5, Figure 7, Figure 10, and Figure 11 for this procedure. Page SERVICE INSTRUCTION

131 1. Clean, degrease, and dry all parts. 2. Inspect four bearings ( , , , and ) for signs of wear or damage (Figure 5, Figure 7, Figure 10, and Figure 11). Replace any damaged bearings. 3. Inspect the thrust washers ( ) for wear and galling (see Figure 10). Replace washers if they show excessive wear, galling, or other damage. 4. Inspect the bearing ( ) for galling or damage (see Figure 11). Using your 6-in. vernier calipers, measure the wall thickness of the bearing. Replace the bearing if the thickness is 23.5 mm (0.928-in.), or less, at any point. 5. Inspect the wear surfaces of all major parts for excessive wear, galling, or other damage. Replace any parts that show excessive wear, galling, or other damage. Prepare Slip Ring Wrist Housing for Assembly Refer to Figure 13 and Figure 14 for this procedure. 1. If you removed the needle bearing ( ), install the bearing into the wrist housing ( ) (see Figure 13). The printed edge of the bearing should show out the bottom of the wrist housing. Pack the needle bearing with EP grease. If you didn t remove the needle bearing, pack the bearing with EP grease. Seal (3x) Bearing Needle Bearing Wrist Housing Figure 13 Installing bearings and seals into wrist housing 2. If the three seals ( ) were removed, install three new o-rings and seals in the wrist housing (see Figure 14 and Tip below). Be very careful to place the o-ring and seals in the correct orientation (see Figure 14). Lubricate the seal surfaces with EP grease. Tip: To aid in getting the o-ring into the groove, it may be helpful to bend it as shown at right. Then push the o-ring down into the groove. If the seals were not removed, lubricate the seal surfaces with EP grease. SERVICE INSTRUCTION Page 245

132 Wrist Housing Seal & O-ring Bearing Figure 14 Installation of O-rings, seals, and bearing into wrist housing 3. Lubricate the bearing ( ) with EP grease and install it into the wrist housing as shown in Figure Set aside the slip ring wrist housing assembly for later installation. Prepare Wrist Manifold for Assembly Refer to Figure 15 for this procedure. See Figure 15 for wrist manifold parts identification Crush Washer (8x) Bearing O-ring Bushing SHCS (5x) SHCS (2x) O-ring SHCS (1x) O-ring (2x) Wrist Manifold Figure 15 Position of wrist manifold parts 1. If you removed the bearing ( ), install the bearing into the wrist manifold ( ). The printed edge of the bearing should show out the bottom of the wrist manifold. Pack the bearing with EP grease. If you didn t remove the bearing, pack the bearing with EP grease. 2. Install new crush washers ( ) onto both SHCS ( ). Heavily lubricate the SHCS with EP grease and install both SHCS into the wrist manifold. 3. Lubricate the o-rings ( and ) and bushing ( ) with o- ring lube and install onto the two SHCS ( ) that you just installed in step 2. Page SERVICE INSTRUCTION

133 4. Install a new crush washer ( ) onto the SHCS ( ). Lubricate the SHCS with EP grease and install into the wrist manifold ( ). Each of the three SHCS types must be placed in the correct wrist manifold bores. 5. Lubricate the o-ring ( ) with o-ring lube and install it into the groove of the wrist manifold ( ). Set the wrist manifold aside for later installation. Prepare Drive Shaft for Assembly Refer to Figure 16 for this procedure. Stand the drive shaft ( ) up on end, shaft up, to prepare it for installation into the wrist housing. Seal Bearing Thrust Washer Backup Ring Drive Shaft Figure 16 Wrist drive shaft parts 1. Lubricate the backup ring ( ) with o-ring grease and install onto the drive shaft. 2. Lubricate the seal ( ) with EP grease and install it onto the drive shaft. 3. Lubricate the thrust washer ( ) and the bearing ( ) with EP grease and install onto the drive shaft. Install Drive Shaft and Gerotor Into Slip Ring Wrist Housing Refer to Figure 17 and Figure 18 for this procedure. 1. Lubricate all the inner surfaces of the wrist housing ( ) with EP grease. 2. Lubricate all outer surfaces of the drive shaft ( ) with EP grease. 3. Use o-ring lube to generously lubricate bores of the bolt holes in slip ring wrist housing below the heli-coils. These bores are where the two, wrist oil supply, SHCS are placed. 4. Carefully slide the wrist housing onto the drive shaft (Figure 17). Seat the housing completely onto the drive shaft. SERVICE INSTRUCTION Page 247

134 Wrist Housing Drive Shaft Figure 17 Seating wrist housing on drive shaft assembly 5. Lubricate the seal ( ) with o-ring lube, check orientation, and install it between the slipring wrist housing and the drive shaft (see Figure 18A). Check orientation and push the seal in far enough not to damage it when you stand the housing up on that end. A B Wrist Housing Seal Wear Plate Drive Shaft Figure 18 Installing Seal into Wrist Housing 6. Lubricate the wear plate ( ) with EP grease and install it onto the drive shaft ( ) (see Figure 18B). You may need an arbor press to fully seat the wear plate over the seal and onto the bearing. Note: Note the wear marks on the wear plate. Circular wears marks go toward the gerotor assembly. Replace the plate in the same orientation as originally installed. Reassemble Gerotor Assembly Refer to Figure 19 for this procedure. The machine tolerances are very tight in the gerotor assembly, therefore you will need to be very careful handling the parts. During assembly, lubricate all parts with petroleum jelly. Page SERVICE INSTRUCTION

135 Drive Shaft Wear Plate Wrist Housing Figure 19 Assembling gerotor into wrist housing 1. Install the locating ring into the wrist housing ( ). Align the holes in the locating ring with the holes in the wear plate ( ). 2. Install the inner rotor. Notice that the inner ring has a chamfer. The chamfer may be placed either side up. 3. Install the outer element. 4. Install the sharp-edged sealing rollers between the outer element and the inner rotor. Be careful not to damage an edge when sliding them into position. 5. Install the anti-rotation rollers between the outer element and the locating ring. Install Gerotor Into Slip Ring Wrist Housing Refer to Figure 20, Figure 21, and Figure 22 for this procedure. 1. Lubricate the gerotor valve plate and lower it into position onto drive shaft ( ) (Figure 20). Carefully align the valve plate so that you cannot see rollers through any of the slots in the plate (Figure 20). SERVICE INSTRUCTION Page 249

136 ! Caution Carefully align the valve plate so that you cannot see rollers through any of the slots in the valve plate. The wrist will not function if you fail to align the valve plate properly. Drive Shaft Gerotor Assembly Valve Plate Slots in Valve Plate Figure 20 Installing the valve plate to gerotor assembly 2. Install the valve plate ( ) onto the drive shaft (see Figure 21). O-ring Seal O-ring O-ring Drive Shaft Valve Plate Figure 21 Installing valve plate O-rings 3. Lubricate the seal ( ) with EP grease. Check seal orientation and, using the seal installation tool ( ), install it onto the drive shaft (see Figure 21). 4. Lubricate new o-rings ( , , and ) with o-ring lube and install onto the valve plate (see Figure 21). Page SERVICE INSTRUCTION

137 Install the Wrist Manifold Onto the Slip Ring Wrist Housing Refer to Figure 5, Figure 7, Figure 22, and Figure 23 for this procedure. 1. Lubricate the upper edge of the wrist housing ( ) with o-ring lube. 2. Install the wrist manifold ( ) onto the wrist housing ( ). Orient the two corresponding pin plug holes on the manifold to the two corresponding pin plug holes on the outside of the wrist housing (see Figure 22). Gently press the manifold into place. Wrist Manifold Wrist Housing Pin Plug Holes Figure 22 Positioning the wrist manifold onto the slip ring wrist housing 3. Install new crush washers ( ) onto the five SHCS ( ) (see Figure 7). Heavily lubricate the SHCS with EP grease and install them into the wrist manifold. Follow this procedure to torque the SHCS: Tip: To hold the slip ring wrist housing steady while you torque the following SHCS, use the same procedure you used in step 6 of Remove the Wrist Manifold From the Slip Ring Housing on page Screw the two SHCS ( ) to finger tightness. This will center the o-rings so that they will properly seal. 5. Tighten all the other SHCS to finger tightness. Torque all eight of the SHCS to 20.3 Nm (15 ft/lbs). Torque only the oil-return SHCS ( ) and the five standard SHCS ( ) to 24.4 Nm (18 ft/lbs). Torque only the five standard SHCS ( ) to 32.5 Nm (24 ft/lbs). 6. Lubricate the two thrust washers ( ) and bearing ( ) with EP grease and install them onto the wrist drive shaft ( ) (see Figure 23). SERVICE INSTRUCTION Page 251

138 Clamp Nut Thrust Washer (2x) HHCS Bearing Drive Shaft Wrist Manifold Figure 23 Installing thrust washers and bearing 7. Install the clamp nut ( ) on the drive shaft with the three threaded holes facing out (see Figure 23). Follow this procedure to torque the clamp nut: a. Torque the clamp nut to 102 Nm (75 ft/lbs) to seat all wrist components. b. Loosen the clamp nut and retorque it to the torque stamped on the nut or to 54 Nm (40 ft/lbs) to set the wrist preload. c. Tighten clamp nut SHCS ( ) to 7 Nm (5 ft/lbs) to secure clamp nut (Figure 23). 8. Install the position sensor shaft ( ) and the three FHMS ( ) that hold it in place (see Figure 5). Use new screws, or apply Loctite 242. Tighten the FHMS. 9. Lubricate o-ring ( ) with o-ring lube and install onto the wrist manifold ( ) (see Figure 23). 10. Remove the wrist housing from the vise. Remove the two HHCS ( ) you used to hold the housing in the vise. Install Wrist to Forearm Refer to Figure 24, Figure 25, Figure 26, and Figure 27 for this procedure. 1. Use liberal quantities of o-ring lube to position the four small o-rings ( ) and one large o-ring ( ) to the wrist base ( ) (see Figure 24). Page SERVICE INSTRUCTION

139 Wrist Base O-rings (4x) O-ring Figure 24 Wrist base O-rings 2. Lubricate four HHCS ( ) with Aqua Lube. Add the washers ( ) to the HHCS and attach the wrist motor/wrist adapter to the wrist base ( ). Torque to 34 Nm (25 ft/lbs) (Figure 25).! Caution Be careful to line up all the oil passages correctly. The wrist and jaw will fail to operate if the oil passages are not aligned correctly. HHCS and Washers (4x) and Wrist Adapter Wrist Base Wrist Motor Figure 25 Installing the wrist motor from the wrist base 3. Attach the linear actuator ( ) to the wrist base. Slide the pin ( ) and the two spacers ( ) in place (see Figure 26). SERVICE INSTRUCTION Page 253

140 Linear Actuator Wrist Base Linear Actuator Guard HHCS and Washers and Pin Spacers Linear Actuator Figure 26 Installing the linear actuator to the wrist base 4. Lubricate two HHCS ( ) with Aqua Lube. Install washers ( ) to the two HHCS and attach linear actuator guard ( ) to the linear actuator (Figure 26). Torque to 11 Nm (8 ft/lbs). Install two cap plugs ( ) onto wrist base (Figure 27). HHCS (2x)_ Hose Guard Cap Plug (2x) Anode Wrist Base Figure 27 HHCS, hose guard, cap plug, and anode location 5. Lubricate the threads of a new anode ( ) with Aqua Lube and install onto the wrist base (see Figure 27). 6. Lubricate the two HHCS ( ) with Aqua Lube and install the hose guard onto the wrist base ( ) (see Figure 27). Torque to 11 Nm (8 ft/lbs). Install the Jaw Nose Block/Jaw Piston Assembly Refer to the appropriate nose block/jaw piston Service Instruction to install the nose block/jaw piston supplied with your slave arm. Page SERVICE INSTRUCTION

141 If you have a PA jaw, refer to the appropriate wrist/jaw adaptor Service Instruction to remove the wrist/jaw adaptor supplied with your slave arm. Read and be familiar with all the steps and requirements before you get started. Return to this point when you have installed your nose block/jaw piston assembly. Go to Install the Jaw Assembly. Install the Jaw Assembly Refer to the appropriate jaw Service Instruction to install the jaw supplied with your slave arm. Read and be familiar with all the steps and requirements before you get started. Return to this point when you have installed your jaw assembly. Test Wrist Functionality After the wrist is reassembled, it should be tested to ensure proper functioning and to determine if adjustment to the wrist preload is necessary. 1. Connect the slave arm to a rate control manifold or other suitable test fixture through which 3000 psi (20000 kpa) hydraulic pressure can be applied to the arm s 5A and 5B supply hoses. Connect the arm s C (compensation return) hose to a hydraulic return or drain fitting that will not exceed 350 psi ((2400 kpa). 2. Apply hydraulic power to each supply line in turn to drive the wrist in each direction for at least a few minutes. Closely inspect the wrist assembly (especially the wrist manifold-pitch plate junction) for leaks. 3. Observe wrist action as it rotates. It should turn relatively smoothly, and at a constant rate. Note: The gerotor drive has an inherent fluctuation in drive torque. A slight "flutter" in wrist torque, especially under heavy load, is normal. The "flutter" may be more noticeable at slow speeds. As long as the degree of flutter is constant, it is normal. If a servo, or proportional control valve, is used, apply minimal pressure to each wrist drive supply hose in turn. The wrist should start easily and turn at a constant rate as slowly as 5-6 rpm. If the wrist is hard to start, resisting turning until it suddenly breaks loose, the flutter is especially pronounced, or if a minimum rotation speed of about 6 rpm is not obtainable, the wrist preload may need to be adjusted. Use the following procedure to adjust the wrist preload. Adjusting Wrist Preload Refer to Figure 23 for this procedure. 1. Remove the wrist motor from the wrist base by following the steps in Remove Wrist from Forearm on page Loosen the clamp nut SHCS ( ) (see Figure 23). 3. Loosen the clamp nut ( ) and retorque it as follows (see Figure 23): SERVICE INSTRUCTION Page 255

142 If the standard preload of 40 ft/lbs (54 Nm) was used, retorque the clamp nut to 30 ft/lbs (41 Nm). If the optional preload of 30 ft/lbs does not improve wrist performance, retorque the clamp nut to 68 Nm (50 ft/lbs). If 30, 40, and 50 ft/lbs torque on the clamp nut do not produce the desired wrist performance, increase the torque in 13.5 Nm (10 foot-pound) steps, up to 149 Nm (110 ft/lbs). 4. Tighten the clamp nut SHCS ( ) to 7 Nm (5 ft/lbs) (see Figure 23). 5. Install the wrist following the steps in Install Wrist to Forearm on page Retest the wrist operation using the steps in Test Wrist Functionality on page 255 above. 7. Repeat Steps 1-6 until acceptable wrist operation is achieved. END OF SERVICE INSTRUCTION Page SERVICE INSTRUCTION

143 Service Instruction Jaw Piston/Nose Block, Description Complete service instructions for the jaw piston/nose block Used in jaw assemblies: , 4-Finger Intermeshing , 6-in. Parallel-Acting ), 11.5-in. Intermeshing Estimated Time to Complete Reference Drawing 2 hour Preparation for Service Below is a list of required tools and materials for this Service Instruction. Look over the list and make sure you have all the materials before you get started. Read through the entire procedure to make sure you understand, and are capable of performing, the service. Take special notice of all notes, warnings, and the terminology section. Tools Needed Materials Needed 11/16-in. 12-point socket Valvoline Val-Plex EP Grease 9/16-in. socket Anti-seize, 1 oz. tube ( ) mm (.750-in.) drill bit or drill rod Aqua Lube ( ) (optional) torque wrench capable of Nm (5-100 Loctite 271 ( ) ft/lbs) torque wrench capable of 406 Nm (300 ft/ Loctite 7471 Primer lbs) bench vise with soft jaws Dow Corning 55 O-ring lube or petroleum jelly pick tool razor blade or X-acto style knife Custom Tools Needed Terminology female sizing tool HHCS = hex head cap screw male installation tool HPU = hydraulic power unit sizing tool Note: If you intend to change bearings ( ) in the nose block ( ), you will need to allow at least 1 hour for the Loctite 271 to harden. SERVICE INSTRUCTION Page 257

144 Note: If you are planning to replace the seals ( and ) you must have replacements on-hand. You must destroy the old seals to remove them.! Caution Some components have protective coatings such as anodizing. Take care not to scratch any protective coatings. Corrosion damage will result. You must remove the jaw assembly before you can perform service on the jaw piston/nose block assembly. See the service instructions for the jaw assembly installed on your slave arm. You can perform the procedures in this Service Instruction with the wrist attached to, or separated from, the slave arm. If possible, perform all assembly work in a clean, dry environment to prevent contamination and damage to bearing surfaces. We recommend that you make a photocopy of this Service Instruction for workbench use. Disable the Slave Arm! Caution Before you can service the arm safely, you must disable electrical and hydraulic functions of the arm. Follow steps below before continuing. 1. Raise the arm to a comfortable working position. 2. Turn off the power to the hydraulic power unit (HPU). Disassemble the Nose Block Disassembly of the intermeshing jaw assumes that all preparations, previously described in this Service Instruction, have been met. Numbers in parentheses refer to the part number of the item. See Figure 1 for basic identification of intermeshing jaw parts. Remove the Jaw Determine the type of jaw installed on your slave arm. Refer to the proper jaw service instruction for the procedure to remove the jaw. Read and be familiar with all the steps and requirements before you get started. Return to this point when you have finished removing the jaw. Page SERVICE INSTRUCTION

145 Wrist Motor Jaw Piston T-bar Plate Bearings(4x) Nose Block Bolt or (fused) HHCS/Washers (4x) / Figure 1 Basic nose block/jaw piston parts identification Remove the Nose Block from the Wrist Motor Refer Figure 1 and Figure 2 for this procedure. HHCS/Washers (4x) / Wrist Motor Nose Block Figure 2 Removing nose block 1. Remove the four HHCS ( ) from the nose block ( ) (see Figure 2). Note: Hydraulic fluid will spill from the wrist assembly as you remove the nose block during the next step. Have a drain pan ready to catch fluid. 2. Pull the nose block out from the wrist assembly ( ). Remove Jaw Piston From Nose Block Refer to Figure 3 for this procedure. SERVICE INSTRUCTION Page 259

146 Seal T-bar Plate Bearing Push Jaw Piston In To Remove Bolt Jaw Piston Bolt or (fused) Nose Block Figure 3 Jaw piston, seals, and bearings identification! Caution To remove seal ( ) in step 2, you must destroy the seal. If you don t have a replacement, do not remove the seal at this time. 1. Remove bearing ( ) from jaw piston ( ). Set aside to inspect later. 2. Remove seal ( ) by carefully cutting across it with a new razor blade or X- acto style knife. Note: Be very careful not to damage the finish on the jaw piston. 3. Place the nose block into a soft-jaw vise. Push the jaw piston all the way into the nose block and, using a 12-point, 11/16-in. socket, remove the bolt ( or [fused]) from the jaw piston. 4. Slide the t-bar plate ( ) off of the bolt. Remove Seals & Bearings from Nose Block Refer to Figure 4 for this procedure. 1. Using a pick tool, carefully remove both bearings ( ) from the nose block ( ). Set the bearings aside to inspect later. Page SERVICE INSTRUCTION

147 ! Caution To remove seals ( ), in the next step, must destroy the seals. If you don t have replacements, do not remove seals at this time. 2. Remove the seals ( ) by carefully cutting across them with a new razor blade or X-acto style knife. Using a pick tool, carefully remove the O-rings that sit under each of the seals. O-ring and Backup Ring and Bearing (2x) Seal (2x) Figure 4 Nose block seals and bearings parts identification! Caution Be very careful not to damage the finish on the nose block. 3. Remove the O-ring ( ) and the backup ring ( ) from the nose block. Clean & Inspect Parts In the following steps you will clean and check all parts for damage, corrosion, chipping, scuffing, and wear. 1. Clean all the parts of the nose block/jaw piston. Use a lintless rag and wipe all the surfaces clean of dirt and hydraulic fluid. 2. Check the jaw piston ( ) for damage and excessive wear. Replace the jaw piston if it is too worn or damaged. 3. Check the t-bar plate ( ) for damage and excessive wear. Replace the t-bar plate if it is too worn or damaged. 4. Check the inner bore surfaces of the nose block ( ) for damage and excessive wear. Check all the outer surfaces on the nose block for damage or cracks. Replace the nose block if you find any unacceptable damage, or cracks. SERVICE INSTRUCTION Page 261

148 ! Caution Do not attempt to repair cracks by welding. The nose block has been heat- treated for strength and any welding will eliminate its strength. Inspect Bearings During the following procedures you will inspect the piston bore bearings and the rod bearings. 1. Inspect bearings ( ) for galling or damage. Using calipers, measure bearing wall thickness. Replace the bearing if thickness is 2.39 mm (0.090-in.) or less at any point. After inspecting the bearings, set them aside until you get to Install Jaw Piston Seal & Bearing. 2. Inspect bearing ( ) for galling or damage. Using calipers, measure bearing wall thickness. Replace the bearing if thickness is 1.55 mm (0.058-in.) or less at any point. After inspecting bearings, set aside until you get to Install O-rings & Bearings Into Nose Block. 3. Using the shaft of an mm (0.750-in.) drill bit or a section of mm (0.750-in.) drill rod, check all bearings ( ) in the nose block for wear. Insert the drill shank, or drill rod, into the bearing and check for play. A pivot pin ( ) may be substituted for the drill bit or drill rod if it is first checked, as in step 1, to verify that it does not exhibit excessive wear. You may also use a new pivot pin. Replace any bearing that has too much play. Install O-rings & Bearings Into Nose Block Refer to Figure 1, Figure 5, Figure 6, and Figure 7 for this procedure. ARM JAW Seal Set (2x) Figure 5 Installing seals into nose block 1. Lightly lube the O-ring/seal sets ( ) with O-ring lube and install them into the nose block ( ) (see Figure 5). Be very careful to place the correct O- ring/seal in the correct location and orientation. Note: To aid in getting the O-ring and seals into the groove, it may be helpful to bend them as shown at right. Then push them down into the grooves. Page SERVICE INSTRUCTION

149 2. Lubricate the bearings ( ) with EP grease and install them into the nose block (see Figure 6). Bearings Figure 6 Installing bearings into nose block 3. Lightly lube the O-ring ( ) and backup ring ( ) with O-ring lube and install them onto the nose block (see Figure 7). ARM JAW O-ring Backup Ring Figure 7 Installing O-ring and back-up ring onto nose block 4. If you are not replacing the bearings ( ) in the nose block (see Figure 1), skip to Assemble Jaw Piston on page 264. Go to step 5 to replace the bearings. 5. Clamp the nose block securely in a soft-jaw vise. Use a 13/16-in. (21 mm) diameter drift to drive the bearing out of the jaw. Note: Heating the jaw assembly with a heat gun, or in an oven, at approximately F ( C), will help soften the adhesive and remove the bearings. 6. Using Loctite 7471 primer, clean the bearing bore to remove all traces of Loctite. 7. Apply a thin coating of Loctite 271 to the outside of the bearing and to the inside of the bearing bore. 8. Press the new bearings into the jaw. When properly installed, the bearing should be flush, or slightly recessed from the jaw surface. 9. Clean off any excess Loctite. Allow the Loctite to cure for 24 hours at 72 F (22 C), or 1 hour at 200 F (94 C), before reinstalling this assembly. SERVICE INSTRUCTION Page 263

150 Assemble Jaw Piston Refer to Figure 8 and Figure 9 for this procedure. Nose Block Jaw Piston Sizing Tool Figure 8 Installing sizing tool and jaw piston into nose block 1. Insert sizing tool ( ) in the end of the jaw piston ( ) (see Figure 8). 2. Lube surfaces of the tool/piston combination and the inner surfaces of the nose block with O-ring lube. Push the tool/piston combination into the nose block ( ) until the piston is completely inside the nose block (see Figure 8). Remove the sizing tool from the piston. 3. Apply anti-seize ( ) to threads and the underside of the bolt head ( or [fused]). Insert the bolt through the t-bar plate ( ) and into the piston (Figure 9). Place the nose block in a soft-jaw vise. Push the t-bar/ piston all the way into the nose block and torque the bolt to 402 Nm (300 ft/lbs). Remove nose block assembly from the vise. Note: Note that the slot in the t-bar aligns with the jaw piston. T-bar Plate Nose Block Push Jaw Piston In To Torque Bolt Jaw Piston Bolt or (fused) Figure 9 Installing jaw piston into nose block Page SERVICE INSTRUCTION

151 Install Jaw Piston Seal & Bearing Refer to Figure 10 for this procedure. Bearing Seal Set Jaw Piston Figure 10 Orientation of seal/o-ring on jaw piston 1. Slide the male installation tool ( ) onto the end of the jaw piston ( ). Lightly lube the seal/o-ring ( ) with O-ring lube and slide it onto the jaw piston as shown in Figure Install female sizing tool ( ) over the seal. Leave in place for 5-10 minutes, then remove the tool. 3. Lubricate the bearing ( ) with EP grease and install it onto the jaw piston. Install the Nose Block Into the Wrist Assembly Refer to Figure 1 for this procedure. 1. Lightly lube all surfaces of the jaw piston with O-ring lube. 2. Slide the nose block/jaw piston assembly into wrist assembly. 3. Coat threads of the four HHCS ( ) with Aqua Lube. Install and torque to 99 Nm (73 ft/lbs). Install the Intermeshing Jaw Refer to the Interrmeshing Jaw Service Instruction under Attach the Intermeshing Jaw to Nose Block Service Instruction, for the procedure to install the intermeshing jaw. END OF SERVICE INSTRUCTION SERVICE INSTRUCTION Page 265

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153 Service Instruction Jaw Piston/Nose Block for P-A Jaw, Estimated Time to Complete Used In: 1 hour Jaw assemblies , 4106, 4107 Preparation for Service Below is a list of required tools and materials for this Service Instruction. Look over the list and make sure you have all the materials before you get started. Read through the entire procedure to make sure you understand, and are capable of performing, the service. Take special notice of all notes, warnings, and the terminology section. Tools Needed 7/16-in. socket Materials Needed Valvoline Val-Plex EP Grease 11/16-in. 12-point socket Anti-seize, 1 oz. tube ( ) torque wrench capable of Nm (5-100 ft/lb) torque wrench capable of 407 Nm (300 ft/lbs) bench vise with soft jaws Aqua Lube ( ) Loctite 271 ( ) Dow Corning 55 O-ring lube or petroleum jelly pick tool razor blade or X-acto style knife Custom Tools Needed Terminology male installation tool HHCS = Hex Head Cap Screw female sizing tool PA = Parallel-Acting (Jaws) sizing tool HPU = Hydraulic Power Unit SERVICE INSTRUCTION Page 267

154 ! Caution If you are planning to replace the seals ( and ), you must have replacements on-hand. You will need to destroy the old seals to remove them.! Caution Some components have protective coatings such as anodizing. Take care not to scratch any protective coatings. Corrosion damage will result. Perform all assembly work in a clean, dry environment if possible. Although assembly of major slave arm components must often be performed under field conditions, the intermeshing jaw should be disassembled and reassembled under clean service conditions to prevent contamination and damage to bearing surfaces. Prepare a clear area on the work surface in which to arrange the components as the intermeshing jaw is disassembled. We recommend that you make a photocopy of this Service Instruction for workbench use. Disable the Slave Arm! WARNING Before you can service the arm safely, you must disable electrical and hydraulic functions of the arm. Follow steps below before you continue. 1. Raise the arm to a comfortable working position. 2. If you have a P slave arm, turn off the power switches located on the master controller and the junction box. 3. Turn off the power to the hydraulic power unit (HPU). 4. If you have a P slave arm, and if power is supplied from a local, independent source, turn off the power to the slave controller. 5. If your arm is equipped with a hydraulic compensation unit, isolate the unit from the arm. Disassemble the Nose Block Disassembly of the intermeshing jaw assumes that all preparations, previously described in this Service Instruction, have been met. Numbers in parentheses refer to the part number of the item. See Figure 1 for basic identification of intermeshing jaw parts. Page SERVICE INSTRUCTION

155 Wrist Motor Wrist Adaptor Nose Block Bolt Jaw Piston T-Bar Plate HHCS (6x) P Figure 1 Basic nose block/jaw piston parts identification Remove the PA Jaw Refer to Parallel-Acting Jaw Service Instruction, for the procedure to remove the PA jaw. Read and be familiar with all steps and requirements before starting. Return to this point once finished removing the jaw. Remove the Nose Block From Wrist/Jaw Adapter Refer to Figure 2 for this procedure. HHCS (6x) P Wrist Motor Nose Block Figure 2 Removing the nose block 1. Remove the six HHCS ( ) from the nose block ( ).! Caution Hydraulic fluid will spill out of the wrist assembly when you remove the nose block during step 2. Have a drain pan ready to catch the fluid. SERVICE INSTRUCTION Page 269

156 2. Pull the nose block out from the wrist motor ( ). Remove Jaw Piston From Nose Block Refer to Figure 3 for this procedure. Seal and O-ring & T-bar Plate Bearing Push Jaw Piston In To Remove Bolt Jaw Piston Bolt Nose Block Figure 3 Jaw piston, seals, and bearings identification! Caution To remove seal ( ) in step 2, you must destroy the seal. If you don t have a replacement, do not remove the seal at this time. 1. Remove bearing ( ) from jaw piston ( ). Set aside to inspect later. 2. Remove seal ( ) by carefully cutting across it with a new razor blade or X-acto style knife. Note: Be very careful not to damage the finish on the jaw piston. 3. Place the nose block into a soft-jaw vise. Push the jaw piston all the way into the nose block and using a 12-point, 11/16-in socket, remove bolt ( ) from the jaw piston. 4. Slide the t-bar plate ( ) off of the bolt. Remove Seals and Bearing from Nose Block See Figure 4 for this procedure. Page SERVICE INSTRUCTION

157 ARM JAW O-ring Seals Note Orientation of Seals Bearing Figure 4 Nose block seals and bearings parts identification! Caution To remove the seals ( ), in step 2, you must destroy the seals. If you don t have replacements, do not remove the seals at this time. 1. Using a pick tool, carefully remove the bearing ( ) from the nose block ( ). Set the bearing aside to inspect later. 2. Remove seals ( ) by carefully cutting across them with a new razor blade or X-acto style knife. Using a pick tool, carefully remove the O-ring that sits under each seal. Note: Be very careful not to damage the finish on the nose block. 3. Using a pick tool, carefully remove the O-ring ( ) from the nose block. Clean and Inspect Parts Refer to Figure 1 for this procedure. In the following steps you will clean and check all the parts for damage, corrosion, chipping, scuffing, and wear. 1. Clean all the parts of the nose block/jaw piston. Use a lintless rag and wipe all the surfaces clean of dirt and hydraulic fluid. 2. Check the jaw piston ( ) for damage and excessive wear. Replace the jaw piston if it is too worn or damaged. 3. Check the t-bar plate ( ) for damage and excessive wear. Replace the t- bar plate if it is too worn or damaged. 4. Check the inner bore surfaces of the nose block ( ) for damage and excessive wear. Check all the outer surfaces on the nose block for damage or cracks. Replace the nose block if you find any unacceptable damage, or cracks. SERVICE INSTRUCTION Page 271

158 ! Caution Do not attempt to repair cracks by welding. The nose block has been heat- treated for strength and any welding will eliminate it s strength. Inspect Bearings During the following procedures you will inspect the bearings ( and ). Refer to Figure 3 and Figure Inspect the rod bearing ( ) for galling or damage (see Figure 4). Using your calipers, measure the wall thickness of the bearing. Replace the bearing if the thickness is 1.55 mm (0.060-in.) or less at any point. After inspecting the bearings, set them aside until you get to Install Seals and Bearing Into Nose Block. 2. Inspect the piston bearing ( ) for galling or damage (see Figure 3). Using calipers, measure the wall thickness of the bearing. Replace the bearing if the thickness is 1.55 mm (0.058-in.) or less at any point. After inspecting the bearings, set them aside until you get to Install Piston Seal And Bearings. Install Seals and Bearing Into Nose Block Refer to Figure 5, Figure 6, and Figure 7 for this procedure. ARM JAW Seals Figure 5 Installing seals into nose block 1. Lubricate seal sets ( ) with O-ring lube and install them into nose block ( ) (Figure 5). Be very careful to place the correct seals in the correct orientation. Tip: : To aid in getting the O-rings and the seals into the grooves, it may be helpful to bend them like this then push the seals down into the grooves. Page SERVICE INSTRUCTION

159 2. Lubricate bearing ( ) with EP grease and install it into the nose block (Figure 6). Rod Bearing Figure 6 Installing rod bearing into nose block 3. Lubricate the O-ring ( ) with O-ring lube and install it onto the nose block (see Figure 7). O-ring Figure 7 Installing O-ring onto nose block Assemble Jaw Piston Refer to Figure 8 and Figure 9 for this procedure. Nose Block Jaw Piston Sizing Tool Figure 8 Installing sizing tool and jaw piston into nose block SERVICE INSTRUCTION Page 273

160 1. Insert sizing tool ( ) in the end of jaw piston ( ) (Figure 8). 2. Lube the surfaces of the tool/piston combination the inner surfaces of the nose block with O-ring lube. Push the tool/piston combination into nose block ( ) until the piston is completely inside the nose block (Figure 8). Remove the sizing tool from the piston. 3. Apply anti-seize ( ) to the threads and underside of the bolt head ( ). Insert bolt ( ) through t-bar plate ( ) and into the piston (Figure 9). Place the nose block in a soft-jaw vise. Push the t-bar/piston all the way into the nose block and torque the bolt to 402 Nm (300 ft/lbs). Remove the nose block assembly from the vise. Note: Note that the slot in the t-bar aligns with the jaw piston. T-bar Plate Nose Block Push Jaw Piston In To Torque Bolt Jaw Piston Bolt Figure 9 Installing jaw piston into nose block Install Piston Seal And Bearings Refer to Figure 10 for this procedure. Bearing Seal & O-ring & Jaw Piston Figure 10 Orientation of seal/o-ring on jaw piston Page SERVICE INSTRUCTION

161 1. Slide the male installation tool ( ) onto the end of the jaw piston ( ). Lightly lube the seal/o-ring ( & ) with O-ring lube and slide it onto the jaw piston as shown in Figure Install the female sizing tool ( ) over the seal. Leave in place for 5-10 minutes, then remove the tool. 3. Lubricate the bearing ( ) with EP grease and install it onto the jaw piston. Install the Nose Block into the Wrist/Jaw Adapter Refer to Figure 1 for this procedure. 1. Lightly lube all surfaces of the jaw piston ( ) with O-ring lube. 2. Slide the nose block/jaw piston assembly into jaw/wrist adapter. 3. Lubricate six HHCS ( ) with Aqua Lube. Install and torque to 28 Nm (21 ft/lbs). Install the PA Jaw Refer to Parallel-Acting Jaw Service Instruction, for the procedure to install the PA jaw. END OF SERVICE INSTRUCTION SERVICE INSTRUCTION Page 275

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163 Service Instruction Wrist/Jaw Adapter for P-A Jaw, Description Complete service instructions for the intermeshing jaw for the parallel-acting jaws (used in jaw assemblies , 4106,4107). Estimated Time to Complete 3 hours Preparation for Service Below is a list of required tools and materials for this Service Instruction. Look over the list and make sure you have all the materials before you get started. Read through the entire procedure to make sure you understand, and are capable of performing, the service. Take special notice of all notes, warnings, and the terminology section. Tools Needed Materials Needed 9/16-in socket Aqua Lube ( ) razor blade or X-acto style knife Dow Corning 55 O-ring lube Custom Tools Needed none needed Terminology HHCS = Hex Head Cap Screw PA = Parallel-Acting (Jaws) HPU = Hydraulic Power Unit! Caution Some components have protective coatings such as anodizing. Take care not to scratch any protective coatings. Corrosion damage will result. You must remove the PA jaw assembly and PA jaw piston/nose block assembly before you can perform service on the wrist/jaw adapter assembly. See the service instructions for the PA jaw assembly and PA jaw piston/nose block assembly. Perform all assembly work in a clean, dry environment if possible. Although assembly of major slave arm components must often be performed under field conditions, the inter- SERVICE INSTRUCTION Page 277

164 meshing jaw should be disassembled and reassembled under clean service conditions to prevent contamination and damage to bearing surfaces. Prepare a clear area on the work surface in which to arrange the components as the intermeshing jaw is disassembled. We recommend that you make a photocopy of this Service Instruction for workbench use. Disable the Slave Arm! WARNING Before you can service the arm safely, you need to disable the electrical and hydraulic functions of the arm. Follow the steps below before you continue. 1. Raise the arm to a comfortable working position. 2. If you have a P slave arm, turn off the power switches located on the master controller and the junction box. 3. Turn off the power to the hydraulic power unit (HPU). 4. If you have a P slave arm, and if power is supplied from a local, independent source, turn off the power to the slave controller. 5. If your arm is equipped with a hydraulic compensation unit, isolate the unit from the arm. Remove the PA Wrist/Jaw Adapter Disassembly of the intermeshing jaw assumes that all preparations, previously described in this Service Instruction, have been met. Numbers in parentheses refer to the SRS part number of the item. See Figure 1 for basic identification of intermeshing jaw parts. Wrist Motor HHCS (NAS) and Washer (4x) and Wrist/Jaw Adapter Figure 1 Basic wrist/jaw adapter parts identification Remove the PA Jaw Assembly Refer to PA Jaw Service Instruction, under Remove PA Jaw From Nose Block on page 3, for the procedure to remove the PA jaw. Read and be familiar with all the steps and requirements before you get started. Return to this point when you have finished removing the PA jaw. Page SERVICE INSTRUCTION

165 Remove Jaw Piston/Nose Block Assembly Refer to "Jaw Piston/Nose Block for Parallel-Acting Jaw" Service Instruction. Follow steps 1-2 under Remove the Nose Block From Wrist/Jaw Adapter on page 3, for the procedure to remove the nose block/jaw piston assembly. Read and be familiar with all steps and requirements before starting. Return to this point when you have finished removing the nose block/jaw piston assembly. Remove and Disassemble the Wrist/Jaw Adapter Refer to Figure 2, Figure 3, and Figure 4 for this procedure. 1. Remove the four HHCS ( ) and washers ( ) from the wrist/jaw adapter ( ) (see Figure 2). HHCS (NAS) and Washer and Wrist/Jaw Adapter Figure 2 Removing HHCS from wrist/jaw adapter 2. Using two 1/4x28 HHCS, evenly push the wrist/jaw adapter off of the wrist motor ( ) (see Figure 3). HHCS (2x) 1/4x28 Wrist/Jaw Adapter Wrist Motor Figure 3 Removing the wrist/jaw adapter from the wrist motor 3. Remove two O-rings ( ) and two back-up rings ( ) from the wrist/jaw adapter (Figure 4). SERVICE INSTRUCTION Page 279

166 O-ring (2x) Back-up Ring (2x) Figure 4 Wrist/adapter O-rings and back-up rings 4. Clean the wrist/jaw adapter with a lintless cloth. Assemble Wrist/Jaw Adapter Refer to Figure 3 for this procedure. 1. Lubricate two new O-rings ( ) and two new back-up rings ( ) with O-ring lube. Install as shown in Figure Lubricate the bore of the wrist motor assembly ( ) with O-ring lube. 3. Install the wrist/jaw adapter ( ) into the wrist motor assembly ( ). Tip: Press the wrist/jaw adapter in slowly to avoid pinching the O-rings and backup rings. Press firmly, and evenly, to seat the adapter into place. 4. Lubricate four HHCS ( ) with Aqua Lube and install, with washers ( ), into the wrist motor assembly ( ). Torque to 99 Nm (73 ft/lb). Install Jaw Piston/Nose Block Assembly Refer to "Jaw Piston/Nose Block for Parallel-Acting Jaw" Service Instruction. Follow steps under Install the Nose Block into the Wrist/Jaw Adapter on page 275, to install the nose block/jaw piston assembly. Return to this point once finished installing the nose block/jaw piston assembly. Install the PA Jaw Assembly Refer to "Parallel-Acting Jaw" Service Instruction, under Attach Jaws to Nose Block on page 10, for the procedure to install the PA jaw. END OF SERVICE INSTRUCTION Page SERVICE INSTRUCTION

167 Service Instruction Parallel-Acting Jaw Description This document is the complete service instruction for rebuilding the parallel acting jaw. It does not include instructions for the jaw piston. For jaw piston service see Jaw Piston/Nose Block for Parallel-Acting Jaw document number Estimated Time to Complete 2 hours Preparation for Service Below is a list of required tools and materials for this Service Instruction. Look over the list and make sure you have all the materials before you get started. Read through the entire procedure to make sure you understand, and are capable of performing, the service. Take special notice of all notes, warnings, and the terminology section. Tools Needed Materials Needed two 7/16-in. sockets and ratchets Valvoline Val-Plex EP Grease ( ) 9/16-in. (15mm) diameter drift Loctite 271 ( ) 0-1-in. (0-25mm) micrometer Aqua Lube ( ) 8-102Nm (5-75 ft/lb) torque wrench Loctite Primer N ( ) bench vise with soft jaws Schilling Robotics Custom Tools Terminology Needed bearing installation tool HHCS = Hex Head Cap Screw PA = Parallel-Acting HPU = Hydraulic Power Unit! Caution Some components have protective coatings such as anodizing. Take care not to scratch any protective coatings. Corrosion damage will result. SERVICE INSTRUCTION Page 281

168 ! Caution If you are planning to replace the jaw bearings ( ) in the rocker link, or the idle link ( ), you will need to allow at least 1 hour, at 94 C (200 F), for the Loctite 271 to harden. Allow 24 hours before service if cured at room temperature. You can perform service to the parallel acting jaw with the wrist attached to, or separated from, the slave arm. Perform all assembly work in a clean, dry environment if possible. Prepare a clear area on the work surface in which to arrange the components as the intermeshing jaw is disassembled. We recommend that you make a photocopy of this Service Instruction for workbench use. Tip: Use of Loctite Primer N will help to reduce cure time. Use Primer N when installing bushings. Apply the primer where ever Loctite is called for and allow the primer to dry the specified time before applying Loctite. Disable the Slave Arm! WARNING Before you can service the arm safely, you must disable electrical and hydraulic functions of the arm. Follow steps below before you continue. 1. If your arm is equipped with a hydraulic compensation unit, isolate the unit from the arm. 2. Secure the arm to the light rack or a work surface beneath the arm to prevent it from falling. 1. Drain the compensation fluid from the slave arm. 1. Raise the arm to a comfortable working position. 2. If you have a P slave arm, turn off the power switches located on the master controller and the junction box. 3. Turn off the power to the hydraulic power unit (HPU). 4. If you have a P slave arm, and if power is supplied from a local, independent source turn off the power to the slave controller. Disassemble PA Jaw Disassembly of the intermeshing jaw assumes that all preparations, previously described in this Service Instruction, have been met. Numbers in parentheses refer to the Schilling Robotics part number of the item. See Figure 1 for basic identification of PA jaw parts. Page SERVICE INSTRUCTION

169 Jaw (2x) Jaw Washer (2x) HHCS (3x) Red Pin (2x) Pin Retainer Washer (1x) Link Pin (2x) Figure 1 Remove HHCS and hinge pins 1. Remove three HHCS ( ), one pin retainer washer ( ), two jaw washers ( ), and two link pins ( ) (see Figure 2). 2. Push the jaw pins ( ) through the nose block and remove from the other side. See rotated view in the next illustration. 3. Rotate the unit to the other side and remove one HHSC ( ) and two link pins ( ) (see Figure 2). 4. Remove the jaw pin, HHCS, and jaw washer assembly, that were pushed through from the other side. Two thrust washers ( ) should fall out of position when the jaw pin ( ) is pushed out. See Figure 6. Note: The HHCS, removed in step 1, may be lightly threaded into each pin and used to pull them out. SERVICE INSTRUCTION Page 283

170 HHCS Jaw Washer Jaw Pin Push from other side Thrust Washer(4x) HHCS (1x) Link Pin (2x) Pin Retainer Washer (1x) HHCS Jaw Washer Jaw Pin Push from other side Figure 2 Removing jaw pins 5. Remove both jaw assemblies from the nose block (see Figure 3). Figure 3 Removing jaw assemblies from nose block Page SERVICE INSTRUCTION

171 Disassembly of Jaw 1. Remove the HHCS ( ) and jaw washer ( ) from jaw pin ( ). 2. Push the jaw link pin, HHSC, and jaw washer assembly out of the jaw freeing the idle links. See Figure Remove the actuator bearing ( ). HHCS Jaw Washer Jaw Pin Jaw Jaw Washer HHSC Idle Link Jaw Actuator Bearing Rocker Link Idle Link Figure 4 Removing idle links and actuator bearing 4. Remove HHCS ( ) and jaw washer ( ) from pivot pin ( ) holding the rocker link ( ) to the jaw ( ) and separate the jaw from the rocker link (see Figure 5). SERVICE INSTRUCTION Page 285

172 HHCS Jaw Washer Jaw Pin Push from other side Jaw Jaw Washer HHSC Jaw Thrust Washer (2x) Rocker Link Figure 5 Remove jaw from rocker link Jaw Thrust Washer Rocker Link Jaw Thrust Washer (4x) Figure 6 Detail showing location of jaw thrust washers Page SERVICE INSTRUCTION

173 Inspect Jaw Components Refer to Figure 7 for this procedure. The jaw is subjected to abuse and long use. Carefully determine the amount of damage and wear that is acceptable before the jaw no longer works properly in your application. 1. Inspect all of the pivot pins ( , , ) for signs of wear, galling or other surface damage. Use a micrometer to measure the pins. Replace any pins that measure 12.6mm (0.496-in.), or less, at any point. 2. Inspect the four idle links ( ) for signs of wear, cracking, twisting, or other deformation. Replace any link arm that shows unacceptable damage. 3. Inspect rocker links ( ) and jaw actuation bearings ( ) for signs of wear, cracking, twisting, or other deformation. Verify that the bearings turn smoothly in the rocker link and they exhibit minimal play. Replace any bearing and/or link arm that shows unacceptable wear or damage. Bearing Rocker Link Figure 7 Checking rocker link for wear and deformation 4. Inspect the eight thrust washers ( ) for signs of wear or deformation. Replace any washers that exhibit wear or damage. See Figure 6. Note: Schilling Robotics recommends that you replace all the washers if it is discovered that any of the washers show signs of wear. 5. Using a jaw pin or , check all of the bearings ( ) in the idle links ( ) and rocker links ( ) for wear. Insert the jaw pin into the bearing and check for play. Replacing Idle Link Bearings Refer to Figure 8 and Figure 9 for this procedure. 1. Using a soft jaw vise to prevent scratching the finish, clamp the idle link securely in a vise. Use a 9/16-in. ( in., or 15 mm) diameter drift to drive the faulty bearing ( ) out of the idle link (see Figure 8). Note: Heating the assembly with a heat gun, or in an oven, to approximately C ( F), will loosen the adhesive and help to remove the bearings. SERVICE INSTRUCTION Page 287

174 Bearings Figure 8 Identifying bearings 2. Clean the bearing bore using solvent and/or Scotch-Brite to remove all traces of Loctite. 3. Apply Loctite 271 to the outside of the jaw bearing ( ) and to the inside of the bearing bore. 4. Using the bearing installation tool ( ), press the new bearing into the idle link (see Figure 9). Use an arbor press if available or start the bearing with a soft jaw vice and then use a mallet to set the proper depth.when properly installed, the bearing should protrude an equal distance (0.6mm or in.) from each side of the idle link. Figure 9 Pressing jaw bearings into idle link 5. Clean off any excess Loctite. Allow the Loctite to cure for 24 hours at 22 C (72 F) or 1 hour at 94 C (200 F) before reinstalling this assembly. Replacing Rocker Link Bearings Refer to Figure 2 and Figure 10 for this procedure. Note: Replace both bearings, even if only one is worn. 1. Using a soft jaw vise to prevent scratching the finish, clamp the rocker link in a vise. Use a 9/16-in. ( in., or 15 mm) diameter drift to drive the faulty bearings ( ) out of the rocker link (see Figure 2). Page SERVICE INSTRUCTION

175 Note: Heating the assembly with a heat gun, or in an oven, at approximately C ( F), will help soften the adhesive and remove the bearings. 2. Clean the bearing bores using solvent and/or Scotch-Brite to remove all traces of Loctite. 3. Apply a thin coating of Primer N and then Loctite 271 to the outside of the jaw bearing ( ) and to the inside of the bearing bore. 4. Using bearing installation tool ( ), press the first new bearing into the rocker link. When properly installed, the bearing should be flush with, or slightly inside, the side of the rocker link (Figure 10). Bearings (4x) Figure 10 Pressing bearings into rocker link 5. Repeat steps 3 and 4 to install the second bearing in the opposite side of the rocker link. 6. Clean off any excess Loctite. Allow the Loctite to cure for 24 hours at 22 C (72 F) or 1 hour at 94 C (200 F) before reinstalling this assembly. Reassemble Jaw Refer to Figure 1 and Figure 11 for this procedure. Be sure that all components are clean before beginning this procedure. Note: All HHCS in the jaw assembly should be torqued to 28.5Nm (21 ft/lb). 1. Lubricate the idle link pivot pin ( ) and the bearings of two idle links ( ) with Aqua Lube. Insert the idle link pivot pin into the pivot holes of the jaw ( ) closest to the gripping surface (see Figure 1). Install one idle link over each end of the pivot pin. 2. Lubricate two HHCS ( ) with Aqua Lube. Add two jaw washers ( ) and install on the ends of the idle link pivot pin ( ) (see Figure 1). Torque both HHCS. SERVICE INSTRUCTION Page 289

176 3. Apply a thin film of Aqua Lube to a pivot pin ( ) and the bearings of a rocker link ( ). 4. Insert the pivot pin, with screw and washer, into the jaw ( ) just far enough to install thrust washer ( ) onto the pin (Figure 11, step A). Note: Keep the washer in place with a thin film of Aqua Lube. 5. Align rocker link ( ) within the jaw and push the pivot pin through the bore until it s just flush with the other side of the rocker link (Figure 11, step B). Install another thrust washer between the jaw and rocker link, and push the pivot pin in completely (Figure 11, step C). HHCS and Jaw Washer and Washers A Pivot Pin Jaw or Nose Block B Rocker Link C Figure 11 Installing rocker link thrust washers. 6. Apply a coating of Aqua Lube to the threads of the HHCS and install the HHCS and jaw washer on the end of the pivot pin. Torque the HHCS. 7. Repeat steps 1-6 with the other jaw components. Attach Jaws to Nose Block Refer to Figure 11 for this procedure. 1. Apply a thin film of Aqua Lube to all surfaces of a jaw actuation bearing ( ) and insert it in the rocker link ( ). 2. Apply a thin film of Aqua Lube to a pivot pin ( ) and the rocker link bearings. Page SERVICE INSTRUCTION

177 3. Insert the pivot pin, with screw and washer, into nose block ( ) just far enough to install a thrust washer ( ) over the pin (Figure 11, step A). Align the rocker link within the nose block and push the pivot pin through the bore until just flush with the other side of the rocker link (Figure 11, step B). Install another thrust washer between the rocker link and the nose block, and push the pivot pin in completely (Figure 11, step C). 4. Apply a coating of Aqua Lube to the threads of the HHCS and install the HHCS and jaw washer on the end of the pivot pin. Torque the HHCS. 5. Ensure that snap rings are securely installed in the grooves of each jaw pin ( ). 6. Apply a thin film of Aqua Lube to two jaw pins and to jaw bearings of the two idle links ( ). Align link jaw bearings with holes in the nose block and insert the jaw pins. 7. Apply a coating of Aqua Lube to threads of two HHCS and install the HHCS and two jaw washers on each side of the nose block so that jaw pins are retained. Torque both HHCS. 8. Repeat steps 1-7 with the other jaw. END OF SERVICE INSTRUCTION SERVICE INSTRUCTION Page 291

178 This page not used. Page SERVICE INSTRUCTION

179 Service Instruction 7.8-in Intermeshing Jaw, & Description Complete service instructions for the Orion 7.8-in Intermeshing Jaw. Does not include servicing of Jaw Piston see Orion Nose Block/Jaw Piston for Intermeshing Jaw Service Instructions. Estimated Time to Complete 2 hours Estimated Time to Complete 2 hours Preparation for Service Below is a list of required tools and materials for this Service Instruction. Look over the list and make sure you have all the materials before you get started. Read through the entire procedure to make sure you understand, and are capable of performing, the service. Take special notice of all notes, warnings, and the terminology section. Tools Needed Materials Needed 2 3/4-in. sockets Aqua Lube ( ) mm (0.750-in.) drill bit or drill rod (optional) Dow Corning 55 o-ring lube 21 mm (13/16-in.) drift Valvoline Val Plex EP grease Nm (5-75 ft/lbs) torque wrench Loctite 271 ( ) bench vise with soft jaws 0-25 mm (0-1-in.) micrometer Custom Tools Needed none needed Terminology HHCS = Hex Head Cap Screw HPU = Hydraulic Power Unit SERVICE INSTRUCTION Page 293

180 Note: If you intend to replace the bearings ( ), you will need to allow at least one hour for the Loctite 271 to harden.! Caution Some components have protective coatings such as anodizing. Take care not to scratch any protective coatings. Corrosion damage will result. You can perform the procedures in this Service Instruction with the wrist attached to, or separated from, the slave arm. If possible, perform all assembly work in a clean, dry environment to prevent contamination and damage to bearing surfaces. We recommend that you make a photocopy of this Service Instruction for workbench use.! Caution During this procedure DO NOT remove the bolt ( ) (see Figure 1). The bolt is not involved in removing the jaws. Bolt Figure 1 DO NOT loosen bolt Disable the Slave Arm! WARNING Before you can service the arm safely, you must disable electrical and hydraulic functions of the arm. Follow steps below before continuing. 1. Raise the arm to a comfortable working position. 2. If you have a P slave arm, turn off the power switches located on the master controller and the junction box. 3. Turn off the power to the hydraulic power unit (HPU). 4. If you have a P slave arm, and if power is supplied from a local, independent source, turn off the power to the slave controller. 5. If your arm is equipped with a hydraulic compensation unit, isolate the unit from the arm. Page SERVICE INSTRUCTION

181 Disassemble the Intermeshing Jaw Disassembly of the intermeshing jaw assumes that all preparations, previously described in this Service Instruction, have been met. Numbers in parentheses refer to the part number of the item. See Figure 2 for basic identification of jaw parts. Jaw Actuator Bearing (2x) Jaw (2x) Nose Block HHCS and Washers (4X) and Figure 2 Basic intermeshing jaw parts identification Remove Interlocking Jaws from Nose Block Refer to Figure 3 and Figure 4 for this procedure. 1. Remove HHCS ( ) and washer ( ) from one end of each of the two pivot pins ( ) holding the jaw assemblies ( ) to the nose block ( ) (Figure 3). Nose Block Pivot Pin (2x) HHCS and Jaw Washers (4x) and Figure 3 Removing the intermeshing jaw 2. Pull out each pivot pin and with attached the HHCS and jaw washer. SERVICE INSTRUCTION Page 295

182 3. Remove each jaw from the nose block. Lift the jaw out so that the jaw actuator bearing ( ) slides off the t-bar plate. The four Dixon bearings ( ) will fall out as you remove the jaws (see Figure 4). Set them aside to inspect later. Dixon Bearings (4x) Pivot Pin (2x) Figure 4 Removing jaws from nose block Inspect Jaw Components Refer to Figure 5 and Figure 6 for this procedure. Often the jaw is subjected to long use, severe service, and abuse. Carefully determine the amount of damage and wear that is acceptable before the jaw no longer works properly for your application. 1. Inspect the pivot pins ( ) for signs of wear, galling, or other surface damage. Use a micrometer to measure any suspect pins and replace any that measure mm (0.746-in.), or less at any point. 2. Inspect jaw actuator bearings ( ) and jaw for signs of wear, cracking, twisting, or other deformation (Figure 5). Verify that bearings turn smoothly in the jaw and that they show no discernible play. Replace any bearing or jaw that shows unacceptable wear or damage. Actuator Bearing Check For Wear and Deformation Figure 5 Checking actuator bearings and jaw for wear and deformation Page SERVICE INSTRUCTION

183 3. Inspect the four bearings ( ) for signs of wear or damage. Replace any bearings that show wear or damage. 4. Check all bearings ( ) in the jaws for wear and excessive play by inserting a new pivot pin, an acceptable used pin, or the shaft of a.750-in (19.05mm) drill or drill rod (Figure 6). Using the procedure in Replacing Jaw Bearings, replace any bearing that has too much play. Bearings Pivot Pin or.750-in (19.05mm)Rod Figure 6 Checking the bearings Replacing Jaw Bearings Refer to Figure 6 for this procedure. 1. Clamp the jaw securely in a soft-jaw vise. Use a 13/16-in (21mm) diameter drift to drive the bearing ( ) out of the jaw ( ). Tip: eating the jaw assembly with a heat gun, or in an oven, at approximately C ( F), will help soften the adhesive and remove the bearings. 2. Clean the bearing bore to remove all traces of Loctite Apply a thin coating of Loctite 271 to the outside of the bearing and to the inside of the bearing bore. 4. Press the new bearings into the jaw. When properly installed, the bearing should be flush, or slightly recessed from the jaw surface. 5. Clean off any excess Loctite 271. Allow the Loctite to cure for 24 hours at 22 C (72 F), or 1 hour at 94 C (200 F), before reinstalling this assembly. Attach the Intermeshing Jaw to Nose Block Refer to Figure 7 for this procedure. 1. Lubricate all surfaces of a jaw actuator bearing ( ) with Aqua Lube and place the actuator bearing into one of the jaws. 2. Lubricate the bearings ( ) with Aqua Lube. SERVICE INSTRUCTION Page 297

184 3. Insert a pivot pin ( ), with HHCS ( ) and washer ( ), into the nose block ( ) just far enough to install a Dixon washer ( ) over the pin (Figure 7, step A). Align jaw ( ) in the nose block and push pivot pin ( ) in until it is just flush with the other side of the jaw (Figure 7, step B). Install another washer between the jaw and nose block, and push the pin in completely (Figure 7, step C). Nose Block Pivot Pin Dixon Washers A B Drawing is not to scale Jaw C Figure 7 Install jaw to nose block 4. Apply a coating of Aqua Lube to the threads of the HHCS ( ) and install the HHCS and washer ( ) to the end of the pivot pin ( ). Torque the HHCS to 99 Nm (73 ft/lbs). 5. Repeat steps 1-4 to attach the other jaw half parts. END OF SERVICE INSTRUCTION Page SERVICE INSTRUCTION

185 Service Instruction Intermeshing Jaw, 11.5-in, Description Complete service instructions for the intermeshing jaw. Does not include servicing of jaw piston see Jaw Piston/Nose Block Service Instruction. Used in Jaw Estimated Time to Complete 2 hour Preparation for Service Below is a list of required tools and materials for this Service Instruction. Look over the list and make sure you have all the materials before you get started. Read through the entire procedure to make sure you understand, and are capable of performing, the service. Take special notice of all notes, warnings, and the terminology section. Tools Needed Materials Needed 2 3/4-in. sockets Aqua Lube ( ) mm (0.750-in.) drill bit or drill rod (optional) Dow Corning 55 o-ring lube 21 mm (13/16-in.) drift Valvoline Val Plex EP grease Nm (5-75 ft/lb) torque wrench Loctite 271 ( ) bench vise with soft jaws 0-25 mm (0-1-in.) micrometer Terminology HHCS = hex head cap screw HPU = hydraulic power unit Note: If you intend to replace the bearings ( ), you will need to allow at least one hour for the Loctite 271 to harden. Service Instruction Page 299

186 ! WARNING Take care not to scratch any protective coatings such as anodizing. Corrosion damage will result. You can perform the procedures in this Service Instruction with the wrist attached to, or separated from, the slave arm. Perform all assembly work in a clean, dry environment if possible. Although assembly of major slave arm components must often be performed under field conditions, the intermeshing jaw should be disassembled and reassembled under clean service conditions to prevent contamination and damage to bearing surfaces. Prepare a clear area on the work surface in which to arrange the components as the intermeshing jaw is disassembled. We recommend that you make a photocopy of this Service Instruction for workbench use Note: During this procedure DO NOT attempt to remove the bolt ( or [fused]) (see Figure 1). The bolt is not involved in removing the jaws. Bolt or [fused] Figure 1 DO NOT loosen bolt Disable the Slave Arm! WARNING Before you can service the arm safely, you need to disable the electrical and hydraulic functions of the arm. Follow the steps below before you continue. 1. Raise the arm to a comfortable working position. 2. Turn off the power to the hydraulic power unit (HPU). 3. If your arm is equipped with a hydraulic compensation unit, isolate the unit from the arm. Page Service Instruction

187 Disassemble the Intermeshing Jaw Disassembly of the intermeshing jaw assumes that all preparations, previously described in this Service Instruction, have been met. Numbers in parentheses refer to the part number of the item. See Figure 2 for basic identification of jaw parts. Jaw Actuator Bearing (2x) Base (2x) Jaw (4x) Nose Block HHCS and Washers (4X) and Figure 2 Basic intermeshing jaw parts identification Remove Interlocking Jaws from Nose Block Refer to Figure 3 and Figure 4 for this procedure. 1. Remove the HHCS ( ) and washer ( ) from one end of each of the two pivot pins ( ) holding the base assemblies ( ) to the nose block ( ) (see Figure 3). Pivot Pin (2x) Nose Block HHCS and Washers (4x) and Figure 3 Removing the intermeshing jaw 2. Pull out each pivot pin and with attached the HHCS and jaw washer. Service Instruction Page 301

188 3. Remove each jaw and base assembly ( and ) from the nose block. Lift the jaw and base assemblies out so that the jaw actuator bearing ( ) slides off the t-bar plate (see Figure 2, on page 3). The four bearings ( ) will fall out as you remove the jaw and base assemblies (see Figure 4). Set them aside to inspect later. Jaw and Base Assembly (2x) Bearings (4x) Figure 4 Removing jaws from nose block Remove the Jaws From the Base Refer to Figure 5 for this procedure. If you are not going to remove the jaws, go to Inspect Jaw Components on page 303. Jaw (4x) Nut (8x) Tie Rod (2x) Spacer (2x) Base (2x) Tie Rod (2x) Figure 5 Removing the jaws from the base 1. Remove one nut ( ) from one of the tie rods ( or , whichever is applicable) and pull the tie rod out of the jaws ( ), spacers ( , if applicable), and base ( ). Repeat for the other jaws. Page Service Instruction

189 Install the Jaws to the Base Refer to Figure 5 for this procedure. If you did not remove the jaws from the bases, go to "Inspect Jaw Components". 1. Lubricate the tie rod body ( or , whichever is applicable) and threads with Aqua Lube. Install into the jaws ( ), spacers ( , if applicable), and base ( ). Torque to 28 Nm (21 ft/lbs). Repeat for the other jaws. Inspect Jaw Components Refer to Figure 6 and Figure 7 for this procedure. Often the jaw is subjected to long use, severe service, and abuse. Carefully determine the amount of damage and wear that is acceptable before the jaw no longer works properly for your application. 1. Inspect the pivot pins ( ) for signs of wear, galling, or other surface damage. Use a micrometer to measure any suspect pins and replace any that measure mm (0.746-in.), or less at any point. 2. Inspect the actuator bearings ( ) and jaw for signs of wear, cracking, twisting, or other deformation (see Figure 6). Verify that the bearings turn smoothly in the base and that they show no discernible play. Replace any bearing or base that shows unacceptable wear or damage. Check For Wear and Deformation Actuator Bearing Bearing (2x) Jaw Not Shown For Clarity Base (2x) Figure 6 Checking actuator bearing and base for wear and deformation 3. Inspect the four bearings ( ) for signs of wear or damage. Replace any bearings that show wear or damage. 4. Check all of the bearings ( ) in the bases for wear and excessive play by inserting a new pivot pin, an acceptable used pin, or the shaft of a mm (0.750-in.) drill or drill rod (see Figure 7). Using the procedure in Replacing Jaw Bearings on page 304, replace any bearing that has too much play. Service Instruction Page 303

190 Bearings (2x) Pivot Pin or.750-in (19.05mm)Rod Figure 7 Checking bearings Replacing Jaw Bearings Refer to Figure 6 for this procedure. 1. Clamp the base securely in a soft-jaw vise. Use a 21 mm (13/16-in.) diameter drift to drive the bearing ( ) out of the base ( ). Note: Heating the base assembly with a heat gun, or in an oven, at approximately C ( F), will help soften the adhesive and remove the bearings. 2. Clean the bearing bore to remove all traces of Loctite Apply a thin coating of Loctite 271 to the outside of the bearing and to the inside of the bearing bore. 4. Press the new bearings into the base. When properly installed, the bearing should be flush, or slightly recessed from the base surface. 5. Clean off any excess Loctite 271. Allow the Loctite to cure for 24 hours at 22 C (72 F), or 1 hour at 94 C (200 F), before reinstalling this assembly. Attach the Intermeshing Jaw to Nose Block Refer to Figure 8 for this procedure. 1. Lubricate all surfaces of a actuator bearing ( ) with Aqua Lube and place the actuator bearing into one of the bases. 2. Lubricate the bearings ( ) with Aqua Lube. 3. Insert a pivot pin ( ), with HHCS ( ) and washer ( ), into the nose block ( ) just far enough to install a bearing ( ) over the pin (see Figure 8, step A). Align the base ( ) in the nose block and push the pivot pin ( ) in until it is just flush with the other side of the jaw (see Figure 8, step B). Install another bearing between the jaw and nose block, and push the pin in completely (see Figure 8, step C). Page Service Instruction

191 Nose Block Pivot Pin Bearings S3586TP A B Base Drawing is not to scale C Figure 8 Install jaw to nose block 4. Apply a coating of Aqua Lube to the threads of the HHCS ( ) and install the HHCS and washer ( ) to the end of the pivot pin ( ). Torque the HHCS to 99 Nm (73ft/lb). 5. Repeat steps 4 to attach the other base. END OF SERVICE INSTRUCTION Service Instruction Page 305

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193 Service Instruction Linear Actuators, , -3939, 4328, & Description Complete service instructions for Orion P intermeshing jaw. Assembly Number , 6.6 cm (2.6-in.) stroke , cm (3.7-in.) stroke , 15.4 cm (6.0-in.) stroke Estimated Time to Complete 1 hour Preparation for Service Below is a list of required tools and materials for this Service Instruction. Look over the list and make sure you have all the materials before you get started. Read through the entire procedure to make sure you understand, and are capable of performing, the service. Take special notice of all notes, warnings, and the terminology section. Tools Needed Materials Needed 1/4-in. socket Dow Corning 55 O-ring lube or petroleum jelly 7/16-in. socket Loctite 271 ( ) 1/8-in. allen wrench Loctite 7471 Primer 3/32-in. allen wrench Valvoline Val Plex EP Grease 9/16-in. open-end wrench mm (0-6-in.) vernier caliper bench vise with soft jaws pick tool razor blade or X-acto style knife Custom Tools Needed Terminology O-ring/seal installation tool SHCS = socket head cap screw female sizing tool FHMS = flat head machine screw linear actuator nose installation tool piston clamp tool nose nut socket tool /8-in. modified socket SERVICE INSTRUCTION Page 307

194 ! Caution Some components have protective coatings such as anodizing. Take care not to scratch any protective coatings. Corrosion damage will result.! Caution If you are planning to replace the linear actuator seals ( and ) (see Figure 3 and Figure 4), you must have replacements onhand. You will need to destroy the old seals to remove them. This Service Instruction assumes that the intermeshing jaw to be serviced has been removed from the slave arm. See the appropriate Service Instruction for linear actuator removal and reinstallation procedures. Perform all assembly work in a clean, dry environment if possible. Although assembly of major slave arm components must often be performed under field conditions, the intermeshing jaw should be disassembled and reassembled under clean service conditions to prevent contamination and damage to bearing surfaces. Prepare a clear area on the work surface in which to arrange the components as the intermeshing jaw are disassembled. We recommend that you make a photocopy of this Service Instruction for workbench use. Disassemble Linear Actuator Disassembly of the intermeshing jaw assumes that all preparations, previously described in this Service Instruction, have been met. Identify the intermeshing jaw you are servicing before beginning this procedure. Model is a short-stroke linear actuators, with a body about 13.9 cm (5.5-in.) long (used in the azimuth and the forearm). Models and are a longer version, with a body about 16.5 cm (6.5-in.) long (used in the shoulder and elbow). Model is a long version used in the Orion system azimuth. Although service for the linear actuators is identical for all models, the housing, deep transducer, and piston cannot be interchanged between the models. Numbers in parentheses refer to the part number of the item. See Figure 1 for basic identification of intermeshing jaw parts. Service Linear Actuator The following procedures combine all linear actuators into one set of instructions. Differences in actuators involve piece part numbers. The general instructions are the same for all linear actuators. Refer to Figure 1 for short-stroke linear actuator parts identification. Page SERVICE INSTRUCTION

195 Note: Where there are differences in part numbers, the following applies: A = , 6.6 cm (2.6-in.) stroke B = and cm (3.7-in.) stroke C = , 15.3 cm (6.0-in.) stroke Actuator Bearing A = B = C = Piston A = B = C = Housing A = B = C = Nose Nut Rod End or ( only) FHMS Deep Transducer A = B = C = See Figure 4 See Figure 3 Figure 1 Linear actuator parts identification Remove Deep Transducer Refer to Figure 1 for this procedure. 1. Using a 3/32-in. allen wrench, remove the two FHMS ( ) that hold the deep transducer in place. 2. Manually extend the piston to its full extension. 3. Plug the actuator s extend port (the hydraulic fitting furthest from the nose nut and piston rod end). Note: Hydraulic fluid will spill out of the intermeshing jaw assembly when you remove the deep transducer during step 4. Have a drain pan ready to catch the fluid. 4. Cover the deep transducer with a heavy shop towel. Manually compress the actuator piston until the deep transducer blows out of it s seat into the towel. SERVICE INSTRUCTION Page 309

196 Remove the Piston Shaft Refer to Figure 2 for this procedure. Figure 2 Holding linear actuator in soft-jawed vise 1. Clamp the housing in a soft-jawed vise. Unscrew the nose nut using the nose nut socket ( ).! Caution Remove the nose nut and piston assembly from the actuator body carefully, to avoid damaging the piston seals and bearing on the threads of the housing! Caution Hydraulic fluid will spill out of the intermeshing jaw assembly when you remove the piston assembly during step 2. Have a drain pan ready to catch the fluid. 2. Pull the piston assembly out of the housing. Be careful not to damage the piston on the housing/nose nut threads as you pull the piston assembly out of the housing. 3. Remove the housing from the soft-jawed vise. Drain all the hydraulic fluid from the housing. Set the housing aside for later inspection. Remove the Nose Nut & Rod End From the Piston Refer to Figure 3 for this procedure. 1. Using a pick tool, carefully remove the bearing ( ) from the piston. Caution! To remove the seal ( ), in step 2, you will need to destroy the seal. If you don t have replacements, do not remove the seal at this time. Page SERVICE INSTRUCTION

197 2. Remove the seal ( ) from the piston by carefully cutting across it with a new razor blade or X-acto style knife. Be very careful not to damage the finish on the piston. 3. Remove the O-ring ( ) from the piston. 4. Install the piston clamp tool ( ) onto the piston. Clamp the piston clamp tool in the soft-jawed vise. Unscrew and remove the rod end ( ) from the piston. 5. Remove the O-ring ( ) from the rod end. 6. Slide the nose nut ( ) off the piston. Set the piston aside to inspect later. Piston A = B = C = Nose Nut O-ring Rod End or ( only) Bearing Seal O-ring Figure 3 Piston & rod end seals Disassemble Nose Nut Refer to Figure 4 for this procedure. Seals (2x) Bearing (2x) Scraper Nose Nut O-ring Figure 4 Nose nut parts identification SERVICE INSTRUCTION Page 311

198 1. Remove the O-ring ( ) from the nose nut ( ). 2. Using a pick tool, carefully remove the bearings ( ) from the nose nut.! Caution To remove the seals ( ), in step 3, and the scraper ( ), in step 4, you will need to destroy the seals and scraper. If you don t have replacements, do not remove the seals and scraper at this time. 3. Remove the seals/o-ring ( ) from the nose nut by carefully cutting across them with a new razor blade or X-acto style knife. Be very careful not to damage the finish on the nose nut. 4. Remove the scraper/o-ring ( ) from the nose nut by carefully cutting across it with a new razor blade or X-acto style knife. Be very careful not to damage the finish on the nose nut. Clean and Inspect Nose Nut & Nose Nut Bearings Refer to Figure 4 for this procedure. 1. Inspect the bearing surfaces of the nose nut ( ). Replace the nose nut if any galling or surface damage is found. Very small scratches and wear marks are normal. 2. Using a 6-in. vernier caliper, measure the wall thickness of the bearings ( ). Replace any bearing with a wall thickness of 1.49 mm ( in.) or less at any point. Replace the Nose Nut Seals & Nose Nut Bearings Refer to Figure 5 and Figure 6 for this procedure. Seals (2x) Bearing (2x) Scraper Nose Nut O-ring Figure 5 Nose nut parts orientation 1. Lightly lube the bearings ( ) with O-ring lube and install them into the nose nut ( ) (see Figure 5). 2. Lightly lube the seals/o-rings ( ) with O-ring lube and install them into the nose nut. See Figure 5 for proper orientation of seals/o-rings. Page SERVICE INSTRUCTION

199 Tip: To aid in getting the seals/o-rings into the grooves, it may be helpful to bend them like this: then push the seals/o-rings down into the grooves. 3. Lightly lube the scraper/o-ring ( ) with O-ring lube and install it into the nose nut. See Figure 5 for proper orientation of the scraper/o-ring. Install using the Tip above. 4. Lubricate the linear actuator resizing tool ( ) with O-ring lube and install into the nose nut (see Figure 6). This will resize the seal and scraper to the proper diameter. Leave the tool in the nose nut until you re ready to install the nose nut onto the piston ( ). Nose Nut Linear Actuator Resizing Tool Figure 6 Installing linear actuator resizing tool into nose nut 5. Lubricate the O-ring ( ) with O-ring lube and install onto the nose nut (see Figure 5). 6. Set the nose nut aside to be installed onto the piston later. Clean and Inspect Piston & Piston Bearings Refer to Figure 3 for this procedure. 1. Inspect the bearing surfaces of the piston. Replace the piston if any galling or surface damage is found. Very small scratches and wear marks are normal. 2. Using a 6-in. vernier caliper, measure the piston bearing ( ) wall thickness. Note: Replace the bearing if the wall thickness is 1.49 mm ( in.) or less at any point. Clean & Inspect Housing Refer to Figure 7 for this procedure. SERVICE INSTRUCTION Page 313

200 Actuator Bearing A = B = C = Housing A = B = C = Anode Figure 7 Servicing the housing 1. Remove the anode ( ) from the side of the housing. Clean the housing. Use a lint-less rag and wipe all the surfaces clean of dirt and hydraulic fluid. 2. Inspect the bore of the housing. Replace the housing if any galling or surface damage is found. Very small scratches and wear marks are normal. 3. Using a new pivot pin, or a pivot pin that has been checked for correct size, check the actuator bearings for wear. Insert the pivot pin into the bearing and check for play. Replace any bearing that permits too much play. 4. Lubricate the threads of a new anode with Aqua Lube and install onto the side of the housing. Clean & Inspect the Deep Transducer Refer to Figure 8 for this procedure. O-ring O-ring Backup Ring Deep Transducer A = B = C = Figure 8 Deep transducer parts 1. Clean the deep transducer. Use a lint-less rag and wipe all the surfaces clean of dirt and hydraulic fluid. 2. Remove the two O-rings ( and ) and the backup ring ( ) from the deep transducer. 3. Inspect the deep transducer. Check for cracks and surface damage to the transducer. 4. Lubricate the two new O-rings and a new backup ring with O-ring lube and install onto the deep transducer. See Figure 8 for proper orientation of O-rings. Page SERVICE INSTRUCTION

201 Reassemble Rod End and Nose Nut onto Piston Refer to Figure 9, Figure 10, and Figure 11 for this procedure. Piston A = B = C = Nose Nut O-ring Rod End or ( only) Bearing Seal O-ring Figure 9 Piston & rod end seals 1. Lubricate the outer surfaces of the piston ( ) and inner surfaces of the nose nut ( ) with O-ring lube. 2. Align the linear actuator resizing tool ( ) with the piston and slide the nose nut onto the piston, threaded-end first (see Figure 10). Remove the tool. Piston A = B = C = Nose Nut Linear Actuator Resizing Tool Figure 10 Installing nose nut onto piston 3. Lubricate the O-ring ( ) with O-ring lube and install it onto the rod end ( ) (see Figure 9). 4. Clean the treads of the piston and rod end with Loctite 7471 primer. SERVICE INSTRUCTION Page 315

202 5. Install the piston clamp tool ( ) onto the piston. Clamp the piston clamp tool in the soft-jawed vise. Use two, small drops of Loctite 271 on the threads of the rod end. Install the rod end into the piston. Torque the rod end to 81 Nm (60 ft/lbs). Remove the piston clamp tool. 6. Lubricate the O-ring ( ) and the seal ( ) with O-ring lube. Use the O-ring/ seal installation tool ( ) to install them onto the jaw piston as shown in Figure 11. Remove the male installation tool and install the female sizing tool ( ) over the piston. This will resize the seal to the proper diameter. Leave the tool on for at least 10 minutes. After 10 minutes, remove the tool. O-ring/seal Installation Tool Female Installation Tool Seal Figure 11 O-ring/seal installation & female sizing tools on the piston 7. Lubricate the bearing ( ) with EP grease and install it onto the piston as shown in Figure 9. Assemble the Short-stroke Linear Actuator Refer to Figure 1, Figure 2, and Figure 12-Figure 18 for this procedure. 1. Apply a light film of EP lube to the inner surfaces of the housing, the outer surfaces of the piston and the threads of the housing and nose nut ( ) (see Figure 1). Carefully slide the piston into the bore of the housing and screw the nose nut into the actuator body. 2. Clamp the housing in a soft-jawed vise as shown in Figure 2. Torque the nose nut to 135 Nm 9100 ft/lbs). Remove the housing from the vise. 3. Completely push the piston into the housing. Line up the mark on the top of the housing with the mark on the deep transducer (see Figure 12). To pick up the magnet sensor that is inside the deep transducer, slowly place the deep transducer into the housing. As you move the deep transducer down into the housing, you will feel the magnet sensor in the deep transducer pick up the magnet attached to the piston. Page SERVICE INSTRUCTION

203 Alignment Marks Deep Transducer A = B = C = Housing A = B = C = Figure 12 Alignment marks on the deep transducer & housing 4. Lubricate the two FHMS ( ) that hold the deep transducer into place with Aqua Lube and install them into the housing. Tighten the FHMS. 5. If the two plug fittings ( ) were removed from the housing, or if a new housing is being used, install the plug fittings now. Inspect the O-rings to ensure they are correctly seated. Lubricate the O-rings with O-ring lube and install the plug fittings into the housing. Torque the plug fittings to 5.1 Nm (45-in./lbs) (see Figure 13). Hydraulic Fittings (2x) Plug Fitting with O-ring (2x) Figure 13 Installing plug & hydraulic fittings 6. If the hydraulic fittings ( ) (see Figure 13) were removed from the housing, or if a new housing is being used, install the hydraulic fittings now. Inspect their O-rings to ensure they are correctly seated. Lubricate the O-rings with O-ring lube and install the hydraulic fittings. Orient the fittings as described below: Forearm linear actuator see Figure 14 Azimuth linear actuator see Figure 15 Shoulder linear actuator see Figure 16 Elbow linear actuator see Figure Azimuth actuator see Figure 18 When the fittings are oriented correctly, tighten the lock nut. SERVICE INSTRUCTION Page 317

204 35 Figure 14 Hydraulic fitting orientation for forearm linear actuator, Figure 15 Hydraulic fitting orientation for azimuth linear actuator, Figure 16 Hydraulic fitting orientation for shoulder linear actuator, & Figure 17 Hydraulic fitting orientation for elbow linear actuator, Figure 18 Hydraulic fitting orientation for azimuth linear actuator, (Orion system ) Page SERVICE INSTRUCTION

205 7. Inspect the assembled actuator. Manually work the piston in and out of the actuator body to be sure that it moves smoothly, without binding. If a hydraulic test bench is available, you may test the actuator for proper action and leaks before installing back into the slave arm. You may also use an air hose (with a rubber tip) to force the piston back and forth. There should be no air leaking from one port when pressure is being applied to the opposite port. 8. Reinstall the actuator into the slave arm. Bleeding an Actuator! WARNING Air in hydraulic lines or components may cause very rapid or jerky slave arm movement. Clear personnel and equipment from the slave arm s range of motion before operation. Bleed screws for all linear actuators except a jaw are located on the side of the actuator body, directly opposite the hose connections for the same extend or retract function. Note that for linear actuators, A hose markings always indicate an extend function, while B markings indicate a retract function. Note: Activate only one actuator at a time during the bleed process. Enter the slave arm s range of motion to loosen or retighten bleed screws only when hydraulic power has been isolated and ALL function controls are returned to their OFF positions 1. Extend the actuator until it is against its full mechanical stop. Loosen the A/extend bleed screw directly opposite the A/extend hose fitting until the o-ring seal is broken. 2. Slowly retract the actuator until it is against the full mechanical stop and all air has stopped coming out of the A bleed port. Note: To avoid extruding the o-ring when tightening a bleed screw, make sure the joint is unloaded or supported. 3. Tighten the A/extend bleed screw and loosen the B/retract bleed screw (opposite the B/retract hose fitting) until the o-ring seal is broken. 4. Slowly extend the actuator once again until it is at its full mechanical stop and all air has stopped coming out of the B bleed port. Retighten the B/retract bleed screw. The actuator is now fully bled. 5. Repeat steps 1 through 4 for any other linear actuator needing to be bled. 6. Test all functions for smooth operation. Check for leaks at all bleed screws. END OF SERVICE INSTRUCTION SERVICE INSTRUCTION Page 319

206 This page not used. Page SERVICE INSTRUCTION

207 Service Instruction Change Forearm Rotary Index Setting Assembly Number Description Complete service instructions for changing the Orion P intermeshing jaw. Estimated Time to Complete 2 hours Preparation for Service Below is a list of required tools and materials for this Service Instruction. Look over the list and make sure you have all the materials before you get started. Read through the entire procedure to make sure you understand, and are capable of performing, the service. Take special notice of all notes, warnings, and the terminology section. Tools Needed Materials Needed 7/16-in. Sockets Aqua Lube ( ) 9/16-in. Socket Dow Corning 55 O-ring lube or petroleum jelly 3/8-in. Socket 3/16-in. hex key 3/32-in. flat-blade screwdriver medium flat-blade screwdriver rubber hammer 1-3-ft 24 gauge wire or equivalent string Custom Tools Needed none needed Terminology HHCS = Hex Head Cap Screw SHCS = Socket Head Cap Screw HPU = Hydraulic Power Unit SERVICE INSTRUCTION Page 321

208 ! Caution Some components have protective coatings such as anodizing. Take care not to scratch any protective coatings. Corrosion damage will result. Introduction to Forearm Rotary Index Settings The Orion P slave arm s range of motion is generally symmetrical, however the rotary actuator s 270 range of motion is set at the factory to work as a right-hand manipulator (in a dual arm installation). As viewed from behind the slave arm (see Figure 1), rotation starts about the 3 o clock position rotating clockwise to about 12 o clock (see Figure 2, position 1). There is no rotation between 12 o clock and 3 o clock. Figure 1 Looking at rotation of the slave arm To accommodate differing installation requirements, the rotation can be indexed to seven other settings (in 45 increments) (see Figure 2). Changing the index setting requires adjusting the orientation between: The slip ring and manifold, The driveshaft coupler and the forearm mounting flange, The rotor and forearm mounting flange. Figure 2 Optional rotary orientations Page SERVICE INSTRUCTION

209 Change the Rotary Actuator Index Setting This procedure assumes the hydraulic power is OFF. Loosen the appropriate hose fittings to allow the actuators to leak down and permit positioning the slave arm joints as needed to simplify disassembly. You must remove the Forearm assembly before you can change the forearm rotary index setting. See the Orion P Forearm, Service Instruction. Perform all assembly work in a clean, dry environment if possible. Although assembly of major slave arm components must often be performed under field conditions, the rotary actuator should be disassembled and reassembled under clean service conditions to prevent contamination and damage to bearing surfaces. Prepare a clear area on the work surface in which to arrange the components as the rotary actuator is disassembled. We recommend that you make a photocopy of this Service Instruction for workbench use. Changing the intermeshing jaw assumes that all preparations, previously described in this Service Instruction, have been met. Numbers in parentheses refer to the part number of the item. Disable the Slave Arm! WARNING Before you can service the arm safely, you need to disable the electrical and hydraulic functions of the arm. Follow the steps below before you continue. 1. Raise the arm to a comfortable working position. 2. Turn off the power switches located on the master controller and the junction box. 3. Turn off the power to the hydraulic power unit (HPU). 4. If power is supplied from a local, independent source, turn off the power to the slave controller. Detach Forearm Assembly From Forearm Rotary Actuator Refer to Figure 3, Figure 4, Figure 5, and Figure 6 for this procedure. 1. Remove the eight HHCS ( ) and washers ( ) securing the manifold cover ( ) to the rotary actuator ( ) (see Figure 3). Remove the manifold cover to expose the wire housing cover ( ) (see Figure 4). SERVICE INSTRUCTION Page 323

210 Manifold Cover HHCS and Washers (8x) and Rotary Actuator Forearm HHCS and Washers (10x) and Figure 3 Manifold cover and rotary actuator 2. Remove the wire housing cover by removing the five SHCS ( ) that hold the cover to the wire housing ( ) (see Figure 4). Remove the large O-ring ( ) and the four smaller O-rings ( ) from the wire housing cover (see Figure 4). O-ring O-ring (4x) Wire Housing Cover Wire Housing SHCS (5x) Figure 4 Wire housing cover and O-ring location 3. Using a 3/32-in. flat blade screwdriver, loosen the terminal screws and remove the forearm sensor wires from the PCB assembly ( ) (see Figure 5). Note: Observe O-ring that the wires are connected across from wires of the same color and striping. Page SERVICE INSTRUCTION

211 PCB Assembly Forearm Sensor Wires Figure 5 Removing position sensor wires from PCB assembly! Caution When you remove the ten HHCS in step 4, the forearm will be loose. The forearm assembly, including wrist and jaw, weighs about 18 kg (40 pounds) and must be supported during removal. Read the entire step before continuing. Be prepared by properly supporting the forearm. 4. Remove the ten HHCS ( ) and washers ( ) from the bottom of the rotary actuator (see Figure 3). Separate the forearm from the rotary actuator and extract the position sensor wires from the rotary actuator. 5. Remove the nine O-rings ( ) from the mounting flange ( ) (see Figure 6). Mounting Flange O-rings (9x) Figure 6 Removing O-rings from mounting flange Remove Wire Housing, Position Sensor, & Manifold/Slip Ring Assembly Refer to Figure 7, Figure 8, and Figure 10 for this procedure. SERVICE INSTRUCTION Page 325

212 O-ring O-ring (3x) Position Sensor Wire Housing Hydraulic Fittings (6x) HHCS and Washer (2x) and Rotary Actuator Adapter Plate Manifold Slip Ring Sensor Driveshaft Figure 7 Rotary actuator area parts 1. Remove the four SHCS ( ) securing the wire housing ( ) to the adapter plate ( ) and lay it to the side (see Figure 7 and Figure 8). Remove the O-ring ( ) from the bottom of the wire housing (see Figure 7). SHCS (4x) Wire Housing Figure 8 Removing wire housing from rotary actuator Page SERVICE INSTRUCTION

213 2. Lift the position sensor ( ) off the adapter plate ( ) and lay it to the side (see Figure 7). 3. Using a flat-blade screw driver, gently pry the sensor driveshaft ( ) up and out of the adapter plate (see Figure 9). Gently Pry Up Here Sensor Driveshaft Adapter Plate Figure 9 Removing the sensor driveshaft 4. Loosen all the hydraulic fittings (6x) on the manifold (see Figure 7). 5. Remove the two HHCS and washers ( and ) from the manifold (see Figure 7). 6. Using a rubber hammer, remove the manifold by tapping upward on the edges of the manifold. Do not pry the manifold off of the actuator. 7. Note the old rotary index setting. The rotary index setting number is located on the slip ring flange ( ) (see Figure 10). Note the new rotary index setting you wish to use in the box below. Note OLD Rotary Index Setting Here: O-ring Slip Ring Manifold Rotary Index Setting Note NEW Rotary Index Setting Here: Figure 10 Noting old and new rotary index settings 8. Remove the O-ring ( ) for the manifold (see Figure 10). 9. Remove the two O-rings ( ) from the end plate ( ) (see Figure 11). SERVICE INSTRUCTION Page 327

214 End Plate O-ring (2x) Figure 11 Removing O-rings Set Coupler to New Rotary Index Setting Refer to Figure 12 and Figure 13 for this procedure. 1. Remove two SHCS ( ) from the coupler and rotate the coupler until the arrow points to the keyway in the rotor (see Figure 12). The arrow and flat should now be aligned with the new index setting number on the mounting flange ( ) (see Figure 12). Keyway Flat Arrow Coupler SHCS (2x) Rotor Figure 12 Rotating coupler to new index setting number Note: The mounting flange/coupler/rotor interface must match the new rotary index setting at the manifold/slip ring interface that you recorded in Figure 10. Page SERVICE INSTRUCTION