Schilling Robotics RigMaster 2 Slave Arm Rate-Controlled, 6.5 Km Submersible

Schilling Robotics RigMaster 2 Slave Arm Rate-Controlled, 6.5 Km Submersible Document No. 011-8204 Models: 199-0274 199-0287 199-0333

Copyright 2016 by Schilling Robotics, LLC. All rights reserved. Schilling Robotics, the FMC Technologies logo, and their frameworks are trademarks and service trademark applications of FMC Technologies. No part of this document may be reproduced or used in any form without the express written permission of FMC Technologies. Descriptions and specifications are subject to change without notice. FMC Technologies Schilling Robotics 24-HR Support USA: 1-(866)342-2562 24-HR Support outside of USA: 44(0)1224-215319 Sales Schilling.Sales@fmcti.com Tech Support Schilling.TS@fmcti.com Customer Service Schilling.CS@fmcti.com Web Site http://www.fmctechnologies.com/schillingrobotics.aspx TECHNICAL MANUAL REVISION LOG PRODUCT: RigMaster Slave Arm, 199-0274, 199-0287, 199-0333 TECHNICAL MANUAL: 011 8204 Description Date Rev. Manual release 11/29/05 Ø Production revision 10/30/06 A Production revision 10/29/07 B Production revision (add model 199-0287) 04/17/08 C Removed incorrect Orion references. Fixed various cosmetic changes, removed rate controlled references, updated spec info, changed relief valve pressure data for wrist drain (p.16), refortted trouble shooting tables, removed references to P-type slave arm. 5/6/14 D Production revision (add model 199-0333) 10/07/14 E Added BOM & Dwg 101-9679 (for 199-0333) 07/8/15 F Added model 199-0333 to cover; replaced spares kit 008-0949 with 008-0977; replaced spares kit 008-0948 with 008-0978 9/15/16 G

Table of Contents Specifications 1 General Description............................... 7 2 Manipulator Arm Specifications...................... 7 3 Hydraulic Specifications........................... 8 3.1 Fluid Selection................................... 8 4 Environmental Specifications....................... 8 Installation 1 RigMaster Overview.............................. 9 2 User-supplied Equipment.......................... 9 3 Installing the Slave Arm........................... 9 3.1 Preparing the Slave Arm Mounting Platform............... 9 3.2 Installing the Control & Drain Hoses................... 11 3.3 Installing Relief Valves............................ 12 3.4 Installing Check Valves............................ 13 4 Installation Startup & Test........................ 13 4.1 Confirm Before First Startup........................ 13 4.2 First Startup................................... 13 4.3 Testing Functions................................ 14 Operation 1 Operation Overview.............................. 15 1.1 RigMaster Overview.............................. 15 2 Factors Affecting Slave Arm Performance............. 15 3 Normal Operation............................... 16 3.1 Pre-Start Checks................................ 16 3.2 Startup Procedure............................... 16 4 Controlling System Functions...................... 17 Troubleshooting Page 3

1 Troubleshooting the Slave Arm..................... 19 2 Troubleshooting Tables........................... 20 2.1 Whole-Arm Troubleshooting Tables.................... 20 2.2 Single Joint Troubleshooting Tables.................... 22 Maintenance & Service 1 Organization.................................... 25 2 Safety First!.................................... 26 2.1 Worksite Safety................................. 26 2.2 Maintenance & Service Safety........................ 26 2.3 Deck Testing.................................... 27 3 Important Service Practices & Procedures............ 27 3.1 Maintenance.................................... 28 4 Basic Service Instructions......................... 29 4.1 Base Assembly Replacement........................ 30 4.2 Shoulder Block Assembly Replacement................. 31 4.3 Arm Segment Assembly Replacement.................. 31 4.4 Boom Replacement............................... 32 4.5 Wrist/Jaw Assembly Replacement..................... 33 4.6 Linear Actuator Assembly Replacement................. 34 4.7 Hydraulic Hose Replacement......................... 36 4.8 Part Lists & Illustrations............................ 37 5 Special Service Instructions........................ 50 5.1 Using the Service Instructions....................... 50 5.2 Start-up Following Service.......................... 50 5.3 Service Instruction List............................ 50 Drawings & Part Lists 1 Organization.................................... 89 2 Index......................................... 89 2.1 Spares Kit..................................... 90 Page 4 Table of Contents

Safety & Service Summary Precautionary Notices This manual provides precautionary notices which carry important information about safety risks to personnel and damage to equipment while installing, operating, servicing, or maintaining this equipment. The form and significance of the notices are shown below.! WARNING A WARNING alerts you to a risk of injury or loss of life. It may also include instructions to help minimize or eliminate the risk.! Caution A CAUTION alerts you to a risk of equipment damage or loss. It may also include instructions to help minimize or eliminate the risk. NOTE: The absence of WARNING and CAUTION notices does not mean that risk is absent. Always use appropriate safety procedures, equipment, and personal protective equipment (PPE) when operating and servicing this equipment. Service Assumption This manual assumes that service personnel are familiar with the general operating principles, safety guidelines, and service practices associated with the types of equipment represented in this manual. Table of Contents Page 5

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Specifications 1 General Description Control method.............................................. Rate control Control input device........................... Optional rate hand controller Number of functions........................................four plus grip Materials of construction..... Titanium, anodized aluminum, 17-4 stainless steel 2 Manipulator Arm Specifications All specifications are based on the standard configuration using Shell Tellus Oil 32 hydraulic fluid, input pressure of 207 bar (3,000 psi) and available flow of 19 lpm (5 gpm). Depth rating......................................... 6,500 msw (21, 327) Reach (from shoulder pivot to tip of standard gripper): Retracted boom................................ 1067 mm (42.0-in.) Extended boom................................ 1,372 mm (54.0-in.) Weight in air.............................................. 64 kg (142 lb) Weight in seawater......................................... 48 kg (105 lb) Lift at full extension, nominal: Retracted boom.....................................270 kg (595 lb) Extended boom.................................... 181 kg (400 lb) Maximum standard gripper opening, nominal............. 289 mm (11.377-in.) Grip force, nominal.................................... 4,448 N (1,000 lbf) Wrist torque, nominal.................................. 205 Nm (150 ft/lb) Wrist rotate, continuous................................... 360, 6-35 rpm Actuator functions.........................................see table below Actuator Functions Actuator Function Type Nominal Mechanical Range Base yaw Linear 105 Shoulder pitch Linear 105 Boom extend/retract Linear 305 mm (12-in.) 011 0753 Page 7

Specifications 3 Hydraulic Specifications Viscosity.............................................. 10.0 cst to 200 cst Available flow............................... 5.7-19.0 l/min (1.5-5.0 gpm) Pressure....... 103 bar (1,500 psi) minimum to 207 bar (3,000 psi) maximum Note: Contact the factory about operation with other pressures and flow rates. Rotary actuator return pressure, maximum.................. 24 bar (350 psi) Filtration................................. 10 microns (25 microns absolute) Hydraulic control hose length extending from base, nominal, all functions..................................... 55-in. (4.6 ft) Control hoses: Working pressure.............................. 207 bar (3,000 psi) Proof pressure.................................. 310 bar (4,500 psi) Burst pressure.................................. 621 bar (9,000 psi) Customer-supplied mating fittings reguired: Control hose fittings............................. -4 JIC male, ¼-in. 3.1 Fluid Selection Select a hydraulic fluid based on its maximum temperature during normal operations. Lower than 54 C (130 F): Use 22 grade oil. Higher than54 C (130 F): Use 32 grade oil. For temperatures above 71 C (160 F), below 0 C (32 F), or when in doubt about which fluid to use, contact your regional technical support representative. Do not use water-based fluids. Actuator Functions (cont.) Actuator Function Type Nominal Mechanical Range Wrist rotate Gerotor 360 Gripper, standard Linear 284 mm (11.2-in.) If a fluid has been specified for this system to meet special environmental or operational requirements, use it and disregard the parameters listed above. Approved hydraulic fluids.......shell Tellus, Royal Purple Marine Hydraulic Oil 4 Environmental Specifications Operating temperature.................... -2 C to +54 C (+28 F to 130 F) Storage temperature....................... -15 C to +71 C (+5 F to 160 F) Humidity........................................ 0% to 100% condensing Page 8 3 Hydraulic Specifications 011 0753

Installation In This Chapter: 1 RigMaster Overview...page 9 2 User-supplied Equipment...page 9 3 Installing the Slave Arm...page 9 4 Installation Startup & Test... page 13 1 RigMaster Overview The RigMaster's five functions are base yaw, shoulder pitch, boom extend and retract, wrist rotate, and jaw open and close. Movement of each joint is achieved using a linear or rotary actuator. RigMaster hydraulic hose connections consist of ten control lines which are connected to the base, shoulder, boom, wrist, and jaw actuators, and one line for the wrist case drain. 2 User-supplied Equipment The following equipment, if not ordered as options from the factory, is required to complete the installation of the slave arm and provide for its control and operation: A hydraulic power source. A hydraulic control manifold. Two relief valves each for all arm functions. Cross-port check valves All hardware, hoses, and fittings for connecting to the slave arm s hydraulic hose fittings. 3 Installing the Slave Arm 3.1 Preparing the Slave Arm Mounting Platform 1. Determine a suitable mounting location for the slave arm guided by the dimensional requirements of the following drawings: Rigmaster Slave Arm, Range of Motion on page 115, sheet 3 of the RigMaster slave arm drawing in the Drawings & Part Lists chapter. Figure 1, Stow dimensions on page 10. Figure 2, Minimum distance to bulkhead hose fittings on page 10. 011 0756 Page 9

Installation Figure 1 Stow dimensions Figure 2 Minimum distance to bulkhead hose fittings 2. Create a sturdy mounting platform that will provide a flat surface for the three mounting holes in the base as shown in Figure 3. 3. Move the slave arm to the mounting platform. Lower the base onto the platform and align the mounting holes in the base and mounting platform. Page 10 Installing the Slave Arm 011 0756

Installation Figure 3 Slave arm mounting dimensions 4. A minimum of three 1/2-20 UNF-2B hex-head cap screws and lockwashers are required to attach the base to the mounting platform. The installation of a fourth fastener, at the rear of the base, is optional (see Figure 3).! Caution Mounting fasteners must be long enough to engage a minimum of 1.2 cm (0.5-in) of the base. Lubricate the threads of the fasteners with AquaShield (Aqualube) and add the lock washers. Install the fasteners through the mounting platform and into the RigMaster base. Torque the fasteners to 102 Nm (75 ft/lbs). 3.2 Installing the Control & Drain Hoses Ten hoses are supplied for connecting RigMaster functions to your control manifold or intermediate bulkhead fittings. The eleventh hose provides case drain from, and compensation to, the wrist assembly. This line must be connected to the return system. Note: IMPORTANT INSTALLATION DIMENSIONS: 1. Bulkhead hose fittings must be located no closer than 610 mm (24-in.) from the slave arm as shown in Figure 2. 2. Minimum bend radius for slave arm hoses is 51 mm (2-in.). 3. If control hose lengths exceed 6 meters (20 ft), consult Customer Service for information about increasing the hose diameter to maintain adequate pressure and flow. A hydraulic schematic diagram of the RigMaster manipulator system can be found in the Drawings & Part Lists chapter. The table below lists the control and drain hose connections at the slave arm, and identifies actuator functions, hose codes, and actuator movements. The slave arm hydraulic hoses are fitted with female -4 JIC fittings for connecting all user-supplied hydraulics. 011 0756 Installing the Slave Arm Page 11

Installation Slave Arm Actuator/ Function Azimuth yaw Shoulder pitch Boom Wrist rotate a Jaw Wrist Drain b Joint Travel Hose Code Left 1A Extend Right 1B Retract Up 2A Extend Down 2B Retract Out 3A Extend In 3B Retract Actuator Movement N/A 4A Rotate CCW N/A 4B Rotate CW Open 5A Extend Close 5B Retract N/A C N/A a. Forearm and wrist roll CW/CCW movements are referenced from behind the slave arm. b. The maximum wrist drain/return pressure is 350 psi. If the wrist drain/return line passes through a filter or is manifolded with other equipment returns, check the return pressure when all equipment is running to be sure it does not exceed the maximum.! Caution The wrist drain/return relief valve cracking pressure range is 350-600 psi. If pressure exceeds 350-600 psi above ambient, the relief valve will crack and release hydraulic fluid into the environment. For a description of how the supplied hydraulic hoses are connected to the manipulator, see the section entitled Hydraulic Hose Replacement of the Maintenance & Service chapter. 3.3 Installing Relief Valves Pressure relief valves must be installed on all control lines to protect slave arm components from the abnormally high pressures generated by overloads or collisions. The fluid release relieves excessive pressure on seals, and reduces stress on mechanical and hydraulic components. When normal working pressures return, the affected relief valves close and allow normal operation to resume. Without relief valves, slave arm components and seals are forced to directly absorb pressures and stresses above their rated working capacity; the result can be damage or breakdown.! Caution Operating the slave arm without relief valves on all control lines can result in damage to components. 1. Adjust the cracking pressure of the A and B line relief valves to the figures shown on the slave arm hydraulic schematic (with 025- prefix) in the Drawings & Part Lists chapter. The cracking pressure may be set closer to the operating pressure of the system, if desired, but be sure the reseal pressure is also above the normal operating pressure range of the system. If it is not, the valve may not reseal during normal operation and the actuator will respond erratically. Page 12 Installing the Slave Arm 011 0756

Installation Note: Do not set the cracking pressure higher than 4500 psi. 2. Connect the relief valves at any point between the hydraulic control manifold and the slave arm hose connections. Note: If a circuit has a restrictor, throttle, or flow control valve, install the relief valve between the actuator and the flow control valve. An illustration of relief valve connections is found on Sheet 1 of the RigMaster slave arm drawing (upper right-hand corner) and the hydraulic schematic in the Drawings & Part Lists chapter. The to tank port on each relief valve allows relieved fluid to be returned to the hydraulic power unit reservoir. 3.4 Installing Check Valves Adding cross-port check valves to the azimuth, shoulder, and boom functions is recommended. A check valve can be installed to the wrist function but may not be effective due to internal leakage of the wrist motor. Do not install a check valve to the jaw function as a hydraulic failure will leave the jaw locked in place (if the jaw is clamped on structure it cannot be disengaged). 4 Installation Startup & Test This section describes procedures for initially checking, starting up, and testing the slave arm after all system components have been installed and interconnected. 4.1 Confirm Before First Startup Before you operate the slave arm, confirm the following: Installation instructions have been completed for the slave arm and all other system components. Individual control valves and hoses are securely connected to the appropriate slave arm hoses for each actuator function. Control hoses are routed and supported/secured to eliminate snagging, kinking, and damage during slave arm operation. A relief valve is installed on the base yaw, shoulder pitch, and boom extend/retract control hose lines. The wrist drain hose is connected to the hydraulic system return. Hydraulic supply and return hoses/fittings are correctly connected and securely tightened to the user s control manifold. Submersible models only. Compensator hoses/fittings for user s hydraulic system are correctly connected and securely tightened. (The slave arm does not require compensation.) 4.2 First Startup! Caution If the wrist drain/return line exceeds 600 psi above ambient, hydraulic fluid will be released into the environment from the relief valve. 1. Clear all personnel or equipment from within the slave arm s range of motion. 011 0756 Installation Startup & Test Page 13

Installation 2. Remove any installation supports from the slave arm. 3. Activate the hydraulic power unit (HPU). 4. Check and confirm: Hydraulic supply pressure is within the range listed in the System Specifications chapter. Hydraulic return or tank pressure is 350 psi or less. If the hydraulic return passes through a filter or is manifolded with other equipment returns before returning to the tank, check the return pressure when all equipment is running to be sure it does not exceed the maximum. No leaks from hoses, fittings, components. 5. Following the manufacturers recommendations, bleed air from the HPU and manifold components. 4.3 Testing Functions 1. Briefly operate control valves and verify that they are correctly matched to slave arm functions. Correct any misconnected hoses. Label the hydraulic controls to match the slave arm s functions and movements. Note: Air in hydraulic lines or components may cause very rapid or jerky slave arm movement. 2. Adjust the restrictor valves, if present, to produce the maximum rate of travel desired for each slave arm function. 3. Purge the slave arm s hydraulic system of air by driving each linear actuator through its full range of travel several times. Installation of your RigMaster Slave Arm is finished. Proceed to the Operation chapter. Page 14 Installation Startup & Test 011 0756

Operation In This Chapter: 1 Operation Overview... page 15 2 Factors Affecting Slave Arm Performance... page 15 3 Normal Operation... page 16 4 Controlling System Functions... page 17 1 Operation Overview 1.1 RigMaster Overview The RigMaster is a hydraulically powered, rate-controlled slave arm with five functions: azimuth yaw, shoulder pitch, boom extend, wrist rotate, and jaw open/close. Movement of each function is achieved using a linear actuator, except the wrist, which uses a rotary actuator. The base, shoulder block, extension boom, and wrist/jaw are the major structural components of the slave arm. Linear actuators control movement of the azimuth, shoulder, boom-extend functions. The actuator body is pinned to one structural member and the actuator rod is pinned to the adjacent structural member. Extending or retracting the actuator rod causes one structural member to pivot or extend in relation to the other. A rotary actuator (gerotor) provides wrist rotation and a small linear actuator, inside the wrist, opens and closes the jaws. 2 Factors Affecting Slave Arm Performance RigMaster's performance specifications for lift, wrist torque and speed, and jaw grip force are based on the use of water-glycol (or an equivalent fluid type) at 3000 psi with an available flow of 5 gpm. At lesser pressures and flow rates, lifting capacity, wrist torque and speed, and jaw grip force will be reduced. Even with an adequately sized HPU, other conditions can reduce the pressure, viscosity, and flow of fluid delivered to the slave arm and diminish performance. These conditions include: extremely high or low fluid temperature fluid contamination plugged filters extreme hose lengths inadequate hose diameters improperly adjusted flow restrictors 011-0757 Page 15

Operation With a consistent hydraulic input, the ability of the slave arm to lift loads also varies with the changing leverage available within each joint and the position and distance of the load from the active joint. For example, the slave arm can lift 181 kg (400 lbs) when the boom is fully extended and up to 270 kg (595 lbs) when the boom is fully retracted. The wrist rotate function is affected by loads in a similar way, most noticeably when the axis of rotation is at or near horizontal: loads closer to the axis of rotation are more easily rotated than loads farther from the axis of rotation. Likewise, a balanced load of any size can be rotated easier than an unbalanced load. A severely unbalanced load can also cause an active actuator to stall and an inactive actuator to drift. The RigMaster slave arm is designed with safety factors well above of its specified load-handling capacity. If possible, avoid operational situations where the safety factors may be exceeded. These situations include: Collisions. Collisions while managing extreme loads. Collisions while managing extreme loads at the slave arm s mechanical limits. Managing extreme loads at the slave arm s mechanical limits. The best protection is anticipating risky situations and planning slave arm operations to minimize risks before manipulating any substantial load. 3 Normal Operation 3.1 Pre-Start Checks Before operating the slave arm, check the following: No personnel or objects are within the slave arm s range of motion. All hoses, fasteners, and fittings are connected and secure. Air has been purged from the hydraulic system if any lines or components have been disconnected for maintenance or repair. 3.2 Startup Procedure! WARNING Air in the hydraulic lines or components may cause very rapid or jerky movement of the slave arm. Before turning on hydraulic power, be sure that no personnel or equipment are within the slave arm s range of motion.! Caution If system pressure on the wrist drain (return) exceeds 350-600 psi above ambient, hydraulic fluid will be released into the environment from the relief valve. 1. Activate the hydraulic power unit. 2. Verify the following conditions: Page 16 3 Normal Operation 011-0757

The hydraulic supply pressure is 207 bar (3,000 psi). The hydraulic system return or tank pressure does not exceed 350 psi. No hydraulic fluid leaks from hoses, fittings, or components. Correct unsatisfactory conditions before proceeding. Operation 3. Purge the slave arm s hydraulic system of air by driving each linear actuator through its full range of travel several times. The slave arm is now ready for normal operation. 4 Controlling System Functions The RigMaster s base yaw, shoulder pitch, boom extend/retract, wrist rotate, and jaw grip are all controlled by the user s hydraulic control manifold. The rate and direction of hydraulic fluid flow determine the function performed. The table below lists each specific slave arm joint/actuator function and the movements that result from the application of hydraulic pressure. Label the hydraulic controls to match slave arm s functions and movements. To terminate operation, turn off or disable hydraulic power to the control manifold and slave arm. Actuator Function Type Nominal Mechanical Range Base yaw Linear 105 Shoulder pitch Linear 105 Boom extend/retract Linear 305 mm (12-in.) Wrist rotate Gerotor 360 Gripper, standard Linear 284 mm (11.2-in.) 011-0757 4 Controlling System Functions Page 17

Operation This page not used. Page 18 4 Controlling System Functions 011-0757

Troubleshooting In This Chapter: 1 Troubleshooting the Slave Arm... page 19 2 Troubleshooting Tables... page 20 1 Troubleshooting the Slave Arm Whole arm symptoms: If all slave arm actuators are unresponsive, sluggish, sagging, erratic, or hard-over, the cause will be found either in the HPU (hydraulic power unit) and equipment supplying hydraulic pressure or the manifold and equipment providing function control. Check supply and return pressures and the supply solenoid (if present) to quickly eliminate the HPU group of causes. Consult the appropriate OEM manual and the tables in this chapter for more specific troubleshooting information on the remaining group of causes. Single function symptoms: When a single function is unresponsive, sluggish, sagging, erratic, or hard-over, the cause will usually be either a single control component failure, including controller, manifold, control cabling, hoses, valves (lock, restrictor, relief), or in a faulty component directly associated with the function (such as actuator, fittings, seals). To eliminate the control component group of possible causes, determine whether or not controlled pressures are reaching the slave arm hoses for the affected function. The tables in this chapter provide more specific troubleshooting information about the function group. Multiple causes: Sometimes a symptom is the result of a group of causes. For example, a sluggish slave arm could be caused by one or more of the following causes: a marginal supply pressure, a faulty solenoid valve, a pinched supply hose, inadequately-sized control hoses, high return pressure, etc. Diagnosing all causes can be difficult: one cause may be intermittent or vary with temperature or time, one cause may initiate another, or no one cause alone may be sufficient to produce a recognizable symptom. If you correct one obvious cause, but the symptom doesn t change or there is only a marginal improvement, more detective work is in order. Start by inspecting the entire slave arm system for clues; get an accurate overall picture of its present condition: Is the HPU extra noisy or running hot? Are the supply and return pressures within specifications? Does the operation of other hydraulic equipment have an effect? 011-0784 Page 19

Troubleshooting Are all hoses clear and functional? Are the symptoms better or worse at startup? At shutdown? Is anything leaking? This is the time when familiarity with the look, feel, sound, and smell of correctly functioning components will help you spot something wrong. Test electrical and hydraulic outputs to eliminate functional components from suspicion. Replace or repair all marginal components and correct all questionable conditions as you go. The ultimate result will be a fully functional and reliable slave arm system. To help prevent the reoccurrence of multiple causes, maintain system components on a regular schedule and take corrective action at the first sign of a symptom. 2 Troubleshooting Tables The following tables are keyed to whole-arm troubleshooting and single-joint troubleshooting. In both these groups are individual tables for troubleshooting slave arm components exhibiting unresponsive, sluggish, erratic, sagging, or hard-over misbehavior. Each table describes a different symptom. Within each table are columns listing the possible causes and corrective actions. Symptoms Column The following terms are used in the Symptoms column to describe behavior of the entire manipulator Arm or a specific functions: Unresponsive: Does not respond to control input. Sluggish: Responds predictably but slowly to control input. Erratic: Responds jerkily or unpredictably to control input. Sagging: Fails to remain in position in absence of control input. Hard Over: Locked firmly against limit of mechanical travel. From the whole-arm or single-joint table collections select the specific symptom the slave arm or function is exhibiting. 2.1 Whole-Arm Troubleshooting Tables These tables are for troubleshooting when the entire slave arm exhibits a specific symptom. Note: A symptom may be the result of more than one cause or the cumulative affect of several marginal causes. For example, a sluggish slave arm may result from clogged filters, a pinched supply hose, inadequate pressure from HPU. SYMPTOM: Entire Slave Arm Unresponsive Possible Causes Corrective Action Very low or no hydraulic pressure and/or flow. Restore electrical power to HPU. Adjust or repair HPU. Adjust or repair supply restrictor valve. Hydraulic fluid low or below pump intake. Add hydraulic fluid. Page 20 2 Troubleshooting Tables 011-0784

Troubleshooting SYMPTOM: Entire Slave Arm Unresponsive (continued) Possible Causes Faulty supply or manifold solenoid valve. Blocked, pinched, or kinked supply hose. Pinched or kinked manifold control hoses. Electrical power failure to manifold controller Manifold controller, controller cabling, or termination failure. Load exceeds slave arm capacity. Clogged hydraulic filters. Adjust or repair solenoid valve. Clear blocked hose/reposition or protect hose to ensure free flow. Reposition or protect hoses to ensure free flow. Restore electrical power. Replace or repair controller, cable, or termination. Reduce load. Corrective Action Check visually-inspectable filters. Replace if clogged or approaching contaminant saturation. Replace all canister-type filters. SYMPTOM: Entire Slave Arm is Sluggish Possible Causes Low hydraulic pressure and/or flow. Hydraulic fluid low Partially blocked, pinched, or kinked supply hose. Excessive demand on HPU Pinched or kinked control hoses. Control or supply hoses not sized for distance from manifold. Hydraulic fluid dirty, contaminated or incorrect type or viscosity, temperature too high or too low to maintain viscosity. Clogged hydraulic filters. Load at or near slave arm capacity. Severe hydraulic leak. Corrective Action Adjust or repair HPU. Adjust or repair supply restrictor valve. Add hydraulic fluid. Unblock supply hose/reposition or protect hose to ensure free flow. Turn off other hydraulic equipment, reduce or stage HPU demand, or increase HPU capacity. Reposition or protect hoses to ensure free flow. Increase hose diameter to provide adequate pressure and flow to slave arm. Replace fluid if dirty, contaminated, or incorrect type or viscosity. Install heater or cooler to keep viscosity within specification. Check visually-inspectable filters. Replace if clogged or approaching contaminant saturation. Replace all canistertype filters. Reduce load. Use shoulder joint to lift heavy loads. Repair leak source. SYMPTOM: Entire Slave Arm is Operating Erratically Possible Causes Corrective Action Air in hydraulic lines. Purge hydraulic system. Load exceeds slave arm capacity. Reduce slave arm loading. 011-0784 2 Troubleshooting Tables Page 21

Troubleshooting SYMPTOM: Entire Slave Arm is Operating Erratically (continued) Possible Causes Corrective Action Hydraulic fluid dirty, contaminated or incorrect type or viscosity, temperature too high or too low to maintain viscosity. Clogged hydraulic filters. Low hydraulic fluid level (possibly intermittent). High HPU demand (steady or intermittent). Partially blocked, pinched, or kinked manifold supply hose. Pinched or kinked control hoses. Intermittent electrical power to HPU or manifold controller. Intermittent wiring fault in controller, cable, or manifold. Replace fluid if dirty, contaminated, or incorrect type or viscosity. Install heater or cooler to keep viscosity within specification. Visually inspect filters. Replace if clogged. Replace all canister-type filters on a regular schedule. Add hydraulic fluid. Increase HPU fluid capacity. Reduce or stage HPU demand, or increase HPU capacity. Clear hose/reposition or protect hose to ensure free flow. Reposition or protect hoses to ensure free flow. Correct power supply problem. Correct wiring fault. SYMPTOM: Entire Slave Arm Hard Over. Possible Causes Corrective Action Manifold controller or controller cable failure. Repair/replace controller or cable. Possible Causes Low hydraulic pressure. Low hydraulic fluid level. Severe hydraulic leak. SYMPTOM: Entire Slave Arm Sagging 2.2 Single Joint Troubleshooting Tables Corrective Action Adjust/repair HPU or supply restrictor valve. Add hydraulic fluid. Reduce or stage HPU demand, or increase HPU capacity. Add hydraulic fluid. Increase HPU fluid capacity. Repair leak source. SYMPTOM: Single Joint/Actuator Sluggish Possible Causes Joint load capacity near limit. Air in control line. Control hose pinched, kinked, or leaking. Partial failure of actuator seal or component. Stuck or faulty relief valve. Corrective Action Reduce slave arm loading. Use combination of joints to manipulate load. Purge hydraulic system. Reroute, protect, replace, or repair control hose. Repair or replace seal or component. Repair or replace relief valve. Page 22 2 Troubleshooting Tables 011-0784

Troubleshooting SYMPTOM: Single Joint/Actuator Sluggish (continued) Possible Causes (Wrist only) Incorrect wrist motor preload. (Wrist only) Excessive return/drain pressure. Corrective Action Service wrist joint and set correct motor preload. Check and clear return line. Check for internal leak in wrist and correct. Load capacity exceeded. SYMPTOM: Single Joint/Actuator Unresponsive Possible Causes Pinched, kinked, or leaking control hose. Faulty, stuck, or frozen relief valve. Faulty control switch, wiring, cable, or cable termination. Actuator failure. (Jaw only) Blocked wrist joint slip ring. (Wrist only) Incorrect wrist motor preload. (Wrist only) Faulty seal. (Wrist only) Excessive return/drain pressure. Corrective Action Reduce joint load. Use combination of joints to manipulate load. Reroute, protect, replace, or repair control hose. Repair or replace relief valve Repair or replace rate control switch, wiring, cable or cable termination. Repair or replace actuator. Repair or replace wrist joint slip ring. Service wrist joint and set correct motor preload. Replace seal. Check and clear return line/check for internal leak in wrist and correct. SYMPTOM: Single Joint/Actuator Sagging or Drifting Possible Causes Faulty actuator seal or component. Faulty relief valve. Faulty lock valve. Hydraulic leak. Extreme load on actuator. Corrective Action Repair or replace actuator seal or component. Repair or replace relief valve. Repair or replace lock valve. Repair leak source. Reduce load or balance load. Sagging linear actuator-driven joints or drifting roll joints are normal with extreme loads or unbalanced loads. SYMPTOM: Single Joint/Actuator Hard Over Possible Causes Corrective Action Controller or controller cable failure. Repair/replace controller or cable. Faulty actuator seal or component. Repair or replace actuator seal or component. 011-0784 2 Troubleshooting Tables Page 23

Troubleshooting Air in control line. SYMPTOM: Single Joint/actuator Operating Erratically Possible Causes Partial actuator failure. Control hose being pinched or kinked by operation. (Jaw only) Blocked wrist joint slip ring port. (Wrist only) Incorrect wrist motor preload. (Wrist only) Low hydraulic pressure. Purge hydraulic system. Repair or replace actuator. Corrective Action Reroute or protect hose to ensure free flow. Clear wrist joint slip ring port. Service wrist joint and set correct motor preload. Provide 1500-3000 psi nominal pressure. Wrist torque and breakaway RPM may become erratic as supply pressure drops. Page 24 2 Troubleshooting Tables 011-0784

Maintenance & Service In This Chapter: 1 Organization... page 25 2 Safety First!... page 26 3 Important Service Practices & Procedures... page 27 4 Basic Service Instructions... page 29 5 Special Service Instructions... page 50 1 Organization This chapter contains information on general maintenance and service instructions for components and assemblies of the RigMaster Slave Arm. Two types of service instructions are provided: Basic Service The Basic Service Instructions section on page 29, cover the less complex procedures shown below. They are followed by part lists and illustrations supporting the instructions. Base Assembly Replacement section on page 30 Shoulder Block Assembly Replacement section on page 31 Arm Segment Assembly Replacement section on page 31 Boom Replacement section on page 32 Wrist/Jaw Assembly Replacement section on page 33 Linear Actuator Assembly Replacement section on page 34 Linear actuator (6-in., base/shoulder) replacement Linear actuator (6-in., shoulder/arm segment) replacement Linear actuator (12-in.) replacement Linear actuator seal, bearing and o-ring replacement Hydraulic Hose Replacement section on page 36 Special Service Information The detailed Special Service Instructions section on page 50 cover the following components: Jaw Piston/Nose Block, 101-3853 Intermeshing Jaw, 101-3586 Wrist, 101-3587 011-0754 Page 25

Maintenance & Service 2 Safety First! Note: The following information is presented as a reminder of the safety issues present when maintaining or servicing a slave arm or manipulator system. It does not cover every possible safety risk and is not meant to replace existing worksite policies, standards, processes, and practices for protecting the safety of personnel working on or around this equipment. 2.1 Worksite Safety! WARNING HYDRAULIC AND MECHANICAL HAZARDS! Before any starting any service, maintenance, configuration, or testing of 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. 2.2 Maintenance & Service Safety Protect yourself! Before you perform any maintenance or service, read the following safety warnings. 2.2.1 Mechanical 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. 2.2.2 Hydraulic Safety! 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. Page 26 2 Safety First! 011-0754

Maintenance & Service Bodily contact with hot hydraulic fluids and sprays or ignited fluids, sprays, or mists. Falls caused by slipping on spilled fluids. 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. 2.3 Deck Testing! WARNING 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. 3 Important Service Practices & Procedures Important practices and procedures for successful manipulator system service: 011-0754 3 Important Service Practices & Procedures Page 27

Maintenance & Service Clean, degrease, and inspect disassembled parts. Replace damaged, worn, or broken 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, on components exposed to the hydraulic system the particles can be drawn into the hydraulic fluid 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.! Caution Excessive torque to 1/4-20 exterior fasteners (above 8 ft-lbs) can strip the hole threads in aluminum components. Follow torque specifications on engineering drawings and service instructions. 3.1 Maintenance Maintenance keeps your slave arm functioning safely and efficiently, helps reduce downtime and service expenses, and extends its service life. This section provides information on recommended maintenance practices and schedules. 3.1.1 Daily Maintenance and Inspections Daily inspections pinpoint real, potential, and emerging problems before they become catastrophic. Complete the following steps daily, or after every duty cycle, to keep your slave arm system in good operating condition: 1. (Submersible models) Thoroughly wash the exterior of the slave arm with fresh water. Remove any entrapped debris. If the slave arm will be out of service for more than a few days, coat exposed actuator rods with a film of hydraulic oil. 2. Inspect the slave arm for loose or missing fasteners (vibration and temperature cycles can cause fasteners to loosen). Replace or retighten fasteners, as needed. 3. Inspect the hydraulic hoses for abrasions or cuts. Repair or replace damaged hoses. Install hose protection or reroute hoses, if practical, to prevent future damage. 4. Inspect the slave arm for hydraulic leaks. Repair any leaks, replace lost fluid, and bleed air as needed. 5. If the slave arm has been subjected to severe service or collision, carefully inspect slave arm components. Verify that the slave arm joints, actuator rod pins, and pivot pins are intact and secure. Inspect the base and arm segments for bends, fractures or cracks, especially around the pin mounts. Inspect linear actuator bodies and shafts for dents, bends, or damaged components. Repair or replace damaged components. Page 28 3 Important Service Practices & Procedures 011-0754

Maintenance & Service 3.1.2 Scheduled Maintenance Regularly scheduled maintenance helps maintain the performance, efficiency, and service life of your slave arm. 1. Develop schedules of inspection, maintenance, and service that fit your slave arm's operating environment and duty cycles. Harsh service environments require more frequent intervals of attention. 2. Perform the inspections, maintenance, or service as scheduled. 3. Keep a log of all inspections, maintenance, and service. 4. Inspect components and observe performance frequently, starting with the first use of the slave arm. This will allow you to note initial conditions, track changes and wear, and set up maintenance and service schedules appropriate to your slave arm's operating environment and duty cycles. The table below contains a minimum maintenance schedule for your slave arm and should be used along with schedules supplied with your HPU and control manifold. Schedule Period After daily operation Every 100 operating hours Every 500 operating hours or per HPU documentation Every 2000 operating hours Every 2000 operating hours or per HPU documentation Every 2000 operating hours or every 3 years (whichever comes first) 4 Basic Service Instructions The Basic Service Instructions cover the procedures shown below. These instructions are supported by the Part Lists & Illustrations on page 14. Base assembly replacement Base Assembly Replacement section on page 30 Shoulder block assembly replacement Shoulder Block Assembly Replacement section on page 31 Arm segment assembly replacement Arm Segment Assembly Replacement section on page 31 Boom replacement Minimum Maintenance Schedule Maintenance Task See Daily Maintenance and Inspections section. Re-torque all external slave arm fasteners. Take a sample of hydraulic fluid and test for water and particulate contamination. Replace if contaminated. (seawater operation) Coat pivot pins and pivot pin bores with silicone grease such as DC-5. Check hydraulic tank fluid level. Clean/replace HPU suction strainers, fluid and breather filters. Replace worn or damaged actuator pins and bushings. Drain and replace hydraulic fluid (filter replacement fluid). Replace all actuator o-rings and seals. Lubricate with Dow Corning DC-4. Clean all o-ring grooves and surfaces. 011-0754 4 Basic Service Instructions Page 29

Maintenance & Service Boom Replacement section on page 32 Wrist/jaw assembly replacement Wrist/Jaw Assembly Replacement section on page 33 Linear actuator replacement Linear Actuator Assembly Replacement section on page 34 Linear actuator (6-inch, base/shoulder) replacement Linear actuator (6-inch, shoulder/arm segment) replacement Linear actuator (12-inch) replacement Linear actuator seal, bearing and o-ring replacement Hydraulic hose replacement Hydraulic Hose Replacement section on page 36 Each individual part identified in a service instruction step is followed by an item number in parentheses. This number corresponds to the item number of the part on the related part list. On the adjacent drawing, this same item number is placed in a circle, with a line drawn to the specific part. Note: The item numbers in this section are provided only for convenient reference between the service procedures that follow and their respective drawings and part lists. They do NOT match the item numbers in the part lists and engineering drawings provided in the Drawings & Part Lists chapter. Note: To get the right part when ordering, use the identification number shown in the Part No. column of the part list. Reference engineering drawings and part lists for the RigMaster slave arm and other sub-assemblies are located in the Drawings & Part Lists chapter. 4.1 Base Assembly Replacement For the base assembly replacement procedure, item numbers in parentheses refer to parts in Figure 1 and Figure 2. 4.1.1 Removing the Base Assembly Refer to Figure 1 for the following steps: 1. Disconnect RigMaster from its hydraulic power source. 2. Remove retaining rings (7), thrust bearings (9), and the extend pin (8) that hold the linear actuator (10) onto the base (3). 3. Remove the retaining rings (7), the thrust bearings (9), and the extend pin (8) that secure the linear actuator (10) to the shoulder block (5). Refer to Figure 2 for the following steps: 4. Remove the retaining ring (7), the thrust bearings (4), and the pivot pin (16) from the base (15) and shoulder block (8). The bearings (5) are not removable. Page 30 4 Basic Service Instructions 011-0754

Maintenance & Service 5. Remove the two screws (18) and the bracket (17) securing the hoses (not shown) to the base (15). 4.1.2 Installing the Base Assembly To install the base assembly, reverse the removal procedure. 4.2 Shoulder Block Assembly Replacement For the shoulder block assembly replacement procedure, item numbers in parentheses refer to parts in Figure 2 on page 40. 4.2.1 Removing the Shoulder Block Assembly 1. Disconnect RigMaster from its hydraulic power source. 2. Perform steps 3, 4, and 5 in the section on removing the base assembly. 3. Remove the retaining rings (7), the two bearings (4), the pivot pin (6), and the cable guide (19) from the shoulder block (8). The bearings (5) are not removable. 4. Remove the retaining rings (14), the thrust bearings (9), and the wrist extend pin (13) securing the linear actuator (11) to the shoulder block (8). 4.2.2 Installing the Shoulder Block Assembly To install the shoulder block assembly, reverse the removal procedure. 4.3 Arm Segment Assembly Replacement For the arm segment assembly replacement procedure, item numbers in parentheses refer to parts in Figure 3 on page 42. 4.3.1 Removing the Arm Segment Assembly 1. Disconnect RigMaster from its hydraulic power source. 2. Remove the retaining rings (13), the thrust bearings (14), and the extend pin (27) securing the linear actuator (15) to the shoulder block (5). 3. Remove the retaining rings (3), the thrust bearings (1), the cable guide (Figure 2 on page 40, item 19), and the shoulder pivot pin (4) securing the arm segment to the shoulder block (5). The bearings (2) are not removable. 4. Remove the eighteen bolts and washers (9, 28) securing the arm segment to the wrist/jaw (11). 5. Push out the wrist extend pin (12) securing the linear actuator (10) to the wrist/jaw (11).! Caution 1. Loosening or disconnecting any hydraulic hose may release hydraulic fluid under residual pressure. 2. Tag hydraulic fittings as you remove them in this procedure. Match tags when reconnecting. 6. Disconnect the five wrist hoses (16) from the base of the wrist/jaw (11). 011-0754 4 Basic Service Instructions Page 31

Maintenance & Service 4.3.2 Installing the Arm Segment Assembly To install the arm segment, reverse the removal procedure. Torque the bolts in step 4 to 28.5 Nm (21 ft-lbs). 4.4 Boom Replacement For the boom replacement procedure, item numbers in parentheses refer to parts in Figure 4 on page 43 and Figure 5 on page 45. 4.4.1 Removing the Boom For the following steps, item numbers in parentheses refer to parts in Figure 4. 1. Disconnect RigMaster from its hydraulic power source. 2. Support the wrist/jaw assembly (5). 3. Manually extend the boom (2) enough to provide access to the wrist-attaching hardware. 4. Remove the eighteen bolts and washers (3, 8) securing the wrist/jaw assembly (5) to the boom (2). 5. Push out the wrist extend pin (7) securing the linear actuator (4) to the wrist/jaw assembly (5).! Caution 1. Loosening or disconnecting any hydraulic hose may release hydraulic fluid under residual pressure. 2. Tag hydraulic fittings as you remove them in this procedure. Match tags when reconnecting. 6. Disconnect the five wrist hydraulic hoses (6) attached to the bottom of the wrist base (5). For the following steps, item numbers in parentheses refer to parts in Figure 5 on page 45. 7. Remove the two bolts (14), the retainer (26), the base extend pin (13), and the two actuator spacers (12) from the linear actuator (6). 8. Remove the two bolts (14), their washers (26), the base extend pin (13), and the two actuator spacers (12) from the linear actuator (11). 9. Remove the retaining rings (Figure 3 on page 42, item 3), the thrust bearings (Figure 3, item 1), and the shoulder pivot pin (Figure 3, item 4) from the arm segment and shoulder block (Figure 3, item 5). 10.Remove bolts (15) and their washers (27) around the perimeter of the side plate (1). Remove the side plate. 11. Carefully pull the boom (4) out of the arm segment. 4.4.2 Installing the Boom For the boom installation procedure, item numbers in parentheses refer to parts in Figure 5 on page 45. Page 32 4 Basic Service Instructions 011-0754

Maintenance & Service 1. Place one of the two short strip bearings (24) into the groove in the top plate (2), and the other into the groove in the bottom plate (2). 2. Place one of the long strip bearings (23) into the groove in the left side plate (3). 3. Place the scraper (22) over the end of the boom (4). Estimate the distance the scraper should be from the end of the boom by noting the location of the scraper grooves in the top, bottom, and side plates (1, 2, 3). 4. Place two of the corner bearings (25) into their grooves on the opposite end of the boom (4). 5. Holding the boom (4) and the corner bearings (25), line up the scraper (22) with the grooves in the top, bottom and left side plates (1, 2, 3), and carefully place the boom into the arm segment. 6. Place the remaining two corner bearings (25) into their slots at the end of the boom (4). 7. Place the remaining long strip bearing (23) into its groove in the right side plate (1). Secure it in place with Aqua Lube or a similar factory-approved lubricant. 8. Replace the shoulder pivot pin (Figure 3 on page 42, item 4) and the two thrust bearings (Figure 3, item 1) into the shoulder block (Figure 3, item 5) and arm segment. 9. Replace the two actuator spacers (12) and the extend pin (13) at the upper end of the linear actuator (6). 10. Install the fitting guide (74) and BHCS (75) to the rear hose fitting (15) of the 12 in linear actuator as shown in Detail B of Figure 5 on page 45. 11. Replace the two actuator spacers (12) and the extend pin (13) at the end of linear actuator (11) that is nearest the wrist (7). 12. Replace the right side plate (1), carefully inserting the scraper (22) into the plate s scraper groove. 13. Replace the two retaining rings (Figure 3 on page 42, item 3) onto the shoulder pivot pin (Figure 3, item 4). 14. Replace the four bolts (14) and the retainers (26) securing linear actuators (6, 11) in place. 15. Replace bolts (15) and washers (27) securing the right plate (1). Torque the bolts to 11 Nm (8 ft-lbs). 4.5 Wrist/Jaw Assembly Replacement Wrist and jaw components are most easily serviced or repaired when the wrist/jaw assembly has been removed from the slave arm. Detailed wrist, jaw, and noseblock service instructions are provided. See Special Service Instructions section on page 50. For the wrist/jaw assembly replacement procedure, item numbers in parentheses refer to parts in Figure 4 on page 43. 4.5.1 Removing the Wrist/Jaw Assembly! Caution 1. Loosening or disconnecting any hydraulic hose may release hydraulic fluid under residual pressure. 011-0754 4 Basic Service Instructions Page 33

Maintenance & Service Note: Tag hydraulic fittings as you remove them in this procedure. Match tags when reconnecting. 1. Disconnect RigMaster from its hydraulic power source. 2. Support the wrist/jaw assembly (5). 3. Manually extend the boom (2) enough to provide access to the wrist-attaching hardware. 4. Remove the eighteen bolts and washers (3, 8) securing the wrist/jaw assembly (5) to the boom (2). 5. Push out the wrist pin (7) securing the wrist/jaw assembly (5) to the linear actuator (4). 6. Disconnect the five wrist hoses (6) at their fittings where they are connected to the bottom of the wrist base (5). 4.5.2 Installing the Wrist/Jaw Assembly To install the wrist/jaw, reverse the removal instructions. Torque the bolts in step 4 to 28.5 Nm (21 ft-lbs). 4.6 Linear Actuator Assembly Replacement! Caution 1. Loosening or disconnecting any hydraulic hose may release hydraulic fluid under residual pressure. The linear actuators can be removed from the RigMaster without unbolting the arm segment from its mounting. However, since linear actuators provide part of the support skeleton for the arm, support the slave arm when you perform the following procedure. Note: Tag hydraulic fittings as you remove them in this procedure. Match tags to reconnect the appropriate fittings. 4.6.1 Removing the 6-Inch Base/Shoulder Linear Actuator For the base/shoulder linear actuator replacement procedure, item numbers in parentheses refer to parts in Figure 1 on page 38. 1. Disconnect the RigMaster from its hydraulic power source. 2. Remove azimuth hydraulic hoses (11, 12) from the side and bottom of the linear actuator (10). 3. Remove the retaining rings (7), the thrust bearings (9), and the extend pins (8) from the base and shoulder ends of the linear actuator (10). 4. Remove the linear actuator (10). 4.6.2 Installing the 6-Inch Base/Shoulder Linear Actuator To install the 6-inch base/shoulder linear actuator, reverse the removal procedure. 4.6.3 Removing the 6-Inch Shoulder/Arm Segment Linear Actuator For the shoulder/arm segment linear actuator replacement procedure, item numbers in parentheses refer to parts in Figure 5 on page 45. Page 34 4 Basic Service Instructions 011-0754

1. Disconnect the RigMaster from its hydraulic power source. Maintenance & Service 2. Disconnect the shoulder hose (18) from the linear actuator (11). 3. Remove the retaining rings (9), thrust bearings (10), and the extend pin (28) from the shoulder end of the linear actuator (11). 4. Disconnect the shoulder hydraulic hose (19) from the linear actuator (11). 5. Remove the bolts (14) and the retainer (26), the extend pin (13), and actuator spacers (12) from the linear actuator (11). 6. Remove the linear actuator (11). 4.6.4 Installing the 6-Inch Shoulder/Arm Segment Linear Actuator To install the 6-inch shoulder/arm linear actuator, reverse the removal procedure. Torque the bolts in step 5 to 217 Nm (160 ft-lbs). 4.6.5 Removing the 12-Inch Linear Actuator from the Arm Segment For the 12-inch linear actuator replacement procedure, item numbers in parentheses refer to parts in Figure 5 on page 45. 1. Disconnect the RigMaster from its hydraulic power. 2. Manually extend the boom (4) enough to provide access to the bolts (5) and the wrist pin (8). 3. Remove the eighteen bolts and washers (5, 29) securing the wrist/jaw assembly (7) to the boom (4). 4. Push out the wrist pin (8) securing the linear actuator (6) to the wrist (7).! Caution 1. Loosening or disconnecting any hydraulic hose may release hydraulic fluid under residual pressure. 2. Tag hydraulic fittings as you remove them in this procedure. Match tags when reconnecting. 5. Disconnect the five wrist hoses (17). 6. Remove bolts (15) and their washers (27) securing the bottom plate (2). Loosen bolts (16) securing the side and top plates (1, 2) of the arm segment just enough to remove the bottom plate (2). 7. Disconnect the extend hose (21) from the wrist end of the linear actuator (6). 8. Remove the bolts (14) and the retainer (26) securing the base extend pin (13) and the actuator spacers (12) to the arm. Carefully pull down the linear actuator (6), disconnect the extend hose (20), and then remove the linear actuator. 4.6.6 Installing the Linear Actuator on the Arm Segment To install the linear actuator, reverse the removal procedure. Torque the bolts in step 3 to 28.5 Nm (21 ft-lbs). Torque the bolts in step 6 to 11 Nm (8 ft-lbs). 011-0754 4 Basic Service Instructions Page 35

Maintenance & Service 4.6.7 Linear Actuator Seal, Bearing, & O-Ring Replacement For the linear actuator disassembly procedure, item numbers in parentheses refer to parts in Figure 6 on page 47 for the 6-inch linear actuator, and Figure 7 on page 49 for the 12-inch linear actuator. Disassembling the Linear Actuator! Caution 1. Loosening or disconnecting any hydraulic hose may release hydraulic fluid under residual pressure. 1. After removing the linear actuator from the arm segment, drain the fluid out of the linear actuator by pushing and pulling the actuator shaft (2) in and out of actuator body (13) several times. 2. Using some force, fully extend the actuator shaft (2). 3. Secure the end of the linear actuator body (13) in a vise, and using a modified 1 5/8-inch deep socket head wrench fitted over the rod end (3), loosen and remove the nose gland (4). 4. To separate the piston (1) from the shaft (2), insert a 1/2-inch ratchet wrench into the hole in the piston and unscrew the piston from the shaft. 5. Remove and replace the seals, bearings, and o-rings (9, 10, 11) on the nose gland (4) and the seals, fittings, and bearings (7, 8) on the piston (1). Assembling the Linear Actuator To assemble the linear actuator, replace all seals, bearings, and o-rings in the nose gland, and then reverse the disassembly procedure. Also install the fitting guide (74) and BHCS (75) to the rear hose fitting (15) of the 12 in linear actuator as shown in Figure 7 on page 49. 4.7 Hydraulic Hose Replacement For the hydraulic hose replacement, item numbers in parentheses refer to parts shown on Figure 4 on page 43 and sheet 1 of the RigMaster slave arm drawing 101-4991 located in the Drawings & Part Lists chapter. 4.7.1 Removing the Hydraulic Hoses! Caution 1. Loosening or disconnecting any hydraulic hose may release hydraulic fluid under residual pressure. 2. Tag hydraulic fittings as you remove them in this procedure. Match tags when reconnecting. See the slave arm drawing 101-4991 in the Drawings & Part Lists chapter for the following steps: 1. Disconnect the RigMaster from its hydraulic power source. Support the arm while disconnecting the hoses. 2. Remove azimuth hoses (9, 10) by unscrewing them from the linear actuator (48). Page 36 4 Basic Service Instructions 011-0754

Maintenance & Service 3. Remove the retaining rings (29), thrust bearings (40), and the wrist extend pin (27) securing the linear actuator (48) to the shoulder block (15). 4. Remove the shoulder hoses (7, 8) by unscrewing them from the linear actuator (48). 5. Loosen the bolts (33), securing the side, top, and bottom plates (12, 13, 14) in place, just enough to remove the bottom plate (14). If the bottom plate cannot be removed by loosening these bolts, it may be necessary to loosen the four large bolts (30). 6. Remove the extend hoses (5, 6) by unscrewing them from the linear actuator (2). See Figure 4 on page 43 for the following steps: 7. Manually extend the boom (2) enough to provide access to the wrist-attaching hardware. 8. Support the wrist/jaw assembly (5). 9. Remove the eighteen bolts and washers (3, 8) securing the wrist/jaw assembly (5) to the boom (2). 10.Remove the five wrist hydraulic hoses (6) by unscrewing them from the wrist/jaw assembly (5). 4.7.2 Installing the Hydraulic Hoses To install the hydraulic hoses, reverse the removal procedure. 1. Torque the bolts (item 33) in step 5 to 8 ft-lbs, and the bolts (item 30) in step 5 to 160 ftlbs (See sheet 1 of the slave arm drawing 101-4991 located in the Drawings & Part Lists chapter. 2. Torque the bolts in step 9 to 21 ft-lbs (see Figure 4 on page 43). 4.8 Part Lists & Illustrations This section contains the part lists and illustrations for all Basic Service Instructions section on page 29. Note: The illustration and part list item numbers in this section ( Part Lists & Illustrations ) are provided only for convenient reference to the item numbers in the preceding service instructions. They do NOT match the item numbers in the part lists and engineering drawings found in the Drawings & Part Lists chapter. 011-0754 4 Basic Service Instructions Page 37

Maintenance & Service Item No. Table 1 Also see Figure 1 Legend for Base Assembly Replacement Part Number Part Description 3 007-0181 BASE 1 5 007-0180 SHOULDER BLOCK 1 7 002-1042 RING, RETAINING, EXTERNAL 4 8 001-3030 PIN, EXTEND, WRIST 2 9 003-0099 THRUST BEARING, DIXON CWW16E24-3 4 10 101-1908 LINEAR ACTUATOR, 6" 1 11 006-0834 AZIMUTH HOSE C2 1 Qty. 12 006-0833 AZIMUTH HOSE C1 1 Base assembly replacement drawing Figure 1 Base assembly replacement Page 38 4 Basic Service Instructions 011-0754

Item No. Table 2 Also see Figure 2 Maintenance & Service Legend for Shoulder Block Replacement Part Number Part Description 1 101-1908 LINEAR ACTUATOR, 6" 1 4 003-0100 BEARING, THRUST, DIXON #CWW24E42-3 4 5 003-0025 BEARING, DIXON #CJ24E26-8 4 6 001-7288 PIN, PIVOT, SHOULDER 1 7 002-1041 RING, RETAINING, EXTERNAL 4 8 007-0180 BLOCK, SHOULDER 1 9 003-0099 THRUST BEARING, DIXON CWW16E24-3 4 11 101-1908 LINEAR ACTUATOR, 6" 1 13 001-3030 PIN, EXTEND, WRIST 2 14 002-1042 RING RETAINING, EXTERNAL 4 15 007-0181 BASE 1 16 001-3035 PIN, PIVOT, AZIMUTH 1 17 001-3116 HOSE GUIDE 1 18 002-1057 SHCS, 1/4-28 X 2-1/2, SS 2 19 001-3117 BRACKET 1 Qty. 011-0754 4 Basic Service Instructions Page 39

Maintenance & Service Shoulder block replacement drawing Figure 2 Shoulder block replacement Page 40 4 Basic Service Instructions 011-0754

Item No. Table 3 Also see Figure 3 Maintenance & Service Legend for Arm Segment Replacement Part Number Part Description 1 003-0100 BEARING, THRUST, DIXON #CWW24E42-3 2 2 003-0025 BEARING, DIXON #CJ24E26-8 2 3 002-1041 RING, RETAINING, EXTERNAL 2 4 001-7288 PIN, PIVOT SHOULDER 1 5 007-0180 SHOULDER BLOCK 1 6 002-0065 HHCS, 1/4-20 X 5/8, SS 2 7 001-7287 PIN, ACTUATOR, SLOTTED, 5.47 LONG 2 8 001-2119 SPACER, ACTUATOR 2 9 002-0052 NAS 6404U3 18 10 101-1909 LINEAR ACTUATOR 12" 1 11 101-3587 WRIST 1 12 001-2117 PIN, EXTEND, WRIST 1 13 002-1042 RING, RETAINING, EXTERNAL 2 14 003-0099 BEARING, THRUST DIXON CWW16E24-3 2 15 101-6361 LINEAR ACTUATOR, 6" 1 16 006-1594 HOSE ASSY, -4 JIC, 93-IN, 5 17 001-4342 RETAINER, PIN 1 27 001-3030 PIN, EXTEND, WRIST 1 Qty. 28 002-2151 WASHER, 1/2 OD X 9/32 ID,.078 THK, SS 18 011-0754 4 Basic Service Instructions Page 41

Maintenance & Service Arm segment replacement drawing Figure 3 Arm segment replacement Page 42 4 Basic Service Instructions 011-0754

Item No. Table 4 Also see Figure 4 Maintenance & Service Legend for Wrist/Jaw & Boom Replacement Part Number Part Description 1 No part number ARM SEGMENT 1 2 001-3029 SPAR (BOOM), 12" 1 3 002-0052 NAS6404U3 18 4 101-1909 LINEAR ACTUATOR, 12" 1 5 101-3587 WRIST 1 6 006-1594 HOSE ASSY, -4 JIC, 93-IN 5 7 001-2117 PIN, EXTEND, WRIST 1 Qty. 8 002-2151 WASHER, 1/2 OD X 9/32 ID,.078 THK, SS 18 Wrist/jaw and boom replacement drawing Figure 4 Wrist/jaw and boom replacement 011-0754 4 Basic Service Instructions Page 43

Maintenance & Service Table 5 Also see Figure 5 Legend for Shoulder & Arm Linear Actuator Disassembly Item No. Part Number Part Description 1 001-7285 RIGHT SIDE PLATE 1 2 001-2110 TOP/BOTTOM PLATE 2 3 001-7286 LEFT SIDE PLATE 1 4 001-3029 SPAR (BOOM) 1 5 002-0052 NAS 6404U3 18 6 101-1909 LINEAR ACTUATOR, 12" 1 7 101-3587 WRIST 1 8 001-2117 WRIST EXTEND PIN 1 9 002-1042 RETAINING RING, EXTERNAL 2 10 003-0099 THRUST BEARING, DIXON CWW16E24-3 2 11 101-6361 LINEAR ACTUATOR, 6" 1 12 001-2119 ACTUATOR SPACER 4 13 001-7287 BASE EXTEND PIN 2 14 002-0065 HHCS, 1/4-20 X 5/8, SS 4 15 002-0188 HHCS, 1/4-20 X 1.5, SS 13 17 006-1594 HOSE ASSY, -4 JIC, 93-IN 5 18 006-0832 SHOULDER HOSE 2A 1 19 006-0831 SHOULDER HOSE 2B 1 20 006-0829 BOOM HOSE C1 1 21 006-0830 BOOM HOSE C2 1 22 001-2588 SCRAPER, BOOM 1 23 003-0098 LONG STRIP BEARING 2 24 003-0097 SHORT STRIP BEARING 2 25 003-0096 CORNER BEARING 4 26 001-4342 RETAINER, PIN 4 27 002-0790 WASHER, 1/4 ID X.50 OD, SS,.032 THK 26 28 001-3030 PIN, EXTEND, WRIST 1 Qty. 29 002-2151 WASHER, 1/2 OD X 9/32 ID,.078 THK, SS 18 Page 44 4 Basic Service Instructions 011-0754

Maintenance & Service Shoulder and arm linear actuator disassembly drawing Figure 5 Shoulder and arm linear actuator disassembly 011-0754 4 Basic Service Instructions Page 45

Maintenance & Service Table 6 Also see Figure 6 Legend for 6-Inch Linear Actuator Assembly Linear Actuator, 6-in Stroke, 101-6361 Rev. B Item P/N Description Qty 1 001-1777 PSTN,LIN ACTR 1.75 1.0000 2 001-2105 SFT,LIN ACTR,6 IN 1.0000 3 001-1779 ROD END,LIN ACTR 1.0000 4 001-2703 GLAND,NOSE,LIN ACTR 1.0000 6 003-0114 BRG,PVT,LIN ACTR,T2 GAMMA 2.0000 7 003-0115 BRG,PSTN,LIN ACTR,T2 GAMMA 2.0000 8 004-0649 SEAL,PSTN,LIN ACTR,T2/3,GAMMA 1.0000 9 004-0669 O-RING,2-031,BUNA 90 1.0000 10 001-0893 BRG,ROD 2.0000 11 004-0650 SEAL,ROD,LIN ACTR,GAMMA 2.0000 12 004-0651 SCRAPER,ROD,LIN ACTR,T2 GAMMA 1.0000 13 007-0797 BODY,LINEAR,ACTUATOR,6 INCHES 1.0000 14 004-0082 O-RING,3-904 BUNA 90.0000 15 006-0108 FIT,HYD,-4,JIC,-4 ST,ELB,MALE 2.0000 16 006-0841 FIT,HYD,-4 JIC BHD,4WTX-SS 1.0000 17 001-9632 TUBE,EXTEND,ACTUATOR,LINEAR 1.0000 18 006-0842 NUT,FIT,JAM,-4,7/16-20,4WLN-SS 1.0000 40 101-6361-WI WORK INSTRUCTIONS.0000 46 010-0184 TOOL,INSTL,M,1.75.0000 47 010-0185 TOOL,SIZING,F,1.75.0000 48 010-0203 TOOL,SIZING,M,1.0.0000 49 010-0759 CROWSFOOT,OPEN END,1 5/8.0000 Page 46 4 Basic Service Instructions 011-0754

Maintenance & Service 6-Inch Linear Actuator Assembly drawing NOTES: 1. ITEMS LISTED BELOW TO BE TORQUED AS INDICATED: ITEMS: TORQUE: 75 240 21 1, 3 FOOT LBS. 4 15 FOOT LBS. FOOT LBS. 2 SERIALIZE IN LOCATION SHOWN. A 2 A PROPRIETARY THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO SCHILLING ROBOTICS. ANY REPRODUCTION, DISCLOSURE, OR USE OF THIS DOCUMENT IS EXPRESSLY PROHIBITED EXCEPT AS SCHILLING ROBOTICS MAY OTHERWISE AGREE TO IN WRITING. 15 14 REF 6 1 7 7 8 16 13 SECTION A-A RELEASED FOR PRODUCTION 15 17 18 2 9 4 6 10 11 10 11 12 3 A REV ZONE DESCRIPTION DATE BY APPR A RELEASED FOR PRODUCTION 7/27/07 PK SLW B - ADDED BALLOON 18, AND NUT IN MODEL AND UPDATE TUBE 17 WITH DIMENSION 11/16/07 VDM AL GENERAL NOTES NEXT ASSEMBLY INTERPRET DIMENSIONING AND TOLERANCING 101-3582 PER ASME Y14.5M-1994. IN ADDITION, S DENOTES REGARDLESS OF FEATURE SIZE. 101-4991 REMOVE ALL BURRS AND BREAK ALL SHARP EDGES ALL MACHINED SURFACES TO BE 63 RMS FINISH UNLESS OTHERWISE NOTED. DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED. DECIMALS.X ±.1.XX ±.02.XXX ±.005 TOLERANCES FRACTIONS ±1/16 DRAWN SIGNATURE DATE SLW 7/19/07 PROJECT DESIGNED AL 7/19/07 ANGLES CHECKED SCALE: DRAWING NUMBER.X ±30'.XX ±15' LEAD SLW TITLE LINEAR, ACTUATOR, 6 INCH WITH HARD LINE BRACKET 1:1 RIGMASTER SIZE SHEET REV 101-6361 C 1 1 B OF - Figure 6 6-Inch Linear Actuator Assembly 011-0754 4 Basic Service Instructions Page 47

Maintenance & Service Table 7 Also see Figure 7 Legend for 12-inch linear Actuator Assembly Linear Actuator, 12-in Stroke, 101-1909 Rev. B Item P/N Description Qty 1 001-1777 PSTN,LIN ACTR 1.75 1.0000 2 001-2103 SFT,LIN ACTR,12 IN 1.0000 3 001-1779 ROD END,LIN ACTR 1.0000 4 001-2703 GLAND,NOSE,LIN ACTR 1.0000 6 003-0114 BRG,PVT,LIN ACTR,T2 GAMMA 2.0000 7 003-0115 BRG,PSTN,LIN ACTR,T2 GAMMA 2.0000 8 004-0649 SEAL,PSTN,LIN ACTR,T2/3,GAMMA 1.0000 9 004-0669 O-RING,2-031,BUNA 90 1.0000 10 001-0893 BRG,ROD 2.0000 11 004-0650 SEAL,ROD,LIN ACTR,GAMMA 2.0000 12 004-0651 SCRAPER,ROD,LIN ACTR,T2 GAMMA 1.0000 13 007-0173 BODY,LIN ACTR,12IN,RIG 1.0000 14 004-0082 O-RING,3-904 BUNA 90.0000 15 001-15050 FIT,HYD,-4,JIC,-4 ST,ELB, MALE 2.0000 40 101-1909-WI WORK INSTRUCTIONS.0000 46 010-0184 TOOL,INSTL,M,1.75.0000 47 010-0185 TOOL,SIZING,F,1.75.0000 48 010-0203 TOOL,SIZING,M,1.0.0000 49 010-0759 CROWSFOOT,OPEN END,1 5/8.0000 Page 48 4 Basic Service Instructions 011-0754

Maintenance & Service 12-inch linear actuator assembly drawing Figure 7 12-inch linear actuator assembly 011-0754 4 Basic Service Instructions Page 49

Maintenance & Service 5 Special Service Instructions This section consists of detailed service instructions for the wrist and jaw assemblies. 5.1 Using the Service Instructions The first page of each Service Instruction provides information about the affected assembly, preparations that should be completed before beginning the service steps, and any materials, chemicals, standard and custom tools that will be needed. Special warnings, tips, and notes are included to help you perform the steps safely, correctly, and quickly. Within the instruction steps, part numbers are placed in parenthesis. Use these numbers to select parts from spares kits or stock, and to order parts from the factory. To reference the part number to the equivalent part on an engineering drawing (in the Drawings & Part Lists chapter), match up the part number on the accompanying part list. Then note the Item number. On the related engineering drawing the item number is placed in a circle, with a line drawn to the specific part. Before beginning any service, review the Safety First! section on page 26 and the Important Service Practices & Procedures section on page 27 of this chapter. 5.2 Start-up Following Service After Minor Service: Follow the pre-start checkout and start-up procedures in the Operation chapter. Be sure to replace any hydraulic fluid lost during maintenance or service and bleed air from the system. After Major Service: Follow Installation Checkout & Test in the Installation chapter before resuming normal 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. 5.3 Service Instruction List Jaw Piston/Nose Block, 101-3853................................ page 51 Intermeshing Jaw, 11.5-in, 101-3586............................. page 61 Wrist, 101-3587............................................... page 69 Page 50 5 Special Service Instructions 011-0754

Service Instruction Jaw Piston/Nose Block, 101-3853 Description Complete service instructions for the jaw piston/nose block 101-3853. Used in jaw assemblies: 101-4102, 4-Finger Intermeshing 101-4103, 6-in. Parallel-Acting 101-4104), 11.5-in. Intermeshing Estimated Time to Complete Reference Drawing 2 hour 101-3853 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 (002-3051) 9/16-in. socket Anti-seize, 1 oz. tube (002-1925) 19.05 mm (.750-in.) drill bit or drill rod Aqua Shield (002-0805) (optional) torque wrench capable of 8-135 Nm (5-100 Loctite 271 (002-0795) 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 (002-0359) pick tool razor blade or X-acto style knife Custom Tools Needed Terminology 010-0175 female sizing tool HHCS = hex head cap screw 010-0174 male installation tool HPU = hydraulic power unit 010-0214 sizing tool 010-0991 Jaw bolt torque tool Note: If you intend to change bearings (003-0050) in the nose block (101-4108), you will need to allow at least 1 hour for the Loctite 271 to harden. SERVICE INSTRUCTION 011 5011 Page 51

Note: If you are planning to replace the seals (004-0616 and 004-0650) 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 52 011 5011 SERVICE INSTRUCTION

Wrist Motor Jaw Piston 001-5395 T-bar Plate 001-5396 Bearings(4x) 003-0050 Nose Block 101-4108 Bolt 001-7520 or 001-5397 (fused) HHCS/Washers (4x) 002-1135/002-1439 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) 002-1135/002-1439 Wrist Motor Nose Block 101-4108 Figure 2 Removing nose block 1. Remove the four HHCS (002-1135) from the nose block (101-4108) (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 (101-3786). Remove Jaw Piston From Nose Block Refer to Figure 3 for this procedure. SERVICE INSTRUCTION 011 5011 Page 53

Figure 3 Jaw piston, seals, and bearings identification! Caution To remove seal (004-0616) 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 (001-5399) from jaw piston (001-5395). Set aside to inspect later. 2. Remove seal (004-0616) 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. Before removing the jaw bolt, place two tongue depressors between the T-bar plate and nose block to protect the anodized finish. 4. Place the nose block into tool 010-0991. (If this tool is not available use a soft-jaw vise.) 5. Push the jaw piston all the way into the nose block and, using a 11/16-inch socket, remove the bolt (001-7520 or 001-5397 [fused]) from the jaw piston. 6. Slide the t-bar plate (001-5396) 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 (001-5398) from the nose block (101-4108). Set the bearings aside to inspect later. Page 54 011 5011 SERVICE INSTRUCTION

! Caution To remove seals (004-0650), 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 (004-0650) 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 004-0542 and 004-0541 Bearing (2x) 001-5398 Seal (2x) 004-0650 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 (004-0542) and the backup ring (004-0541) 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 (001-5395) for damage and excessive wear. Replace the jaw piston if it is too worn or damaged. 3. Check the t-bar plate (001-5396) 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 (101-4108) 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 011 5011 Page 55

! 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 (001-5399) 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 (001-5398) 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 19.05 mm (0.750-in.) drill bit or a section of 19.05 mm (0.750-in.) drill rod, check all bearings (003-0050) in the nose block for wear. Insert the drill shank, or drill rod, into the bearing and check for play. A pivot pin (001-4551) 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) 004-0650 Figure 5 Installing seals into nose block 1. Lightly lube the O-ring/seal sets (004-0650) with O-ring lube and install them into the nose block (101-4108) (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 56 011 5011 SERVICE INSTRUCTION

2. Lubricate the bearings (001-5398) with EP grease and install them into the nose block (see Figure 6). Bearings 001-5398 Figure 6 Installing bearings into nose block 3. Lightly lube the O-ring (004-0542) and backup ring (004-0541) with O-ring lube and install them onto the nose block (see Figure 7). ARM JAW O-ring 004-0542 Backup Ring 004-0541 Figure 7 Installing O-ring and back-up ring onto nose block 4. If you are not replacing the bearings (003-0050) in the nose block (see Figure 1), skip to Assemble Jaw Piston on page 58. 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 280-300 F (140-150 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 011 5011 Page 57

Assemble Jaw Piston Refer to Figure 8 and Figure 9 for this procedure. Nose Block 101-4108 Jaw Piston 001-5395 Sizing Tool 010-0214 Figure 8 Installing sizing tool and jaw piston into nose block 1. Insert sizing tool (010-0214) in the end of the jaw piston (001-5395) (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 (101-4108) until the piston is completely inside the nose block (see Figure 8). Remove the sizing tool from the piston. 3. Before applying a torque to the jaw bolt, place two tongue depressors between the T-bar plate and nose block to prevent the T-bar from damaging the anodized surface. 4. Apply anti-seize (002-1925) to threads and the underside of the bolt head (001-7520 or 001-5397 [fused]). Insert the bolt through the t-bar plate (001-5396) and into the piston (Figure 9). Use tool 010-0991 to torque the jaw bolt. (If this tool is not available, use a soft jaw vice.) Push the t-bar/piston all the way into the nose block and torque the bolt to 217 Nm (160 ft/lbs). Remove nose block assembly from the vise. Note: Note that the slot in the t-bar aligns with the jaw piston. Page 58 011 5011 SERVICE INSTRUCTION

Figure 9 Installing jaw piston into nose block Install Jaw Piston Seal & Bearing Refer to Figure 10 for this procedure. Bearing 001-5399 Seal Set 004-0616 Jaw Piston 001-5395 Figure 10 Orientation of seal/o-ring on jaw piston 1. Slide the male installation tool (010-0174) onto the end of the jaw piston (001-5395). Lightly lube the seal/o-ring (004-0616) with O-ring lube and slide it onto the jaw piston as shown in Figure 10. 2. Install female sizing tool (010-0175) over the seal. Leave in place for 5-10 minutes, then remove the tool. 3. Lubricate the bearing (001-5399) 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 (002-1135) with Aqua Shield. Install and torque to 99 Nm (73 ft/lbs). SERVICE INSTRUCTION 011 5011 Page 59

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 Page 60 011 5011 SERVICE INSTRUCTION

Service Instruction Intermeshing Jaw, 11.5-in, 101-3586 Description Complete service instructions for the intermeshing jaw. Does not include servicing of jaw piston see Jaw Piston/Nose Block 101-3774 Service Instruction. Used in Jaw 101-4104. 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 (002-0805) 19.05 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 8-102 Nm (5-75 ft/lb) torque wrench Loctite 271 (002-0795) 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 (003-0050), you will need to allow at least one hour for the Loctite 271 to harden. Service Instruction 011 5025 Page 61

! 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 (001-7520 or 001-5397 [fused]) (see Figure 1). The bolt is not involved in removing the jaws. Bolt 001-7520 or 001 5397 [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 62 011 5025 Service Instruction

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) 001-2908 Base (2x) 101-4113 Jaw (4x) 001-2099 Nose Block 101-3853 HHCS and Washers (4X) 002-0277 and 002-0071 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 (002-0277) and washer (002-0071) from one end of each of the two pivot pins (001-4551) holding the base assemblies (101-4113) to the nose block (101-3853) (see Figure 3). Pivot Pin (2x) 001-4551 Nose Block 101-3853 HHCS and Washers (4x) 002-0277 and 002-0071 Figure 3 Removing the intermeshing jaw 2. Pull out each pivot pin and with attached the HHCS and jaw washer. Service Instruction 011 5025 Page 63

3. Remove each jaw and base assembly (001-2099 and 101-4113) from the nose block. Lift the jaw and base assemblies out so that the jaw actuator bearing (001-2908) slides off the t-bar plate (see Figure 2, on page 3). The four bearings (003-0006) 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) 003-0006 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 65. Jaw (4x) 001-2099 Nut (8x) 002-0063 Tie Rod (2x) 001-2122 Spacer (2x) 001-2100 Base (2x) 101-4113 Tie Rod (2x) 001-2121 Figure 5 Removing the jaws from the base 1. Remove one nut (002-0063) from one of the tie rods (001-2121 or 001-2122, whichever is applicable) and pull the tie rod out of the jaws (001-2099), spacers (001-2100, if applicable), and base (101-4011). Repeat for the other jaws. Page 64 011 5025 Service Instruction

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 (001-2121 or 001-2122, whichever is applicable) and threads with Aqua Lube. Install into the jaws (001-2099), spacers (001-2100, if applicable), and base (101-4011). 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 (001-4551) for signs of wear, galling, or other surface damage. Use a micrometer to measure any suspect pins and replace any that measure 18.94 mm (0.746-in.), or less at any point. 2. Inspect the actuator bearings (001-2908) 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 001-2908 Bearing (2x) 003-0006 Jaw Not Shown For Clarity Base (2x) 101-4113 Figure 6 Checking actuator bearing and base for wear and deformation 3. Inspect the four bearings (003-0006) for signs of wear or damage. Replace any bearings that show wear or damage. 4. Check all of the bearings (003-0050) in the bases for wear and excessive play by inserting a new pivot pin, an acceptable used pin, or the shaft of a 19.05 mm (0.750-in.) drill or drill rod (see Figure 7). Using the procedure in Replacing Jaw Bearings on page 66, replace any bearing that has too much play. Service Instruction 011 5025 Page 65

Bearings (2x) 003-0050 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 (003-0050) out of the base (101-4113). Note: Heating the base assembly with a heat gun, or in an oven, at approximately 140-150 C (280-300 F), will help soften the adhesive and remove the bearings. 2. Clean the bearing bore to remove all traces of Loctite 271. 3. 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 (001-2908) with Aqua Lube and place the actuator bearing into one of the bases. 2. Lubricate the bearings (003-0006) with Aqua Lube. 3. Insert a pivot pin (001-4551), with HHCS (002-0277) and washer (002-0071), into the nose block (101-3853) just far enough to install a bearing (003-0006) over the pin (see Figure 8, step A). Align the base (101-4113) in the nose block and push the pivot pin (001-1840) 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 66 011 5025 Service Instruction

Nose Block 101-3853 Pivot Pin 001-4551 Bearings 003-0006 S3586TP A B Base 101-4113 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 (002-0277) and install the HHCS and washer (002-0071) to the end of the pivot pin (001-4551). Torque the HHCS to 99 Nm (73ft/lb). 5. Repeat steps 4 to attach the other base. END OF SERVICE INSTRUCTION Service Instruction 011 5025 Page 67

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Service Instruction Wrist, 101-3587 Description Complete service instructions for the RigMaster wrist. Estimated Time to Complete Reference Drawing 3 hour 101-3587 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 Valvoline Val-Plex EP Grease 9/16-in. socket Loctite 271 (002-0795) 1-1/2-in. socket Loctite 242 5/32-in. allen wrench Aqua Lube (002-0805) 1/4-in. socket Dow Corning 55 o-ring lube or petroleum jelly 0-25 mm (0-1-in.) micrometer 6-in. vernier calipers flat blade screwdriver torque wrench capable of 8-102 Nm (5-75 ft/lb) torque wrench capable of 0-8.5 Nm (0-75- in./lb) new razor blade or X-acto style knife Custom Tools Needed Terminology 010-0237 jaw rod sleeve installation tool HHCS = hex head cap screw 010-0480 clamp nut tool SHCS = socket head cap screw 010-0236 bearing installation tool FHMS = flat head machine screw 010-0238 piston clamp tool PA=parallel-acting 010-0525 lip seal installation tool Service Instruction 011 5030 Page 69

Read and be familiar with all the steps and requirements of this service instruction before you start. Be Prepared!! Caution Avoid damaging protective coatings or surface treatments. Corrosion can result.! Caution Some slave arm components may retain hydraulic pressure, even when the HPU has been disabled. Bleed off residual pressure to the components being serviced by slowly loosening hydraulic hoses and/or other hydraulic fittings. In this Service Instruction, the wrist assembly is removed from the slave arm, and the jaw and noseblock assemblies are detached from the wrist assembly (other Service Instructions describe how to remove the jaw and noseblock assemblies). Note: The three seals (004-0803) located in the slip ring wrist housing (101-3784) are destroyed during removal. Be sure you have replacements on-hand. Note: The wrist motor cannot be reassembled without new crush washers (004-0576). These components are one use only items. Be sure that you have eight of these washers on-hand before starting this procedure. Disable the Slave Arm 1. Raise the arm to a comfortable working position and support non-locking functions. Note: bolts. Extend the boom fully for easy access to the wrist mounting 2. Turn off the power to the hydraulic power unit (HPU). 3. If your system is equipped with a compensation unit, isolate it from the slave arm. Remove Wrist From Slave Arm Refer to Figure 1 for this procedure. Page 70 011 5030 Service Instruction

Boom 001-3029 Linear Actuator 101-1909 Wrist 101-3587 Wrist Base 001-3033 Wrist Pin 001-2117 Washer (18x) 002-2151 HHCS (18x) 002-0052 Hydraulic Hose (5x) 006-1594 Figure 1 Removing wrist from boom! Caution When you remove the eighteen HHCS in step 1, the wrist will separate from the slave arm. Support the wrist before proceeding. 1. Support the Wrist. Remove the eighteen HHCS and washers (002-0052 and 002-2151) that secure the wrist (101-3587) to the boom (001-3029). 2. Push the wrist pin (001-2117) out of the wrist base (001-3033) and linear actuator (101-1909). Note: Before performing step 3, make sure the hydraulic hoses connected to the wrist base are identified. If the hoses are unmarked, label them with a permanent marker (see Figure 2). Figure 2 Hose designations 3. Disconnect the five hydraulic hoses (006-1594) from the wrist base. Service Instruction 011 5030 Page 71

Remove the Jaw Assembly Refer to Service Instruction 011-5025 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 Service Instruction 011-5011 to remove the nose block/jaw piston installed on your slave arm. Remove Wrist Base From Wrist Refer to Figure 3 for this procedure. Figure 3 Removing wrist base from wrist 1. Remove the four HHCS (001-4697) that hold the wrist base (001-3033) to the wrist (101-3372). Pull the wrist base off the wrist and remove the o-rings (004-0222 (5x) and 004-0017 (1x). Remove the Wrist Manifold From the Slip Ring Housing Refer to Figure 4, Figure 5, and Figure 6 for this procedure. Note: The wrist motor cannot be reassembled without new crush washers (004-0576). These components are one installation only items. Be sure that you have eight new washers on-hand before starting this procedure. 1. Remove the o-ring (004-0017) from the wrist manifold (101-3782) (see Figure 4). 2. Using a 5/32-in. allen wrench, loosen, but do not remove the SHCS (002-1133) on the clamping nut (001-5103) (see Figure 4). Using a 1-1/2-in. socket, or the clamping nut torque tool (010-0480), remove the clamping nut (001-5103) from the drive shaft (001-4438) (see Figure 4). 3. Remove the two thrust washers (003-0092) and thrust bearing (003-0091) from the drive shaft (001-3785). Page 72 011 5030 Service Instruction

HHCS 5 x 001-4557, 2 x 001-4448, & 1 x 001-4449 Valve Plate 001-1832 Gerotor 101-3373 Wrist Drive Shaft 001-4438 Clamping Nut 001-5103 HHCS 002-1133 Wrist Manifold 101-3782 Slip Ring Wrist Housing 101-3784 Figure 4 Basic wrist motor parts identification 4. Using a 1/4-in. allen wrench, remove the eight SHCS (001-4577, 001-4448, and 001-4449) from the wrist manifold. You will find that two SHCS (001-4448) may not come out. You may leave them in, for now. They will come out when you remove the wrist manifold (101-4759) in step 5. Remove the crush washer (004-0576) from each SCHS. Note: The three different SHCS types must be reinstalled according to the assembly drawing. The SHCS are not interchangeable. 5. Remove the wrist manifold from the wrist housing (101-3784) (See the Tip below). Note: Removing the wrist manifold may be difficult. 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 (002-1628) that hold the nose block to the wrist motor, hold the wrist motor in a soft-jaw vise (see Figure 5). Screw two HHCS (001-4697) that held the jaw motor to the wrist base into the wrist manifold (see Figure 5). Squeeze the screws together and evenly pull up to remove the wrist manifold (see Figure 5). Service Instruction 011 5030 Page 73

HHCS (2x) 001-4697 or longer (for disassembly purposes only) Wrist Manifold 101-3782 Wrist Housing 101-3784 HHCS 002-1628 Figure 5 Removing the wrist manifold from the wrist housing 6. Remove the o-rings (004-0445 and 004-0698) and the bushing (001-1984) from both of the SHCS (001-4448) that remained in the wrist manifold during step 4 (see Figure 6). Remove both SHCS from the wrist manifold. Remove the crush washers (004-0576) from each SCHS (see Figure 6). Wrist Manifold 101-3782 O-ring (2x) 004-0698 Washer (8x) 004-0576 O-ring 004-0110 Bushing 001-1984 SHCS (2x) 001-4448 Bearing 003-0011 O-ring 004-0698 Figure 6 Disassembling the wrist manifold 7. Remove the o-ring (004-0110) from the wrist manifold (see Figure 6). 8. If the bearing (003-0011)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 6). If not damaged, the bearing may remain in the wrist manifold. Final Wrist Motor Disassembly Refer to Figure 7, Figure 8, Figure 9, and Figure 10 for this procedure. 1. Remove the o-rings (004-0081, 004-0017, and 004-0413) from the valve plate (001-1832) (see Figure 7). Page 74 011 5030 Service Instruction

Valve Plate 001-1832 O-ring 004-0017 O-ring 004-0413 O-ring 004-0081 Figure 7 Removing valve plate o-rings 2. Using the two HHCS (001-4557) (used to secure the wrist manifold to the wrist housing - see Figure 4), remove the valve plate by lifting it up as shown in Figure 8. HHCS (2x) 001-4557 (for disassembly purposes only) Seal 004-0574 Driveshaft 101-3785 Valve Plate 001-1832 Wrist Housing 101-3784 Figure 8 Removing the valve plate 3. Remove the seal (004-0574) from the valve plate (001-1832), or the drive shaft (101-4438), depending on where the seal is when you remove the valve plate (see Figure 8). 4. Turn the slip ring wrist housing face down over a flat surface and allow the gerotor assembly (101-3373) and wear plate (001-2060) to fall out of the wrist housing. Set the gerotor assembly aside for later inspection (see Inspect the Gerotor Assembly on page 77). 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 (101-3373) is made up of precision parts. Handle these parts carefully. Do not damage the edges of any of the parts. Service Instruction 011 5030 Page 75

6. Remove the seal (004-0617), backup ring (001-4437), thrust washer (003-0074), and roller bearing (003-0013) from the wrist housing (see Figure 9). Driveshaft 101-3785 Back-up Ring 004-0574 Thrust Washer 003-0074 Seal 004-0617 Figure 9 Removing parts from wrist housing 7. Using a small pick tool, remove the bearing (001-4454) from the wrist housing (101-3784) (see Figure 10). Set aside bearing to inspect later. Seal (3x) 004-0803 Bearing 001-4454 Needle Bearing 003-0031 Wrist Housing 101-3784 Figure 10 Removing seals, bearing, and needle bearing from wrist housing! Caution The three seals (004-0803) will be destroyed during removal in step 8. If you don t have replacements, do not remove the seals. 8. Remove the three seals (004-0803) (see Figure 10) 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 (003-0031) is damaged, remove it from the wrist housing by evenly tapping it out using a small brass drift (see Figure 10). Page 76 011 5030 Service Instruction

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 the parts for corrosion, chipping, scuffing, and wear. The gerotor is assembled with factory-matched parts. If any part is damaged, you must replace the entire assembly. Refer to Figure 11 for this procedure. See Figure 11 for basic identification of gerotor parts (101-3373). Figure 11 Gerotor components! Caution The gerotor assembly (101-3373) 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 Service Instruction 011 5030 Page 77

unit. All parts of the gerotor assembly are factory-matched and cannot be interchanged with parts from other gerotors. 3. Inspect the inner rotor for wear. The coating on the inner rotor will degrade under extreme conditions and exhibit 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 4, Figure 6, Figure 9, and Figure 10 for this procedure. 1. Clean, degrease, and dry all parts. 2. Inspect the four bearings (003-0031, 003-0013, 003-0011, and 003-0091) for signs of wear or damage (see Figure 4 on page 73, Figure 6 on page 74, Figure 9 on page 76, and Figure 10 on page 76). Replace any damaged bearings. 3. Inspect the thrust washers (003-0074) for wear and galling (see Figure 9 on page 76). Replace washers if they show excessive wear, galling, or other damage. 4. Inspect the bearing (001-4454) for galling or damage (see Figure 10 on page 76). 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 12 and Figure 13 for this procedure. 1. If you removed the needle bearing (003-0031), install the bearing into the wrist housing (101-3784) (see Figure 12). 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) 004-0803 Bearing 001-4454 Needle Bearing 003-0031 Wrist Housing 101-3784 Figure 12 Installing bearings and seals into wrist housing 2. If the three seals (004-0803) were removed, install three new o-rings and seals in the wrist housing (see Figure 13 and Tip below). Be very careful to place the o-ring and seals in the correct orientation (see Figure 13). Lubricate the seal surfaces with EP grease. Page 78 011 5030 Service Instruction

Note: 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. 3. If the seals were not removed, lubricate the seal surfaces with EP grease. Bearing 001-4454 Wrist Housing 101-3784 Seal & O-ring 004-0803 Figure 13 Installation of o-rings, seals, and bearing into wrist housing 4. Lubricate the bearing (001-4454) with EP grease and install it into the wrist housing as shown in Figure 13. 5. Set aside the slip ring wrist housing assembly for later installation. Prepare Wrist Manifold for Assembly Refer to Figure 14 for this procedure. See Figure 14 for wrist manifold parts identification. Crush Washer (8x) 004-0576 Bearing 003-0011 O-ring 004-0110 Bushing 001-1984 SHCS (5x) 001-4577 SHCS (2x) 001-4448 O-ring 004-0698 SHCS (1x) 001-4449 O-ring (2x) 004-0698 Wrist Manifold 101-3782 Figure 14 Position of wrist manifold parts 1. If you removed the bearing (003-0011), install the bearing into the wrist manifold (101-4759). The printed edge of the bearing should show out the bottom of the wrist manifold. Pack the bearing with EP grease. Service Instruction 011 5030 Page 79

If you didn t remove the bearing, pack the bearing with EP grease. 2. Install new crush washers (004-0576) onto both SHCS (001-4448). Heavily lubricate the SHCS with EP grease and install both SHCS into the wrist manifold. 3. Lubricate the o-rings (004-0445 and 004-0698004-0698) and bushing (001-1984) with o-ring lube and install onto the two SHCS (001-4448) that you just installed in step 2. 4. Install a new crush washer (004-0576) onto the SHCS (001-4449). Lubricate the SHCS with EP grease and install into the wrist manifold (101-3782). Each of the three SHCS types must be placed in the correct wrist manifold bores. 5. Lubricate the o-ring (004-0110) with o-ring lube and install it into the groove of the wrist manifold (101-4759). Set the wrist manifold aside for later installation. Prepare Drive Shaft for Assembly Refer to Figure 15 for this procedure. Stand the drive shaft (001-3785) up on end, shaft up, to prepare it for installation into the wrist housing. Seal 004-0575 Bearing 003-0013 Thrust Washer 003-0074 Backup Ring 001-4437 Drive Shaft 101-3785 Figure 15 Wrist drive shaft parts 1. Lubricate the backup ring (001-4437) with o-ring grease and install onto the drive shaft. 2. Lubricate the seal (004-0575) with EP grease and install it onto the drive shaft. 3. Lubricate the thrust washer (003-0074) and the bearing (003-0013) with EP grease and install onto the drive shaft. Install Drive Shaft & Gerotor Into Slip Ring Wrist Housing Refer to Figure 16 and Figure 17 for this procedure. 1. Lubricate all the inner surfaces of the wrist housing (101-3784) with EP grease. 2. Lubricate all outer surfaces of the drive shaft (101-3785) with EP grease. 3. Use o-ring lube to generously lubricate the bores of the bolt holes in the slip ring wrist housing below the heli-coils. These bores are where the two, wrist oil supply, SHCS are placed. Page 80 011 5030 Service Instruction

4. Carefully slide the wrist housing onto the drive shaft (see Figure 16A). Seat the housing completely onto the drive shaft. A B Wrist Housing 101-3784 Drive Shaft 101-3785 Seal 004-0617 Figure 16 Instancing drive shaft assembly & seal to wrist housing 5. Lubricate the seal (004-0617) with o-ring lube, check orientation, and install it between the slip ring wrist housing and the drive shaft (see Figure 16B). Check orientation and push the seal in far enough not to damage it when you stand the housing up on that end. 6. Lubricate the wear plate (001-2060) with EP grease and install it onto the drive shaft (001-4438) (see Figure 17). 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. Wear Plate 001-2060 Drive Shaft 101-3785 Wrist Housing 101-3784 Figure 17 Installing wear plate into wrist housing Reassemble Gerotor Assembly Refer to Figure 18 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. Service Instruction 011 5030 Page 81

Drive Shaft 101-3785 Wear Plate 001-2060 Wrist Housing 101-3784 Figure 18 Assembling gerotor into wrist housing 1. Install the locating ring into the wrist housing (101-3784). Align the holes in the locating ring with the holes in the wear plate (001-2060). Be sure to install with the narrow groove facing up and the large groove facing down. 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 19 and Figure 20 for this procedure. 1. Lubricate the gerotor valve plate and lower it into position onto the drive shaft (101-3785) (see Figure 19). Carefully align the valve plate so that you cannot see rollers through any of the slots in the plate (see Figure 19). Page 82 011 5030 Service Instruction

! 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 correctly. Drive Shaft 101-3785 Gerotor Assembly 101-3373 Valve Plate Slots in Valve Plate Figure 19 Installing the valve plate to gerotor assembly 2. Install the valve plate (001-1832) onto the drive shaft (see Figure 20). O-ring 004-0017 Seal 004-0574 Drive Shaft 101-3785 O-ring 004-0413 O-ring 004-0081 Valve Plate 001-1832 Figure 20 Installing valve plate o-rings 3. Lubricate the seal (004-0574) with EP grease. Check seal orientation and, using the seal installation tool (010-0525), install it onto the drive shaft (see Figure 20). 4. Lubricate new o-rings (004-0081, 004-0017, and 004-0413) with o-ring lube and install onto the valve plate (see Figure 20). Service Instruction 011 5030 Page 83

Install the Wrist Manifold Onto the Slip Ring Wrist Housing Refer to Figure 4, Figure 6, Figure 21, and Figure 22 for this procedure. 1. Lubricate the upper edge of the wrist housing (101-3784) with o-ring lube. 2. Install the wrist manifold (101-3782) onto the wrist housing (101-3784). 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 21). Gently press the manifold into place.. Wrist Manifold 101-3782 Wrist Housing 101-3784 Pin Plug Holes Figure 21 Positioning the wrist manifold onto the slip ring wrist housing 3. Install new crush washers (004-0576) onto the five SHCS (001-4577) (see Figure 6 on page 74). Heavily lubricate the SHCS with EP grease and install them into the wrist manifold. Follow this procedure to torque the SHCS: Note: To hold the slip ring wrist housing steady while you torque the following SHCS, use the same procedure you used in step 5 of Remove the Wrist Manifold From the Slip Ring Housing on page 72. a. Screw the two SHCS (001-4448) to finger tightness. This will center the o-rings so that they will properly seal. b. Tighten all the other SHCS to finger tightness. c. Torque all eight of the SHCS to 15 ft/lb (20.3 Nm). d. Torque only the oil-return SHCS (001-4449) and the five standard SHCS (001-4577) to 24.4 Nm (18 ft/lb). e. Torque only the five standard SHCS (001-4577) to 32.5 Nm (24 ft/lb). 4. Lubricate the two thrust washers (003-0092) and bearing (003-0091) with EP grease and install them onto the wrist drive shaft (101-3785) (see Figure 22). Page 84 011 5030 Service Instruction