ati maintenance

Quick Change Installation and Operation Manual

Document #9620-20-B-310 Series Base Tool Changer-22

Pinnacle Park 1031 Goodworth Drive Apex, NC 27539 Tel: 919.772.0115 Fax: 919.772.8259 www.ati-ia.com Email: [email protected]

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4. Maintenance

WARNING: Do not perform maintenance or repair on Tool Changer or modules unless the Tool is safely

supported or docked in the tool stand, all energized circuits (e.g. electrical, air, water, etc.) are turned off,

pressurized connections purged and power discharged from circuits in accordance with the customers

safety practices and policies. Injury or equipment damage can occur with Tool not docked and energized

circuits on. Dock the Tool safely in the tool stand, turn off and discharge all energized circuits, purge all

pressurized connections, verify all energized circuits are de-energized before performing maintenance

or repair on Tool Changer or modules.

NOTICE:7KHFOHDQOLQHVVRIWKHZRUNHQYLURQPHQWVWURQJO\LQXHQFHVWKHWURXEOHIUHHRSHUDWLRQRIWKH7RROChanger. The dirtier the environment, the greater the need for protection against debris. Protection of the entire

EOAT, the Master, the Tool, and all of the modules may be necessary. Protective measures include the following:

1) Placement of tool stands away from debris generators.

2) Covers incorporated into the tool stands.

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4.1 Preventive Maintenance7KH7RRO&KDQJHUDQGRSWLRQDOPRGXOHVDUHGHVLJQHGWRSURYLGHDORQJOLIHZLWKUHJXODUPDLQWHQDQFH$YLVXDOLQVSHFWLRQDQGSUHYHQWLYHPDLQWHQDQFHVFKHGXOHLVSURYLGHGLQWKHWDEOHEHORZGHSHQGLQJXSRQWKHDSSOLFDWLRQ'HWDLOHGDVVHPEO\GUDZLQJVDUHSURYLGHGLQSection 8Drawings RIWKLVPDQXDO5HIHUWRPRGXOHVHFWLRQVIRUGHWDLOHGSUHYHQWLYHPDLQWHQDQFHVWHSVIRUDOOXWLOLW\PRGXOHV

Table 4.1Maintenance

Application(s) Tool Change Frequency Inspection Schedule

General Usage Material Handling Docking Station> 1 per minute Weekly

< 1 per minute Monthly

Welding/Servo/Deburring, Foundry Operations (Dirty Environments) All Weekly

Checklist

Mounting Fasteners

Inspect fasteners for proper torque, interferences, and wear. Tighten and correct as required. Refer to 7DEOH)DVWHQHU6L]H&ODVVDQG7RUTXH6SHFLFDWLRQV

Ball Bearings/Alignment Pins/Bushings/Bearing Race

Inspect for wear and proper lubrication. MobilGrease XHP222 Special a NLGI #2 lithium complex grease with PRO\EGHQXPGLVXOGHDGGLWLYHLVVXJJHVWHGIRUORFNLQJPHFKDQLVPDQGDOLJQPHQWSLQOXEULFDWLRQ2YHUWLPHlubricants can become contaminated with debris. Therefore, it is recommended to thoroughly clean the existing

grease and replace with new as needed. See 6HFWLRQ&OHDQLQJDQG/XEULFDWLRQRIWKH/RFNLQJ0HFKDQLVPDQGAlignment Pins.

Inspect for excessive alignment pin/bushing wear, may be an indication of poor robot position during pickup/drop-off. Adjust robot position as needed. Check tool stand for wear and alignment problems. To replace worn alignment pins,

refer to 6HFWLRQ$OLJQPHQW3LQ5HSODFHPHQW. Inspect for wear on the ball bearings/bearing race, may be an indication of excessive loading.

Sensors and Cables

Inspect sensor cable connectors for tightness, if loose tighten connections. Inspect sensor cables for any damage, cuts, and abrasion. Replace as necessary. Refer to 6HFWLRQ,QGLYLGXDO

/RFNDQG8QORFN6HQVRU$VVHPEOLHV5HSODFHPHQW and 6HFWLRQ57/6HQVRU&DEOH5HSODFHPHQW3URFHGXUH.Hoses

Inspect hose connection for tightness and leaks. If leaking or loose secure hose connection. Inspect hoses for interferences, abrasions, cuts, and leaks. Replace as required.

Electrical Contacts/Pin Block (Modules)

Inspect for damage, debris, and stuck/burnt pins. Clean pin blocks as required, refer to 6HFWLRQ3LQ%ORFNInspection and Cleaning.

Seals (Modules)

Inspect for wear, abrasion, and cuts. Refer to Section 14After repair is complete, return all circuits to normal operation (e.g. electrical, air, water, etc.).




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4.2 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins

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FRXSOLQJWKHFDPDQGWKHDOLJQPHQWSLQVFigure 4.1Cleaning Ball Bearings and Outer Surfaces of Male Coupling

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Figure 4.2Cleaning Ball Bearings, Cam and Inner Surfaces of Male Coupling




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Figure 4.3Check Ball Bearing Movement

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Figure 4.4Apply Lubricant to Locking Mechanism

Apply Lubricant on Inner

Surface of Male Coupling

Apply Lubricant on Alignment Pins

and Outer Surface of Male Coupling

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Figure 4.5Clean Tool Plate Surfaces of locking Mechanism

Clean Bushing Surfaces

Clean Bearing Race

Surfaces

.

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4.3 Pin Block Inspection and Cleaning

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Figure 4.6Inspect Master and Tool Pin Blocks

Tool Module Pin Block

Master Module Pin Block

Note: Pin blocks shown are for

illustration purposes only.

Weld DebrisWeld Debris

Blackened Pins

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NOTICE: Do not use an abrasive media, cleaners, or solvents to clean the contact pins. Using

abrasive media, cleaners, or solvents will cause erosion to the contact surface or pins to stick.

Clean contact surfaces with a vacuum and non-abrasive media such as a nylon brush (ATI Part

Number 3690-0000064-60)

Figure 4.7Clean Pin Blocks with a Nylon Brush

,QVSHFWWKH0DVWHUDQG7RROSLQEORFNVIRUVWXFNSLQVRUVHYHUHSLQEORFNGDPDJHFigure 4.8Stuck Pin and Pin Block Damage

Stuck Pins

Severe Pin Block Damage

Note: Pin blocks shown are for

illustration purposes only.

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