Orion 7F Rate Manip PDF

Remote Systems Products
Orion Manipulator System

Model No. 199–0229 & 199-0230
Position-Controlled, 6.5 Km Submersible
S/N______________________
Technical Manual
Document No. 011–9182
© - SCHILLING ROBOTICS - 2005
SCHILLING ROBOTICS, the SCHILLING ROBOTICS logo, and their frameworks are trademarks
and service trademark applications of SCHILLING ROBOTICS. Other names mentioned, regis-
tered or not, are the property of their respective companies.
Your comments about our products and technical manuals are invited. Please contact:
Schilling Robotics
201 Cousteau Place, Davis, CA 95616 • Telephone: (530) 753-6718 • Fax: (530) 753-8092
E-mail: sales@schilling.com • service@schilling.com • Web Site: http://www.schilling.com
TECHNICAL MANUAL REVISION LOG

PRODUCT Orion 7P, M/N 199-0229, 199-0230
MANUAL 011-9182
Sec. Page Description Rev Date

Original publication and revisions to -4 10/07/03
011-0569 p 41 Rev 101-3853 part list (101-4102,03, 04), F to G A 01/25/04
p 38 Rev 101-4102 dwg, C to D
p 45 Rev 101-4104 dwg , C to D
011-0565 p 20 Add forearm roll bleedpoint 12/14/04
011-0569 p 64, 77 Rev 101-3842 (101-4116/4117) part list: A to B 01/17/05
p 22 Rev 101-3786 dwg, B to C 05/03/05
p 30 Rev 101-3938, part list C to D
p 32 Rev 101-3939, part list C to D
p 28 Add 101-3796 part list & drawing
011-0568 011-5036 Add 101-3796 work instruction 05/06/05
011-0569 p 67, 80 Rev 101-3915 (101-4116, 4117) part list D to E B 05/31/05
p 68 Rev 101-3916 (101-4116) part list C to D
011-0569 p 44 Rev 101-4103 dwg D to E C 07/11/05
p 57 Rev 101-4106 dwg B to C
p 62 Rev 101-4107 dwg B to C
p 3 Rev 005-3600 dwg E to F
Page 0 of x • 011–9182
Table of Contents
Specifications
1 Slave Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Ranges of Motion . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Telemetry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Systems 199-0229, 199-0230 . . . . . . . . . . . . . . . . . . . 6
3.2 Dual Arm Systems 199-0232, 199-0233, 199-0250 . . . . . . . . . 7
3.3 Systems 199-0251, 199-0252 . . . . . . . . . . . . . . . . . . . 7
3.4 System 199-0254 . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 Master Controller . . . . . . . . . . . . . . . . . . . . . . . . . 9
7 Slave Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8 Password Information . . . . . . . . . . . . . . . . . . . . . . 10
9 Custom Features . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation
011–9182 • Page i
• Table of Contents
1 User-Supplied Equipment . . . . . . . . . . . . . . . . . . . . . 1
2 Installation Overviews . . . . . . . . . . . . . . . . . . . . . . 1
3 Slave Arm Configuration Options . . . . . . . . . . . . . . . . . 3

3.1 Forearm Roll Index . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Jaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Installing the Slave Arm . . . . . . . . . . . . . . . . . . . . . . 4
5 Installing the Slave Controller. . . . . . . . . . . . . . . . . . . 5

5.1 Hydraulic Power Connections . . . . . . . . . . . . . . . . . . . . 6
6 Installing the Compensator . . . . . . . . . . . . . . . . . . . . 7
7 Power and Telemetry Connections . . . . . . . . . . . . . . . . 9

7.1 Deck Test Connections . . . . . . . . . . . . . . . . . . . . . . . 9
7.2 Remote Operation Connections . . . . . . . . . . . . . . . . . . 10
8 Installing the Master Controller . . . . . . . . . . . . . . . . . 11

8.1 For Deck Testing . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.2 For Remote Operation . . . . . . . . . . . . . . . . . . . . . . 12
9 Installing the Junction Box . . . . . . . . . . . . . . . . . . . 13

9.1 For Deck Test Testing . . . . . . . . . . . . . . . . . . . . . . 13
10 Slave Controller Connections . . . . . . . . . . . . . . . . . 14

10.1 For Deck Testing . . . . . . . . . . . . . . . . . . . . . . . . 14
10.3 Telemetry Configuration . . . . . . . . . . . . . . . . . . . . . 15
11 Completing the Installation . . . . . . . . . . . . . . . . . . 15

11.1 First-Time Installations . . . . . . . . . . . . . . . . . . . . . 15
11.2 Repeat Installations . . . . . . . . . . . . . . . . . . . . . . . 16
12 Charging and Bleeding the Compensation Circuit . . . . . . . 17
13 First Startup Tutorial . . . . . . . . . . . . . . . . . . . . . . 20
Page ii of x • 011–9182
Table of Contents •
13.1 Using the Master Controller . . . . . . . . . . . . . . . . . . . . 21
13.2 Master Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
13.3 First Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
13.4 The Startup Process . . . . . . . . . . . . . . . . . . . . . . . 24
13.5 The DEPLOY Menu . . . . . . . . . . . . . . . . . . . . . . . . 27
13.6 The MAIN menu . . . . . . . . . . . . . . . . . . . . . . . . . 27
14 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
14.1 The OPERATE Menu . . . . . . . . . . . . . . . . . . . . . . . 29
14.2 Operating the Slave Arm . . . . . . . . . . . . . . . . . . . . . 30
15 The SET LIMITS and SET STOW Menus . . . . . . . . . . . . . 31

15.1 Entering the Password . . . . . . . . . . . . . . . . . . . . . . 31
15.2 Setting Slave Arm Movement Limits . . . . . . . . . . . . . . . . 32
15.3 Setting the Stow and Deploy Sequence . . . . . . . . . . . . . . 34
15.4 Testing the Movement Limits and Stow Sequence . . . . . . . . . 36
16 Submersible System Options . . . . . . . . . . . . . . . . . . 37
17 System Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 37
18 Moving Ahead . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Operation
1 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 The Control System . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 The Control Process . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Menu Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 Factors Affecting Slave Arm Performance . . . . . . . . . . . . . . 10
1.5 Avoiding Slave Arm Damage . . . . . . . . . . . . . . . . . . . . 11
2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1 Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2 Startup Sequence . . . . . . . . . . . . . . . . . . . . . . . . . 13
011–9182 • Page iii of x

2.3 DEPLOY Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4 Using the MAIN Menu. . . . . . . . . . . . . . . . . . . . . . . 16
2.5 Operation and Shutdown of the Slave Arm . . . . . . . . . . . . . 17
2.6 System Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 20
3 Performance Options . . . . . . . . . . . . . . . . . . . . . . 22
3.1 OPTIONS Menu . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2 SETUP Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4 System Fault and Error Diagnosis . . . . . . . . . . . . . . . . 33

4.1 Diagnosing Problems . . . . . . . . . . . . . . . . . . . . . . . 33
5 Adjusting the LCD Screen Viewing Angle . . . . . . . . . . . . 40
Troubleshooting
1 Diagnostic Help . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Screen-Displayed Symptoms . . . . . . . . . . . . . . . . . . . . 2
2.2 Master Arm Symptoms . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Slave Arm Behavior Defined . . . . . . . . . . . . . . . . . . . . 4
2.4 Entire Slave Arm Symptoms . . . . . . . . . . . . . . . . . . . . 5
2.5 Slave Arm Joint Symptoms . . . . . . . . . . . . . . . . . . . . . 6
3 System Fault and Error Diagnosis . . . . . . . . . . . . . . . . . 9

3.1 Control System Orientation . . . . . . . . . . . . . . . . . . . . . 9
3.2 Using the DIAGNOSTICS Menus . . . . . . . . . . . . . . . . . . 11
3.3 Diagnosing Problems . . . . . . . . . . . . . . . . . . . . . . . 11
3.4 Enabling and Disabling System Error Checking . . . . . . . . . . . 16
4 Electrical Component Diagnosis . . . . . . . . . . . . . . . . . 18

4.1 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2 Wireway Short and Open Circuits . . . . . . . . . . . . . . . . . 18
4.3 Diagnosing Servo Valve Failures. . . . . . . . . . . . . . . . . . 18
Page iv of x • 011–9182
4.4 Diagnosing Solenoid Valve Failure . . . . . . . . . . . . . . . . . 19
4.5 Diagnosing Potentiometer Failure . . . . . . . . . . . . . . . . . 19
4.6 Master Controller PC Board Diagnosis. . . . . . . . . . . . . . . . 20
4.7 Slave Controller PC Board Diagnosis . . . . . . . . . . . . . . . . 22
4.8 Customer Service Assistance. . . . . . . . . . . . . . . . . . . . 25
Maintenance and Service
1 Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Important Service Practices & Procedures . . . . . . . . . . . . 2
3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.1 Daily Maintenance and Inspections . . . . . . . . . . . . . . . . . 3
3.2 Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . 3
3.3 Hydraulic System Maintenance . . . . . . . . . . . . . . . . . . . 4
4 Junction Box Service . . . . . . . . . . . . . . . . . . . . . . . 5

4.1 Fuse Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 5
5 Master Controller Service . . . . . . . . . . . . . . . . . . . . . 5

5.1 Accessing Internal Components . . . . . . . . . . . . . . . . . . 5
5.2 Fuse Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 6
5.3 Adjusting the LCD Screen Viewing Angle . . . . . . . . . . . . . . 7
5.4 Master Controller EPROM Chip Replacement. . . . . . . . . . . . . 8
6 Shortening the Hydraulic Hoses . . . . . . . . . . . . . . . . . 9
7 Slave Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.1 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.2 Internal Access . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7.3 Replacing the Solenoid Filter . . . . . . . . . . . . . . . . . . . . 12
7.4 Replacing an Actuator Controller Board . . . . . . . . . . . . . . . 13
7.5 Accessing the Servo Valves, Jaw Bypass Valve, and Filter . . . . . . 15
7.6 Replacing a Servo Valve . . . . . . . . . . . . . . . . . . . . . . 16
011–9182 • Page v of x
7.7 Removing the Jaw Bypass Valve. . . . . . . . . . . . . . . . . . 17
8 System Adjustments. . . . . . . . . . . . . . . . . . . . . . . 18
8.1 Changing the System Telemetry Configuration . . . . . . . . . . . 18
8.2 Setting Servo Valve Voltage Offsets . . . . . . . . . . . . . . . . 22
9 Service Instructions . . . . . . . . . . . . . . . . . . . . . . . 24
9.1 Using the Service Instructions. . . . . . . . . . . . . . . . . . . 25
9.2 Start-up Following Service . . . . . . . . . . . . . . . . . . . . 25
Drawings & Part Lists

1 Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
– PAGE BREAK –
Page vi of x • 011–9182
Safety & Service Summary

Precautionary Notices
This manual provides precautionary notices which carry important information about
safety risks to personnel and damage to equipment while operating or maintaining
this equipment.
The form and significance of the notices are shown below.
! WARNING
A WARNING alerts you to a condition, situation, procedure, or action
where there is a risk of severe injury or loss of life. It may also
include instructions to help minimize or eliminate the risk.
! Caution
A CAUTION alerts you to a condition, situation, procedure, or action
where there is a risk of minor to moderate injury to personnel and/or
damage or destruction of equipment. 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 and equipment 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 equip-
ment represented in this manual.
– PAGE BREAK –
011–9182 • Page vii of x

This page not used.
Page viii of x • 011–9182

Security Password
Model No.____________________
Serial No._____________________
This is your privilege level 5 password:
1357
! Caution
Misuse of the menus accessible with this password can cause mal-
functions of the manipulator system, injury to personnel, and/or
damage to equipment. See the OPERATION chapter in your techni-
cal manual for complete information on how to use the level 5
password.
The password for privilege level 5 is set at the factory and cannot be changed. It pro-
vides access to all configurable system menus, including those for setting privilege
levels and passwords for other operators. See the OPERATION chapter in your tech-
nical manual for complete information on how to use the level 5 password.
This is your privilege level 1 through 4 temporary password: 0000
The temporary password “0000” is provided for short-term access to privilege levels 1
through 4 during installation and first startup. This password can be changed to meet
your security/privilege level requirements for normal operation.
Privilege level 0 is the default level, always available at system startup and requiring
no password. While permitting operation, it restricts access to almost all system con-
figuration menus and security features. An operator using a correctly configured
manipulator should need no higher privilege level. Levels above 0 require passwords
and allow access to specific manipulator system configuration menus.
Keep this document in a secure place.
011–9182 • Page ix of x
This page not used.
Page x of x • 011–9182
Specifications
In This Chapter:
Slave Arm .............................................................................page 1
Telemetry .............................................................................page 6
Electrical ...............................................................................page 6
Hydraulic ..............................................................................page 8
Environmental.......................................................................page 9
Master Controller ..................................................................page 9
Slave Controller ....................................................................page 9
Custom Features .................................................................page 10
1 Slave Arm
Model numbers:
Orion 7P. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101-4116
Orion 7PE (extended upper arm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101-4117
1.1 Functions
Table 1 shows the nominal range and actuator type for each slave arm function.
Table 1 Slave Arm Functions
Actuator
Function Nom. Range
Type
Azimuth yaw, left/right Linear 120°

Shoulder pitch, up/down Linear 120°
Elbow pitch, up/down Linear 120°
Forearm roll, CW/CCW Rotary vane 270°
Wrist pitch, up/down Linear 120°
Wrist roll, CW/CCW Gerotor 360° continuous
Jaw Options
011–0564 1 Slave Arm • Page 1

• Specifications
Actuator
Function Nom. Range
Type
Jaw, 4 in, parallel acting, 101-4106 Linear 3.8 in

Jaw, 6 in, parallel acting, 101-4107 Linear 6 in
Jaw, 6 in, parallel acting, 101-4103 Linear 6 in
Jaw, 6 in, 3-finger, intermeshing, 101-4105 Linear 6 in
Jaw, 7.8 in, 4-finger, intermeshing, 101-4102 Linear 7 in
Jaw, 12 in, 4-finger, intermeshing, 101-4104 Linear 11.5 in
Maximum reach, nominal (Az. pin to T-bar):

Std. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60.3 in. (153 cm)**
Extended-Reach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.8 in. (185 cm)**
Lift at full horizontal extension, nominal:
Std. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 lb (68 kg)*
Extended Reach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 lb (61 kg)*
Maximum lift, nominal:
Std. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550 lb (250 kg)*
Extended Reach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 lb (227 kg)*
Forearm torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240 ft/lb (326 Nm)*
Wrist torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 ft-lb (170 Nm)*
Wrist rotation speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35 rpm*
Jaw Grip force (at T-bar slot, fully open jaws). . . . . . . . . . . . . .1000 lbf (4448 N)*
Weight in air:
Std. model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 lb (54 kg)
Extended-Reach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 lb (61 kg)
Weight in sea water (submersible models):
Std. model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 lb (38 kg)
Extended-Reach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 lb (43 kg)
* Using Shell Tellus 32 at 3000 psi, 5 gpm
** Reach varies slightly with type of jaw
1.2 Ranges of Motion

Full mechanical ranges of motion are shown in Figure 1 and Figure 2
Note: The range-of-motion drawings show the maximum mechanical limits. You
can limit the range-of-motion by setting software travel limits for the individual
joints.
Page 2 • 1 Slave Arm 011–0564

Specifications •
Figure 1 Horizontal Ranges of Motion
Figure 2 Vertical Ranges of Motion

• Specifications
1.3 Dimensions
z Slave arm extended dimensions: see Figure 3 and Figure 4
z Slave arm stow dimensions: see Figure 5 and Figure 6
z Mounting dimensions: Figure 7
(60.3) [1531 mm]
(3.8) [97 mm]
(21.7) (19.7)
[550 mm] [499 mm] (1.8) [44 mm]
Figure 3 P Model Extended Dimensions
(72.8) [1848 mm]
(3.8) [97 mm]
(1.8) [44 mm]
(34.2) [867 mm] (19.7) [499 mm] (16.2) [412 mm]
Figure 4 PE Model Extended Dimensions
Page 4 • 1 Slave Arm 011–0564

Specifications •
Figure 5 Stow Dimensions
Figure 6 Stow Dimensions, Extended-Reach Models
z For minimum stow dimensions, the azimuth and forearm can be rotated until the
wrist/jaw assembly lays alongside the azimuth/base assembly.

• Specifications
Figure 7 Orion P & PE Mounting Dimensions
2 Telemetry
The factory set telemetry protocol is RS232. The system may also be operated using
RS422 (485). To change system protocol, see "Changing the System Telemetry Con-
figuration," in the “Maintenance & Service” chapter.
3 Electrical
3.1 Systems 199-0229, 199-0230

Junction Box 101-4017
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 to 260 VAC, 50/60 Hz
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 to 260 VAC, 50/60 Hz and ±12VDC
Page 6 • 2 Telemetry 011–0564

Specifications •
Master controller 101-4198-2
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 to 260 VAC, 50/60 Hz
Slave controller 101-3912

Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .±12 VDC
3.2 Dual Arm Systems 199-0232, 199-0233, 199-

0250
Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 to 260 VAC, 50/60 Hz
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 to 260 VAC, 50/60 Hz and ±12VDC

Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 to 260 VAC, 50/60 Hz
Slave controller 101-3912 & 101-3912-1

Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .±12 VDC
3.3 Systems 199-0251, 199-0252

Junction Box 101-4017-1
Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 to 260 VAC, 50/60 Hz
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 to 260 VAC, 50/60 Hz and ±24VDC

Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 to 260 VAC, 50/60 Hz

Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±24 VDC
3.4 System 199-0254

Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 to 260 VAC, 50/60 Hz
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±24VDC

Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±24VDCz
011–0564 3 Electrical • Page 7

• Specifications
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .±24VDC
3.5 Power Consumption

Table 2 Component Power Consumption
Watts
Component
Start Run
Master controller 60 15
Slave controller + solenoid 120 30
4 Hydraulic
Table 3
Approved Hydraulic Fluids for

Manipulators & Slave Arms*
Petroleum-based Fluids
Shell Tellus 32
Mobil DTE 24
Chevron Hydraulic AW 32
Texaco Rando 32
Castrol Hyspin AWS 32
Glycol-based Fluids
Houghto-Safe 620
Vegetable-based Fluids
Hydro-Safe ISO VG 32
* Use lower viscosity fluids in cold cli-
mates
Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 cSt to 200 cSt

Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5-5.0 gpm (5.7-19.0 l/min)*
Minimum operating pressure . . . . . . . . . . . . . . . . . 1500 psi minimum (103.5 bar)
Nominal operating pressure . . . . . . . . . . . . . . . . . . . 3000 psi nominal (207 bar)*
Relief valve cracking pressure . . . . . . . . . . . . . . . . . . . 3100-4100 psi (211-279 bar)
Return pressure, maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 psi (24.11 bar)
Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 microns (25 microns absolute)
Page 8 • 4 Hydraulic 011–0564

Specifications •
Control hose . . . . . . . . . . . . . . . . . . . . . 1/4-inch hose, 3000 psi working pressure
Control hose fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -4 JIC female
*Contact the factory for information about operation using other fluids, pressures,
and/or flow rates.
5 Environmental
Operating temperature . . . . . . . . . . . . . . . . . . . . . .-2° C to 60° C (28° F to 140° F)
Storage temperature. . . . . . . . . . . . . . . . . . . . . . . . . -15° C to 71° C (5° F to 160° F)
Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0% to 100% condensing
Ambient pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21,000 fsw (6500 msw)
6 Master Controller
Console:
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1 in. (48.5 cm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 in. (15.2 cm)
Height (less master arm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 in. (6.9 cm)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 lb (4.3 kg)
Master Arm:
The master arm is a kinematic replica of the Orion slave arm.
Telemetry Protocol:
Factory default . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .RS232
Optional setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS422 (485)
7 Slave Controller
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.4 in. (44.1 cm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6 in. (21.7cm)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 in. (20 cm)
Weight in air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 lb (11 kg)
Weight in sea water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 lb (8 kg)
011–0564 5 Environmental • Page 9

• Specifications
8 Password Information
Some control and configuration menus for this manipulator system are password
protected. A sheet listing factory-set passwords is located at the end of the Table of
Contents.
9 Custom Features
Custom features, if present, are described on the following page(s).
Page 10 • 8 Password Information 011–0564

Installation
In This Chapter:
User-Supplied Equipment......................................................page 1
Installation Overviews ..........................................................page 1
Slave Arm Configuration Options ..........................................page 3
Installing the Slave Arm .......................................................page 4
Installing the Slave Controller ..............................................page 5
Installing the Compensator...................................................page 7
Power and Telemetry Connections ........................................page 9
Installing the Junction Box .................................................page 13
Slave Controller Connections ..............................................page 14
Completing the Installation ................................................page 15
Charging and Bleeding the Compensation Circuit ................ page 17
First Startup Tutorial ..........................................................page 20
1 User-Supplied Equipment
The following services and equipment are required to complete the installation of the
slave arm:
z Electrical power sources. See the “Specifications” chapter for details.
z A hydraulic power source. See the “Specifications” chapter for details.
z All hoses and fittings for connecting hydraulic power to the slave controller
z Connectors and cables as needed for integration into long-line system
2 Installation Overviews
Figure 1 shows typical system components and how they are interconnected for deck-
testing. Figure 2 illustrates two configuration options for a long-line system.
011–0565 1 User-Supplied Equipment • Page 1

• Installation
Figure 1 Deck Test Configuration
Figure 2 Long-Line Configuration Options
Page 2 • 2 Installation Overviews 011–0565

Installation •
3 Slave Arm Configuration Options
3.1 Forearm Roll Index

Although the Orion range of motion is generally symmetrical, the forearm roll range
of motion (270°) is indexed at the factory for operation as the right-hand manipulator
system in a dual arm installation (unless ordered otherwise). As viewed from behind
the slave arm and looking down the forearm rotational axis, travel starts approxi-
mately at the 3 o’clock position and continues clockwise to approximately 12 o’clock
(see index position 1, Figure 3, Forearm Roll Index Options 1-8. on page 3). There is
no forearm travel between the 12 o’clock and 3 o’clock positions.
To accommodate left-hand installations and other custom installation requirements
the forearm range of motion (270°) can also be re-indexed to seven other orientations
(in 45° increments). All eight index settings are shown in Figure 3, Forearm Roll
Index Options 1-8. on page 3 (index position No.2 is the standard factory setting).
Service Instructions for re-indexing forearm roll are located in the “Maintenance and
Service“ chapter. The procedure should be done in a service facility before the slave
arm is permanently installed.
Figure 3 Forearm Roll Index Options 1-8.
3.2 Jaw
When hydraulics are disabled, whether through operator control or hydraulic failure,
a bypass valve in the slave controller causes the jaw relaxes its grip. Objects held by
the jaw may be released or dropped. If you prefer that the jaw lock when hydraulic
power is disabled, the bypass valve must be removed. See the “Junction Box Service”
on page 5 in the “Maintenance and Service“ chapter for details.
011–0565 3 Slave Arm Configuration Options • Page 3

• Installation
4 Installing the Slave Arm

1. Select a suitable mounting location (see the “Specification” chapter for slave arm
dimensions and range-of-motion).
2. Create a sturdy mounting platform that will provide a flat surface for the
minimum mounting footprint and three mounting holes for the azimuth base as
shown on Figure 4.
Note: A full-size 1:1 drilling template, drawing 050-0711, is located under the
Oversize Drawings tab.
Figure 4 Orion P & PE Mounting Dimensions
!Caution
Keep the forward edge of the mounting platform inside the desig-
nated limit to avoid interference with the shoulder actuator (see note
2, Figure 4).
Three 1/2-inch or M12 hex-head cap screws, flat washers, lock washers, and hex nuts are
required to attach the azimuth base to the mounting platform.
The platform mounting holes may be tapped to receive the fasteners if the platform mate-
Page 4 • 4 Installing the Slave Arm 011–0565

Installation •
rial and thickness are determined to be adequate. The material should engage a minimum
of 0.5-in. or 1.2 cm of the fastener threads.
3. Mount the slave arm to the mounting platform and torque as specified below.
— 1/2-inch fasteners: 60 ft-lb/81 Nm
— M12 fasteners: 50 ft-lbs/68 Nm
5 Installing the Slave Controller

The slave controller can be mounted in any orientation and up to 10 ft from the slave
arm. Use the four 3/8-16 threaded holes located in its base.
Note: Mount the slave controller as close to the slave arm as practical: the
response of the azimuth actuator (and the other linear actuators to a lesser degree)
is increasingly “springy” as the length of the extension hoses increases.
The hose extension kit (101-3959) can be used to extend the hose length beyond 10 ft.
However, it is important to remember that hose lengths longer than 20 ft will cause
pressure/flow irregularities and springiness in slave arm movements. Contact
Schilling Robotics for information about increasing the hose diameters to maintain
adequate pressure and flow.
1. Determine a suitable mounting location for the slave controller as close to the
slave arm as practical.
Note: A full size 1:1 mounting and clearance template, drawing 050-0755, is pro-
vided under the “Oversize Drawings” tab.
2. Prepare the platform. Fastener specifications and hole dimensions are shown in
Figure 5. Mount the slave controller. Coil and stow excess wireway cable lengths.
Figure 5 Slave Controller Mounting Dimensions
3. Connect the slave arm hoses, matching the hose codes.
011–0565 5 Installing the Slave Controller • Page 5

• Installation
Note: See the “Maintenance & Service”chapter for information on how to shorten
and reterminate a hydraulic hose with reusable fitting 006-1205 (OEM Aeroquip
63-190600-4).
4. Route the hoses back to the slave controller in their permanent configuration. If
you are using the full hose lengths, attach the hoses to the slave controller, matching
hose and fitting codes.
5. If the hoses will be shortened, mark the hoses at the point they will be cut and
disconnect them from the slave arm hose fittings.
6. Proceed to the next section.
Table 1
Hose Code/Function Designations
Hose Actuator Hose

Actuator
Code Movement Termination
AZIMUTH YAW, LEFT 0A EXTEND FEMALE -4 JIC

AZIMUTH YAW, RIGHT 0B RETRACT FEMALE -4 JIC
SHOULDER PITCH, UP 1A EXTEND FEMALE -4 JIC
SHOULDER PITCH, DOWN 1B RETRACT FEMALE -4 JIC
ELBOW PITCH, UP 2A EXTEND FEMALE -4 JIC
ELBOW PITCH, DOWN 2B RETRACT FEMALE -4 JIC
FOREARM ROLL, CCW 3A CCW FEMALE -4 JIC
FOREARM ROLL, CW 3B CW FEMALE -4 JIC
WRIST SWING, EXTEND 4A EXTEND MALE -4 JIC
WRIST SWING, RETRACT 4B RETRACT MALE -4 JIC
WRIST ROTATE, CCW 5A CCW FEMALE -4 JIC
WRIST ROTATE, CW 5B CW FEMALE -4 JIC
JAW, OPEN 6A EXTEND FEMALE -4 JIC
JAW, CLOSED 6B RETRACT FEMALE -4 JIC
FOREARM AUXILIARY 1 7A N/A FEMALE -4 JIC
FOREARM AUXILIARY 2 7B N/A FEMALE -4 JIC
WRIST DRAIN/1500 PSI C N/A FEMALE -4 JIC
RELIEF
WIREWAY COMPENSATION NONE N/A 1/4-IN TUBE
RECEPTACLE
(SWAGELOK)
5.1 Hydraulic Power Connections

Before you proceed, be sure the HPU supply and return ratings meet the hydraulic
specifications listed at the beginning of this chapter.
Page 6 • 5 Installing the Slave Controller 011–0565

Installation •
1. Connect the hydraulic supply hose to the fitting labeled “supply” on the slave
controller using a female -4 JIC fitting, and connect the hydraulic return hose to the
fitting labeled “return” using a female -6 JIC fitting.
Note: -4JIC = SUPPLY FITTING

-6JIC = RETURN FITTING
6 Installing the Compensator

The compensator, P/N 101-4470, provides hydraulic pressure compensation to cavi-
ties within the slave controller and slave arm wireways when the slave arm is sub-
merged in water. Because of the sring-loaded diaphragm, the compensated pressure
is slightly higher than the ambient water pressure.
Refer to Figure 6 and Figure 7.
1. Determine a mounting location for the compensator within hose-length of the
slave controller, and no more than 6 ft above it. A flat horizontal surface is preferable,
so that one of the 1/4-in NPT ports is at the high point (for the relief valve). If the
compensator must be sidewall mounted, a 1/2-in NPT port will be highest, and a
bushing will be required to relocate the relief valve.
Figure 6 Compensator Mounting Dimension
2. Drill the mounting surface to mate with the mounting bracket bolt pattern shown
in Figure 6.
011–0565 6 Installing the Compensator • Page 7

• Installation
!Caution
Do not use Loctite or similar compounds containing bisphenol A fuma-
rate on fittings or hardware contacting the polyurethane compensator
housings. They can cause brittleness and micro-cracking.
Nylok or “patch” type hardware and Teflon tape for fittings are rec-
ommended.
3. Mount the compensator using 6mm or 1/4-in stainless-steel hardware. Relocate

the bleed valve to the highest port as needed (see Figure 7).
4. Connect the compensator hose to either of the two ports on the compensator
body.
Compensator Ports
Bleed Valve
Figure 7 Compensator Ports
5. Connect the compensator hose to the -4 JIC male fitting on the slave controller
labeled “wire way comp.”
6. If you want to “dry-test” the compensation system, charge the compensator half-
full with air (the spring-loaded diaphragm will produce a pressure of about 1
atmosphere, 10 psi). Check for leaks by spraying all connections and compensated
components with a mild detergent or window cleaner. Active bubbles or foam
indicate a leak. Or, install a pressure gauge on the compensation system and check
the pressure gauge over a minimum of 2 hours. If a pressure drop occurs, check for
leaks using the method described above.
!Caution
Do not fill or purge the compensation system until the system is com-
pletely installed and safe operation has been tested and confirmed.
See “Completing the Installation” on page 15.
7. For information on charging the compensator, see “Charging and Bleeding the
Compensation Circuit” on page 17. Although the compensation system can be charged
now, the slave arm must be moved to several positions to bleed it. This is best
accomplished when the Orion 7P system is completely installed, tested, and safe
movement limits and stow/deploy positions have been set.
Page 8 • 6 Installing the Compensator 011–0565

Installation •
7 Power and Telemetry Connections

Long-line and deck-test connection options are discussed in section 7.1, “Deck Test
Connections” and section 7.2, “Remote Operation Connections” that follow. Imple-
mentation of these options start with “Installing the Master Controller” on page 11.
Telemetry Protocol
The factory set telemetry protocol is RS232. The system may also be operated using
RS422 (485). To change system protocol, see section 8.1, "Changing the System
Telemetry Configuration," on page 18 of the “Maintenance & Service” chapter.
Electrical Power
Manipulator system components may be powered by 12VDC, 24VDC, and/or 90-
260VAC. See the “Specifications” chapter for the power requirements of your system
components.
7.1 Deck Test Connections

The Orion 7P manipulator system includes all components needed for deck-testing or
local operation. The connections are shown in Figure 8.
Figure 8 Deck-Test Connection
011–0565 7 Power and Telemetry Connections • Page 9

• Installation
7.2 Remote Operation Connections
In typical ship-based applications, the slave arm and slave controller of the Orion 7P
Manipulator system are mounted to a remotely operated vehicle (ROV) and separated
from the master controller by hundreds to thousands of meters as shown in Figure 9.
Orion telemetry must be routed through your long-line telemetry system. Power must
be available on the ROV for the slave controller and in the control station for the mas-
ter controller. See the “Specifications” chapter for component power requirements.
Figure 9 Long-Line Power and Telemetry Options
Integrating the Orion manipulator system into a long-line system is usually done
using one of the options below:
Option 1
The preferred integration option is to use the bulkhead connector (005-1839) to link
the master controller telemetry with your long-line system and supply power to the
master controller. You will need to supply a Burton power/telemetry cable whip for
Page 10 • 7 Power and Telemetry Connections 011–0565

Installation •
connecting the slave controller to ROV telemetry and DC power. This option leaves
the junction box and deck test cable (101-4018) available for deck and bench testing.
Option 2
Plug the junction box AC cord into a 90-240 VAC source to power the master control-
ler. Use the spare plug connector (005-1838) to link telemetry from the junction box
to your long-line system. You will need to supply a Burton connector and whip for
connecting the slave controller to ROV telemetry and DC power. For deck testing, the
junction box must be disconnected from control station electrical power and teleme-
try.
Cutting the deck test cable (101-4018) to provide a whip is not recommended for
either option, as you will have no way to bench or deck-test the manipulator system.
Note: Bulkhead connector 005-1839 and plug connector 005-1838 are supplied
for making long-line connections.
8 Installing the Master Controller

The master controller (Figure 10), has no mount-
ing hardware, and can be placed on any flat, dry
surface. Connect its cable to the appropriate con-
nector on the junction box.
The master controller may be powered by 90-
260VAC or 24VDC power. See the “Specifica-
tions” chapter for details.
Figure 10 The Master Controller
!Caution
The master arm is a precision instrument. Never use it to lift or carry
the master controller by the master arm. Always support the master
arm, or rest it on the faceplate, when you carry the master controller.
Do not force master arm joint limits.
8.1 For Deck Testing

Connect the master controller cable to connector P2 on the junction box (see Figure
11).
011–0565 8 Installing the Master Controller • Page 11

• Installation
8.2 For Remote Operation
Option 1
Wire the bulkhead connector (005-1839) to connect with your long-line telemetry
system and provide power for the master controller (see the “Specifications” chapter
for power requirements).
Connector pin assignments are the same as shown for junction box connector P2 in
Figure 11 and Figure 12 (also see the 035- system schematic in the “Drawings & Part
Lists” chapter). Connect the master controller power/telemetry cable to the bulkhead
connector.
Not used in 24
VDC Systems
Figure 11 Junction Box Connector Pin Assignments, 90-260VAC/12 or 24VDC

Systems
Page 12 • 8 Installing the Master Controller 011–0565

Installation •
Figure 12 Junction Box Connector Pin Assignments, 24VDC Systems
Option 2
Connect the master controller power/telemetry cable to junction box connector P2
(see Figure 13).
9 Installing the Junction Box

The junction box uses no mounting hardware, and can be placed on any flat, dry sur-
face. See the “Specifications” chapter for information on input and output voltages.
9.1 For Deck Test Testing

Refer to Figure 13.
1. Connect the junction box AC power cord to a 90-260 VAC power source.
2. Connect the cable from the master controller to connector P2.
3. Connect the deck test cable (005-4018) to connector P3 and the Burton connector
on the slave controller.
011–0565 9 Installing the Junction Box • Page 13

• Installation
Figure 13 Junction Box Connections

Option 1
No connections are necessary. The junction box is used only for deck testing.
Option 2
1. Use the plug connector (005-1838) for linking telemetry from the junction box
connector P3 (Figure 13) to your long-line telemetry. Pin assignments are shown in
Figure 14.
Note: If you are using an auxiliary computer for system control, connect its
cable to the RS-232 port (P4).
2. Connect the master controller cable to connector P2.
10 Slave Controller Connections
10.1 For Deck Testing

Connect the deck test cable (005-4018) between the slave controller and the junction
box connector P3 (Figure 13).
101-3912 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±12 VDC
Page 14 • 10 Slave Controller Connections 011–0565

Installation •
101-4806 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±24 VDC

Options 1 and 2
A user-supplied Burton connector and whip is used to connect the slave controller
bulkhead connector to ROV telemetry and DC power (see the “Specifications” chap-
ter for power requirements). Connector pin assignments are shown in Figure 14.
Figure 14 J1 Deck Test Cable Wiring
10.3 Telemetry Configuration

The factory-set telemetry default protocol is RS232. The system can also be config-
ured to RS422/485 half duplex telemetry by changing jumper settings on:
z The opto-iso PC board in the master controller
z The base module/SCU PC board in the base module
For detailed instructions see the “Maintenance and Service” chapter: section 8.1,
"Changing the System Telemetry Configuration," on page 18.
11 Completing the Installation

After all the Orion 7P components are installed, the system is started to confirm oper-
ation, configure the stow/deploy and movement limits menus for safe operation, and
charge/bleed the compensation system. The process is discussed below, based on
whether this is a “first time” or repeat installation.
11.1 First-Time Installations

If this is your first installation of a Orion 7P manipulator system, we recommend
011–0565 11 Completing the Installation • Page 15

• Installation
completing the “First Startup Tutorial” on page 20. The tutorial takes you step by step
through the basics of operation, and explains how to configure slave arm stow points
and movement limits.
Once the slave arm has these menus configured for safe operation, return to section
entitled “Charging and Bleeding the Compensation Circuit” on page 17. Once the
compensation is functional, the Orion 7P manipulator system will be ready for nor-
mal service.
Refer to the “Operation“ chapter for complete information about the startup, configu-
ration, and operation of the manipulator system and the diagnostics for the control
system.
11.2 Repeat Installations

If you are already familiar with the installation and operation of the Orion 7P manip-
ulator system, complete the steps outlined below. Refer to the “Operation“ chapter, if
necessary, for additional information.
1. Complete the following checks before you start-up the manipulator system.
— No people or objects are within the slave arm's range-of-motion
— Installation is complete for all system components
— The electrical power source(s) meets the power requirements (see the “Specifica-
tions” chapter).
— Power and telemetry cable or conductor connections are sound and correct
— Slave arm hydraulic supply and return connections are secure and correct, and
meet the pressure requirements (see the “Specifications” chapter).
— (Submersible systems) Compensator hoses and fittings are sound and con-
nected
— All hoses are routed and secured to reduce the risk of snagging and kinking dur-
ing slave arm movement
— Installation supports are removed from the slave arm
2. Energize hydraulic power to the Orion 7P components.
3. Turn on electrical power to the Orion 7P components:
z Deck testing with the junction box:
— Turn on junction box, then the master controller.

z Long-line:
— Turn on power to slave controller, then master controller.
Page 16 • 11 Completing the Installation 011–0565

Installation •
!Caution
1. Air in hydraulic lines or components can cause very rapid or jerky
slave arm movement upon start-up. Sagging or physically moved
joints may return to their original positions.
Clear personnel and equipment from the slave arm’s range of motion
BEFORE startup!
2. The slave arm is equipped with a return relief valve on the upper
arm segment to protect components from excessive return pressure.
If system return pressure exceeds 500 psi hydraulic fluid will be
released from the relief valve.
3. 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 the filter and/or other equipment is running to
be sure that pressure does not exceeds 500 psi.
4. Set a stow sequence that will allow the slave arm to be safely stowed within its
environment.
a. See section 3.2.2, "The SET LEVEL Menu: Entering Passwords," on page 26 in
the “Operation” chapter.
b. See section 3.2.5, "Setting the Stow/Deploy Sequence," on page 29 in the
“Operation” chapter.
5. Set slave arm movement limits that allow safe operation of the slave arm within
its environment (see “Setting Slave Arm Movement Limits” on page 27 in the
Operation chapter).
6. Operate the system to test all control, programming, and slave arm functions.
7. When you have confirmed the Orion 7Pl manipulator system is functioning
correctly, proceed to “Charging and Bleeding the Compensation Circuit” on page 17,
below.
12 Charging and Bleeding the Compensation Cir-

cuit
This section provides instructions for filling and purging the compensator and com-
pensation system used with submersible models.
011–0565 12 Charging and Bleeding the Compensation Circuit • Page 17

• Installation
!Caution
1. Damage may occur to compensated components or enclosures if
the slave arm is submerged while large amounts of air remain in the
compensation system. Be sure the compensator is correctly installed
and air is bled from the compensation system as instructed in this
section.
2. Compensation fluid must be non-conductive. Conductive fluids will

damage electrical components.
The compensator itself holds slightly 2 liters (.053 gals.) of fluid. Although the
hydraulic and compensation systems are separate, it is preferable that the same fluid
be used in both applications, with this important exception: the compensation fluid
must be non-conductive.
Charging and Bleeding the Compensation Circuit

Charge and bleed the compensation system only after verifying that all compensated
components are functioning correctly and can be safely positioned for access to the
bleed fittings.
Damage may occur to compensated components or enclosures if components are sub-
merged while large amounts of air remain in the compensation system. Verify that
the compensator is correctly installed and air has been bled from all compensated
components.
1. Charge the compensator through one of its unused fittings.
!Caution
Charging pressures above 20 psig (1.4 bar) will cause the discharge
of compensation fluid or vapor from the relief valve.
2. Fill the compensator.

a. Pump fluid into the compensator until the yellow band on the piston
approaches the “full” band on the housing - do not overfill.
b. Crack the relief valve at the top of the compensator until compensation fluid
emerges without air.
Note: It will be necessary to continually fill the compensator as you bleed the
Orion manipulator compensation circuit.
3. Fill the slave controller.

a. Remove the plug or lift the relief valve on the cover to bleed the air (depending
on which component is the highest).
b. Reseal when compensation fluid emerges without air.
4. Bleed the wrist wireway (see Figure 15).
Page 18 • 12 Charging and Bleeding the Compensation Circuit 011–0565

Installation •
Hose Guard
001-5215
HHCS, 2x
002-0065
8 ft/lb (11Nm)
Wrist Wireway
Figure 15 Bleeding the Wrist Wireway
a. Remove the hose guard to gain access to the wrist fittings.

b. Loosen the wrist wireway fitting. Allow the compensator pressure provided
by the piston spring fill the wireway hose.
c. Retighten fitting when fluid emerges.
d. Replace hose guard.
5. Bleed the forearm roll wire housing (see Figure 16).
a. Loosen the socket-head bleed screws for the Wire Housing and Forearm Roll
Sensor Cable.
Wire Housing Bleed Screw
Forearm Roll Sensor

Cable Bleed Screw
Forearm & Wrist Roll
Cable
Forearm Wire Housing
Forearm Roll Sensor Cable
Figure 16 Bleeding the Forearm Roll Wireways
b. Retighten screws when fluid emerges.

6. Bleed the azimuth, shoulder, and elbow actuators (see Figure 17).
a. On the elbow actuator, loosen the Allen-head bleed screw located at the
opposite end of the block to which the wireway fittings are attached.
011–0565 12 Charging and Bleeding the Compensation Circuit • Page 19

• Installation
Typical Actuator
Bleed Screw
Figure 17 Bleeding the Azimuth, Shoulder, and Elbow Actuators
b. Retighten screw when fluid emerges without air.

c. Repeat steps a & b with the shoulder and azimuth actuators.
Note: It is not possible to bleed the wrist pitch actuator; the bleed screw is not
accessible.
7. Bleed any remaining air from the compensator and fill the compensator.
Note: DO NOT fill completely. Leave a small amount of diaphragm travel to

allow for thermal expansion.
Inspect compensation system components, hoses, and connections for leaks and cor-
rect all leaks.
13 First Startup Tutorial

The objective of this tutorial is to guide you through the first startup of your Orion
manipulator system. Following a a brief orientation to the control system, you will
start, operate, configure the LIMIT and STOW menus, and shutdown your system in
a series of hands-on exercises. If your Orion is submersible, you will then be prepared
to safely maneuver the slave arm as needed to fill and bleed the compensator system
(see “Charging and Bleeding the Compensation Circuit” on page 17).
After you have completed this tutorial, you will be ready to explore the remainder of
Orion's operational options, configuration menus, and system diagnostics and put
them to use in your applications. Complete information can be found in the “Opera-
tion” chapter.
If, at any time, the response of the slave arm or the master controller differs from this
tutorial, or you have unresolved questions about a procedure or step, STOP, disable
slave arm hydraulics, and refer to the appropriate section in the “Operation” chapter
for guidance and additional details. Return to this tutorial only when the difference or
question has been resolved and the system is functioning normally.
Page 20 • 13 First Startup Tutorial 011–0565

Installation •
13.1 Using the Master Controller
To direct the slave arm, the operator
moves the master arm (Figure 18), a func-
tional replica of the slave arm.
The operator configures and diagnoses
manipulator system operation by access-
ing appropriate master controller menus
and making changes through keystroke
inputs.
The front panel of the master controller,
shown in Figure 19, provides the following
control components:
zElectrical power switch
zDisplay screen
zFunction and control keys
zMaster arm
zAuxiliary jaw switch
Figure 18 Master Controller
LCD Screen
Power
Jaw Switch
Switc Master Arm
Control Keys
Power Switch
Power Switch
Function Keys
Figure 19 Master Controller Front Panel
Power Switch
The rocker switch at the left of the LCD screen controls electrical power for the mas-
ter controller only and is used mainly to reset the master controller when necessary.
Overall power to the master controller and the slave controller is controlled sepa-
rately by an electrical master switch on the junction box (unless an alternate power
supply has been provided for the slave controller).
The master controller power switch is normally turned off only after the slave arm has
011–0565 13 First Startup Tutorial • Page 21

• Installation
been moved to a safe position (stowed), frozen, and slave arm hydraulics have been
disabled.
Data Display Screen

An LCD screen in the center of the master controller front panel provides you with
information about system status and available operating options. Example screens
are used throughout this section. In most menus, the operational state of the slave
arm is shown in the upper right corner of each menu using the following designa-
tions:
z LIVE indicates the master arm is enabled and will produce corresponding move-
ments of the slave arm
z FRZ (freeze) indicates that the slave arm cannot be directed by the master arm.
Some menus open with the slave arm status in FRZ or the freeze button at the tip
of the master arm has been pushed (press the freeze button again to re-engage the
master arm)
z LOCK indicates that the arm is frozen and cannot be unfrozen from the current
menu. The manipulator control system automatically locks the slave arm for
menus or states in which the slave arm should not be operated. To unfreeze the
slave arm, you must move to another menu. Communications errors may also lock
the system to prevent damage
Auxiliary Jaw Switch

The auxiliary jaw switch is located opposite the master arm and provides the same
functions as the jaw bands on the master arm.
z Move switch forward = Jaw closes
z Move switch rearward = Jaw opens
Function and Control Keys

Eight function keys flank the screen as shown on Figure 19, Master Controller Front
Panel on page 21. These keys are used to select menus, enter programming data, or to
activate/deactivate functions. In each menu, the function of each active key is dis-
played on the screen beside the key. (If no key label appears on the screen, the corre-
sponding key is not used in that menu.)
The four control keys in the diamond pattern on the right side of the display have var-
ious uses, which are called out in the appropriate menus, startup, or warning screens,
or in the applicable section of the Operation chapter.
13.2 Master Arm

The master arm is a miniature replica of the slave arm. Each master arm joint or
function matches a similar joint or function on the slave arm (Figure 20, Master Arm
Tip Controls on page 23).

Installation •
The small size of the master arm allows you to easily control all functions with the
forearm, wrist, and fingers. These functions include:
z Slave arm freeze. Pressing the button on the end of the master arm freezes the
slave arm in its current position
z Slave arm joint movement. Flexing a master arm joint produces a corresponding
movement of the slave arm joint
z Forearm roll. The slave arm forearm rotates to the same degree (position) that the
outer forearm segment of the master arm is rotated
z Wrist rotate. Rotating the master arm wrist collar rotates the slave arm wrist. How
the slave arm wrist responds depends on the selected mode of operation
Figure 20 Master Arm Tip Controls
— RATE: rotating the collar from the null point initiates continuous slave arm wrist
rotation in the same direction, with its speed (rate) increasing with the degree
of collar rotation
— POS (position): the slave arm wrist rotates to the same degree (position) the col-
lar is rotated from its null point
z Jaw grip. Squeezing the textured jaw bands on the master arm wrist activates the
grip function (Figure 20). The precise way in which the jaws will respond to this
action depends on the current jaw mode setting.
— TOG (toggle): fully opens or closes the jaw
— POS (position): moves the jaw in either direction for as long as the jaw band is
squeezed
— CLMP (clamp): Provides jaw control similar to the POS mode. After grasping an
object, continuing to squeeze the jaw band for a brief period causes the jaw to
clamp down and LOCK with maximum force. To release the jaw, use the JAW
MD: key to select the TOG or POS mode
— LOCK: Locks the jaw in its current position and prevents the jaw from being
operated with the master arm. To escape from the LOCK mode, use the JAW

• Installation
Note: When hydraulics are disabled, whether through operator control or
hydraulic failure, a bypass valve in the slave controller causes the jaw relaxes its
grip. If you prefer that the jaw lock when hydraulic power is disabled, the bypass
valve can be removed. See the Special Service and Configuration” section in the
Maintenance and Service chapter.
13.3 First Startup

Complete the following checks before you start-up the manipulator system.
z No people or objects are within the slave arm's range-of-motion
z Installation is complete for all system components
z The electrical power source(s) meets the system power specifications
z Power and telemetry cable or conductor connections are sound and correct
z Slave arm hydraulic supply and return connections are secure and correct, and
meet the system pressure specifications
z (Submersible systems) Compensator hoses and fittings are sound and con-
nected
z All hoses are routed and secured to reduce the risk of snagging and kinking during
slave arm movement
z Installation supports are removed from the slave arm
!Caution
Activating hydraulic power without having completed all steps in the
pre-start checks and startup sequence can cause injury to personnel
and damage to equipment.
13.4 The Startup Process

To start up the manipulator system, follow the steps below:
1. Clear personnel and equipment from the slave arm's range of motion.
2. Turn on the HPU.
3. Turn on electrical power:
— Deck-Test configuration (Using the Junction Box and deck-test cable). Turn on
junction box, then turn on master controller.
— Long-line configuration (Using long-line telemetry and power) Turn on power to
the slave controller first. Then turn on power to the master controller.

Installation •
!Caution
If the slave controller is not turned on first, correct communications
may not be established and the slave arm may move unpredictably
when hydraulic power is enabled.
4. When you turn on the master controller, the message “Establishing

Communications with slave arm” will appear briefly.
Note: (If the master controller fails to establish communication with the slave
controller, a “fatal telemetry error” message will appear. Refer to the “Trouble-
shooting” chapter for more information on determining the cause of the malfunc-
tion.)
5. If the slave arm is at or near the Stow position, the Startup screen (“Startup
Screen“) will follow the “establishing communications” message.
SCHILLING ROBOTIC SYSTEMS

ORION-7P MANIPULATOR SYSTEM
--------------------------------
Startup Procedure:
1.Verify arm position.
2.Turn on HPU power.
3.Enable arm hydraulics.
4.Turn hydraulics off if
the slave arm moves from
its current position.
5.Press DOWN key to exit.
Hydr:OFF <8
--------------------------------
Version 014-0608 Rev. B
Figure 21 Startup Screen

--------------------------------
WARNINGS:
Arm not near a STOW point
(DEPLOY will be bypassed)
Exit <8
--------------------------------
Figure 22 WARNINGS: Screen

• Installation
(If the slave arm is not at or near the stow position, a warning screen (Figure 22) will fol-
low the “establishing communications” message indicating that the DEPLOY menu,
which normally follows the Startup menu, will not be displayed as part of the startup
sequence. Press EXIT <8 to continue to the Startup screen.
(The appearance of other warning screens or the system error screen indicates a commu-
nication or system problem. Refer to the section entitled “System Fault and Error Diag-
nosis” on page 9 in the Troubleshooting chapter.)
6. Proceed with the steps listed in the Startup screen.

a. Verify arm position. The slave arm should be at or near the stow point.
b. Turn on the HPU (hydraulic power unit) to provide pressure up to the slave
controller.
c. Enable hydraulic power to the slave arm by pressing the Hydr: <8 key. The
display will change to “Hydr: ON <8“ to indicate that the hydraulic isolation
valve in the slave controller is open. Observe the slave arm for any
movement with reference to the CAUTION! notices below:
Note: The elbow, forearm roll, wrist roll, and jaw joints are not equipped with
lockvalves and may sag or drift when hydraulic power is disabled. It is normal for
them to return to their last commanded or stow position when hydraulic power is
enabled. Be prepared for this movement: clear personnel and equipment from the
slave arm's range of motion BEFORE enabling hydraulics.
!Caution
The azimuth, shoulder, and wrist pitch joints are equipped with lock-
valves to maintain their positions during shutdown and regardless of
hydraulic or slave arm status. They should not move more than
slightly when hydraulics are enabled (unless they have been manu-
ally repositioned while the system was shutdown). If they begin mov-
ing more than a slight distance, immediately press 8> HYDR again to
disable hydraulic power to the slave arm until the cause can be deter-
mined.
d. Disable hydraulic power to the slave arm by again pressing the Hydr: <8
key. The display will change to “Hydr:OFF <8" to indicate that the hydraulic
isolation valve in the slave controller is closed.
e. Press the DN key to exit the startup menu (The bottom key of the four in the
diamond pattern to the right of the display and function keys). If the slave
arm was at or near the Stow position at startup, the DEPLOY menu (Figure
23) will appear.
Note: If a warning screen appeared before the startup menu screen indicating
the slave arm was not at or near the stow position, the DEPLOY menu will be
bypassed and the startup menu will exit to the MAIN menu (“MAIN Menu“).

Installation •
13.5 The DEPLOY Menu
DEPLOY
--------------------------------
Deploy <5
Stow <6
Pnt:IN Stop <7
EXIT <8
--------------------------------
After deploying, press EXIT key
Figure 23 DEPLOY Menu
The DEPLOY menu allows the operator to initiate a pre-programmed sequence of

positions that move the slave arm between a compact, protected position (Stow <6)
and an operational position (Deploy <5). The operator may also stop (Stop <7) the
deploy sequence, or bypass the DEPLOY menu altogether (EXIT <8). The stow/
deploy sequence can be changed using the SET STOW menu (see “The SET LIMITS
and SET STOW Menus” on page 31).
1. Do not use the DEPLOY menu at this time:
Note: If this is the initial installation, the Deploy and Stow positions have both
been factory set to approximate the position of the slave arm in the shipping case.
Unless the slave arm has been manually moved from its shipping position during
installation, the Stow and Deploy commands will have little effect.
!Caution
If this manipulator system was previously installed elsewhere, the
existing Deploy and Stow positions may be unsafe or unsuitable for
the slave arm’s new environment.
2. The stow commands will be reset a little later in this tutorial. Press EXIT <8 and
proceed to the MAIN menu screen.
13.6 The MAIN menu

The MAIN menu (Figure 24) provides access to five submenus for the operation,
setup, configuration, diagnosis, and shutdown of the manipulator system:
z 1> OPERATE: This menu is used to direct the slave arm with the master arm. Key
controls toggle between jaw operation modes, different slave arm scaling values,
and enable or disable slave arm hydraulics. Slave arm joints can be selectively fro-

• Installation
zen in the FREEZE submenu. All controls and menus are accessible at security
level 0
z 2> OPTIONS: Submenus are provided to configure slave arm speed and jaw speed,
and to scale the degree of slave arm movement relative to master arm movement.
All menus are accessible at security level 0
z 3> SETUP: Submenus are provided to configure slave arm movement limits, pro-
gram the stow/deploy sequence, set system error checking, set security levels and
passwords, and edit master controller memory locations. These submenus require
a password or a security level higher than 0 to use
z 4> DIAGNOSE: Used to view diagnostic information about the master arm, slave
arm and master controller, and to view details of system error conditions. All
menus are accessible at security level 0
z SHUTDOWN <5: Used to stow the slave arm and disable slave arm hydraulics in
preparation for shutting down the manipulator system. All menus are accessible at
security level 0
MAIN MENU LOCK

--------------------------------
1> OPERATE SHUT DOWN <5
2> OPTIONS
3> SETUP
4> DIAGNOSE
--------------------------------
UP key turns hydraulics OFF
Figure 24 MAIN Menu
The operational status of the slave arm is shown in the upper right hand corner of the
MAIN menu screen. Three states are possible:
z LIVE indicates the master arm is enabled and will produce corresponding move-
ments of the slave arm
z FRZN (freeze) indicates that master arm control of the slave arm is disabled and
the slave arm is idle (frozen). FRZ status occurs when opening certain menus or
after pushing the freeze button at the tip of the master arm. Press the freeze button
again to activate the master arm for control of the slave arm
z LOCK indicates that the slave arm is locked out of operation. The manipulator
control system automatically locks the slave arm for menus or states in which the
slave arm should not be operated. Communications errors may also lock the slave
arm to prevent abnormal operation
Operation is not possible in the MAIN menu so the slave arm status field shows

Installation •
LOCK.
Hydraulics in the MAIN menu are turned off by pressing the UP key (The top key of
the four in the diamond pattern to the right of the display and function keys)
Press 1> OPERATE to access the OPERATE menu (Figure 25).
14 Operation
14.1 The OPERATE Menu

Normal operation of the manipulator system takes place in the OPERATE menu. Use
the master arm for direct control of the slave arm. Use the master controller keys to
select among control options, enter the FREEZE submenu, control hydraulic power,
or exit back to the main menu. To prevent unintended or unexpected movement, the
OPERATE menu (Figure 25) always opens with the slave arm in the freeze (FRZ)
state.
OPERATE FRZN
--------------------------------
1> FREEZE Jaw Md:CLMP <5
2> Hydr:OFF Wrist Md:POS <6
3> Scale Tog:100%
EXIT <8
--------------------------------
Turn on hydraulics
Figure 25 OPERATE Menu
The OPERATE menu offers the following submenus for configuring slave arm perfor-
mance:
z 1> FREEZE: Displays a menu for freezing and unfreezing individual slave arm
joints
z 2> Hydr:(OFF/ON field): Toggles the state of the slave controller hydraulic isola-
tion valve between OFF and ON. 2> Hydr: must be ON to provide hydraulic power
to the slave arm
z 3> Scale Tog: (% field): Toggles between different movement scales (scaling of
master arm movement to slave arm movement)
The Freeze and Scale Tog menus are fully explained in the Operation chapter. They
will not be configured in this tutorial.
011–0565 14 Operation • Page 29

• Installation
z JAW MD: (TOG, POS, LOCK jaw mode field) <5: Toggles between the three jaw
operating modes:
POS (position): Squeezing the forward band causes the jaws to close until the band
is released. Squeezing the aft band causes the jaws to open until the band is released
— TOG (toggle): Squeezing the forward jaw band toggles the jaw between fully
closed and fully opened. The aft jaw band has no function in TOG mode
— CLMP (clamp): Provides jaw control similar to the POS mode. After grasping
an object, continuing to squeeze the jaw band for a brief period triggers the jaw
to clamp and LOCK with maximum force. To release the jaw, use the JAW MD:
key to select the TOG or POS mode
z EXIT <8: Exits to the MAIN Menu
14.2 Operating the Slave Arm
!Caution
Air in hydraulic lines or components may cause very rapid or jerky
slave arm movement upon startup. Joints that have sagged may
return to their original position. Clear personnel and equipment from
the slave arm's range of motion BEFORE startup.
1. Enable slave arm hydraulic power. Press the 2> Hydr: key (field changes to ON).
2. Verify that the status field (at upper right) reads FRZ. Grip the master arm, move
it from its parked position, and position it for comfortable operation of the slave arm.
Press the freeze button at the tip of the master arm (status field changes to LIVE): the
slave arm will now move to match the movements of the master arm.
3. Keep master arm movements small and slow until you develop a feel for the
response of the slave arm. Remember, you can use the freeze button at the tip of the
master arm to immobilize the slave arm, reposition the master arm to a more
comfortable position, and then push the tip button again to resume operation.
During initial operation of the slave arm:
z Use caution when approaching the mechanical travel limits of each joint and any
equipment within the range of motion
z At this time, do not use the slave arm to manipulate any objects
z Toggle to each of the jaw modes (Jaw MD <5) and test their operation
Page 30 • 14 Operation 011–0565

Installation •
15 The SET LIMITS and SET STOW Menus

Now is a good time to set the slave arm's movement limits and stow/deploy sequence.
Movement limits protect fixed objects and equipment within the slave arm's range of
motion and prevent running joints into their mechanical hard-stops. Setting a stow/
deploy sequence allows you to safely deploy and stow the slave arm with the push of a
button. The SET LIMITS and SET STOW menus are accessible from the SETUP
menu.
1. While in the OPERATION menu press the 2> Hydr: key to disable hydraulic
power.
2. Press the EXIT <8 key to return to the MAIN menu.
3. Press the 3> SETUP key to display the SETUP menu (Figure 26).
SETUP LOCK
--------------------------------
1> SET LIMITS MEMORY <5
2> SET STOW SECURITY <6
3> SET SV OFFSET DISPLAY <7
4> SET ERR CHECKS EXIT <8

--------------------------------
Figure 26 SETUP Menu
4. Before making changes within the SET LIMITS and SET STOW menus you must
first access security level 1 or higher by entering a locally or factory assigned
password.
15.1 Entering the Password

The master controller offers two password-protected security levels for accessing
menus that allow configuration of sensitive or critical system functions:
z Level 0 is the default level available at system startup. No password is required.
Full system operation is available at level 0, including access to error-checking and
diagnostic menus. A level 0 operator using a fully configured manipulator system
will usually need no higher security level
z Levels 1 through 4 require a locally-set password, and allow access to the SET
LIMITS, SET STOW, and SET SV OFFSET menus. (Levels 2-4 are functionally
equivalent to level 1 on this model and may be disregarded.)
011–0565 15 The SET LIMITS and SET STOW Menus • Page 31

• Installation
z Level 5 requires the factory-assigned password, and allows access to all configura-
tion and security menus. Level 5 access is required to set or change passwords for
security levels 1-4
1. From the SETUP menu, select 6> SECURITY to display the SECURITY menu.
2. From the SECURITY menu, press the 1> SET LEVEL key to display the SET
LEVEL menu (Figure 27). The cursor will appear in the Level: field, while the current
security level is displayed at the bottom of the screen). To change the current level,
press the Inc < 5 or Dec <6 until the level for which you have a password is displayed
in the Level: field. Press the Select <7 key to select (enter) that level.
SET LEVEL
--------------------------------
Level:1 Inc <5
Password:****
Dec <6
Select <7
Current user's
Privilege Level:0 EXIT <8
--------------------------------
Figure 27 SET LEVEL Menu
3. The cursor will then drop to the first digit of the Password: field, changing the
asterisk (*) to 0 (zero). Press the Inc <5 or Dec <6 key until the first number of the
four-digit password appears. Press the Select <7 key to enter the number and move
on to the next password number. Repeat until all four numbers of the password have
been entered.
4. When all four numbers are entered, press the Select <7 key again. The Current
User's Security Level: field will now show the new level.
5. Exit back to the SECURITY menu by pressing the EXIT <8 key. Exit from the
SECURITY menu to return to the SETUP menu.
15.2 Setting Slave Arm Movement Limits

The limits of motion of each slave arm joint (excluding the wrist and jaw) are config-
ured in the SET LIMITS menu).
Page 32 • 15 The SET LIMITS and SET STOW Menus 011–0565

Installation •
SET LIMITS FRZ

--------------------------------
COUNT:01 Last <5
LIMIT: Next <6

AZI LEFT
Teach <7
EXIT <8
--------------------------------
Figure 28 SET LIMITS Menu
To set movement limits for individual slave arm joints, follow these steps:
1. From the SETUP menu, press the 1> SET LIMITS key to display the SET LIMITS
menu.
!Caution
While the SET LIMITS menu is open, slave arm joints are capable of
full mechanical travel. Previously set movement limits (if retained) or
newly set limits will not engage until you have exited from the SET
LIMITS menu.
2. Unfreeze the arm by pressing the master arm freeze button.

3. This menu will display both the function count (in the COUNT: field) and the
function name (in the LIMIT: field) for the limit being set. The sequence of limits and
their corresponding limit numbers are shown in Table 2. (There is no movement limit
for the wrist or jaw.) As the table shows, the azimuth left limit is the first function to
be limited. The counter will display 01, while the LIMIT: field will display AZI LEFT.
Table 2 Slave Arm Joint Limits
Slave Arm Joint Limits
Limit
Joint Travel Limit
No.
Azimuth AZI LEFT 01

AZI RIGHT 02
Shoulder SHO DOWN 03
SHO UP 04
Elbow Pitch ELB DOWN 05
ELB UP 06

• Installation
Slave Arm Joint Limits (cont.)
Limit
Joint Travel Limit
No.
Forearm Roll ROL CCW 07

ROL CW 08
Wrist Pitch PIT RETRACT 09
PIT EXTEND 10
4. Unfreeze the arm by pressing the master arm freeze button. Move the slave arm to
the leftmost desired position for the azimuth function. To set this limit close to the
mechanical limit, move the azimuth gently to the limit, then slightly back. All
movement limits should be at least slightly less than the mechanical limits.
5. Press the Teach <7 key to enter that position as the limit (Figure 28, SET LIMITS
Menu on page 33. The counter will automatically increment to the next function
number.
6. Repeat steps 4 and 5 to set limits for the remaining joints. You may return to and
reteach a previous limit by pressing the Last <5 key until the desired limit appears on
the screen. You may skip ahead by pressing the Next <6 key instead of Teach <7. If
you skip or do not teach a joint limit, its existing limit setting will be retained when
you exit the SET LIMITS menu.
7. When all limits have been set, move the arm to any position inside the new limits
and press the EXIT <8 key. The new or retained movement limits will be saved. (If
you have positioned any joint outside these limits, the arm will move to a position
within the limits when the arm is unfrozen.)
8. Press the EXIT <8 key to return to the MAIN menu. Press the 3> SETUP key to
display the SETUP menu (Figure 26, SETUP Menu on page 31). Press the 2> SET
STOW key to display the SET STOW menu.
15.3 Setting the Stow and Deploy Sequence

The stow/deploy path is a sequence of up to 16 fixed slave arm positions (or points)
that the operator selects in the SET STOW menu (Figure 29). The manipulator sys-
tem calculates how to move the slave arm most efficiently between the selected
points. The stow/deploy sequence can be reset at any time to accommodate changes
in operational needs or the operating environment.
The stow/deploy sequence is used in the DEPLOY menu (automatically displayed as
part of the startup process) and the SHUTDOWN menu. In either menu, when the
Deploy <5 key is pressed, the slave arm moves automatically from the Stow position
to the Deploy position; when the Stow <6 key is pressed, the slave arm automatically
first moves to the Deploy position and then to the Stow position.
In planning a stow/deploy sequence for your manipulator system, the following fac-

Installation •
tors should be considered:
z You can issue a command to stop the slave arm at any time during the sequence,
but the slave arm will continue to move until it reaches the next programmed point
in the sequence. A stow/deploy sequence with more points can be stopped sooner
z The control system calculates how to move the slave arm most efficiently from one
point to the next in the sequence, so using just a few points leaves much of the
slave arm movement up to the control system. If the slave arm is mounted in a
working environment with fixed obstacles or equipment, be sure to program
enough points into the sequence to guide the slave arm around them
The current stow/deploy sequence can be changed in the SET STOW menu (Figure
29).
SET STOW FRZ

--------------------------------
POINT:03 Last <5
Next <6
Teach <7
4> Number of points:10 EXIT <8

--------------------------------
Taught point 02
Figure 29 SET STOW Menu
To set a new stow/deploy sequence, follow these steps:

1. Verify you are in the SET STOW menu (If you have turned off the master
controller since setting the movement limits, you must reset the security level to 1 or
higher as directed in “Entering the Password” on page 31.
2. Press the 4> Last Stow Point: key to increment to the desired number of total
stow points. Select any number between 02 and 16 (After 16 the number defaults to
02).
3. Unfreeze the slave arm by pressing the master arm freeze button.
!Caution
Movement points in the stow/deploy sequence can be selected from
the slave arm's full mechanical range of motion. Limits to slave arm
movement programmed in the SET LIMITS menu do not apply slave
arm movements while setting or running a stow/deploy sequence.
4. With the POINT: field at 01 (corresponding to the Stow position) move the slave
arm to the desired position. Press the TEACH <7 key to save the position (only the

• Installation
position of the arm is entered, not the time or number of motions needed to get it
there). The POINT: field will automatically increment to the next point.
5. Repeat step 4 to set each successive point in the stow/deploy sequence. To reteach
previous points, press the LAST <5 key. Skip previously taught points by pressing the
NEXT <6 key instead of TEACH <7.
The last (highest) point taught will be the final deploy point, after which the field will not
increment.
6. Press the EXIT <8 key to save the settings.
15.4 Testing the Movement Limits and Stow

Sequence
1. Exit all menus and return to the MAIN menu.
2. Enter the OPERATE menu. Enable hydraulics and move the master arm into
correspondence with the slave arm. Press the freeze button at the tip of the master
arm (status LIVE) and operate the slave arm. Carefully test the movement limits you
have set. Approach the mechanical limits, objects, and equipment slowly and with
caution until you are sure the limits you set will prevent collisions.
3. Move the slave arm to approximate the deploy point you have set. Freeze the slave
arm and park the master arm on the faceplate of the master controller.
Note: (DEPLOY and SHUTDOWN menus)

When you press the Stow <6 key, the slave arm will first return to the deploy posi-
tion before beginning the Stow sequence. Be prepared for this movement. To avoid
unplanned movements like this at shutdown, move the slave arm to the approximate
deploy point before entering the SHUTDOWN menu and using the Stow command.
4. Exit to the MAIN menu and access the SHUT DOWN menu (Figure 30).
SHUT DOWN DPLY

--------------------------------
Deploy <5
Stow <6
Pnt:IN Stop <7
4> Hydr to OFF EXIT <8

--------------------------------
After stowing, turn off hydr.
Figure 30 SHUTDOWN Menu

Installation •
5. From the SHUT DOWN menu test the Stow and Deploy commands. Test the Stop
command. Note that:
a. The POINT field counts each point in the Stow and Deploy sequence.
b. You can stop the sequence by pressing the Stop <7 key. The slave arm will
halt when it reaches the next point in the sequence.
c. You can reverse the stow sequence at any time by pressing the key for the
opposite direction.
6. Terrestrial Systems: Proceed to “System Shutdown” on page 37.
16 Submersible System Options

If you have installed a compensator with this manipulator system for submersible
operation, return to OPERATION menu and proceed to the Installation section enti-
tled Filling and Bleeding the Compensation Section (Submersible Models). If you
will not complete the compensation setup at this time, proceed to “System Shut-
down“.
17 System Shutdown
To shut down the manipulator system, follow these steps:
1. Direct the slave arm to a position that approximates the deploy position. Exit the
OPERATION menu.
2. From the MAIN menu, Select 5> SHUT DOWN menu (Figure 31).
SHUT DOWN DPLY

--------------------------------
Deploy <5
Stow <6
Pnt:IN Stop <7

--------------------------------
Figure 31 SHUTDOWN Menu
011–0565 16 Submersible System Options • Page 37

• Installation
!Caution
(DEPLOY and SHUTDOWN menus)
When you press the Stow <6 key, the slave arm will first return to its
deployed position before beginning the Stow sequence. Be prepared
for this movement. To avoid unplanned movements like this at shut-
down, direct the slave arm to the approximate deploy point before
entering the SHUTDOWN menu and using the Stow command.
3. Press the Stow >6 key to move the slave arm to its stowed position.
4. Press the 4> Hydr to OFF key to close the slave controller hydraulic isolation
valve.
5. Turn off power to the hydraulic power unit.
6. Turn off power to the master controller with the switch on the left side of the
faceplate.
7. Turn off power at the junction box.
18 Moving Ahead
After the compensation system has been bled (submersible systems only, see the
Installation chapter), the Orion manipulator system will be ready for normal opera-
tion. Refer to the “Operation“ chapter for complete information on system startup,
configuration, operation, performance options, error checking, and control diagnos-
tics.
Page 38 • 18 Moving Ahead 011–0565

Operation
In This Chapter:
System Overview ..................................................................page 1
Operation ............................................................................page 12
Performance Options ..........................................................page 22
System Fault and Error Diagnosis .......................................page 33
Adjusting the LCD Screen Viewing Angle ............................ page 40
This chapter covers Orion operation and is divided into four sections:
z System overview. An introduction to the Orion manipulator system, including
the slave arm and its range of motion, and a general description of control compo-
nent functions and use
z Operation. A hands-on, practical guide to operating the Orion manipulator sys-
tem, including startup and shutdown
z Performance options and configurations. This section describes slave arm
performance options and how they are selected and/or configured for normal
operation
z System fault and error diagnosis. This section describes how to diagnose
problems with the slave arm position sensors, master arm, and master controller,
and to display and reset system error conditions
For a simplified step-by-step guide to initial operation and configuration see the First
Startup Tutorial in the Installation chapter.
1 System Overview
Orion is a hydraulically powered, remotely controlled manipulator system, composed
of the following parts:
z The hydraulically powered, seven function slave arm, tipped with a jaw tool to
grasp and manipulate objects
z The slave controller, which serves as a hub for the control and distribution of
hydraulic fluid to the slave arm, the distribution of electrical power to slave arm
011–0566 1 System Overview • Page 1

• Operation
electrical assemblies, and the routing and processing of control telemetry between
the master controller and slave arm
z The master controller, which controls the slave arm. This assembly contains:
— The master arm, a small replica of the slave arm, which the operator manipu-
lates to direct the slave arm
— A Liquid Crystal Display (LCD) screen flanked by function and control keys. The
operator uses the keys to select operating options, and uses the screen to view
system information
— Electronic assemblies and software that control telemetry between the master
arm and slave controller
z A junction box that connects to an electrical power source, and links the master
controller with the slave controller and slave arm
z Electrical cables and hydraulic hoses that connect system components
z Submersible models are supplied with a compensator unit that provides compen-
sated pressure for the slave controller and telemetry wireways
1.1 The Control System
1.1.1 Master Controller

The master controller contains the following components:
z Display screen
z Electrical power switch
z Function and control keys
z Master arm
z Auxiliary Jaw Switch
Display Screen
An LCD screen in the center of the master controller front panel (Figure 1) provides
you with information about system status and available operating options. Example
screens are used throughout this chapter.
The LCD screen has a temperature sensor and compensator circuit to automatically
stabilize the viewing angle across a broad range of environmental temperatures. The
compensator circuit is also adjustable to suit local ambient temperature ranges and
viewing angles (see “Adjusting the LCD Screen Viewing Angle” on page 40).
Page 2 • 1 System Overview 011–0566

Operation •
LCD Screen
Power
Jaw Switch
Switc Master Arm
Control Keys
Power Switch
Power Switch
Function Keys
Figure 1 Master Controller Front Panel
Power Switch
The rocker switch at the left of the LCD display controls electrical power for the mas-
ter controller only. Overall power to the master controller and the slave controller is
controlled separately by a master switch on the junction box (unless an independent
power supply has been provided for the slave controller).
The master controller power switch should be turned off only after the slave arm has
been stowed and slave arm hydraulics disabled.
Master Arm
The master arm (Figure 2) is a miniature replica of the slave arm. Each master arm
joint or function matches a similar joint or function in the slave arm.
Q0730TP1.dwg
Q0730TP1.cdr
Q0730TP1 eps
Figure 2 The Master Arm and Tip Controls
The small size of the master arm allows you to easily control all functions with the fin-

• Operation
gers, wrist, and forearm. These functions include:
z Slave arm joint movement. Flexing a master arm joint produces a corresponding
movement of the slave arm joint
z Slave arm freeze. Pressing the freeze button at the tip of the master arm disables
its control output, leaving the slave arm idle at its present position
z Forearm roll. Rotation of the outer forearm segment of the master arm produces
the same degree of rotation in the slave arm forearm
z Wrist rotate. Rotation of the wrist collar produces rotation of the slave arm wrist.
How the slave arm wrist responds depends on the selected mode of wrist operation
— RATE: rotating the collar from its null point initiates continuous slave arm wrist
rotation in the same direction, with speed (rate) increasing with the degree of
collar rotation
— POS (position): the slave arm wrist rotates to the same degree (position) the
collar is rotated from its null point
z Jaw grip. Squeezing the textured jaw bands on the master arm wrist activates the
jaw. The precise way in which the jaw responds depends on the selected jaw mode
— TOG (toggle): fully opens or closes the jaw
— POS (position): moves the jaw in either direction for as long as the appropriate
jaw band is squeezed
— CLMP (clamp): Provides jaw control similar to the POS mode. After grasping an
clamp down and LOCK with maximum force. To release the jaw, use the JAW
a bypass valve in the slave controller causes the jaw relaxes its grip. Objects held by
power is disabled, the bypass valve must be removed. See “Removing the Jaw Bypass
Valve” in the “Maintenance and Service” chapter for details.
Function Keys
Eight function keys flank the screen. The four keys on the left of the display are, from
the top down, keys 1, 2, 3, and 4. The keys on the right of the display are, from the top
down, keys 5, 6, 7, and 8. These keys are used to select menus or to activate/deacti-
vate functions. In each menu, the function of each active key is displayed in the screen
field beside the key.
Control Keys
The four keys in the diamond pattern on the right side of the display are called control

Operation •
keys. In this manual, the top key is called UP, the bottom key is DN, the left key is LF,
and the right key is RT. These keys have various uses, which are identified in the
appropriate menus and startup or warning screens.
Auxiliary Jaw Switch

The auxiliary jaw switch is located opposite the master arm and provides the same
functions as the jaw bands on the master arm (Figure 1, Master Controller Front
Panel on page 3).
z Move switch forward = Jaw closes
z Move switch rearward = Jaw opens
!Caution
Do not interchange master controllers between standard Orions and
Extended-Reach Orions. The software is NOT compatible and will
cause control problems.
1.2 The Control Process

Control processes are diagrammed in Figure 3, Control System on page 6. Standard
Orion control telemetry uses an RS-485 serial interface and all slave arm control
functions are connected on a common bus. Telemetry is bi-directional and the control
of each slave arm function except the jaw utilizes a closed loop: position feedback
from each slave arm joint is compared with position data from each master arm joint
(as adjusted by the operator) and any differential initiates the application of hydraulic
power to appropriate slave arm joints until position correspondence is achieved.
Slave arm position data is also sent to the master controller for use in diagnostic
menus where it can be compared with master arm data for troubleshooting the sys-
tem.
Operator inputs to the master controller are generated by moving master arm joints,
pressing the master arm freeze button (to idle the slave arm in its current position),
and squeezing the master arm jaw bands, or using the auxiliary jaw button (to initiate
the jaw functions). Each physical action is translated into a varying analog voltage by
the potentiometer in each joint of the master arm (or by switches for the jaw func-
tion). The analog data from each joint is converted to a digital “command” value,
given a digital address specific to its function, and all commands of a given instant are
grouped into a packet. This packet is sent to the slave controller and distributed to all
the actuator controller boards. A DIP switch on each board is configured to only
accept a command with its address and disregard all others.

• Operation
Electrical Power
Source
Analog master arm Digitized slave arm

joint position data command data
Position data for diagnostics

Master Arm Junction Box
Electrical power Electrical power
Digitized slave arm command data
Digitized slave arm position data
Electrical power
Slave Controller Hydraulic Supply

Digitized slave arm Current to Solenoid Valve
position data control valve
Digitized slave arm command

data & electrical power
Actuator Actuator
Controller Board Controller Board
Current to Current to
control valve control valve
Analog slave arm joint position data
Servo Valve Servo Valve

Electrical power
Hydraulic Hydraulic
fluid fluid
Slave Arm Slave Arm

Hydraulic Hydraulic
Actuator Actuator
Open-Loop Control
(jaw)
Closed-Loop Control
Slave Arm Joint (azimuth, shoulder,
Potentiometer elbow, forearm roll,
wrist pitch & wrist
roll)
Figure 3 Control System

Operation •
Simultaneously, potentiometers in the slave arm are translating physical positions
into varying analog voltages which are also converted into a digital value. The actua-
tor controller board then compares the joint's position data with the command posi-
tion data sent by the master controller. If the data are the same, no slave arm joint
movement results. If the data are not the same, the actuator controller board applies
a voltage to that joint’s servo valve, causing the servo valve to release fluid to the
appropriate port of its hydraulic actuator. The resulting actuator movement drives
the slave arm joint towards the commanded position. When the joint feedback data
corresponds with the position data commanded by the master controller the servo is
closed and slave arm stops moving.
The jaw does not have a potentiometer to provide position feedback. Instead, master
controller commands can only move the jaw in a specific direction (toggle open or
closed), move the jaw as long as a jaw band (or auxiliary jaw switch) is squeezed
(position mode), or switch the jaw to a software-initiated function (clamp mode).
Opening or closing the jaw to a specific position is only possible with visual guidance.
1.2.1 Security Levels

The master controller offers three security levels for accessing menus that allow con-
figuration of sensitive or critical system functions (two of the levels are password-pro-
tected):
z Level 0 is the default level available at system startup. No password is required.

Full system operation is available at level 0, including access to menus for error-
checking, diagnostics, and configuration of some functions. A level 0 operator
using a fully configured manipulator system will usually need no higher security
level
z Levels 1 through 4 require a password, and allow access to the SET LIMITS, SET
STOW, and SET SV (servo valve) OFFSET menus. (Levels 2-4 are functionally
equivalent to level 1 on this model and may be disregarded.)
z Level 5 requires the factory-assigned password, and allows access to all configura-
tion and security menus. Level 5 access is required to set or change passwords for
security levels 1-4 (and to edit the master memory under factory supervision)
1.2.2 Enabling and Disabling Slave Arm Hydraulics

Hydraulic pressure to the manipulator system is controlled by a hydraulic isolation
valve located in the slave controller. To operate the slave arm the hydraulic pressure
must be enabled (turned on). To isolate the slave arm the hydraulic pressure must be
disabled (turned off).
The hydraulic isolation valve is normally enabled and disabled by operator input to
the master controller keyboard, but may also be disabled automatically by the master
controller when system errors are detected or when certain menus are accessed where
slave arm operation is unneeded or unsafe.

• Operation
1.3 Menu Overview
1.3.1 Menu Structure

The operator operates and configures the manipulator system by accessing appropri-
ate master controller menus and making keystroke and master arm inputs. The menu
structure and hierarchy is shown in Figure 4.
Establishing Communications with

Slave Arm
Incompatible
EPROM
Warnings: Startup System

Keys Error Screen Errors
Stow In Error
Deploy
Menu
Deploy
Stow
Stop
Main
Menu
Operate Options Setup Shutdown Diagnostics

Menu Menu Menu Menu Menu
Set Limits Master

Hydraulics Speed Set Stow Slave
Scale toggle Jaw Speed Set SV Offset Show Errors
Jaw Mode Scale Set ERR Checks
Wrist Mode Memory Deploy
Freeze Stow
Security Stop
Menu Hydraulics
Set Password
Set Level
Figure 4 Software Menu Structure
1.3.2 MAIN Menu

The MAIN menu (Figure 5) is provided at the end of the startup process and offers

Operation •
access to all the menus for slave arm operation, shutdown, configuration, and diag-
nostics:
MAIN MENU LOCK

--------------------------------
2> OPTIONS
3> SETUP
4> DIAGNOSE
--------------------------------
Figure 5 MAIN Menu
The menu functions are described below:

z 1> OPERATE: This menu is used for normal operation with the master arm and
also is used to freeze selected slave arm functions, toggle through jaw operation
modes, enable or disable slave arm hydraulics, and toggle between different slave
arm scaling values
z 2> OPTIONS: Used to set slave arm speed and jaw speed, and to set an alternate
scale for slave arm movement relative to master arm movement (toggle-selected in
the OPERATE menu)
z 3> SETUP: Used to set slave arm movement limits, program the stow/deploy
sequence, set system error checking, set security levels and passwords, and edit
master controller memory locations
z 4> DIAGNOSTICS: Used to diagnose faults in the slave arm position sensors, mas-
ter arm and master controller, and to display, reset, and configure system error
checking
z SHUT DOWN <5: Used to stow the slave arm and disable slave arm hydraulics in
preparation for shutting down the manipulator system
1.3.3 Slave Arm Operational Status

The operational status of the slave arm is shown in the upper right corner of most
menus using the following designations:
z LIVE indicates the master arm control of the slave arm is enabled
z FRZ (freeze) indicates that master arm control of the slave arm is disabled and
the slave arm is idle (frozen). FRZ status occurs when opening certain menus or
after pushing the freeze button at the tip of the master arm. Press the freeze button
again to activate the master arm for control of the slave arm

• Operation
z LOCK indicates that the arm is frozen and cannot be unfrozen from the current
menu. The manipulator control system automatically locks the slave arm for
menus or states in which the slave arm should not be operated. To unfreeze the
slave arm, you must move to another menu. Communications errors may also lock
the system to prevent damage
1.4 Factors Affecting Slave Arm Performance

Orion’s performance specifications for lift, forearm torque, wrist torque and speed,
and jaw grip force are based on the use of Shell Tellus 32 (or an equivalent fluid type)
at 3000 psi with a flow rate of 5 gpm. The Orion will provide serviceable performance
at pressures down to 1500 psi, but lifting capacity, wrist torque and speed, and jaw
grip force will be reduced.
Even with an adequately sized HPU, factors such as extremely high or low fluid tem-
perature, fluid contamination, plugged filters, extreme hose lengths, or inadequate
hose diameters can affect the pressure, viscosity, or flow of fluid delivered to the slave
arm and diminish performance.
With a consistent hydraulic input, the ability of each function to manipulate loads
varies with the changing leverage within each joint and the position and distance of
the load from the active joint. The greatest mechanical leverage of a joint usually
occurs around mid-travel of the actuator, when a line between the actuator pin and
joint pivot pin is at a right angle to the force applied by the actuator rod. At a mini-
mum, the Orion slave will manipulate 100 lb at any point within its range of motion.
In many areas within the range of motion, performance increases because:
z Active joints are closer to mid-travel, where their leverage is greatest
z The load is closer to the active joints
For instance, when the slave arm is fully extended horizontally, the shoulder joint is
near mid-travel and can lift about 120 lb (55 kg) held in the jaws. Lifting ability
increases to nearly 500 lb (227 kg) as the elbow folds and the load gets closer to the
shoulder joint.* Imagine a similar situation with your own arm: lifting a bucket of
water with your arm fully extended horizontally is more difficult than lifting it nearer
your body with your elbow bent. (Although the human arm does not move and flex
exactly like the Orion slave arm, it can serve as a useful model for understanding how
different joints handle loads and for developing strategies for safe load and task man-
agement.)
The forearm roll and wrist rotate functions are affected by loads in a similar way,
most noticeably when their axis of rotation is 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 or backdrive.

Operation •
!Caution
Extreme loads may put the slave arm at risk under certain situations.
See “Avoiding Slave Arm Damage” on page 11.
1.5 Avoiding Slave Arm Damage

Orion is designed with safety factors well in excess of its rated load capacities. How-
ever, operational situations can occur where safety factors may be exceeded, placing
the slave arm and surrounding equipment/personnel at risk. These situations
include:
z Collisions
z Collisions while manipulating extreme loads
z Collisions and/or extreme loads at the slave arm’s mechanical limits
Collisions and extreme loads can also produce communications and telemetry errors
that may trigger automatic system shutdown by error-checking software. Under cer-
tain field situations, it may be expedient to disable error checking in order to assure
uninterrupted operation. However, the operator should be aware that disabled error
checking puts the slave arm at greater risk. (see “Enabling and Disabling System
Error Checking” on page 39)
Steps the operator can take to mitigate the risks are discussed below:
1. Collisions:
Try to anticipate situations where there is a risk of collision and, if possible, modify
operations to avoid them. If collisions are an unavoidable part of the job, avoid
operating the slave arm near its mechanical limits. If a collision appears imminent,
try to move all joints to mid-travel. In this configuration, either relief valve for each
actuator can crack as needed, and there is sufficient travel available for the actuators
to backdrive.
2. Collisions while manipulating extreme loads:
Try to anticipate situations where there is a risk of collision and, if possible, modify
operations to avoid them. If it is safe and practical to do so, release the load before a
collision. If collisions are an unavoidable part of the job, avoid operating the slave
arm near its mechanical limits. If collision appears imminent, try to move all joints to
mid-travel. In this configuration, either relief valve for each actuator can crack as
needed, and there is sufficient travel for the actuators to backdrive.
3. Collisions while manipulating extreme loads at the slave arm’s mechanical limits
and manipulating extreme loads at the slave arm’s mechanical limits:
As a joint approaches its mechanical limits, the leverage of its linear actuator
diminishes and joint components are at greatest risk from the stresses generated by
collision and/or extreme loads.
a. Avoid running the actuators to their mechanical limit while carrying extreme
loads. Stopping the actuator short of the mechanical limit allows the relief
valve to crack (if excessive pressure develops from the momentum of the load)

• Operation
and relieve stress on the joint (see “Setting Slave Arm Movement Limits” on
page 27). You can also protect the slave arm by setting movement limits that
prevent slave arm joints from reaching their mechanical limits (except as part
of a programmed stow/deploy sequence).
b. Avoid using the azimuth to move extreme loads when the forearm is folded
in and the jaws/load are near the base. Avoid moving the elbow joint to its
downward travel limit (used for stow position only) when the slave arm is
heavily loaded. Slave arm joints are subject to very high stress in these
positions. You can also protect the slave arm by setting movement limits
that prevent the slave arm joints from reaching these specific positions
during normal operation (see “Setting Slave Arm Movement Limits” on page
27).
c. Substantial loads should be lifted with the shoulder joint and moved
horizontally with the azimuth joint.
Understanding the interaction between the Orion slave arm’s abilities and its loads
can help you use it more effectively and protect it from damage. The best protection is
anticipating situations with the potential for risk and planning slave arm operations
to minimize any risks, before manipulating any substantial load.
Note: Collisions and extreme loads can cause unusual joint movements
(reversed, overly slow or accelerated, etc.) that may trigger automatic system shut-
down by error-checking software. Under certain field situations, it may be expedi-
ent to disable error checking in order to assure uninterrupted operation. However,
the operator should be aware that disabled error checking puts the slave arm at
greater risk. (see “Enabling and Disabling System Error Checking” on page 39.)
2 Operation
!Caution
Activating hydraulic power without having completed all steps in the
pre-start checks and startup sequence can cause injury to personnel
and damage to equipment.
Note: If wrist drain/return pressure exceeds 350 psi above ambient, the relief
valve will crack and release hydraulic fluid into the environment.
2.1 Pre-Start Checks

Each time you prepare to start up the manipulator system, make the following
checks:
All fasteners and fittings are properly tightened and in good condition

Operation •
All hoses are safely routed to avoid kinks, snagging, and contact with sharp edges or
rough surfaces
Hydraulic components, hoses, and fittings are sound and free of leaking
Air has been purged from the hydraulic system if any connections have been opened
for service or maintenance
All electrical connections between the master controller, junction box, slave control-
ler, and slave arm are secure; electrical cables are safely routed to avoid damage
2.2 Startup Sequence

To start up the system, follow the steps below.
1. Clear personnel and equipment from the slave arm’s range of motion. Turn on
electrical power to the system with the switch on the junction box. If your system has
independent electrical power to the slave controller, enable slave controller power
first; then turn on power at junction box and master controller.
Note: For systems with independent electrical power to the slave controller.
Enable power to the slave controller FIRST, before turning on the master controller.
Otherwise, correct communications may not be established and the slave arm may
move unpredictably when hydraulic power is enabled.
2. Turn on power to the master controller with the switch on the left side of the
controller front panel. The message “Establishing Communications with slave arm”
will appear briefly and then default automatically to the next message screen.
Note: If the master controller fails to establish communication with the slave
controller, a “fatal telemetry error” message will appear. Refer to the Troubleshoot-
ing chapter for more information on correcting the cause of the malfunction.
3. If the slave arm is near the stow position, and all system equipment and
communications are functioning correctly, the Startup Procedure screen (Figure 6)
will follow the “establishing communications” message.

• Operation

--------------------------------
Startup Procedure:
1.Verify arm position.
2.Turn on HPU power.
3.Enable arm hydraulics.
4.Turn hydraulics off if
the slave arm moves from
its current position.
5.Press DOWN key to exit.
Hydr:OFF <8
--------------------------------
Figure 6 Startup Screen
If hardware, software, or other communication errors are detected other message

screens may appear instead:
The WARNINGS: screen (Figure 7) appears if the slave arm is not near the stow posi-
tion (the DEPLOY menu, which normally follows the Startup menu, will be bypassed
in the startup sequence) or if keyboard errors are present (refer to the Troubleshoot-
ing chapter and/or the System Fault and Error Diagnosis section in this chapter.)
Press the Exit <8 key to proceed to the Startup Procedure screen (keyboard errors
need not be corrected if emergency operation of the slave arm is essential)

--------------------------------
WARNINGS:
Arm not near a STOW point
(DEPLOY will be bypassed)
Exit <8
--------------------------------
Figure 7 WARNINGS Screen
The appearance of other warning screens or the system error screen indicates a com-
munication or system problem. Refer to System Error and Fault Diagnosis in the
Operation chapter, and/or the Troubleshooting chapter.
4. Proceed with the steps listed in the Startup screen.
a. Verify arm position. The slave arm should be at or near the stow point.
b. Turn on the HPU (hydraulic power unit) to provide pressure up to the slave
controller.

Operation •
c. Enable hydraulic power to the slave arm by pressing key 8, Hydr:OFF <8.
The display will change to “Hydr:ON <8.” to indicate that the hydraulic
isolation valve in the slave controller is open.
Note: The elbow, forearm roll, wrist roll, and jaw joints are not equipped with
lockvalves and may sag or drift when hydraulic power is disabled. It is normal for
them to return to their last commanded or stow position when hydraulic power is
enabled. Be prepared for this movement: clear personnel and equipment from the
slave arm's range of motion BEFORE enabling hydraulics.
Note: The azimuth, shoulder, and wrist pitch joints are equipped with lockvalves
to maintain their positions during shutdown and regardless of hydraulic or slave
arm status. They should not move more than slightly when hydraulics are enabled
(unless they have been manually repositioned while the system was shutdown). If
they begin moving more than a slight distance, immediately press 8> HYDR again
to disable hydraulic power to the slave arm until the cause can be determined.
5. Press the DN control key (The bottom key of the four in the diamond pattern to
the right of the display and function keys) to exit the startup menu. If the slave arm
was at or near the Stow position at startup, the DEPLOY menu (Figure 8) will appear.
(If a warning screen appeared before the startup menu screen indicating the slave
arm was not at or near the stow position, the DEPLOY menu will be bypassed and the
startup menu will exit to the MAIN menu. (see “Using the MAIN Menu” on page 16).
2.3 DEPLOY Menu
DEPLOY
--------------------------------
Deploy <5
Stow <6
Pnt:IN Stop <7
EXIT <8
--------------------------------
After deploying, press EXIT key
Figure 8 DEPLOY Menu
The DEPLOY menu allows the operator to initiate a pre-programmed sequence of

positions that move the slave arm between a compact, protected position (Stow <6)
and an operational position (Deploy <5). The operator may also stop (Stop <7) the
Deploy sequence, or bypass the DEPLOY menu altogether (EXIT <8). The stow/
deploy sequence can be changed using the SET STOW menu (see “Setting the Stow/

• Operation
Deploy Sequence” on page 29).
1. Deploy the slave arm by pressing Deploy <5. (There will be a slight delay before
the process begins.) Note that:
a. As the slave arm moves toward the deployed position, the PNT: field displays
each successive point number in the sequence.
b. You can stop the deployment by pressing the Stop <7 key. (The slave arm
will stop when it reaches the next point in the sequence.)
c. You can reverse the deployment sequence by pressing the Stow <6 key.
2. Press the EXIT <8 key to go to the MAIN menu.
2.4 Using the MAIN Menu
MAIN MENU LOCK

--------------------------------
2> OPTIONS
3> SETUP
4> DIAGNOSE
--------------------------------
Figure 9 MAIN Menu
The MAIN menu (Figure 9) provides access to the five submenus described below.
Press the key adjacent to the menu to select it.
z 1> OPERATE: Select this menu to direct the slave arm with the master arm. Key
controls toggle between jaw operation modes, different slave arm scaling values,
and enable or disable slave arm hydraulics. Slave arm joints can be selectively fro-
zen in the FREEZE submenu. All controls and menus are accessible at security
level 0
z 2> OPTIONS: Submenus are provided to configure slave arm speed and jaw speed,
and to scale the degree of slave arm movement relative to master arm movement.
z 3> SETUP: Submenus are provided to configure slave arm movement limits, pro-
gram the stow/deploy sequence, set system error checking, set security levels and
passwords, and edit master controller memory locations. These submenus require
a password or a security level higher than 0 to use

Operation •
z 4> DIAGNOSE: Used to view diagnostic information about the master arm, slave
arm and master controller, and to view details of system error conditions. All
menus are accessible at security level 0
z SHUTDOWN <5: Used to stow the slave arm and disable slave arm hydraulics in
preparation for shutting down the manipulator system. All menus are accessible at
security level 0
Disable hydraulics in the MAIN menu by pressing the UP key; Enable by pressing the
DOWN key (The upper and lower keys, respectively, of the four in the diamond pat-
tern to the right of the display and function keys).
2.5 Operation and Shutdown of the Slave Arm

Normal operation of the manipulator system takes place in the OPERATE menu. Use
the master arm for direct control of the slave arm. Use the master controller keys to
select among function options, enter the FREEZE submenu, control hydraulic power,
or exit back to the main menu. The slave arm is stowed and the manipulator system is
disabled in the SHUTDOWN menu. To prevent unintended or unexpected move-
ment, the OPERATE menu (Figure 10) always opens with the slave arm in the freeze
(FRZ) state.
1. From the MAIN menu press the 1> OPERATE key to access the Operate menu
(Figure 10).
OPERATE FRZ
--------------------------------
1> FREEZE Jaw Md:CLMP <5
2> Hydr:OFF Wrist Md:POS <6
3> Scale Tog:100%
EXIT <8
--------------------------------
Turn on hydraulics
Figure 10 OPERATE Menu
!Caution
Air in hydraulic lines or components may cause very rapid or jerky
slave arm movements. Sagging joints may return to their original
position when hydraulics are enabled. Clear personnel and equipment
from the slave arm’s range of motion BEFORE startup.
2. If hydraulic power is not enabled, press the 2> Hydr key.

• Operation
2.5.1 Using the Master Arm
1. Verify that the status field (at upper right) reads FRZ. Grip the master arm, move
it from its parked location, and position it for convenient operation of the slave arm.
Then press the freeze button at the tip of the master arm (status field changes to
LIVE): the slave arm will now move to match the movements of the master arm.
NOTE: The freeze function is also useful when a manipulation task results in an awkward position
for the master arm. Press the Freeze button, reposition the master arm for more comfortable opera-
tion, and press the Freeze button again (to resume operation). These actions re-index the new mas-
ter arm position to the existing position of the slave arm.
2. Operate the slave arm as desired. To optimize the Orion for a specific task and/or
worksite, refer to Section 3, Performance Options, for information on system
functions that can be selected, set, and/or re-configured using the OPERATE,
OPTIONS, and SETUP menus.
2.5.2 Selecting the Wrist Mode (Toggle)

Press the Wrist Md: <6 key to toggle between POS (position) and RATE modes of
control (described below).
z RATE: rotating the collar from the null point initiates continuous slave arm wrist
rotation in the same direction, with its speed (rate) increasing with the degree of
collar rotation. To stop wrist rotation, you can either freeze the master arm or
rotate the master arm wrist collar back to its null point
z POS (position): the slave arm wrist rotates to the same degree (position) the col-
lar is rotated from its null point
Note: The wrist position-sensor has a null zone of approximately 5 degrees. If

the wrist has halted in this zone or is passing through it when control is toggled
from RATE to POS mode, the bottom line of the OPERATE menu will display a
prompt to rotate the collar slightly in either direction. This will move the wrist out of
its null zone and allow the master controller to correctly coordinate collar and wrist
movements in the position mode.
The null point (no wrist movement initiated) of the wrist collar is not a fixed position
and can be located anywhere along the collar’s mechanical travel. The null point
always resets to the collars position at the moment when the slave arm is unfrozen
(using the master arm freeze button). This action prevents unintended operation of
the wrist if the collar position changed while the slave arm was frozen.
If the null position is too close to one of the collar’s mechanical stops to achieve the
desired wrist position or rotation rate, freeze the slave arm, and rotate the wrist collar
away from the mechanical stop until there is adequate travel to direct the wrist as
desired. Then unfreeze the slave arm and continue the task.

Operation •
Note: If the wrist will not remain stable when the slave arm is frozen, the wrist’s
servo offset may need adjustment. The procedure is described in the section 8.2,
"Setting Servo Valve Voltage Offsets," on page 22 in the “Maintenance and Service”
chapter.
2.5.3 Selecting the Jaw Operating Mode (Toggle)

Press the Jaw Md: <5 key to toggle between the four jaw function modes (POS, TOG,
CLMP, LOCK):
z TOG (toggle): fully opens or closes the jaw
z POS (position): moves the jaw in either direction for as long as the jaw band is
squeezed
z CLMP (clamp): Provides jaw control similar to the POS mode. After grasping an
clamp down and LOCK with maximum force. To release the jaw, use the JAW MD:
z LOCK: Locks the jaw in its current position and prevents the jaw from being
operated with the master arm. To escape from the LOCK mode, use the JAW MD:
2.5.4 Freezing Individual Slave Arm Joints (Toggle)

Access path: MAIN/OPERATE/FREEZE
FREEZE FRZ
--------------------------------
1> Azi: LIVE Pit: FRZ <5
2> Sho: LIVE Wrs: LIVE <6
3> Elb: LIVE All LIVE <7
4> Rol: LIVE EXIT <8

--------------------------------
Figure 11 FREEZE Menu
Freezing individual joints is useful for tasks where only some joints are required to
move and/or where greater stability of specific individual slave arm joints is desired.
1. From the OPERATE menu press the 1> FREEZE key. The FREEZE menu (Figure
11) allows individual slave arm joints to be frozen so that they will not respond to
master arm movements. Select among 1> Azi (azimuth), 2> Sho (shoulder), 3> Elb
(elbow), 4> Rol (forearm roll), Pit <5 (wrist pitch), and Wrs <6 (wrist). To unfreeze
all joints, press the All LIVE <7 key.

• Operation
2. Press the key next to each joint to toggle the field between FRZ and LIVE.
3. After making your selections, press the 8> EXIT key to return to the OPERATE
menu. Press the master arm freeze button to unfreeze the slave arm. Joints set to FRZ
in the FREEZE menu will remain frozen. Joints set to LIVE can be directed with the
master arm.
All FREEZE menu joint settings return to the default value (LIVE) when power to the
master controller is interrupted.
2.5.5 Scaling Slave Arm Movement (Toggle)

The 3> Scale Tog key toggles between the default scale value of 100% and a lesser pre-
selected scale value. A scale value of 100% produces one-to-one travel correspon-
dence between master arm and slave arm movement. (For example, rotating the mas-
ter arm elbow joint 50 degrees causes the slave arm elbow joint to move 50 degrees.)
Toggling to a scale value of less than 100% reduces slave arm movement to that per-
centage of master arm movement, allowing finer slave arm control. The manipulator
system offers position scaling from 10% to 100% in increments of 10%. At startup the
selectable scale defaults to 100% and must be reset if lesser values are required.
1. Use the master arm tip to freeze the slave arm.
2. Press the 3> Scale Tog key to toggle between the standard 100% scale of slave arm
movement and a pre-selected lesser scale. Scaling affects only the azimuth, shoulder,
elbow, forearm roll, and wrist pitch functions (wrist roll and jaw functions always
remain at 100%). You must freeze the slave arm before toggling between scales. The
speed of slave arm movements is not affected by changes in scaling.
Although the alternate scale value is retained when power to the master controller is
interrupted, the OPERATION menu always reopens with the Scale Tog value at 100%.
To set the alternate scaling value, follow these steps:
1. From the MAIN menu press the 2> OPTIONS key to display the OPTIONS menu
(Figure 13).
2. The number next to 3> Scale Sel shows the current alternate scaling value. Press
the 3> Scale Sel key to increment this number by 10%. (At 100%, the value defaults to
10%.)
3. When the desired alternate scaling value is displayed, press the EXIT <8 key to
save and return to the MAIN menu.
The Scale Sel setting is retained in memory even if power to the master controller is
interrupted.
2.6 System Shutdown

To shut down the manipulator system, follow these steps:
Note: Be sure to release objects from the jaws before shutdown. The jaw relaxes
after hydraulics are turned off, and a grasped object will be dropped.

Operation •
1. Release any objects from the grasp of the jaw.
2. Move the slave arm to a position that approximates the final deployed position.
Exit the OPERATION menu.
3. From the MAIN menu, press the SHUT DOWN <5 key to display the
SHUTDOWN menu (Figure 12). The status field shows that the slave arm is locked,
preventing operation by the master arm.
SHUT DOWN DPLY

--------------------------------
Deploy <5
Stow <6
Pnt:IN Stop <7

--------------------------------
Figure 12 SHUT DOWN Menu
Note: When you press the Stow <6 key, the slave arm will first return to the final
deployed position before beginning the Stow sequence. Be prepared for this move-
ment.
4. Press the Stow <6 key to move the slave arm to its stowed position.
Note that:
a. Before beginning the Stow sequence, the slave arm will first return to the
deployed position.
b. As the slave arm moves towards Stow, the PNT: field displays each
successive point number in the sequence. The final point (01) is displayed as
IN.
c. You can stop the sequence by pressing the Stop <7 key. The slave arm will
halt when it reaches the next point in the sequence.
d. You can reverse the stow sequence at any time by pressing the Deploy <5
key.
5. Press the 4> Hydr key to close the slave controller hydraulic isolation valve.
6. Turn off power to the hydraulic power unit.
7. Turn off power to the master controller with the switch on the left side of the
faceplate. Turn off power to the slave controller (if independently supplied).

• Operation
3 Performance Options
The Orion can be optimized for a specific task and/or worksite by selecting, setting, or
configuring system functions using the OPTIONS, and SETUP menus.
3.1 OPTIONS Menu

Access path: MAIN/OPTIONS
OPTIONS FRZ
--------------------------------
1> Dyn:FAST
2> Jaw Speed:2
3> Scale Sel:050%
EXIT <8
--------------------------------
Figure 13 OPTIONS Menu
Dyn (slave arm speed) and Jaw Speed settings return to default values when power to
the master controller in interrupted. The Scale Sel setting is retained.
3.1.1 Controlling Slave Arm Speed

Slave arm speed can be toggled between two dynamic modes: FAST and SLOW. In
the FAST mode, the speed of slave arm movement matches all but the most rapid
movements of the master controller. This speed is useful in operations where quick
response and close correspondence to rapid movements of the master arm are useful,
and in submersible operation where slave arm movements are slow by water resis-
tance. SLOW mode is intended for use when people are near the slave arm and may
need to avoid its movements or where speed-limited movements are needed for spe-
cific tasks or equipment handling.
1. Press the 1> Dyn key to toggle between SLOW and FAST modes.
2. Press EXIT <8 to save setting and return to the MAIN menu.
Slave arm speed defaults to FAST when power to the master controller is interrupted.
Page 22 • 3 Performance Options 011–0566

Operation •
Note: When the manipulator system is operating in SLOW mode, avoid rapid
movements of the master arm. Slave arm response will lag and may make it diffi-
cult to avoid obstacles or direct the slave arm to an exact position. For exact slave
arm movements or positioning, slow your movements of the master arm until the
slave arm can match them.
3.1.2 Controlling Jaw Opening and Closing Speed

When the jaw is in POSITION mode, you can specify the speed of jaw movement with
the Jaw Speed function. In the OPTIONS menu (Figure 13), the number next to 2>
Jaw Speed shows the current jaw speed. The higher the number, the greater the jaw
speed. Possible jaw speeds range from 1 (slowest) to 4 (fastest).
1. Press the 2> Jaw Speed key to increment the speed by 1. After jaw speed 4 the
value defaults to 1.
2. Press EXIT <8 to save setting and return to the MAIN menu.
Jaw speed defaults to 1 when power to the master controller is interrupted.
3.1.3 Slave Arm Scale Selection

The 3> Scale Tog key in the OPERATE menu toggles between the default scale value
of 100% and a lesser pre-selected scale value. A scale value of 100% produces one-to-
one correspondence between master arm and slave arm movement. A scale value of
less than 100% reduces slave arm movement to that percentage of master arm move-
ment, allowing finer slave arm control. Scaling is selectable in increments of 10%
from 10% to 100%. At startup the selectable scale defaults to 100% and must be reset
if lesser values are required.
To set the alternate scaling value, follow these steps:
1. From the MAIN menu press the 2> OPTIONS key to display the OPTIONS menu
(Figure 13, OPTIONS Menu on page 22).
2. The number next to 3> Scale Sel shows the current alternate scaling value. Press
the 3> Scale Sel key to increment this number by 10%. (At 100%, the value defaults to
10%.)
3. When the desired alternate scaling value is displayed, press the EXIT <8 key to
save and return to the MAIN menu.
The Scale Sel setting is retained in memory even if power to the master controller is
interrupted.
3.2 SETUP Menu

Access path: MAIN/SETUP
The SETUP menu (Figure 14) contains the following sub-menus for configuring func-
011–0566 3 Performance Options • Page 23

• Operation
tions:
z 1> SET LIMITS (set slave arm movement limits)
z 2> SET STOW (program the stow and deploy sequences)
z 3> SET SV OFFSET (Set servo valve offsets). See the “Special Procedures, Settings,
and Specifications” section of the Maintenance and Service chapter for informa-
tion about adjusting the servo valve offsets
z 4> SET ERR CHECKS (set system error checking parameters
z MEMORY <5 (edit master controller memory locations). Edit memory locations
only under direction from Schilling service personnel
z SECURITY <6 (set and access security levels, set passwords)
SETUP LOCK
--------------------------------
1> SET LIMITS MEMORY <5
2> SET STOW SECURITY <6
3> SET SV OFFSET
4> SET ERR CHECKS EXIT <8

--------------------------------
Figure 14 SETUP Menu
To configure the menus within the Setup menu, except MEMORY<5, you must first
access security level 1 or higher by entering a local- (or factory-assigned level 5) pass-
word in the SECURITY menu. Only the level 5, factory-assigned password will pro-
vide access for configuring the MEMORY <5 menu.
Note: A sheet listing the passwords is located at the end of the Table of Contents.
Settings in all SETUP submenus are retained even if power to the master controller is
interrupted.
3.2.1 The SECURITY Menu

Access path: MAIN/SETUP/SECURITY

Operation •
SECURITY LOCK
--------------------------------
1> SET LEVEL
2> SET PASSWORD
EXIT <8
--------------------------------
Figure 15 SECURITY Menu
Entering or changing the passwords for each level is done via the SECURITY menu,
which is accessed by pressing the 6> SECURITY key in the SETUP menu (Figure 15).
The master controller offers three password-protected security levels for accessing
menus that allow configuration of sensitive or critical system functions:
1. Level 0 is the default level available at system startup. No password is required.
Full system operation is available at level 0, including access to error-checking and
diagnostic menus. While level 0 does allow operator access to the SET ERR CHECKS
menu, all other SETUP submenus are inaccessible. A level 0 operator using a fully
configured manipulator system will usually need no higher security level.
2. Levels 1 through 4 require a password, and allow access to the SET LIMITS, SET
STOW, and SET SV OFFSET menus. (Levels 2-4 are functionally equivalent to level 1
on this model and may be disregarded.)
3. Level 5 requires the factory-assigned password, and allows access to all
configuration and security menus. Level 5 access is required to set or change
passwords for security levels 1-4.
Table 1 lists configuration menus and the security level needed to make changes.
Table 1
Security Levels for Accessing System Functions

Required Security
Function
Level
Setting the stow/deploy sequence 1-5

Setting joint movement limits 1-5
Setting servo offset 1-5
Setting new passwords for security levels 1-4 5
Directly editing master controller memory locations 1-5
All other functions 0-5

• Operation
3.2.2 The SET LEVEL Menu: Entering Passwords
Access path: MAIN/SETUP/SECURITY/SET LEVEL
SET LEVEL
--------------------------------
Level:1 Inc <5
Password:****
Dec <6
Select <7
Current user's
--------------------------------
Figure 16 SET LEVEL Menu
Menus requiring security levels above 0 are accessed using a local- or factory-
assigned password.
Note: A sheet listing the passwords is located at the end of the Table of Contents.
To enter a password perform the following steps:

1. From the SETUP menu, press the SECURITY <6 key to access the SECURITY
menu.
2. From the SECURITY menu, press the 1> SET LEVEL key to display the SET
LEVEL menu (Figure 16). The cursor will appear in the Level: field (the current
security level is displayed at the bottom of the screen). To change the current level,
press the Inc <5 or Dec <6 keys until the desired level is displayed. Press the Select <7
key to enter the level.
3. After selecting a security level, the cursor will drop to the first digit of the
Password: field, changing the asterisk (*) to a zero (0). Press the 5> Inc or 6> Dec
keys until the first number of the four-digit password appears. Press the Select <7 key
to enter the number and move on to the next password number. Repeat until all four
numbers of the password have been entered.
4. Press the Select <7 key once more to enter the password. The Current User’s
Security Level: field will show the new level.
5. Press the EXIT <8 key until you exit to the desired menu.
3.2.3 Setting and Changing Passwords

Access path: MAIN/SETUP/SECURITY/SET PASSWORD

Operation •
SET PASSWORD
--------------------------------
Level:1 Inc <5
Password:****
Dec <6
Select <7
Current user's
--------------------------------
Figure 17 SET PASSWORD Menu
The SET PASSWORD menu allows an operator with the factory-assigned level 5 pass-
word to set or change passwords for security levels 1 through 4. If the SET PASS-
W OR D m en u i s selected whi le i n secur ity level 4 or lower , the m essa ge
“INSUFFICIENT SECURITY LEVEL” appears below the menu. The password for
security level 5 cannot be changed.
To set a password, follow these steps:
1. Ensure that the current security level is 5. (If you aren’t sure what the current
level is, access the SET LEVEL menu (MAIN/SETUP/SECURITY/SET LEVEL) and
note the level displayed on the screen). Enter the level 5 password if necessary.
2. From the SETUP menu, press the 6> SECURITY key.
3. From the SECURITY menu, press the 2> SET PASSWORD key to display the SET
PASSWORD menu (Figure 17),
4. The cursor will appear next to the Level: field. Press the Inc <5 or Dec <6 key until
the desired level is displayed. Press the Select <7 key to enter the level.
5. The cursor will then drop to the first digit of the Password: field. Press the 5> Inc
or 6> Dec key to set the first number of the password. Press the 7> Select key to move
on to the next password digit. Repeat until all numbers of the new password have
been entered.
6. Press the EXIT <8 key until you exit to the desired menu.
3.2.4 Setting Slave Arm Movement Limits

Access path: MAIN/SETUP/SETLIMITS

• Operation
SET LIMITS FRZ

--------------------------------
COUNT:01 Last <5
LIMIT: Next <6

AZI LEFT
Teach <7
EXIT <8
--------------------------------
Figure 18 SET LIMITS Menu
Slave arm joint movements are ultimately limited by the mechanical range of each
joint (see the range-of-motion drawings at the beginning of this chapter). For the pro-
tection of the slave arm or personnel and equipment within the operational envelope
of the slave arm it is often necessary to software-limit the movement range of slave
arm joints. The software set limits for each joint (excluding the wrist and jaw) are
configured in the SET LIMITS menu (Figure 18).
Accessing the SET LIMITS menu requires a security level of 1 or higher. If the SET
LIMITS menu is selected while in security level 0, the message “INSUFFICIENT
SECURITY LEVEL” appears below the menu.
To set movement limits for individual slave arm joints, follow these steps:
1. Ensure that the current security level is 1 or higher. If you aren’t sure what the
current level is, display the SET LEVEL menu (MAIN/SETUP/SECURITY/SET
LEVEL) and note the level displayed on the screen. Enter a 1 or higher security level
password if necessary.
2. From the SETUP menu, press the 1> SET LIMITS key to display the SET LIMITS
menu.
Note: While the SET LIMITS menu is open, slave arm joints are capable of full
mechanical travel. Previously set limits (if retained) or newly set limits will not
engage until you have exited from the SET LIMITS menu.
3. The SET LIMITS menu will identify the joint function by a number (in the
COUNT: field) and the function description (in the LIMIT: field) for the limit being
set. The sequence of joint functions and their corresponding numbers are shown in
Table 2. (There are no movement limits for the wrist and jaw.)
As the table shows, the azimuth left limit is the first function in the sequence. The COUNT: field
will display 1, while the LIMIT: field will display AZI LEFT

Operation •
Table 2
Joint Limit Numbers
Joint Travel Limit Limit

No.
Azimuth Yaw AZI LEFT 01

AZI RIGHT 02
Shoulder Pitch SHO DOWN 03
SHO UP 04
Elbow Pitch ELB DOWN 05
ELB UP 06
Forearm Roll ROL CCW 07
ROL CW 08
Wrist Pitch PIT RETRACT 09
PIT EXTEND 10
4. Unfreeze the arm by pressing the master arm freeze button. Move the slave arm to
the leftmost desired position for the azimuth function. To set this limit close to the
mechanical limit, move the azimuth gently to the limit, then slightly back. All
movement limits should be at least slightly less than the mechanical limits.
5. Press the Teach <7 key to enter that position as the limit. The counter will
automatically increment to the next function/number.
6. Repeat steps 4 and 5 to set limits for the remaining joints. You may return to and
reteach a previous limit by pressing the Last <5 key until the desired function appears
on the screen. You may skip functions by pressing the Next <6 key instead of
Teach <7. If you do this, the existing limit setting for the skipped function will be
retained when you exit the SET LIMITS menu.
7. When all limits have been set, move the arm to any position inside the new limits,
freeze the slave arm, and press the EXIT <8 key. The new or retained movement
limits will be saved. (If you have positioned any joint outside these limits, the arm will
move to a position within the limits the next time the arm is unfrozen.)
8. You should immediately test the new limits to ensure that the slave arm’s range of
movement is acceptable. Use caution near equipment until you are certain that the
new limits prevent collisions.
3.2.5 Setting the Stow/Deploy Sequence

Access path: MAIN/SETUP/SET STOW
Requires level 1 or higher password.

• Operation
SET STOW FRZ

--------------------------------
POINT:03 Last <5
Next <6
Teach <7
4> Number of points:10 EXIT <8

--------------------------------
Taught point 02
Figure 19 SET STOW Menu
The stow/deploy path is a sequence of up to 16 fixed slave arm points (or positions)
that the operator selects in the SET STOW menu (Figure 19). The manipulator system
calculates how to move the slave arm most efficiently between the selected points.
The stow/deploy sequence can be reset at any time to accommodate changes in oper-
ational needs or the operating environment.
The stow/deploy sequence is used in the DEPLOY menu (automatically displayed as
part of the startup process) and the SHUTDOWN menu. In either menu, when the
Deploy <5 key is pressed, the slave arm moves from its stow position to its deployed
position; when the Stow <6 key is pressed, the slave arm first moves to the deployed
position and then moves to the stow position.
In planning a stow/deploy sequence for your manipulator system, the following fac-
tors should be considered:
z You can issue a command to stop the slave arm at any time during the sequence,
but the slave arm will continue to move until it reaches the next programmed point
in the sequence. A stow/deploy sequence with more points can be stopped sooner
z The control system calculates how to move the slave arm most efficiently from one
point to the next in the sequence, so using just a few points leaves much of the
slave arm movement up to the control system. Be sure to program enough points
into the sequence to guide the slave arm around obstacles and equipment
To set a new stow/deploy sequence, follow these steps:
1. Ensure that the current security level is 1 or higher. If you aren’t sure what the
current level is, display the SET LEVEL menu (MAIN/SETUP/SECURITY/SET
LEVEL) and note the level displayed on the screen. Enter a 1 or higher security level
password if necessary.
2. From the SETUP menu, press the 2> SET STOW key to display the SET STOW
menu.

Operation •
Note: Movement points in the stow/deploy sequence can be selected from the
slave arm’s full mechanical range of motion. Limits to slave arm movement pro-
grammed in the SET LIMITS menu have no effect upon slave arm movements while
setting or running a stow/deploy sequence.
3. Press the 4> Number of points: key until the desired number of stow points shows
in the field. Select any number of points from 2 to 16.
4. Unfreeze the slave arm by pressing the master arm freeze button. The POINT:
field will display 01, corresponding to the Stow position.
5. Move the slave arm to the desired Stow position (typically where the slave arm is
most compact or protected when not in use). Press the Teach <7 key to save the
position (only the position of the arm is entered, not the time or number of motions
needed to get it there). The POINT: field will automatically increment to 02.
6. Move the slave arm to the desired 02 position. Press the Teach <7 key to save the
position. Repeat to set each successive point in the stow/deploy sequence. You may
return to and re-teach previous points by pressing the Last <5 key. You may skip
previously taught points by pressing the Next <6 key.
7. The highest point taught is considered the deployed point. After this point is
taught, the POINT: field will not increment.
8. Press the EXIT <8 key to save the settings.
Note: (DEPLOY and SHUTDOWN menus)

When you press the Stow <6 key, the slave arm will first return to its final Deploy
position before beginning the Stow sequence. Be prepared for this movement. To
avoid major unplanned movements like this at shutdown, direct the slave arm to the
approximate deploy point before using the Stow command.
3.2.6 Enabling and Disabling System Error Checking

Access path: MAIN/SETUP/SET ERR CHECKS
All menus are accessible at security level 0.
The Set Error Checks function allows you to selectively enable and disable monitoring
of Control, Continuity and Telemetry errors. (Time-out errors cannot be disabled.)
Normally, all system error monitoring should be left enabled so that operational
faults will shut down the slave arm and prevent damage to the arm or its surround-
ings. However, there may be circumstances where uninterrupted operation of the arm
is necessary despite a known fault (such as a faulty position sensor), to diagnose a
fault, or because collisions or extreme loads are likely to cause repeated system shut-
downs. Good judgment is a necessity: error monitoring exists to protect the slave arm
(and its surroundings) from damage. An automatic shutdown due to error checking
indicates the slave arm is at risk. Disabling error checking indicates the operator's
awareness and acceptance of increased risk.
See “Setting the Stow/Deploy Sequence” on page 29 for a detailed description of the
four types of system errors.

• Operation
To enable and disable system error checks, follow these steps:
1. From the MAIN menu, select 3> SETUP. The SETUP menu will appear.
SET ERR CHECKS LOCK

--------------------------------
[01]Contin
Change <5
Check:ENA
2> Last Disable all <6
3> Next Enable all <7
4> Save as default EXIT <8

--------------------------------
Figure 20 SET ERR CHECKS Menu
2. From the SETUP menu, press the 4> SET ERR CHECKS key to display the SET
ERR CHECKS menu (Figure 20).
The system error type and its current status will appear in the upper left of the screen.
The three error types that can appear are:
z [01]Contin (Continuity)
z [02]Control
z [03]Telem (Telemetry)
The type 04 error, Time-out, cannot be disabled and thus does not appear in this
menu.
The flag in the Check: field specifies whether or not the selected error check is
enabled (ENA) or disabled (DIS). Enabled, an occurrence of the error type will cause
a system error condition and a resulting shutdown of the slave arm hydraulics. Dis-
abled, errors of this type will not result in a shutdown and the system will continue
operating. (The condition causing the error may result in limited or erratic perfor-
mance of the slave arm, however.)
3. To view and set the other error types, press 2> Last and 3> Next until the desired
error type is displayed.
4. To enable or disable checking for the displayed error type, press the Change <5
key to toggle the Check: flag between ENA and DIS. To disable checking for all error
types, press the Disable all <6 key. To enable checking for all error types, press the
Enable all <7 key.
5. If you wish the changes to error checking to be temporary (lasting for the current
session only), you can exit the SET ERR CHECKS menu by pressing the EXIT <8 key.
If you want the changes to be permanent (until changed again), press the 4> Save as
default key.

Operation •
Press the EXIT <8 key to exit the SET ERR CHECKS menu.
3.2.7 Set SV Offset

Use of this menu is described in the “Junction Box Service” section in the “Mainte-
nance and Service” chapter.
3.2.8 Memory
This menu should only be used under direction from Schilling Robotics service per-
sonnel.
4 System Fault and Error Diagnosis

Access path: MAIN/DIAGNOSE
DIAGNOSTICS LOCK
--------------------------------
1> MASTER
2> SLAVE
3> SHOW ERRORS
EXIT <8
--------------------------------
Figure 21 DIAGNOSTICS Menu
The DIAGNOSTICS menu (Figure 21) provides access to menus that display system
diagnostic information. The options under this menu can be used to diagnose faults
in the slave arm position sensors, master arm and master controller, and to display,
reset, and configure system error checking.
To enter the DIAGNOSTICS menu, press the 4> DIAGNOSE key from the MAIN
menu.
4.1 Diagnosing Problems

z If the master arm is not properly responding to control inputs, proceed to “Diag-
nosing Master Arm Joint Problems” on page 34
011–0566 4 System Fault and Error Diagnosis • Page 33

• Operation
z If you suspect that one or more of the master controller keys, or the master arm
freeze button is not working properly, proceed to “Diagnosing Master Controller
Key and Freeze Button Failures” on page 35
z If you suspect that the slave arm is not properly positioning itself, or that the cor-
respondence between the master arm and the slave arm is not accurate, proceed to
“Diagnosing Slave Arm Positioning Failures” on page 36
z If the slave arm has frozen automatically and an ERR flag is appearing in the top
line of the LCD display, proceed to “Diagnosing and Resetting System Errors” on
page 37
4.1.1 Diagnosing Master Arm Joint Problems

Access path: MAIN/DIAGNOSE/MASTER
MASTER TEST LOCK

--------------------------------
Position: Jaw Bands:
Azi: +0120 -0021
Sho: +0415 +0004
Elb: -1021
Rol: -0045
Pit: +0924
Wrs: +1011
Keys:00000100000000 EXIT <8
--------------------------------
Figure 22 MASTER TEST Menu
Press the 1> MASTER key in the DIAGNOSTICS menu to display the MASTER TEST
screen (Figure 22). The slave arm is automatically locked in this menu, allowing the
master arm to be safely moved for diagnostic purposes.
For this procedure, you will be viewing the values displayed for each joint in the Posi-
tion: column and the jaw bands in the Jaw Bands: column. A value of zero indicates
that the joint is at the approximate midpoint of its range of motion. Positive values
indicate movement either up, to the right, or clockwise (when the master arm is
viewed from behind); negative numbers indicate movement down, to the left, or
counterclockwise. The two jaw band values will jump from a very low (near-zero)
value to a very high (1000 or more) value when squeezed.
If a master arm joint is not being moved, the position value should either not change
or should fluctuate only slightly. A changing position value for an immobile joint
probably indicates a failure in a master arm potentiometer or a master controller
printed circuit board. Conversely, a position value that does not change or changes
only slightly when the joint is moved also indicates a failure of this type.
Page 34 • 4 System Fault and Error Diagnosis 011–0566

Operation •
Apparent discontinuities in master arm data (for example, a slight movement of a
master arm joint causes a large change in position data, or vice versa) may indicate a
failed master arm joint potentiometer.
4.1.2 Diagnosing Master Controller Key and Freeze

Button Failures
MASTER TEST LOCK

--------------------------------
Azi: +0120 -0021
Sho: +0415 +0004
Elb: -1021
Rol: -0045
Pit: +0924
Wrs: +1011
Keys:00000100000000 EXIT <8
--------------------------------
screen (Figure 23). For this diagnostic procedure, you will be viewing the binary val-
ues (0 or 1) in the Keys: field.
The digits in this field display the status of each key and the freeze button, which lets
you diagnose problems with master controller keys or the master arm freeze button.
Each digit in this field corresponds to one key or to the freeze button. If the key or
button is operating correctly, the character for that key or button will be 0 when it is
not being pressed and 1 when it is pressed. If a failure has occurred, the display will
show the same value for the corresponding digit whether the key or button is pressed
or not.
Use Table 3 to identify the functions in the Keys: field. In this table, the “character
position” column indicates how far from the left the character is. (For example, the
eleventh character from the left shows the status of the down key.)

• Operation
Table 3
Master Controller Function Key Diagnosis
Character
Position
Function
(from
left)
1 Function key 1
2 Function key 2
3 Function key 3
4 Function key 4
5 Up key (UP)
6 Left key (LF)
7 Left master arm freeze button (functional
in dual-arm systems only)
8 Master arm freeze button (in dual-arm
systems, for the right master arm only)
9 Function key 5
10 Function key 6
11 Down key (DN)
12 Right key (RT)
13 Function key 8
14 Function key 7
4.1.3 Diagnosing Slave Arm Positioning Failures

Access path: MAIN/DIAGNOSE/SLAVE
Press the 2> SLAVE key in the DIAGNOSTICS menu to display the SLAVE TEST
screen (Figure 24).
The slave arm will be frozen when you enter this menu (while the slave arm is frozen,
master arm position values are not read, so the display will not change as you move
the master arm). Press the master arm freeze button to unfreeze it and evaluate the
master arm to slave arm positioning correspondence.

Operation •
SLAVE TEST FRZ

--------------------------------
Cmd: Fdbk: Diff:
Azi: +0101 +0099 -0002
Sho: +0427 +0427 +0000
Elb: -0005 -0010 +0005
Rol: +0026 +0026 +0000
Pit: +0900 +0924 +0024
Wrs: -1025 -1035 +0010
Jaw: +0036
EXIT <8
--------------------------------
Figure 24 SLAVE TEST
When the master arm is moved, the master arm position values in the Cmd: (com-
mand) column should change as rapidly as the arm is moved. If they do not, you
should evaluate the master arm’s performance as described in “Diagnosing Master
Arm Joint Problems”. The values in the Fdbk: (feedback) column, representing the
position sensor information from the slave arm, should catch up with the Cmd: values
whenever the movement of the master arm is halted. Although the values in the Diff
(difference) column may reach the high hundreds when the master arm is moved
quickly, they should drop to single digits (indicating close correspondence between
the master and slave arm positioners) whenever the master arm is not being moved.
If a large difference between the command and feedback values persists (i.e. a value
greater than 25 in the difference column), check the servo offset value for that joint
(seesection 8.2, "Setting Servo Valve Voltage Offsets," on page 22 in the “Mainte-
nance and Service” chapter). If the servo offset is properly nulled, or cannot be nulled,
a faulty slave arm position sensor is most likely at fault.
Since the jaw has no position sensors, no feedback or difference values are displayed
for these joints.
4.1.4 Diagnosing and Resetting System Errors

Access path: MAIN/DIAGNOSE/SHOW ERRORS
Press the 3> SHOW ERRORS key in the DIAGNOSTICS menu to display the SHOW
ERRORS screen (Figure 25).
If the ERR flag has appeared in the top line of all menus, the system error informa-
tion will appear on the left side of the display. If there is no system error, or if the Clr
Errs <5 key has been pressed, “No Errors” will appear instead. There are four error
types that may appear in this screen:
z Control errors indicate that the system is unable to accurately control one or more
joints. The Control flag will be followed by one or more letters in brackets, which
indicate the joint or joints experiencing control errors (Azimuth, Shoulder, Elbow,

• Operation
Roll, Pitch, Wrist, Jaw, B = slave controller). In addition to system errors, colli-
sion, driving the slave arm against an immovable object, or an extreme load may
also trigger a control error
z Continuity errors indicate that a joint position sensor reported an unexpectedly

large position change in a short time. This error may indicate that the sensor has
failed, or that an external force, such as a collision or an extreme or immovable
load) has pushed the joint out of position. The Contin flag will be followed by one
or more letters in brackets, indicating the joint or joints experiencing continuity
errors (Azimuth, Shoulder, Elbow, Roll, Pitch, Wrist, Jaw, B = slave controller)
z Telemetry errors occur when the master controller loses contact with one or more
joint position sensors. This error may be caused by faulty position sensor, by a
faulty connection between the master controller and the slave arm, or by a failure
of the slave arm slave controller. The Telem flag will be followed by one or more
letters in brackets, indicating the source of the error (Azimuth, Shoulder, Elbow,
Roll, Pitch, Wrist, Jaw, B = slave controller)
z Time-out errors occur when the slave arm slave controller receives no communica-
tions for 500 milliseconds (one-half second) or longer. This error may be caused
by a failure of electrical power to the slave arm slave controller, or by a faulty con-
nection between the master controller and the slave controller
SHOW ERRORS ERR LOCK

--------------------------------
ERRORS: Clr Errs <5
Telem [A,S,E,R,P,W,J,B]
Timeout
Warnings: Update <6
Hydr OFF
Hydr On <7
EXIT <8
--------------------------------
Hydr OFF
Figure 25 SHOW ERROR Menu
To clear a system error condition, press the Clr Errs <5 key. New control, continuity,
telemetry and timeout errors will not generate a new display. If the ERR flag reap-
pears in the top line of the menu, press the Update <6 key to display the new errors.
All except timeout errors may be disabled in the SET ERROR CHECKS menu (see
“Enabling and Disabling System Error Checking” on page 39).
Some errors may be followed by warnings. The most common warning is that slave
arm hydraulics have been disabled (for safety reasons). Slave arm hydraulics may be
re-enabled by pressing the Hydr On <7 key.
Press the EXIT <8 key to exit the SHOW ERRORS menu.

Operation •
4.1.5 Enabling and Disabling System Error Checking
Access path: MAIN/SETUP/SET ERR CHECKS
SET ERR CHECKS LOCK

--------------------------------
[01]Contin
Change <5
Check:ENA

--------------------------------
The Set Error Checks function allows you to selectively enable and disable monitoring
of Control, Continuity and Telemetry errors. (Timeout errors cannot be disabled.)
Normally, all system error monitoring should be left enabled so that operational
faults will shut down the slave arm and prevent damage to the arm or its surround-
ings. However, there may be circumstances where uninterrupted operation of the arm
is necessary despite a known fault (such as a faulty position sensor), to diagnose a
fault, or because collisions or extreme loads are likely to cause repeated system shut-
downs.
Good judgment is a necessity: error monitoring exists to protect the slave arm (and its
surroundings) from damage. An automatic shutdown due to error checking indicates
the slave arm is at risk. Disabling error checking indicates the operator's awareness
and acceptance of increased risk.
See “Setting the Stow/Deploy Sequence” on page 29 for a detailed description of the
four types of system errors.
1. From the MAIN menu, select 3> SETUP. The SETUP menu will appear.
2. From the SETUP menu, press the 4> SET ERR CHECKS key to display the SET
ERR CHECKS menu (Figure 26)
z [02]Control
The type 04 error, Timeout, cannot be disabled and thus does not appear in this

• Operation
menu.
operating. (The condition causing the error may result in limited or erratic perfor-
mance of the slave arm, however.)
Enable all <7 key.
5. If you wish the changes to error checking to be temporary (lasting for the current
session only), you can exit the SET ERR CHECKS menu by pressing the EXIT <8 key.
If you want the changes to be permanent (until changed again), press the 4> Save as
default key.
5 Adjusting the LCD Screen Viewing Angle

The LCD screen is provided with a temperature sensor and compensation circuit that
maintains the viewing angle over a broad temperature range. However, if the viewing
angle is not acceptable, the compensation range can be shifted to suit local viewing or
temperature conditions by adjusting a trimmer potentiometer inside the master con-
troller (see “Adjusting the LCD Screen Viewing Angle” in the “Maintenance and Ser-
vice” chapter).
Page 40 • 5 Adjusting the LCD Screen Viewing Angle 011–0566

Troubleshooting
In This Chapter:
Diagnostic Help .....................................................................page 1
Troubleshooting Tables.........................................................page 2
System Fault and Error Diagnosis .........................................page 9
Electrical Component Diagnosis ..........................................page 18
1 Diagnostic Help
This chapter has three main troubleshooting sections, each with a different diagnostic
format or method.
Troubleshooting Tables:
Use these tables to diagnose observable performance or the behavior of major slave
arm or system components.
System Fault and Error Diagnosis:

Use the master controller’s diagnostic menu to troubleshoot slave arm performance
and control malfunctions.
Electrical Component Diagnosis:

Discusses symptoms and troubleshooting within the context of individual electrical
and control components.
The essential materials in each section are interrelated in many ways and it is worth
becoming familiar all of them. Then, if a satisfactory diagnosis cannot be achieved
using one format, another one is readily available.
Since major manipulator system components are interactive, the component that dis-
plays a symptom may not be the cause of the malfunction. To narrow the field of pos-
sible causes, regardless of your diagnostic approach, first eliminate those that are the
easiest to check or correct:
1. Thoroughly inspect all system components for obvious faults or damage
(damaged or disconnected cables, hydraulic leaks, etc.
2. Make sure components are receiving the specified electrical power:
011–0567 1 Diagnostic Help • Page 1

• Troubleshooting
a. The junction box is connected to an electrical power source, the power switch
is on, and the fuse is intact.
b. If you are not using the junction box, check that the master controller and
slave controller are connected to appropriate power sources.
c. If the slave controller is powered by a separate or local source, make sure the
power source is operational and that power is reaching the cable connector
at the slave controller
Correct electrical supply problems BEFORE continuing diagnostics.
3. Make sure the slave controller is receiving the specified hydraulic power:
a. Supply pressure/flow and return pressure are within the specified range.
b. Isolation valve is working (sounds/hose twitch)
c. The HPU reservoir is full and the filters are clean.
Correct hydraulic supply and return problems BEFORE continuing diagnostics.
4. Test electrical cables for continuity, shorts, and insulation resistance, or

substitute with known functional spare cables.
5. Use the master controller’s DIAGNOSTICS menu to eliminate or isolate telemetry
malfunctions.
6. Substitute new or known functional spares for easily accessible suspect
components.
Remedy or rule out each possible cause of the malfunction until the source is isolated.
2 Troubleshooting Tables
The troubleshooting tables are organized by major component:
z Master controller screen
z Master arm
z Entire slave arm
z Individual slave arm joints
References within each table may direct you to other sections in this chapter provid-
ing additional information or diagnostic tools for determining the cause and correc-
tion of a malfunction.
2.1 Screen-Displayed Symptoms

The master controller screen provides diagnostic information as described in “System
Fault and Error Diagnosis” on page 9.
Page 2 • 2 Troubleshooting Tables 011–0567

Troubleshooting •
Table 1
Screen-Displayed Symptoms
Symptom Possible Cause Remedy
Master controller power is on Transient electrical problem. Turn master controller

(as indicated by the power power switch off.
light), but the screen display is
Loose connection to the faceplate Secure connection.
completely blank.
assembly.
LCD display screen failure. Replace display.
Master controller CPU board fail- Replace board.
ure.
Master controller display board Replace board.
failure.
Pressing a key does not execute Contaminated key switch con- Clean key switch contacts.
the appropriate function; mas- tacts.
ter arm data screen confirms
that key failure has occurred Master controller CPU board fail- Replace board.
ure.
(see “Diagnosing Master Con-
troller Key and Freeze Button Keypad gasket failure. Replace keypad gasket.
Failures” on page 12)
Keypad switch board failure. Replace board.
On master arm data display, Master arm potentiometer failure. Replace master arm.
position data for one joint
Master controller analog board Replace board.
changes even though the joint
is not moving (see “Diagnosing failure.
Master Arm Joint Problems” on
page 11).
On master arm data display, Loose connection between master Secure connection.
position data for multiple joints controller CPU board and analog
changes even though the joints board.
are not moving (see “Diagnos-
ing Master Arm Joint Problems” Master controller analog board Replace board.
failure.
on page 11).
ure.
Viewing Angle for LCD screen Ambient temperature too cold or Adjust compensation cir-
not acceptable. viewing angle outside of compen- cuit trim-pot (see“Adjust-
sated range. ing the LCD Screen
Viewing Angle” on page 7
in the “Maintenance and
Service” chapter.
2.2 Master Arm Symptoms

If the problem affects one or more slave arm joints, see “Using the DIAGNOSTICS
Menus” on page 11 for information on determining whether a master arm or slave
joint is at fault.
If you have identified a joint problem using the master arm data display, see Table 1,
Screen-Displayed Symptoms, for fault isolation information.
011–0567 2 Troubleshooting Tables • Page 3

• Troubleshooting
Table 2
Master Arm Symptoms

Master arm Master arm wiring failure or Replace master arm.

freeze button freeze button failure.
works intermit-
tently or not at
all.
ure.
Master controller motherboard Replace board.
failure.
Wrist collar does Master controller analog board Replace board.
not actuate slave failure.
arm wrist.
Wrist collar failure. Replace master arm.
Slave controller analog board fail- Replace board.
ure.
Wrist potentiometer failure. Replace potentiometer.
Wrist servo valve failure. Replace servo valve.
Actuator controller board failure. Replace board.
Pressing jaw Master controller analog board Replace board.
bands, or auxil- failure.
iary jaw switch,
does not actuate Jaw band failure. Replace master arm.
slave arm jaw. Auxiliary jaw switch failure. Replace auxiliary jaw
switch.
ure.
Jaw servo valve failure. Replace servo valve.
2.3 Slave Arm Behavior Defined

The following tables use the terms below to describe slave arm behavior.
z Unresponsive: Does not respond to control input.
z Sluggish: Responds predictably but slowly to control input.
z Erratic: Responds unpredictably to control input.
z Sagging: Fails to remain in position in the absence of control input.
z Hard over: Locked firmly against limit of mechanical travel.

Troubleshooting •
2.4 Entire Slave Arm Symptoms
Use this table to troubleshoot problems that affect all slave arm joints. If only one
joint is affected, see Table 4.
Table 3
Slave Arm Symptoms (All Joints/functions)

Slave arm is unre- Damaged wiring or loose connec- Check cable/connectors for continuity
sponsive. tion in any cable between master and shorts. Check connections.
controller and slave arm.
Electrical power failure to master Restore electrical power. Check
controller or slave controller. cables and connectors for continuity.
Blown fuses in master controller, Determine and repair cause. Replace
junction box, or slave controller. with new fuse (slave controller fuses
are auto-resetting and non-replace-
able).
Master arm or master controller (see Table 2)
board failure
Slave controller analog or CPU Replace board.
board failure.
Supply solenoid valve failure. Replace solenoid valve.
Very low or no hydraulic pressure Restore electrical power to HPU.
and/or flow. Adjust or repair HPU.
Reservoir low. Add hydraulic fluid.
Filters clogged. Clean or replace.
Blocked, pinched, or kinked sup- Clear, reposition, or protect hoses to
ply or control hoses. ensure free flow.
Load exceeds slave arm capacity. Reduce load. Use shoulder joint to lift
heavy loads.
Slave arm is receiv- Supply solenoid valve failure. Replace/repair solenoid valve.
ing hydraulic power
even though dis-
abled by master con- ure.
troller. TURN OFF
HPU IMMEDIATELY!

• Troubleshooting
Slave Arm Symptoms (All Joints/functions) (cont.)

Entire slave arm is Intermittent fault in cables, mas- Substitute components.

erratic. ter controller, or slave controller.
Damaged slave arm wiring har- Replace wiring harness.
ness.
ure.
Slave controller CPU board fail- Replace board.
ure.
Air in hydraulic lines. Bleed hydraulic system.
Low hydraulic fluid level (possi- Add hydraulic fluid. Increase HPU
bly intermittent). fluid capacity.
High HPU demand (steady or Reduce or stage HPU demand, or
intermittent). increase HPU capacity.
Partially blocked, pinched, or Clear, reposition, or protect hoses to
kinked supply or control hoses. ensure free flow.
Intermittent electrical power to Check power supply, cables, and con-
HPU, master controller, or slave nectors.
controller.
Entire slave arm is Low hydraulic pressure/flow. Adjust or repair HPU.
sluggish. Adjust or repair supply restrictor
valve (if present).
Fluid level low. Add hydraulic fluid.
Filters clogged. Clean or replace.
Partially blocked, pinched, or Clear, reposition, or protect hoses to
kinked supply or control hoses. ensure free flow.
Excessive demand on HPU Turn off other hydraulic equipment,
reduce or stage HPU demand, or
increase HPU capacity.
Control or supply hoses not sized Increase hose diameter to provide
for distance from manifold. adequate pressure and flow to slave
arm.
Hydraulic fluid dirty, contami- Replace fluid if dirty, contaminated,
nated or incorrect type or viscos- or incorrect type or viscosity. Install
ity, temperature too high or too heater or cooler to keep viscosity
low to maintain viscosity. within specification.
Load at or near slave arm capac- Reduce load. Use shoulder joint to lift
ity. heavy loads.
Severe hydraulic leak. Repair leak source.
2.5 Slave Arm Joint Symptoms

Use this table to troubleshoot problems that affect one joint. If all joints are affected,
see Table 3, “,” on page 5.

Troubleshooting •
See “Diagnosing Master Arm Joint Problems” on page 11 for information on deter-
mining whether a slave arm joint symptom is actually being caused by the master
arm.
Table 4
Individual or Multiple Joint Symptoms

Joint leaks hydraulic Actuator/hose leak (from any Replace actuator seals. Tighten
fluid. slave arm actuator). or replace hose.
One or more joints are Master arm potentiometer or mas- See Table 2.
hard over. ter controller board problem
Servo valve failure. Replace servo valve.

Actuator potentiometer failure. Replace potentiometer.
Actuator controller board failure Replace board.
Faulty actuator seal or component. Repair or replace actuator seal or
component.
One joint is unrespon- Master arm potentiometer or mas- See Table 2 and section “Diag-
sive. ter controller board failure. nosing Master Arm Joint Prob-
lems”.
Joint potentiometer failure. Replace potentiometer.
Incorrect actuator controller board Set correct address.
address.
One joint is erratic. Master arm joint or master con- See Table 2.
troller board failure.
Joint potentiometer failure. Replace potentiometer.

• Troubleshooting
Individual or Multiple Joint Symptoms (cont.)

One joint is sluggish. Servo valve failure. Replace servo valve.

Master arm joint or master con- See Table 2.
troller board failure
Load at or near joint’s capacity Reduce load. Use shoulder for
near limit. heavy loads.
Control hose clogged, pinched, Clear, reposition, protect, or
kinked, or leaking. replace hose to ensure full flow.
Partial failure of actuator seal or Repair or replace seal or compo-
component. nent.
Stuck or faulty relief valve. Repair or replace relief valve.
(Wrist only) Incorrect wrist motor Service wrist joint and set correct
preload. motor preload.
(Wrist only) Excessive return/ Clear return line. Check for inter-
drain pressure. nal leak in wrist. Adjust return
manifold.
Multiple joints are unre- Master controller analog board Replace board.
sponsive. failure.
ure.
Azimuth, shoulder, or Lock valve failure. Replace lock valve.
elbow sags or moves
freely when hydraulics
are off.
A joint moves when Actuator controller board failure. Replace board.
there is no command to
move. Master arm potentiometer or mas- See Table 2.
ter controller board failure.
Slave arm joint potentiometer fail- Replace potentiometer.
ure.
Incorrect actuator controller board Set correct address (see “Replac-
address. ing an Actuator Controller Board”
on page 13 in the “Maintenance &
Service” chapter
Single joint/actuator Faulty actuator seal or component. Repair or replace actuator seal or
sagging or drifting. component.
Faulty relief valve. Repair or replace relief valve.
Hydraulic leak. Repair leak.
Extreme load on linear actuator or Reduce or balance load. Sagging
unbalanced load on roll actuator. linear actuators or drifting roll
joints are normal with extreme or
unbalanced loads.

Troubleshooting •
3 System Fault and Error Diagnosis
3.1 Control System Orientation

The control of each slave arm function (except the jaw) utilizes a closed loop, in which
control software compares position feedback from each slave arm joint with operator
inputs to the master controller and directs hydraulic power to the slave arm as
needed to achieve correspondence. Control functions are diagrammed in Figure 1,
Control System on page 10. Standard Orion control telemetry is bi-directional and
uses an RS-485 serial interface. All slave arm control functions are connected on a
common bus.
Operator inputs to the master controller are generated by moving master arm joints,
pressing the master arm freeze button (to freeze the slave arm in its current position),
and squeezing the master arm jaw bands, or pressing the auxiliary jaw switch (to
operate the jaw functions). Each physical action is translated into a varying analog
voltage by the potentiometer in each joint of the master arm (or by switches for the
jaw function). An A-D (analog to digital) converter in the master controller converts
the analog data into a digital value (or “command”). Then, a digital address for the
corresponding slave arm joint is added to each command and all commands of a
given instant are grouped into a packet. This packet is sent to the slave controller and
distributed to the actuator controller board for each joint. Each board is configured to
accept commands with its address and to disregard all others.
Simultaneously with the creation and distribution of digital command values, poten-
tiometers in each slave arm joint are translating physical positions into varying ana-
log voltages. An analog-to-digital converter on each actuator controller board
converts each joint’s analog data into a digital value. The actuator controller board
then compares the joint's position data with the command position data sent by the
master controller. If the data are the same, no slave arm joint movement results. If
the data are not the same, the actuator controller board applies a voltage to that
joint’s servo valve, causing the servo valve to release fluid to the appropriate port of
its hydraulic actuator. The resulting actuator movement drives the slave arm joint
towards the commanded position. When the joint feedback data corresponds with the
position data commanded by the master controller the servo is closed and slave arm
stops moving.
The jaw does not have a potentiometer to provide position feedback: instead, master
controller commands can only move the jaw in a specific direction (toggle open or
closed), move the jaw as long as a jaw band is squeezed, or the auxiliary jaw switch is
pressed (position mode), or switch the jaw to a software initiated function (clamp
mode). Directing the jaw to a specific position is only possible with visual guidance.
Diagnostic Feedback Data

Master arm and slave arm digital position data are also provided to diagnostic menus
within the master controller. This information can be displayed on the master con-
troller screen for evaluating master controller and slave arm problems.

• Troubleshooting
Electrical Power
Source
Digitized slave arm
position data (for
diagnostics)
Analog master arm Digitized slave arm
joint position data command data
Master Arm Junction Box
Electrical power Electrical power
Digitized slave arm command data
Digitized slave arm position data
Electrical power
Slave Controller Hydraulic Supply

Digitized slave arm Current to Solenoid Valve
position data control valve
Digitized slave arm command

data & electrical power
Actuator Actuator
Controller Board Controller Board
Current to Current to
control valve control valve
Analog slave arm joint position data
Servo Valve Servo Valve

Electrical power
Hydraulic Hydraulic
fluid fluid
Slave Arm Slave Arm

Hydraulic Hydraulic
Actuator Actuator
Open-Loop Control
(jaw)
Closed-Loop Control
Slave Arm Joint (azimuth, shoulder,
Potentiometer elbow, elbow roll,
wrist swing & wrist
roll)
Figure 1 Control System

Troubleshooting •
3.2 Using the DIAGNOSTICS Menus
Access path: MAIN/DIAGNOSE
Security level: 0 or higher
DIAGNOSTICS LOCK
--------------------------------
1> MASTER
2> SLAVE
3> SHOW ERRORS
EXIT <8
--------------------------------
Figure 2 DIAGNOSTICS Menu
The DIAGNOSTICS menu (Figure 2) provides access to menus that display system
diagnostic information. The options under this menu can be used to diagnose faults
in the slave arm position sensors, master arm and master controller, and to display,
reset, and configure system error checking.
To enter the DIAGNOSTICS menu, press the 4> DIAGNOSE key from the MAIN
menu.
3.3 Diagnosing Problems

z If the master arm is not properly responding to control inputs, proceed to “Diag-
nosing Master Arm Joint Problems” on page 11
z If you suspect that one or more of the master controller keys, or the master arm
freeze button is not working properly, proceed to “Diagnosing Master Controller
Key and Freeze Button Failures” on page 12
z If you suspect that the slave arm is not properly positioning itself, or that the cor-
respondence between the master arm and the slave arm is not accurate, proceed to
“Diagnosing Slave Arm Positioning Failures” on page 13
z If the slave arm has frozen automatically and an ERR flag is appearing in the top
line of the LCD display, proceed to “Diagnosing and Resetting System Errors” on
page 14
3.3.1 Diagnosing Master Arm Joint Problems

Security level: 0 or higher.

• Troubleshooting
MASTER TEST LOCK

--------------------------------
Azi: +0120 -0021
Sho: +0415 +0004
Elb: -1021
Rol: -0045
Pit: +0924
Wrs: +1011
Keys:00000100000000 EXIT <8
--------------------------------
screen (Figure 3). The slave arm is automatically locked in this menu, allowing the
master arm to be safely moved for diagnostic purposes.
For this procedure, you will be viewing the values displayed for each joint in the Posi-
tion: column and the jaw bands in the Jaw Bands: column. A value of zero indicates
that the joint is at the approximate midpoint of its range of motion. Positive values
indicate movement either up, to the right, or clockwise (when the master arm is
viewed from behind); negative numbers indicate movement down, to the left, or
counterclockwise. The two jaw band values will jump from a very low (near-zero)
value to a very high (1000 or more) value when squeezed.
If a master arm joint is not being moved, the position value should either not change
or should fluctuate only slightly. A changing position value for an immobile joint
probably indicates a failure in a master arm potentiometer or a master controller
printed circuit board. Conversely, a position value that does not change or changes
only slightly when the joint is moved also indicates a failure of this type.
Apparent discontinuities in master arm data (for example, a slight movement of a
master arm joint causes a large change in position data, or vice versa) may indicate a
failed master arm joint potentiometer.
3.3.2 Diagnosing Master Controller Key and Freeze

Button Failures
screen (Figure 3, MASTER TEST Menu on page 12). For this diagnostic procedure,
you will be viewing the binary values (0 or 1) in the Keys: field.
The digits in this field display the status of each key and the freeze button, which lets
you diagnose problems with master controller keys or the master arm freeze button.
Each digit in this field corresponds to one key or to the freeze button. If the key or

Troubleshooting •
button is operating correctly, the character for that key or button will be 0 when it is
not being pressed and 1 when it is pressed. If a failure has occurred, the display will
show the same value for the corresponding digit whether the key or button is pressed
or not.
Use Table 5 to identify the functions in the Keys: field. In this table, the “character
position” column indicates how far from the left the character is. (For example, the
eleventh character from the left shows the status of the down key.)
Table 5
Master Controller Function Key Diagnosis

Character Position Function
(from left)
1 Function key 1
2 Function key 2
3 Function key 3
4 Function key 4
5 Up key (UP)
6 Left key (LF)
7 Left master arm freeze button (functional
in dual-arm systems only)
8 Master arm freeze button (in dual-arm
systems, for the right master arm only)
9 Function key 5
10 Function key 6
11 Down key (DN)
12 Right key (RT)
13 Function key 8
14 Function key 7
3.3.3 Diagnosing Slave Arm Positioning Failures

Access path: MAIN/DIAGNOSE/SLAVE
Press the 2> SLAVE key in the DIAGNOSTICS menu to display the SLAVE TEST
screen (Figure 4).The slave arm will be frozen when you enter this menu (while the
slave arm is frozen, master arm position values are not read, so the display will not
change as you move the master arm). Press the master arm freeze button to unfreeze
it and evaluate the master arm to slave arm positioning correspondence.

• Troubleshooting
SLAVE TEST FRZ

--------------------------------
Cmd: Fdbk: Diff:
Azi: +0101 +0099 -0002
Sho: +0427 +0427 +0000
Elb: -0005 -0010 +0005
Rol: +0026 +0026 +0000
Pit: +0900 +0924 +0024
Wrs: -1025 -1035 +0010
Jaw: +0036
EXIT <8
--------------------------------
Figure 4 SLAVE TEST Screen
When the master arm is moved, the master arm position values in the Cmd: (com-
mand) column should change as rapidly as the arm is moved. If they do not, you
should evaluate the master arm’s performance as described in “Diagnosing Master
Arm Joint Problems” on page 11. The values in the Fdbk: (feedback) column, repre-
senting the position sensor information from the slave arm, should catch up with the
Cmd: values whenever the movement of the master arm is halted. Although the val-
ues in the Diff (difference) column may reach the high hundreds when the master
arm is moved quickly, they should drop to single digits (indicating close correspon-
dence between the master and slave arm positioners) whenever the master arm is not
being moved.
If a large difference between the command and feedback values persists (i.e. a value
greater than 25 in the difference column), check the servo offset value for that joint.
(Refer to the section on Special Procedures, Service Settings, and Specification in the
Maintenance and Service chapter for details.) If the servo offset is properly nulled, or
cannot be nulled, a faulty slave arm position sensor is most likely at fault.
Since the jaw has no position sensors, no feedback or difference values are displayed
for these joints.
3.3.4 Diagnosing and Resetting System Errors

Access path: MAIN/DIAGNOSE/SHOW ERRORS
Press the 3> SHOW ERRORS key in the DIAGNOSTICS menu to display the SHOW
ERRORS screen (Figure 5). If there is no system error, or if the Clr Errs <5 key has
been pressed, “No Errors” will appear instead. If the ERR flag has appeared in the top
line of all menus, the system error information will appear on the left side of the dis-
play. Errors are identified by joint or function using the following letter code:

Troubleshooting •
SHOW ERRORS ERR LOCK

--------------------------------
ERRORS: Clr Errs <5
Telem [A,S,E,R,P,W,J,B]
Timeout
Warnings: Update <6
Hydr OFF
Hydr On <7
EXIT <8
--------------------------------
Hydr OFF
Figure 5 SHOW ERROR Menu
There are four error types that may appear in this screen:
A = Azimuth
S = Shoulder
E = Elbow
R = Roll
P = Pitch
W = Wrist
J = Jaw
B = Slave Controller
z Control errors:
indicate that the system is unable to accurately control one or more joints. The
Control flag will be followed by one or more letters in brackets, which indicate the
joint or joints experiencing control errors (Azimuth, Shoulder, Elbow, Roll, Pitch,
Wrist, Jaw, B = slave controller). In addition to system errors, collision, driving
the slave arm against an immovable object, or an extreme load may also trigger a
control error.
z Continuity errors:
indicate that a joint position sensor reported an unexpectedly large position
change in a short time. This error may indicate that the sensor has failed, or that
an external force, such as a collision or an extreme or immovable load) has pushed
the joint out of position. The Contin flag will be followed by one or more letters in
brackets, indicating the joint or joints experiencing continuity errors (Azimuth,
Shoulder, Elbow, Roll, Pitch, Wrist, Jaw, B = slave controller).
z Telemetry errors:
occur when the master controller loses contact with one or more joint position
sensors. This error may be caused by faulty position sensor, by a faulty connection
between the master controller and the slave arm, or by a failure of the slave arm

• Troubleshooting
slave controller. The Telem flag will be followed by one or more letters in brackets,
indicating the source of the error (Azimuth, Shoulder, Elbow, Roll, Pitch, Wrist,
Jaw, B = slave controller)
z Timeout errors:
occur when the slave arm slave controller receives no communications for 500
milliseconds (one-half second) or longer. This error may be caused by a failure of
electrical power to the slave arm slave controller, or by a faulty connection
between the master controller and the slave controller
To clear a system error condition, press the Clr Errs <5 key. New control, continuity,
telemetry and timeout errors will not generate a new display. If the ERR flag reap-
pears in the top line of the menu, press the Update <6 key to display the new errors.
All except timeout errors may be disabled in the SET ERROR CHECKS menu (see
“Enabling and Disabling System Error Checking” on page 16).
Some errors may be followed by warnings. The most common warning is that slave
arm hydraulics have been disabled (for safety reasons). Slave arm hydraulics may be
re-enabled by pressing the Hydr On <7 key.
Press the EXIT <8 key to exit the SHOW ERRORS menu.
3.4 Enabling and Disabling System Error Checking

Access path: MAIN/SETUP/SETUP MISC/SET ERR CHECKS
The SET ERR CHECKS menu (Figure 6) allows you to selectively enable and disable
monitoring of Control, Continuity and Telemetry errors. (Timeout errors cannot be
disabled.) Normally, all system error monitoring should be left enabled so that opera-
tional faults will shut down the slave arm and prevent damage to the arm or its sur-
roundings. See “Diagnosing and Resetting System Errors” on page 14 for a detailed
description of the four types of system errors.
SET ERR CHECKS LOCK

--------------------------------
[01]Contin
Change <5
Check:ENA

--------------------------------
There may be circumstances where uninterrupted operation of the arm is necessary

Troubleshooting •
despite a known fault (such as a faulty position sensor), in order to diagnose a fault,
or because collisions or extreme loads are likely to cause repeated system shutdowns.
!Caution
Disabling error-checking requires good judgment. The error monitor-
ing functions protect the slave arm (and its surroundings) from dam-
age. An automatic shutdown due to error-checking indicates the slave
arm is at risk.
DISABLING ERROR-CHECKING INDICATES THE OPERATOR’S AWARE-

NESS OF INCREASED RISK OF DAMAGE.

1. From the MAIN menu, select 3> SETUP, then 2> SETUP MISC.
2. From the SETUP MISC menu, press the 3> SET ERR CHECKS key to display the
SET ERR CHECKS menu (Figure 6, SET ERR CHECKS Menu on page 16).
z [02]Control
The type 04 error, Timeout, cannot be disabled and thus does not appear in this
menu.
operating (although the condition causing the error may result in limited or erratic
performance of the slave arm).
Enable all <7 key.
5. If you wish the changes to error checking to be temporary (lasting until power to
the master controller is disabled), you can exit the SET ERR CHECKS menu by
pressing the EXIT <8 key. If you want the changes to be permanent (until changed
again), press the 4> Save as default key.

• Troubleshooting
4 Electrical Component Diagnosis
4.1 Fuses
Single-use, replaceable fuses are present in the master controller and junction box.
The slave controller is protected by auto resetting, non-replaceable fuses. A blown or
tripped fuse in any of these components may be caused by a surge or spike in the sup-
plied power or an internal malfunction. The result is a non-operational manipulator
system until the cause is corrected and the fuse replaced. If the slave controller fuse
has tripped, operation may resume when it resets. If the cause hasn’t been corrected,
it will trip again.
If a fuse has tripped, first verify that power supplied to the junction box (and slave
controller, if independently supplied) is stable and within the specified voltage and
Hz (see “Electrical Specifications” in the Installation chapter). Check cables for visible
damage. Test cable power conductors for continuity, internal shorts, and shorts to
ground. Correct any problems. To rule out a supply surge or spike as the cause,
replace any blown fuses and turn on power to the system. If the fuse blows again, look
for internal failures. See “Master Controller PC Board Diagnosis” on page 20 for
information on diagnosing circuit board problems.
4.2 Wireway Short and Open Circuits

Wireways are the transparent tubing and wires that run between the position-sensing
potentiometers in the slave arm joints and the slave controller. An individual wireway
that gets pinched or damaged could produce an intermittent, short, or open circuit to
the enclosed wires. The wires are also susceptible to damage or faulty termination at
the potentiometer and the controller board within the slave controller.
The symptoms of an intermittent connection are erratic or jerky operation of the
affected joint. A shorted or open connection usually results in an unresponsive or
hard-over joint (see Table 4 on page 7). Diagnosis using the SLAVE TEST diagnostic
screen would show unchanging or erratic data in the feedback column, similar to the
feedback from a faulty potentiometer (also see “Diagnosing Slave Arm Positioning
Failures” on page 13 and “Actuator Controller Board” on page 22).
Note: Always inspect and test wireway wires and terminations before trouble-
shooting or replacing a potentiometer or any control board.
4.3 Diagnosing Servo Valve Failures

In the most common failure mode, the servo valve opens wide in one direction and
remains open. This is called a “hard-over” condition, because the faulty servo valve
drives the corresponding slave arm joint hard to its mechanical limit. The joint
remains in this position and does not respond to master controller inputs.
A servo valve can also fail by only partially opening, causing the corresponding joint
Page 18 • 4 Electrical Component Diagnosis 011–0567

Troubleshooting •
to respond sluggishly to control inputs.
If joint travel velocity is faster in one direction than the other, the servo valve offset
voltage may require adjustment (see section 8.2, "Setting Servo Valve Voltage Off-
sets," on page 22 in the “Maintenance and Service” chapter). This condition does not
necessarily indicate servo valve failure and most commonly occurs after a servo valve
or other control software or hardware has been replaced without resetting the offset
voltage.
You can conclusively diagnose a faulty servo valve by replacing the suspect valve with
a spare, but first eliminate master controller and slave controller telemetry errors
using the master controller diagnostics menu described in “System Fault and Error
Diagnosis” on page 9.
4.4 Diagnosing Solenoid Valve Failure

The solenoid valve in the slave controller controls the slave arm hydraulic supply.
This valve can malfunction by failing to open (resulting in an unresponsive slave
arm), partially opening (resulting in sluggish slave arm movement), or failing to close
(resulting in slave arm movement even when the master controller display says
hydraulics are off).
To determine if an unresponsive slave arm is being caused by solenoid valve failure,
enable slave arm hydraulics and listen for the valve to click as it opens. If this test is
inconclusive, disable slave arm hydraulics at the master controller. Open the slave
controller to expose the base module/SCU board, and then enable slave arm hydrau-
lics. If the LED 6 indicator light on the board lights up, current is being sent to the
solenoid valve. Listen for the valve to click as it goes on. If it does not, either the sole-
noid valve or its cartridge may need to be replaced (see “Base Module/SCU Board
LED Diagnostics” on page 23 for more information).
4.5 Diagnosing Potentiometer Failure

For each slave arm or master arm joint except the jaw, the degree of extension or
rotation is measured with a potentiometer. A 5VDC reference voltage is applied
across the resistor element. Actuator travel moves a wiper along the element and pro-
duces a voltage that varies with the wiper position. This analog voltage is converted to
a digital value in the master controller or actuator controller board for use by control
software.
Potentiometer failures in both the master arm or slave arm typically produce either a
hard-over condition in the associated joint or in jerky or erratic joint movement.
Potentiometer outputs (after conversion from analog voltages to digital position data)
should be checked in the MASTER TEST and SLAVE TEST diagnostic screens (access
path: MAIN/DIAGNOSE) on the master controller before disassembling or servicing
any hardware (see “Using the DIAGNOSTICS Menus” on page 11 for additional infor-
mation about interpreting this data for troubleshooting purposes).
Hard-over or unresponsive conditions can result under the following conditions:
011–0567 4 Electrical Component Diagnosis • Page 19

• Troubleshooting
z The wiper is broken or stuck
z Potentiometer conductors are open or shorted
z Potentiometer signals are prevented from reaching the actuator controller board
by an open connection or broken wire between the potentiometer (slave arm) and
the actuator controller board (slave controller)
z The actuator controller board is not producing the proper reference voltage (5 v)
Jerky or erratic movement can result from:

z A wiper contact or ribbon that is worn or contaminated
z A wiper that does not move smoothly
z An intermittent connection between the potentiometer and the controller board
See the slave arm wiring diagram in the Drawings and Part Lists chapter for informa-
tion necessary to check potentiometer reference and output voltages. connector for
proper voltages. A functional potentiometer should show a varying voltage from the
wiper that changes proportionally with movement of the joint. Disconnected from its
controller module, a faulty potentiometer will show infinite resistance between any
two potentiometer leads (also see “Actuator Controller Board” on page 22).
Slave arm potentiometers and the complete master arm assembly are not considered
to be user serviceable. You can conclusively diagnose a faulty slave arm potentiometer
by replacing the suspect unit with a spare. A suspect master arm potentiometer can
be checked by either replacing the master arm assembly or the complete master con-
troller unit.
!Caution
Confirm that a replacement master controller has the same operating
voltage.
4.6 Master Controller PC Board Diagnosis

If you suspect that a printed circuit board has failed, the easiest way to confirm a fail-
ure is to replace the suspect board with a spare.
4.6.1 Master Controller Boards

If the manipulator system has been subjected to excessive voltage or a voltage spike,
the fuse on the mother board (2) may need replacement (see section 5.2, "Fuse
Replacement," on page 6 in the “Maintenance and Service” chapter for fuse specifica-
tions). Inspect the fuse before proceeding with troubleshooting. Verify that the supply
voltage is stable and within specification.
If you suspect a master controller board malfunction, you can replace the board set
(CPU board plus analog board) with a spare set. (If you replace a CPU board, be sure
to remove the software PROM from the original board and insert it into the replace-
ment board before you install the replacement board (see section 5.4, "Master Con-

Troubleshooting •
troller EPROM Chip Replacement," on page 8 in the “Maintenance and Service”
chapter). If replacing the entire board set fixes the problem, you can replace individ-
ual boards from the original set until you isolate the faulty board.
The opto-iso board’s LED indicator lights can be used to diagnose some communica-
tion failures. See “Base Module/SCU Board LED Diagnostics” for more information.
4.6.2 Opto-Iso PC Board LED Diagnosis

The opto-iso board (5) has four LEDs that light in the presence of specific telemetry
activity (see Figure 7 for their location and function).
DS3 = XMIT RS485
DS1 = RCV RS485
DS4 = XMIT RS232
DS2 = RCV RS232
Figure 7 Opto-Iso PC Board Diagnostic LEDs
LED functions are described in Table 6. LEDs DS1 and DS3 are active only if your sys-
tem uses the RS-485 communication protocol; DS2 and DS4 are active only for the
RS-232 communication protocol.

• Troubleshooting
Table 6
Opto-Iso PC Board LED Diagnostics

Comm.
LED State Explanation
Protocol
DS1 RS485 On Data is being received by the master controller

from the base module/SCU board or an actuator
controller board.
Off No data is being received by the master controller
controller board.
DS2 RS232 On Data is being received by the master controller
controller board.
Off No data is being received by the master controller
controller board.
DS3 RS485 On The master controller is transmitting data to the
slave controller. If system uses RS485, this light
should always be on.
Off The master controller is not functioning correctly or
system is not using RS485 telemetry.
DS4 RS232 On The master controller is transmitting data to the
slave controller. If system uses RS232, this light
Off The master controller is not functioning correctly or
system is not using RS232 telemetry.
4.7 Slave Controller PC Board Diagnosis

If you suspect that a printed circuit board has failed, the easiest way to confirm a fail-
ure is to replace the suspect board with a spare.
4.7.1 Actuator Controller Board

Each actuator control module on the slave controller motherboard board provides the
5V reference voltage to its position-sensing potentiometer and the A-D (analog to dig-
ital) conversion of the potentiometer’s feedback voltage.
If SLAVE TEST feedback data for a joint indicates a problem (see “Diagnosing Slave
Arm Positioning Failures” on page 13) check the reference voltage (+5V) and feedback
voltage (0-5V) at the terminal strip of the appropriate actuator controller board.
z If the reference and feedback voltages appear normal, the actuator controller
board’s A-D converter may be at fault
z If the reference voltage is OK, but the feedback voltage is erratic or absent, the
potentiometer or its wiring may be at fault

Troubleshooting •
z If the reference voltage is erratic or absent, the actuator board’s voltage regulator
may be at fault
Each actuator control module on the slave controller motherboard board is config-
ured with a specific address for the joint/actuator its servo will control. When the
master controller generates a command packet to the slave arm, each individual com-
mand is encoded with its unique address. Every actuator controller board receives the
complete packet, but accepts only the command encoded with its address. Commands
with other address are disregarded.
If a replacement board is not configured, or configured with the wrong address, the
actuator it controls will not function as intended. Wrong addresses can have two con-
sequences:
z If the board is configured with an address the control system does not recognize,
the board will disregard all master controller movement commands and the joint
will remain unresponsive
z If the board is configured with the address of a different joint, it will respond to
commands for that joint. For example, if the actuator controller board for the
shoulder is configured with the azimuth’s address, the shoulder will attempt to
comply with azimuth movement commands
An incorrect address can be diagnosed using the FREEZE menu (access path: MAIN/
OPERATE/FREEZE). Freeze the malfunctioning joint. If the joint continues to
respond to general master arm movements, its address may be incorrect. Careful
manipulation of the master arm and observation of slave arm responses may indicate
the other joint with which it shares an address. Another approach is to continue freez-
ing joints until it becomes inactive.
Instructions for setting actuator board addresses can be found in “Replacing an Actu-
ator Controller Board” on page 13 in the “Maintenance and Service” chapter.
4.7.2 Base Module/SCU Board

The slave controller’s LED indicator lights can be used to diagnose some manipulator
system communication failures and failure of the solenoid valve that controls slave
arm hydraulic supply. See “Base Module/SCU Board LED Diagnostics” for more
information.
Two components on the base module/SCU board (U4 and U5) contain software pro-
grams that must be compatible with software in the master controller. Before you
replace a base module/SCU board with a spare, verify that these parts on the spare
are marked with the same part and revision number as those on the original board.
Contact Schilling Robotics if you need assistance with this verification.
4.7.3 Base Module/SCU Board LED Diagnostics

You can use the diagnostic LEDs on the base module board to diagnose some manip-
ulator system communication problems and failure of the solenoid valve that controls
slave arm hydraulic supply. Figure 8 shows the location of each LED on the board.

• Troubleshooting
Figure 8 Base Module/SCU Board Diagnostic LEDs
The LEDs function as described in Table 7. Some LEDs are used only if your system
uses the RS-485 communication protocol; others are used only for the RS-232 com-
munication protocol.
Table 7
Base Module/SCU Board LED Diagnostics

Indicator Comm.
State Explanation
Light Protocol
LED 1 RS-232 On Data is being transmitted from the master con-

troller to the base module board. In your sys-
tem, this light should always be on.
Off No data is being transmitted from the master
controller to the base module board.
LED 2 RS-232 On Data is being transmitted from the base module
board or an actuator controller board to the
master controller.
Off No data is being transmitted from the base
module board or an actuator controller board to
the master controller.

Troubleshooting •
Base Module/SCU Board LED Diagnostics (cont.)

Indicator Comm.
State Explanation
Light Protocol
LED 3 RS-485 On The base module board is receiving data from

the master controller. In your system, this light
Off The base module board is not receiving data
from the master controller.
LED 4 RS-485 On An actuator controller board or the base module
board is transmitting data to the master control-
ler.
Off No transmissions are taking place from an actu-
ator controller board or the base module board
to the master controller.
LED 5 RS-485 On The base module board is set to receive a data
transmission from the master controller. In your
system, this light should always be on.
Off The base module board is set to send a data
transmission to the master controller. The trans-
mitted data could be from the base module
board or an actuator controller board.
LED 6 Not in use.
LED 7 Not in use.
LED 8 N/A On Sending current to the solenoid valve that con-
trols slave arm hydraulic supply (enabling the
slave arm hydraulic supply).
Off No Current to the solenoid valve that controls
slave arm hydraulic supply (disabling the slave
arm hydraulic supply).
4.8 Customer Service Assistance

To help speed diagnosis and problem resolution, please have the following informa-
tion available when you contact Schilling Robotics customer service.
1. What are the symptoms of the problem?
2. Is the problem intermittent or constant?
3. If the problem is intermittent, under what conditions does it occur?
4. Was the affected part of the manipulator system subjected to excessive loads or
adverse conditions (such as vibration, heat, or shock)?
5. Did the problem occur suddenly or gradually?
6. Does the problem appear to affect other functions?
7. What system functions are still operable?

• Troubleshooting
8. Has anyone tried to fix the problem? If so, have actuators and/or actuator control
modules been interchanged with those from another Orion slave arm or from spares?
9. What is the system serial number? (You can find the serial number on the slave
arm base segment.) If the problem is appears to be electrical or software-related,
what is the part number of the master controller software PROM? (The PROM is on
the master controller CPU board; it is labeled with its part number, which starts with
the numbers “014.”)
10. Are there any additional relevant details?

Maintenance and Service
In This Chapter:
Safety Alerts .........................................................................page 2
Important Service Practices & Procedures ............................page 2
Maintenance .........................................................................page 2
Junction Box Service .............................................................page 5
Fuse Replacement ...................................................................... page 5
Master Controller Service ......................................................page 5
Fuse Replacement ...................................................................... page 6
Adjusting the LCD Screen Viewing Angle ....................................... page 7
Master Controller EPROM Chip Replacement................................... page 8
Shortening the Hydraulic Hoses ............................................page 9
Slave Controller ..................................................................page 10
Fuses ..................................................................................... page 10
Internal Access ........................................................................ page 11
Replacing the Solenoid Filter ...................................................... page 12
Replacing an Actuator Controller Board ....................................... page 13
Accessing the Servo Valves, Jaw Bypass Valve, and Filter .............. page 15
Replacing a Servo Valve ............................................................ page 16
Removing the Jaw Bypass Valve ................................................. page 17
System Adjustments ...........................................................page 18
Changing the System Telemetry Configuration ............................. page 18
Setting Servo Valve Voltage Offsets ............................................ page 22
Service Instructions............................................................page 24
Service instructions cover major repairs, including:
— Slave arm azimuth, upper arm, forearm roll actuator, forearm, wrist, jaws, linear
actuators, pitch assembly, yaw assembly, wrist, jaw, and linear actuators
— Master controller faceplate
— Compensator
Drawings and part lists to support the work instructions can be found in the “Draw-
ings & Part Lists” chapter. To troubleshoot a problem, see the “Troubleshooting”
chapter.
011–0568 • Page 1
• Maintenance and Service
1 Safety Alerts
Observe the following WARNING and CAUTION notices.
! WARNING
ELECTRICAL, HYDRAULIC, AND MECHANICAL HAZARDS! Before you
service the manipulator system, turn off hydraulic and electrical
power. Always observe appropriate safety procedures.
!Caution
Even when the slave arm has been hydraulically isolated, high pres-
sure may remain in some components. Wear safety goggles, bleed
system pressure where possible, and open hydraulic components and
fittings slowly to allow safe release of pressure.
2 Important Service Practices & Procedures

Always observe the following practices and procedures when you work on the slave
arm:
z Turn off electrical power to the master controller, junction box, and slave con-
troller
z Turn off power to the HPU
z Support the slave arm when hydraulic connections are opened or mechanical
joints are disconnected
z Some components retain hydraulic pressure. Open hose connections and other
hydraulic fittings slowly to allow pressure to dissipate. Be prepared for fluid spills
z Clean, degrease, and inspect disassembled parts before reassembling
z Replace any o-rings or seals that are broken, damaged, or shows signs of wear.
Apply Dow Corning® 55 o-ring lubricant or petroleum jelly before installation (do
not use lubricants that contain suspended particles such as molybdenum or graph-
ite — the particles can be drawn into the hydraulic system and clog filters)
z Apply a small amount of Aqua Lube thread lubricant (or equivalent) to all slave
arm fasteners before reinstallation unless they are exposed to the hydraulic system
or you are directed otherwise by a service instruction or engineering drawing
z Torque fasteners to the specified value
3 Maintenance
Maintenance keeps your slave arm functioning safely and efficiently, helps reduce
Page 2 • 1 Safety Alerts 011–0568

Maintenance and Service •
downtime and service expenses, and extends its service life. This section provides
information on recommended maintenance practices and schedules.
3.1 Daily Maintenance and Inspections

Daily inspections reveal existing, 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 new 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
3.2 Periodic Maintenance

Regularly scheduled maintenance helps maintain the performance, efficiency, and
service life of your Orion manipulator system.
1. Develop schedules for inspection, maintenance, and service that fit your
manipulator system'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.
Inspect components and observe performance frequently, starting with the first use
of the slave arm, and record your notes. Documenting initial conditions helps you to
track changes and wear, and set up maintenance and service schedules appropriate to
your slave arm's operating environment and duty cycles.
Table 1 contains a minimum maintenance schedule for your manipulator system and
should be used along with the schedule supplied with your HPU and other equip-
ment.
011–0568 3 Maintenance • Page 3

Table 1 Recommended Minimum Maintenance Schedule (cont.)
Recommended Minimum Maintenance Schedule

Schedule Period Maintenance Task
After daily operation “Daily Maintenance and Inspections” on page 3
Every 100 operating hours Retorque all external slave arm fasteners.
Check a sample of hydraulic fluid for water and par-

ticulate contamination. Replace if contaminated.
(seawater operation) Recoat pivot pins and pivot pin

bores with silicone grease such as DC-5.
Every 500 operating hours or per Check hydraulic tank fluid level. Clean/replace HPU
HPU documentation suction strainers, fluid and breather filters.
Every 2000 operating hours Replace worn or damaged actuator pins and bushings.
Every 2000 operating hours or per Drain and replace hydraulic fluid (filter replacement
HPU documentation fluid).
Every 2000 operating hours or every Replace all actuator o-rings and seals. Lubricate with
3 years (whichever comes first) Dow Corning® DC-4. Clean all o-ring grooves and
surfaces.
3.3 Hydraulic System Maintenance

Consistent maintenance of your hydraulic system extends the service life of your
Orion slave arm and minimizes downtime. The following steps are the basis of an
effective hydraulic maintenance schedule (see your HPU documentation for complete
details):
1. Use hydraulic fluid of the proper type and viscosity. Very high viscosities can
cause cavitation damage to pumps and valves, and sluggish slave arm performance.
Low viscosities can impair dynamic lubrication, and reduce system efficiency and
slave arm performance.
2. Maintain the correct level of hydraulic fluid. Low or inadequate levels can cause
high fluid temperature and allow air to enter the system. Filter all added fluid.
3. Sample and inspect hydraulic fluid for particle and moisture contamination on a
regular schedule. Contaminated fluid is the prime cause of premature wear and
component failure. Replace contaminated fluid with fresh filtered fluid. Install
additional fluid and breather filters as needed to ensure clean fluid.
4. Exclude air from the system by keeping all connections tight and purging
connections that have been opened. Air in the hydraulic system can cause erratic
slave arm operation and premature wear of pumps and valves.
Page 4 • 3 Maintenance 011–0568

5. Clean/replace the HPU fluid filters, breather filters, and suction strainers per
recommendations of manufacturers (see your HPU documentation) or as required in
a program of regular fluid inspection.
6. To avoid hose leaks and blowouts regularly inspect system hoses for cuts,
abrasions, insufficient slack, and excessive bending or flexing (particularly at
fittings). Repair or replace damaged hoses. Install hose protection or reroute hoses, if
practical, to prevent new damage.
7. Inspect the HPU regularly during operation: excessive heat or noise can indicate
hydraulic, mechanical, or electrical problems. See your HPU documentation for
troubleshooting HPU symptoms. HPU malfunctions and breakdowns can introduce
contaminates into the hydraulic fluid. Always flush the hydraulic system and replace
with fresh, filtered fluid after major HPU repairs.
4 Junction Box Service

This section contains information on special maintenance and service procedures not
covered in the Service Instructions.
Fuse Replacement . . . . . . . . . . . . . Littlefuse T 6.3AL 250V (SRS P/N 005-0587)
The fuse is located under the fuse symbol, between the power switch and the power-
in socket. Use the tab on the fuse cover to pry out the fuse for replacement or inspec-
tion.
4.1 Fuse Replacement

The fuse is located under the fuse symbol, between the power switch and the power-
in socket. Use the tab on the fuse cover to remove the fuse for replacement or inspec-
tion.
Replacement fuse . . . . . . . . . . . . . . Littlefuse T 6.3AL 250V (SRS P/N 005-0587)
5 Master Controller Service

This section contains special maintenance and service procedures not covered in the
Work Instructions.
5.1 Accessing Internal Components
5.1.1 Removing the Faceplate

1. Turn off the master controller and disconnect the whip from its power source.
2. Remove the four screws holding the master controller faceplate to the enclosure
(Figure 1).
011–0568 4 Junction Box Service • Page 5

Remove Screws (4X)
Swing Faceplate Up To Left
Figure 1 Removing the faceplate
3. Lift the faceplate assembly out of the enclosure. Swing it up and over to the left
until it is upside down (Figure 1). This will expose the face of the CPU PC board. Take
care to immobilize the master arm and avoid stressing the cables connected to the
boards in the enclosure.
5.1.2 Installing the Faceplate

4. Carefully swing the faceplate assembly back over and seat it on the enclosure.
Reinstall the four mounting screws.
Check that no wires or cables are pinched between the faceplate and the enclo-
sure.
5.2 Fuse Replacement

Replacement fuse . . . . . . . Littlefuse microfuse 5ALF 125V (SRS P/N 005-1896).
To check or replace the fuse follow these steps:
1. Open the master controller as described in section 5.1.1, "Removing the
Faceplate," on page 5.
2. Check or replace the fuse. The fuse (F1) and a spare fuse (F1A) are located at the
corner of the master controller PC board (Figure 2).
F1
F1A
Figure 2 Master controller fuse (F1) and spare fuse (F1A)
Page 6 • 5 Master Controller Service 011–0568

3. Close the master controller as described in section 5.1.2, "Installing the
5.3 Adjusting the LCD Screen Viewing Angle

The LCD screen comes with a temperature sensor and compensation circuit that
keeps the viewing angle stable over a broad temperature range. If you find the view-
ing angle is not acceptable for your work environment, adjust it as follows:
1. Before changing the LCD screen angle, check the current angle:
a. Turn on power to the master controller under work environment conditions.
— The slave controller and slave arm need do not need to be powered up for this
test.
b. Allow the master controller to reach its normal operating temperature (5-10
minutes). It is not unusual for the viewing angle to be unacceptable for the
first few minutes of operation.
To adjust the LCD screen viewing angle follow these steps:
2. Locate the LCD adjustment potentiometer (labeled R1 on the PC board) (Figure
3).
Figure 3 LCD Adjustment potentiometer
3. Use a small flat blade screwdriver, adjust this potentiometer:

— Move viewing angle toward top of the LCD: Turn screw CW 1/8 turn.
— Move viewing angle toward the side of the LCD: Turn screw CCW 1/8 turn.
4. Put the master controller faceplate back on its enclosure. Connect power and turn
on the master controller. Allow the master controller to reach its normal operating
temperature (5-10 minutes). Check the viewing angle.
— If the angle is good, replace the four screws.
— If the viewing angle requires further adjustment, repeat steps 1-5 until the view-
ing angle is acceptable.
011–0568 5 Master Controller Service • Page 7

5.4 Master Controller EPROM Chip Replacement
!Caution
PC board components can be damaged by static electricity. Wear a
grounded anti-static wrist band handling PC boards or chips.
To replace the EPROM chip on the master controller CPU board, perform the follow-
ing steps (also refer to the master controller drawing in the “Drawings & Part Lists”
chapter).
2. Remove the elastic band (if present) from the locking clips securing the EPROM.
Pull the clips away from the EPROM and extract it from the socket (see Figure 4).
3. Confirm that all pins on the new EPROM (014-0695) are aligned and straight.
Orient the EPROM with its notch towards the edge of the CPU board and press it
gently into the socket until the locking clips snap into place. Install the elastic band
over the locking clips.
Locking clips
Notch Edge of
Notch CPU board
EPROM
Band
Figure 4 EPROM chip and associated hardware
!Caution
Installing the chip backwards will damage system electronic assem-
blies. Locate notch on chip to edge of CPU board.

Page 8 • 5 Master Controller Service 011–0568

6 Shortening the Hydraulic Hoses

The following instructions describes how to shorten and reterminate a hydraulic hose
with reusable fitting 006-1205 (OEM Aeroquip 63-190600-4).
1. Determine the required hose length and mark the hose at the cut-off point.
Disconnect both ends of the hose from components.
2. Wrap the hose with masking tape at the cut-
off point and cut square through the taped area
using a cut-off saw fitted with an abrasive blade
(you can also use a fine-tooth hacksaw, as
shown in Figure 5). Remove the tape and trim
any loose wires flush with the tube stock.
Remove any burrs on the bore of the tube stock
with a knife.
3. Trim the hose jacket back about 1-1/2 in.
1-1/2” from the end, exposing the braid, as shown in
Figure 5.
Figure 5
4. Match and install new hose code tags to the appropriate hoses, at least 2-inches
from the hose ends. Hose code/functions designations are shown in the table above.
5. Install the socket onto the hose end (Figure 6,
arrow). Push the new sleeve over the end of the
tube and under the wire braid by hand as shown in
Figure 6. Complete positioning of the sleeve by
pushing the hose end against a flat surface. It is
critical that the tube stock butts against
the inside shoulder of the sleeve (nearly
flush with the flat end-face of the sleeve).
Visually confirm this orientation.
Figure 6
6. Clamp the hex of the nipple in a vise (male

fitting shown). Push the hose and sleeve over
nipple as shown in Figure 7. Work the hose with
twisting motion until it is seated against the
nipple chamfer (at the base of the nipple).
Figure 7
7. As shown in Figure 8A below, push the socket forward on the hose and thread
onto the nipple.
011–0568 6 Shortening the Hydraulic Hoses • Page 9

8. As shown in Figure 8B below, use a wrench to tighten the nipple hex until it
bottoms on the socket hex and the corners of nipple and socket hexes align.
A B
Figure 8
9. Clean interior of hose assembly with compressed air or flush with mineral spirits
or hot water (150F max.). If the hose will not be reconnected immediately, cap or plug
end fittings.
10. Inspect the fitting assembly. The gap between the nipple hex and the socket
should be 1/32-in. or less. The nut on a female fitting should swivel freely.
11. Proof testing:
!Caution
Conduct hose tests with adequate safeguards to protect the operator.
Test the hose assembly at 6000 psi (twice the recommended working pressure of the
hose). Hold the test pressure for not more than one minute and not less than 30 sec-
onds. When test pressure is reached, visually inspect hose assembly for any leaks,
bulges, or any movement of the hose in relation to the hose fitting. Correct any
defects before placing the hose into service.
12. Install the hoses between the slave arm and slave controller, matching the hose
and fitting codes.
7 Slave Controller
This section contains special maintenance and service procedures not covered in the
Work Instructions.
For additional details, refer to drawing and part list 101-3912 in the “Drawings and
Part Lists” chapter.
7.1 Fuses
Fuse Replacement: Slave controller circuits are protected by self-resetting, non-
Page 10 • 7 Slave Controller 011–0568

replaceable fuses.
7.2 Internal Access
7.2.1 Opening the Slave Controller

To access internal slave controller components, perform the following steps:
1. Disable electrical power and hydraulic power to the slave controller.
2. Isolate the compensation system and drain the slave controller cavity.
3. Remove the twelve SHCS and washers securing the slave controller lid (Figure 9).
Remove the lid.
Remove 10-24 Screw & Washer (12X
Figure 9 Slave Controller Lid Screws
With the lid removed the following special service procedures can be performed:
z “Replacing the Solenoid Filter” on page 12
z “Replacing an Actuator Controller Board” on page 13
z “Changing the Slave Controller Protocol” on page 20
With the lid removed and the motherboard swung aside, the following special service
procedures can be performed (“Accessing the Servo Valves, Jaw Bypass Valve, and
Filter” on page 15):
z “Replacing a Servo Valve” on page 16
z “Removing the Jaw Bypass Valve” on page 17
7.2.2 Closing the Slave Controller

1. Replace the slave controller lid o-ring (004-0870). Make sure it is completely
seated before installing lid. Install the twelve 10-24 x 1-in screws and washers, and
torque to 45 in/lb (Figure 9).
011–0568 7 Slave Controller • Page 11

7.3 Replacing the Solenoid Filter
The solenoid valve assembly contains a tubular, mesh-screen hydraulic filter which
can be removed for cleaning. The most common symptom of a clogged filter is slug-
gish operation of all slave arm functions despite adequate hydraulic pressure and flow
from the HPU.
This procedure assumes the lid has been removed from the slave controller. The sole-
noid filter assembly is shown in Figure 10, Solenoid Filter Access on page 12.
1. Remove the six 10-24 x 1-1/2 screws from the filter block and lift off the filter cap/
filter assembly (Figure 10).
Filter Block
Filter Cap
10-24 Screw (6x
Figure 10 Solenoid Filter Access
2. Remove the filter from the cap. Use compressed air to blow out passages in cap.
3. Install a new filter into cap (check that o-ring is present) or replace original filter
after cleaning with ultrasound (Figure 11).
O-ring 004-0695 Filter and

O-ring
O-ring 004-0222
Filter Cap
Figure 11 Filter, Filter Cap, and O-Rings
4. Install new o-rings 004-0695 and 004-0222 to cap (Figure 11).

5. Replace the filter cap and secure with the six 10-24 x 1-1/2-in screws. Torque the
screws to 45 in/lb.

6. Replace the slave controller lid as described in section 7.2.2, "Closing the Slave
Controller," on page 11.
7.4 Replacing an Actuator Controller Board
!Caution
When any actuator controller board is replaced, the new board’s DIP
switch must be set with the address of the actuator it will control. If
the controller board has the wrong address, the actuator may not
respond to commands or may respond to commands intended for a
different actuator.
When any controller board is replaced on the motherboard, its DIP switch must be set
with the address of the actuator it will control. If the controller board has the wrong
address, the actuator may not respond to commands or may respond to commands
intended for a different actuator.
!Caution
When you handle the PC boards or other electronic components, wear
an anti-static wrist band attached to earth ground or a large metal
object.
The actuator/joint designation and DIP switch settings are printed on the mother-
board beneath each of the actuator controller boards.
1. Complete the steps in section 7.2, "Internal Access," on page 11.
2. Locate the controller board to replace.
3. Remove the harness at J5 (Figure 12). Press all five tabs on connector J4 to
remove the ribbon cable.
4. Squeeze the three tabs and lift the board straight up off the standoffs.
Harness to J5
Tabs (3x)
Connector J4
Figure 12 Removing Harness, Ribbon Cable and Controller Board

5. Set the DIP switches on the replacement controller board as outlined below:
The DIP switch unit is shown in Figure 13. The individual switches are labeled, left to
right, with numbers from 1 through 8 across the bottom of the switch unit. Each
switch contains a sliding tab. The switch is in the “on” position when the sliding tab is
moved towards the “on” label. The switch is in the “off” position when the sliding tab
is moved closest to its number.
ON
1 2 3 4 5 6 7 8
Figure 13 Setting Controller Board Address Switches
The actuator/joint designation and DIP switch settings are printed on the mother-
board beneath each of the actuator controller boards. Switch settings for each joint
are also shown in Table and Table .
— Use a non-conducting tool for moving switches.
Table 2
Standard (Right-Hand) Slave Arm Settings

Joint
Joint Name Sw 1 Sw 2 Sw 3 Sw 4 Sw 5 Sw 6 Sw 7 Sw 8
No.
0 Azimuth On On On On On On On On
1 Shoulder Off On On On On On On On
2 Elbow On Off On On On On On On
3 Forearm roll Off Off On On On On On On
4 Pitch On On Off On On On On On
5 Wrist Off On Off On On On On On
6 Jaw On Off Off On On On On Off
Table 3
Left-Hand Slave Arm Settings

Joint
No.
0 Azimuth On On On Off On On On On
1 Shoulder Off On On Off On On On On
2 Elbow On Off On Off On On On On

Left-Hand Slave Arm Settings (cont.)

Joint
No.
3 Forearm roll Off Off On Off On On On On

4 Pitch On On Off Off On On On On
5 Wrist Off On Off Off On On On On
6 Jaw On Off Off Off On On On Off
6. Install the new controller board. While installing the board, be careful not to
damage the pins that the board seats on.
7. Install the ribbon cable and wire harness (Figure 12).
7.5 Accessing the Servo Valves, Jaw Bypass

Valve, and Filter
The following steps assume the slave controller lid has been removed (section 7.2,
"Internal Access," on page 11):
1. On the base module board, press all five tabs on connector J2 to remove the
ribbon cable (Figure 14).
Ribbon Cable
Connector J2
Motherboard
Base Module Board
Figure 14 Removing Base Module Board Ribbon Cable
2. Remove the wire harness from J5 on the jaw, wrist, and pitch controller boards
(Figure 15). Feed the wires down through the holes in the motherboard.

Wire Harness J5(3x)
Motherboard
Retaining Screw
Jaw Bypass Valve
Figure 15 Removing Wire Harness at J5 (3x)
3. Remove the three 6-32 screws that hold the motherboard in place (Figure 15).
Carefully swing the motherboard up and to the side.
With the motherboard swung aside, the following service procedures are possible:
z “Replacing a Servo Valve”
z “Removing the Jaw Bypass Valve” on page 17
7.6 Replacing a Servo Valve

This procedure assumes the motherboard has been swung aside and the servo valves
are accessible (“Accessing the Servo Valves, Jaw Bypass Valve, and Filter” on page
15).
Lockvalves and associated assemblies for other servo valves vary with function. To
replace a servo valve follow the steps below:
1. Remove the four 6-32 screws that hold the servo valve in place (Figure 16,
Removing Servo Valve on page 17). Remove the servo valve and the o-ring that lies
under it.

Servo Valve
6-32 Screw (4x)
10-24 Screw (4x

Bypass Valve
Lockvalve
Lockvalve
Manifold
Figure 16 Removing Servo Valve
2. Lubricate a new o-ring with o-ring lube and install. Install the new servo valve
and torque 6-32 screws to 5 in/lb.
3. Swing the motherboard back into position. Secure it with the three 6-32 screws
and torque them to 5 in/lb. Feed the wire harnesses up through the motherboard and
connect to the J5 connector on the controller boards (“Removing Wire Harness at J5
(3x)” on page 16). Connect the ribbon cable to the base module board (“Removing
Base Module Board Ribbon Cable” on page 15).
7.7 Removing the Jaw Bypass Valve

a bypass valve in the slave controller causes the jaw to relax its grip. Objects held by
power is disabled, the bypass valve must be removed.
Note: This procedure requires four new SHCS, 10-24 x 1-1/2-in (Schilling P/N
002-0197), and cannot be completed without them (see Orion Spares Kit 008-0127
or Slave Controller Spares Kit 008-0132).
This procedure assumes the motherboard has been swung aside and the servo valves
are accessible (“Accessing the Servo Valves, Jaw Bypass Valve, and Filter” on page
15).
Note: It is not necessary to remove or separate the servo valve from the lock-
valve for this procedure.

1. Locate the jaw servo valve (Figure 16).
2. Remove the four 10-24 screws that secure the servo valve/lockvalve assembly and
the jaw bypass valve to the slave controller manifold.
3. Carefully move the servo valve/lockvalve assembly aside and remove the bypass
valve block and the bottom four o-rings.
4. Add four new o-rings to the bottom of the servo valve/lockvalve assembly. Place
the servo valve/lockvalve assembly onto the slave controller manifold and align the
mounting holes.
5. Install the four new SHCS 10-24 x 1-1/2-in (P/N 002-0197) and torque to 45 in/
lb.
6. Swing the motherboard back into position. Secure it with the three 6-32 screws
and torque them to 5 in/lb. Feed the wire harnesses up through the motherboard and
connect to the J5 connector on the controller boards (Figure 15). Connect the ribbon
cable to the base module board (Figure 14).
8 System Adjustments
8.1 Changing the System Telemetry Configuration

This manipulator system can be operated using RS232 or RS422/485 half duplex
telemetry. RS232 is the factory default. To alter the telemetry configuration you must
change jumper settings on:
z the opto-iso PC board in the master controller
z the slave controller PC board in the slave controller
8.1.1 Changing the Master Controller Protocol

To configure the jumper settings in the master controller, complete the steps in
“Accessing Internal Components” on page 5 to access to the opto-iso PC board (Fig-
ure 17). Then proceed to the steps below:
Page 18 • 8 System Adjustments 011–0568

Figure 17 Opto-Iso PC board
1. Set the jumpers for the desired telemetry option using Table and Figure 18.
Table 4
Opto-Iso PCB Jumper Settings

RS422(485)
Switch
Number HALF DUPLEX RS232
(DEFAULT)
SW1 PIN 1-2 PIN 2-3

SW2 1-2 2-3
SW3 1-2 1-2
SW4 1-2 1-2
SW5 1-2 2-3
SW6 1-2 2-3
SW7 1-2 2-3
011–0568 8 System Adjustments • Page 19

= RS232 HD (DEFAULT) = RS422 (RS485) HD
Figure 18 Opto-Iso PCB Jumper Settings
2. Carefully swing the faceplate assembly back over and seat it on the enclosure.
Check that no wires or cables are pinched between the faceplate and the lip of the
enclosure. Install the four mounting screws.
3. Proceed to “Changing the Slave Controller Protocol” on page 20.
8.1.2 Changing the Slave Controller Protocol

To configure the jumpers in the slave controller, complete the steps in section 7.2,
"Internal Access," on page 11 to gain access to the base module/SCU PC board (the
small board located above the solenoid and filter). Then proceed to the steps below:
1. Set the jumpers on the base module/SCU PC board for the desired telemetry
option using Table 5 and Figure 19.

DEFAULT
= RS485 HD
= RS232 HD
Figure 19 Telemetry Jumper Settings
Table 5
Slave Controller Opto-Iso PCB Jumper Settings
Jumper RS422(485) RS232

Number HALF DUPLEX (DEFAULT)
JP4 PINS 1-2 PIN 2-3

JP5 1-2 2-3
JP6 1-2 2-3
JP7 1-2 2-3
JP8 1-2 2-3
JP9 1-2 2-3

2. Replace the slave controller lid o-ring (004-0870). Make sure it completely seated
before installing lid. Install the twelve 10-24 x 1-in screws and washers, and torque to
45 in/lb (Figure 9).
Note: Have you also reset the jumpers on the opto-iso PC board in the master
controller? If not, see “Changing the System Telemetry Configuration” on page 18.
8.2 Setting Servo Valve Voltage Offsets

The servo offset adjustment balances the response of a servo valve to control input so
the speed of actuator movements is consistent in both directions of travel. Correct
adjustment also keeps the actuators without lockvalves (wrist pitch/yaw, wrist, jaw)
immobile when the servo valve is inactive (no control input pending) and reduces sag
and/or drift when hydraulics are disabled. The key physical symptoms indicating the
need for adjustment are:
z A joint that moves faster in one direction than the other (given similar control
inputs). This is most noticeable following a high speed movement of the master
arm, when the servo valve is fully driven
z Spontaneous joint drift in the wrist pitch/yaw, wrist, or jaw functions
z An increase in the sag or drift of the wrist pitch/yaw, wrist, or jaw functions when
hydraulics are disabled
The servo valve offset for each function is set at the factory but should be checked and
adjusted when a servo valve, control module, actuator, or other control software or
hardware within the master controller, base module, or control module has been ser-
viced or replaced. Component wear, temperature, and other environmental factors
may also affect the servo valve response and initiate the need for offset adjustment.
The servo offset for each joint (including the wrist and jaw) is set independently, and
does not affect the offset for any other joint. The goal is to equalize the servo valve's
null position so that when it is activated the servo can provide an equivalent hydraulic
flow to either port of the actuator. This will ensure balanced travel rates and minimize
sagging and drift in the functions without lockvalves.
!Caution
Changes to the servo offsets can change the positioning response of
the slave arm joint. If the slave arm movement limits and/or stow
sequence are critical to prevent damage to the slave arm or work
area, you should immediately reset them (see the “Operation” chap-
ter for details).
To set the slave arm servo offsets, follow these steps:

1. Set the current privilege level to 1 or higher. (If you aren't sure what the current
level is, display the SET LEVEL menu, as described in the Operation chapter, and
note the level displayed on the screen). Enter the password and change to a higher
privilege level if necessary.

2. From the OPERATE menu toggle the jaw mode to POS. Make sure hydraulics are
enabled (ON).
3. From the MAIN menu, select 3> SETUP. From the SETUP menu, select SET SV
OFFSET <7 (Figure 20).
SET SV OFFSET FRZ

--------------------------------
1> Joint:Azimuth Inc Offset <5
Pos Error:+0004
Dec Offset <6
SV Offset:-050
EXIT <8
--------------------------------
Figure 20 Setting Servo Offsets
4. The slave arm should be positioned so that all joints are near the centers of their
ranges of motion. If any of the joints are at or near their limits, unfreeze the arm and
reposition it, then freeze it again.
5. The joint for which servo offset is being set will appear in the 1> Joint: field. You
can cycle through the joints by pressing 1> Joint.
6. For each joint, a value will appear in the Pos Error: field. The goal is to get this
value as close to zero as possible. (In practice, the lowest absolute value between
+0009 and -0009 is acceptable.) If the displayed value is not near-zero, press the 5>
Inc Offset and 6> Dec Offset keys to adjust the value in the SV Offset: field until the
Pos Error: field value is lowest.
Note: The slave arm will move slightly after each increment or decrement of the
servo offset. You should wait a few seconds after each change for the arm, and the
values, to stabilize.
7. Press 1> Joint: to move to the next joint. Repeat steps 6 and 7 until the servo
offsets for all joints except the wrist and jaw (azimuth, shoulder, elbow, pitch and
yaw) have been nulled.
8. Wrist offset adjustment: If necessary, reposition the arm so that you can see the
wrist, and freeze the arm again.
The wrist does not have position feedback, so adjustment of its servo offset is less pre-
cise. Normally, you will need to adjust the wrist servo offset only if the servo valve has
been serviced, or if the wrist rotates spontaneously. To null the wrist servo offset, per-
form the following adjustment procedure:
a. Press 1> Joint until the adjacent field reads WRI.

b. Press 5> Inc Offset until the wrist begins rotating slowly. Note the SV Offset
value (it may be relatively large).
c. Press 6> Dec Offset until the wrist begins rotating slowly in the opposite
direction. Again note the SV Offset value.
d. Add the two offset values algebraically (that is., include the plus or minus
signs). If, for example, the positive offset value was +260 and the negative
offset value was -60, their algebraic sum is +200. Divide this value by 2.
Increment or decrement the SV offset to match this result (+100, in the
example).
9. Jaw offset adjustment: If necessary, reposition the arm so that you can see the
jaw, and freeze the arm again. The jaw mode must be set, in the OPERATE menu, to
POS for this step.
The jaw does not have position feedback, so adjustment of its servo offset is less pre-
cise. Normally, you will need to adjust the jaw servo offset only if the servo valve has
been serviced, or if the jaw slowly opens or closes spontaneously. To null the jaw
servo offset, perform the following adjustment procedure:
a. Press 1> Joint until the adjacent field reads JAW.
b. Press 5> Inc Offset until the jaw begins closing slowly. Note the SV Offset
value (it may be relatively large). (Allow the jaw to close all or most of the
way.)
c. Press 6> Dec Offset until the jaw begins opening slowly. Again note the SV
Offset value.
d. Add the two offset values algebraically (that is, include the plus or minus
signs). If, for example, the positive offset value was +500 and the negative
offset value was -240, their algebraic sum is +260. Divide this value by 2.
Increment or decrement the SV offset to match this result (+130, in the
example).
10. Press 8> EXIT to exit the SET SV OFFSET menu and save the new settings.
!Caution
Changes to the servo offsets can change the positioning response of
the slave arm joints. Reset the slave arm movement limits and/or
stow sequence immediately if the settings are needed to prevent
damage to the slave arm or work area (see the “Operation” chapter
for details).).
9 Service Instructions
This section includes detailed service instructions, information on how to use them,
and steps for restarting your slave arm after service.
Page 24 • 9 Service Instructions 011–0568

9.1 Using the Service Instructions
Preliminary Information and Requirements
The first section of each Service Instruction provides information about the specific
component or assembly to which it applies and the estimated length of time to com-
plete the instruction. Following are sections listing the materials, chemicals, standard
and custom tools you will need to provide, and preparations you will need to com-
plete before starting service. Acronyms and other potentially ambiguous terminology
within the text are defined.
Part Identification
Within the instruction steps, individual parts are identified by a number in parenthe-
ses. This number corresponds to the SRS part number of the part on the part list (see
“Drawings & Part Lists” chapter). On the related drawing, this number is placed in a
box, with a line drawn to the specific part.
Alert Symbols
Contained in the service instructions are special paragraphs that will help you per-
form the procedures more efficiently or safely:
z A “Note” paragraph contains added information that you will need to consider
while performing a specific procedure.
z A “Tip” paragraph contains information that will help you perform a procedure
quicker or easier.
z A “Caution” paragraph may indicate a critical process, an unexpected result, or
other action where equipment is at risk.
z A “Warning” paragraph indicates a risk of personal safety or severe damage to
equipment. Pay close attention to warnings.
Before beginning any service, review the required maintenance and service practices
and safety alerts outlined at the start of the chapter.
9.2 Start-up Following Service

After Minor Service:
Follow the “Pre-Start Checks” on page 14 and “Startup Sequence” on page 15 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 the procedures in The “Installation Checkout and Test” section of the Installa-
tion chapter befor 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.
011–0568 9 Service Instructions • Page 25

This page not used.
Page 26 • 9 Service Instructions 011–0568

•
Service Instructions List
Service and work instructions are listed below. Not all will apply to your manipulator
system.
z “Azimuth 101-3915”
z “Upper Arm, Standard, 101-3916”
z “Upper Arm, Extended, 101-4064 & 101-4409”
z “Forearm Rotary Actuator, 101-3781”
z “Forearm, 101-3918”
z “Wrist, 101-3786”
z “Master Controller Faceplate, 101-3796”
z “Wrist/Jaw Adapter for P-A Jaw, 101-3833”
z “Parallel-Acting Jaw 101-4106 & 101-2239 (obsolete)”
z “7.8-in Intermeshing Jaw, 101-4102 & 101-3569”
z “Jaw Piston/Nose Block 101-3853”
z “Linear Actuators, 101-3938, -3939, -4328”
z “Changing Forearm Rotary Index Setting”
z “Compensator, 101-4470”
011–0568 • Page 1
•
This page not used.
Page 2 • 011–0568
Service Instruction
Azimuth 101-3915
Estimated Time to Complete

2 hours
Preparation for Service

Below is a list of required tools and materials for this Service Instruction. Look over the list and
make sure you have all the materials before you get started. Read through the entire procedure to
make sure you understand, and are capable of performing, the service. Take special notice of all
notes, warnings, and the terminology section.
Tools Needed Materials Needed

7/16-in socket Valvoline® Val-Plex EP Grease
1/2-in socket AquaLube (002-0805)
0-1-in (0-25mm) micrometer Dow Corning® 55 O-ring lube or petroleum jelly
Dow Corning® 5 Silicone Grease
Schilling Robotics Custom Tools Terminology

Needed
none needed HHCS = Hex Head Cap Screw
HPU = Hydraulic Power Unit
SHCS = Socket Head Cap Screw
!Caution
Some components have protective coatings such as anodizing. Take care
not to scratch any protective coatings. Corrosion damage will result.
SERVICE INSTRUCTION 011–5019-1 Page Page 1 of 8

Note: To remove the azimuth assembly you will need to remove the slave arm from the
azimuth. You will need an adequate means of supporting the arm when it is re-
moved.
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 com-
ponents as the intermeshing jaw is disassembled. We recommend that you make a photocopy of this
Service Instruction for workbench use.
Disable the Slave Arm
! WARNING
Before you can service the arm safely, you need to disable the electrical
and hydraulic functions of the arm. Follow the steps below before you
continue.
1. Raise the arm to a comfortable working position.

2. Turn off the power switches located on the master controller and the junction box.
3. Turn off the power to the Hydraulic Power Unit (HPU).
4. If power is supplied from a local, independent source, turn off the power to the slave con-
troller.
5. If your arm is equipped with a hydraulic compensation unit, isolate the unit from the arm.
Remove the Azimuth

Disassembly of the intermeshing jaw assumes that all preparations, previously described in this Ser-
vice Instruction, have been met.
Numbers in parentheses refer to the Schilling Robotics part number of the item. See Figure 1 for
basic identification of intermeshing jaw parts.
Page Page 2 of 8 011–5019-1 SERVICE INSTRUCTION

HHCS and
Hose Guard Base HHCS (4x) Retainer (2x) Pin (2x) Washer (3x)
001-4647 001-5086 002-0065 001-4342 001-4594 002-0065 and
002-0790
Bearing (4x)
001-5368
Hose Guard
Anode 001-5087
002-1440
Bumper (2x)
001-4646 Azimuth Linear Actuator
101-3938
HHCS (4x)
002-0065 Connector
101-3943
Bumper (2x)
001-5095
Spacer (2x)
001-5094
Bearing (2x)
001-5368
Azimuth Pin HHCS (2x)

001-5096 001-4711 002-0134
Figure 1 Azimuth Basic Parts Identification

Remove Slave Arm from Azimuth Assembly
Refer to Figure 1 and Figure 2 for this procedure.
HHCS (2x) Shoulder Linear Actuator

002-0065 101-3939
Retainer (2x) Actuator Guard

001-4342 001-4710
Pin Upper Arm

001-4594
Anode
002-1440
Base Pin
001-5086 001-4711
Azimuth HHCS and Washers (2x)

001-5096 002-0134 and 002-0790
Spacer (2x)
001-5094
Figure 2 Removing the Slave Arm
1. Remove the two anodes (002-1440) from the base (001-5086) and the azimuth (001-
5096) (see Figure 1 and Figure 2).
2. Remove the three HHCS and washers (002-0065 and 002-0790) and remove the hose
guard (001-5087) (see Figure 1).
3. Remove the four HHCS (002-0065) and remove the hose guard (001-4647) and two
bumpers (001-4646) (see Figure 1).
! WARNING
After the next step, the slave arm will not be supported. Properly sup-
port the slave arm to avoid personal injury and damage to the slave arm
and attached hydraulic hoses.
4. At the shoulder linear actuator (101-3939), remove the two HHCS (002-0134), washers
(002-0790), and actuator guard (001-4710) from the upper arm (see Figure 2). Slide the
pin (001-4711) out of the upper arm (see Figure 2).
5. Remove the two HHCS (002-0065) and retainer pin (001-4342) from the upper arm (see
Figure 2). Slide the pin (001-4594) out of the upper arm (see Figure 2). As you remove
the slave arm from the azimuth (001-5096), carefully move the slave arm to the side.
Remove Azimuth from Base Assembly


Base Retainer HHCS (2x)
(4x) Pin Connector
001-5086 001-4342 002-0065 001-4594 101-3943
Azimuth
001-5096
Spacer (2x) SHCS and Washers (4x)

001-5094 002-0399 and 002-0405
HHCS (2x) Pin Hydraulic Hose (2x) Azimuth Linear Actuator

002-0134 001-4711 101-3938
Figure 3 Removing Azimuth Linear Actuator from Base Assembly
1. At the azimuth linear actuator (101-3938), remove the two HHCS (002-0065) and retain-
er pin (001-4342) from the base (001-5086) (see Figure 3). Slide the pin (001-4594) out
of the base (see Figure 3).
2. If you do not need to service the azimuth linear actuator, skip to step 3.
Remove the four SHCS (002-0399) and washers (002-0405) from the connector (101-
3943) (see Figure 3) and the actuator. Remove the connector.
3. Remove the two HHCS (002-0065) and retainer pin (001-4342) from the base (see Figure
4). Remove the pin (001-4594) and slide the azimuth out of the base enough to perform
step 4 (see Figure 4).
Azimuth Pin HHCS (2x) Retainer Pin

001-5096 001-4594 002-0065 001-4342
Bumper (2x) Base

001-5095 001-5086
Bearing (6x)
001-5368
Figure 4 Removing Azimuth from Base Assembly
4. Remove the two HHCS (002-0134), slide the pin (001-4711) out, and remove the two
spacers (001-5094) (see Figure 3). Remove the actuator from the base.

Note: Do not allow the actuator to hang from the hydraulic hoses.
5. If you do not need to service the azimuth linear actuator, skip to step 6.
If you need to service the azimuth linear actuator, remove the hydraulic hoses from the
actuator (see Figure 3). To service the actuator, see Orion P Service Instructions for "Lin-
ear Actuators, 101-3938, -3939, -4328".
6. Remove the two bumpers (001-5095) from the azimuth (see Figure 4).
Inspect Azimuth Components

1. Inspect the bearings (001-5368) for signs of excessive wear or damage (see Figure 1 and
Figure 6). Replace any damaged bearing.
2. Inspect the pins (001-4594 and 001-4711) for signs of excessive wear, galling, or other
damage (see Figure 1). Use a micrometer to measure the pins. Replace any damaged pin,
or any pin with a diameter of 0.997-in or less (25.3 mm or less).
3. Inspect the bumpers (001-4646 and 001-5095) (see Figure 1). Replace if damaged or ex-
cessively compressed.
4. Inspect the azimuth (001-5096) and base (001-5086) for signs of twisting, cracking, or
other damage (see Figure 1). Replace if damage is found.
Install Azimuth into Base Assembly

Base Pin HHCS (2x)
(4x) Pin Connector
001-5086 001-4342 002-0065 001-4594 101-3943
Azimuth
001-5096
Spacer (2x) SHCS and Washers (4x)

001-5094 002-0399 and 002-0405
HHCS (2x) Pin Azimuth Linear Actuator

002-0134 001-4711 101-3938
Figure 5 Installing Azimuth Linear Actuator into Base Assembly
1. If you did not service the azimuth linear actuator, skip to step 2.
If you serviced the azimuth linear actuator, lightly lube the sealing surfaces of the hydrau-
lic fittings with EP grease. Install the hydraulic hoses to the azimuth linear actuator (see
Figure 5). Tighten the hose fittings finger tight, then one-sixth of a turn to tighten the
hose fitting.

2. Lubricate the two HHCS (002-0134) with AquaLube (see Figure 5). Lubricate the pin
(001-4711) with EP grease (see Figure 5). Install the spacers (001-5094) and azimuth lin-
ear actuator (101-3938) into the azimuth (001-5096) (see Figure 5). Slide the pin into
place. Install two HHCS and torque to 8 ft/lb (11 Nm).
3. Install the two bumpers (001-5095) onto the azimuth (001-5096) (see Figure 6).
Azimuth Pin HHCS (2x) Retainer Pin
001-5096 001-4594 002-0065 001-4342
Bumper (2x) Base

001-5095 001-5086
Bearing (6x)
001-5368
Figure 6 Installing Azimuth into Base Assembly
4. Lubricate the two bearings (001-5368) with EP grease (see Figure 6). Place the azimuth
into position in the base (see Figure 6). Lubricate the pin (001-4594) with EP grease and
install into the base and azimuth (see Figure 6).
5. Apply AquaLube to the threads of the two HHCS (002-0065) (see Figure 6). Install two
HHCS and the retainer pin (001-4342) onto base (see Figure 6). Torque to 8 ft/lb (11
Nm).
6. If you did not service the azimuth linear actuator, skip to step 7.
Apply AquaLube to the threads of the four SHCS (002-0399) (see Figure 5). Fill the cav-
ity of the connector (101-3943) with DC5 grease. Using four SHCS and washers (002-
0405), install the connector to the shoulder linear actuator (101-3938) (see Figure 5).
Torque to 10-in/lb (1.1 Nm). Wipe away excess DC5 grease.
7. Apply AquaLube to the threads of the two HHCS (002-0065) (see Figure 5). Lubricate
the retainer pin (001-4342) with EP grease (see Figure 5). Align the shoulder linear actu-
ator with the base and insert the pin (001-4594) (see Figure 5). Install two HHCS and re-
tainer pin (001-4342) (see Figure 5). Torque to 8 ft/lb (11 Nm).

Install Slave Arm onto Azimuth Assembly
HHCS (2x) Shoulder Linear Actuator
002-0065 101-3939
Pin (2x) Actuator Guard

001-4342 001-4710
Pin Upper Arm

001-4594
Anode
002-1440
Base Pin
001-5086 001-4711
Azimuth HHCS and Washers (2x)

001-5096 002-0134 and 002-0790
Spacer (2x)
001-5094
Figure 7 Installing the Slave Arm
1. Apply AquaLube to the threads of the four HHCS (002-0065) (see Figure 7). Lubricate
the two pins (001-4594) with EP grease. Place the upper arm into position on the base
(see Figure 7). Slide the pins (001-4594) through the upper arm and into the base (see Fig-
ure 7).
2. Apply AquaLube to the threads of the two HHCS (002-0065) (see Figure 7). Install two
HHCS and the retainer pin (001-4342) onto upper arm (see Figure 7). Torque to 8 ft/lb
(11 Nm).
3. Position the shoulder linear actuator (101-3938) into the azimuth (001-5096) (see Figure
7). Lubricate the pin (001-4711) with EP grease and, with the two spacers (001-5094),
slide into place (see Figure 7).
4. Apply AquaLube to the threads of the two HHCS (002-0134). Install the washers (002-
0790) to the two HHCS and attach the linear actuator guard (001-4710) to the shoulder
linear actuator (see Figure 7). Torque to 8 ft/lb (11 Nm).
5. Apply AquaLube to the threads of the four HHCS (002-0065). Install the hose guard
(001-4647) and two bumpers (001-4646) onto the base (see Figure 1). Torque to 24-in/lb
(2.7 Nm).
6. Apply AquaLube to the threads of the two HHCS. Install the hose guard (001-5087) with
HHCS and washers (002-0065 and 002-0790) (see Figure 1). Torque to 8 ft/lb (11 Nm).
7. Apply AquaLube to the threads of the two anodes (002-1440). Install them to the base
and the azimuth (see Figure 1 and Figure 7).
END OF SERVICE INSTRUCTION

Service Instruction
Upper Arm, Standard, 101-3916

3 hours


9/64-in allen wrench Valvoline® Val-Plex EP Grease
3-32-in allen wrench AquaLube (002-0805)
7/16-in socket Dow Corning® 55 O-ring lube or petroleum jelly
9/16-in socket Dow Corning® 5 Silicone Grease
9/16-in open-end wrench
3/32-in flat-blade screwdriver
Schilling Robotics Custom Tools Need- Terminology

ed
!Caution

!Caution
Replace hydraulic hoses only with the designated PDH (Pressure Diag-
nostic Hose) spares:
Orion 7 PE Standard Orion QUEST 7PE

-4 Hose, 1B 006-1507-4 006-1507-36
-4 Hose, 1A 006-1507-3 006-1507-35
-4 Hose, 2A 006-1507-20 006-1507-37
-4 Hose, 2B 006-1507-21 006-1507-38
Replacement with hoses of other jacket types (steel, etc.) will result in
premature hose failure.
The procedures in this Service Instruction assume that the intermeshing jaw will be removed from,
and then reattached to, the azimuth. The roll (elbow) joint will need to be detached from and reat-
tached to the upper arm assembly as part of the servicing.
! WARNING
continue.

4. If power is supplied from a local, independent, source turn off the power to the slave con-
troller.
Introduction
The serviceable areas of the intermeshing jaw assembly are the:
• Hydraulic hoses
• Elbow linear actuator with its pivot pins and bearings
• Shoulder linear actuator with its pivot pins and bearings
• Shoulder joint pivot pin and bearing
• Roll (elbow) joint pivot pin and bearings

Remove the Upper Arm
Upper Arm HHCS and Washers (8x) Manifold Cover

001-4600 002-1804 and 002-1439 001-5088
Roll Base
001-5093
Shoulder Linear Actuator Elbow Linear Actuator

101-3939 101-3939
Figure 8 Upper Arm Parts Identification
Remove Elbow Parts

Refer to Figure 9, Figure 10, Figure 11, and Figure 12 for this procedure.
HHCS and Washers (8x)

002-1804 and 002-1439
Manifold Cover
001-5088
Upper Arm
001-4600
Forearm Rotary Actuator

101-3781
Forearm
007-0360
Figure 9 Manifold Cover and Forearm Rotary Actuator
1. Remove the eight HHCS (002-1804) and washers (002-1439) securing the manifold cov-
er (001-5088) to the top of the forearm rotary actuator (101-3781) (see Figure 9). Remove
the manifold cover to expose the wire housing cover (001-5267) (see Figure 10).
2. Remove the five SHCS (002-0158) that hold the wire housing cover (001-5267) to the
top of the wire housing (see Figure 10). Remove the wire cover housing cover and re-
move the large o-ring (004-0139) and the four smaller o-rings (004-0086) from the wire
housing cover (see Figure 10).

O-ring O-ring (4x) Wire Housing Cover
004-0139 004-0086 001-5267
Wire Housing SHCS (5x)

001-5266 002-0158
Figure 10 Wire Housing Cover and O-ring Location
3. Using a 3/32-in flat-blade screwdriver, remove the position sensor wires from the PCB
assembly (101-4016) (see Figure 11).
Note: Note that the wires are connected across from wires of the same color and strip-
ing.
Position Sensor Wires Wire Housing O-ring (2x)

001-5266 004-0130
SHCS (4x)
002-1550
PCB Assembly Position Sensor

101-4016 101-3917
Rotary Actuator
101-3781
Adapter Plate
001-5210
Figure 11 Removing Position Sensor Wires and Position Sensor
4. Remove the four SHCS (002-1550) securing the wire housing (001-5266) to the rotary
actuator (101-3781) (see Figure 11). Lift the wire housing off and remove the o-ring (004-
0130) from the bottom of the wire housing.
5. Carefully lift the position sensor (101-3917) straight up and off the rotary actuator (see
Figure 11). Try not to rotate the sensor as you lift it from the actuator. Set the sensor aside.
6. Remove the o-ring (004-0130) from the bottom of the position sensor (see Figure 11).

Note: Before continuing to step 7, make sure the hydraulic hose ends at the manifold
are clearly labeled. Use a permanent marker and tape to label unmarked hoses.
!Caution
Hydraulic fluid will spill out of the hydraulic hoses when you remove
them during step 7. Have a drain pan ready to catch the fluid.
7. Remove all the hydraulic hoses (8x) from the slipring manifold (101-4023) (see Figure
12).
Hydraulic Hoses (6x)
Slipring Manifold
101-4023
Figure 12 Removing the Hydraulic Hoses from the Slipring Manifold
Remove Roll Base/Forearm

Refer to Figure 13 for this procedure.
! WARNING
After step 8, the elbow/forearm of the slave arm will not be supported.
Properly support the slave arm to avoid personal injury and damage to
the forearm.
8. Support the forearm. Remove the two HHCS (002-0134) and slide the pin (001-4711)
out of the roll base and elbow linear actuator (101-3939).
9. Support the forearm. Remove the four HHCS (002-0065) and two pins (001-4342)
from the roll base. Remove the pins (001-4596) from the roll base and upper arm. Set the
forearm aside.
1. Remove the two cap plugs (002-1784) from each side of the roll base (001-5093).

Roll Base
001-5093
Elbow Linear Actuator

101-3939
HHCS (2x)
002-0134
Pin
001-4711
Pin
001-4596
Pin Retainer2x)
001-4342
HHCS (4x) Cap Plug (2x) Bearing

002-0065 002-1784 001-5368
Figure 13 Removing Roll Base/Forearm
Remove Linear Actuators from Upper Arm

Anode Upper Arm

002-1440 001-4600
(opposite side)
Azimuth
001-5096
Pin
001-4711
101-3939
Pin
001-4594
002-0134 and 002-0790 Pin Retainer
001-4342
Shoulder Linear Actuator Spacer (2x) Actuator Guard HHCS
101-3939 001-5094 001-4710 002-0065
Figure 14 Removing Actuators from Upper Arm
1. Remove the anode (002-1440) from the upper arm (001-4600) (see Figure 14).
2. At the elbow linear actuator (101-3939), remove the two HHCS (002-0065) and pin (001-
4342) from the upper arm (see Figure 14). Slide the pin (001-4594) out of the upper arm
(see Figure 14).

3. Remove the four SHCS (002-0399) and washers (002-0405) from the connector (101-
3979) (see Figure 15) and the actuator. Push the connector up, and through, the cutout in
the upper arm (see Figure 15).
To the service linear actuator, see Orion P "Linear Actuators, 101-3938, -3939, -4328"
Service Instruction.
Shoulder Linear Actuator Cutout (2x) Elbow Linear Actuator
101-3939 101-3939
Connector Connector
101-3978 101-3979
SHCS and Washers (8x) Bearing (2x)

002-0399 and 002-0405 001-5368
Figure 15 Removing Connectors from Linear Actuators
4. At the shoulder linear actuator (101-3939), remove the two HHCS (002-0065) and pin
(001-4342) from the upper arm (see Figure 14). Slide the pin (001-4594) out of the upper
arm (see Figure 14).
5. Remove the two HHCS (002-0134), washers (002-0790), and the linear actuator guard
(001-4710) from the shoulder linear actuator (101-3939) (see Figure 14). Slide the pin
(001-4711) out and remove the two spacers (001-5094) (see Figure 14).
6. Remove the four SHCS (002-0399) and washers (002-0405) from the connector (101-
3978) (see Figure 15) and the actuator. Push the connector up, and through, the cutout in
the upper arm (see Figure 15, on page 7).
To the service linear actuator, see Orion P "Linear Actuators, 101-3938, -3939, -4328"
Service Instruction.
Remove the Upper Arm from the Azimuth

1. Remove the two HHCS (002-0065) and pin (001-4342) from the upper arm. Slide the pin
(001-4594) out of the upper arm. As you remove the upper arm (001-4600) from the az-
imuth (001-5096), carefully feed all the hoses out of the upper arm.
Inspect Upper Arm Parts


1. Inspect the bearings (001-5368) for cracks, excessive wear, or other damage (see Figure
13, Figure 14, Figure 15, and Figure 16). Replace any damaged bearing.
2. Inspect the pins (001-4596, 001-4594, and 001-4711) for signs of excessive wear, gall-
ing, or other damage (see Figure 13, Figure 14, and Figure 16). Replace any damaged pin.
3. Inspect the upper arm (001-4600) for signs of cracking, twisting, deformation, or other
damage. Replace if damaged.
Azimuth
001-5096
Pin
001-4594
Retainer Pin (2x)

001-4342
HHCS (2x) Upper Arm
002-0065 001-4600
Figure 16 Upper Arm Hardware
Install the Upper Arm onto the Azimuth

1. Carefully feed all the hoses into the upper arm (001-4600). The hoses should follow a
straight path through the upper arm, with no twists or sharp bends.
2. Apply EP grease to the pin (001-4594). Align the upper arm to the azimuth (001-5096)
and insert the pin.
3. Apply AquaLube to the threads of the two HHCS (002-0065). Install two HHCS and the
pin (001-4342) onto the upperarm. Torque to 8 ft/lb (11 Nm).
Install Linear Actuators into Upper Arm

1. Lubricate the o-ring and back-up ring (004-0062 and 004-0064) on the deep transducer
(101-3993) of each linear actuator (101-3939) with o-ring lube (see Figure 17).
O-ring
004-0062
Deep Transducer
101-3993
Backup Ring
004-0064
Figure 17 Lubricating Deep Transducer O-rings

2. If the linear actuators (101-3774) were serviced, reattach the hydraulic hoses. Hoses 1A
and 1B are be attached to the shoulder actuator (see Figure 18). Hoses 2A and 2B attach
to the elbow actuator (see Figure 18). Apply a thin coat of EP grease to the sealing surface
of each hose fitting. Tighten each hose fitting finger tight, then one-sixth of a turn to
tighten the hose fitting.
Hose 1B Hose 1A Hose 2A Hose 2B
Figure 18 Routing Hydraulic Hoses
3. Feed both connectors (101-3978 and 101-3979) through the cutouts in the upper arm (see
Figure 15). Be sure you have the correct connector in the correct cutout and the hoses
follow a straight path through the upper arm, with no twists or sharp bends.
4. Lubricate the four SHCS (002-0399) with AquaLube (see Figure 15). Fill the cavity of
the connector (101-3978) with DC5 grease. Using four SHCS and washers (002-0405),
install the connector to the shoulder linear actuator (see Figure 15). Torque to 28-in/lb
(1.1 Nm). Wipe away excess DC5 grease.
5. Attach the shoulder linear actuator to the azimuth (001-5096) (see Figure 19). Lubricate
the pin (001-4711) with EP grease and, with the two spacers (001-5094), slide into place
(see Figure 19).
6. Lubricate the two HHCS (002-0134) with AquaLube. Install the washers (002-0790) to
the two HHCS and attach the linear actuator guard (001-4710) to the shoulder linear ac-
tuator (see Figure 19). Torque to 8 ft/lb (11 Nm).
7. Apply EP grease to the pin (001-4594). Align the shoulder linear actuator with the upper
arm and insert the pin (see Figure 19). Apply AquaLube to the threads of the two HHCS
(002-0065). Install two HHCS and the pin (001-4342) onto the upper arm (see Figure 19).
Torque to 8 ft/lb (11 Nm).
the connector (101-3979) with DC5 grease. Using four SHCS and washers (002-0405),
install the connector to the elbow linear actuator (101-3939) (see Figure 15). Torque to
28-in/lb (1.1 Nm). Wipe away excess DC5 grease.
9. Apply EP grease to the pin (001-4594). Align the elbow linear actuator with the upper
arm and insert the pin (see Figure 19). Apply Aqua Lube to the threads of the two HHCS

Anode Upper Arm
002-1440 001-4600
(opposite side)
Azimuth
001-5096
Pin
001-4711
101-3939
Pin
001-4594
002-0134 and 002-0790 Pin Retainer
001-4342
Shoulder Linear Actuator Spacer (2x) Actuator Guard HHCS
101-3939 001-5094 001-4710 002-0065
Figure 19 Installing Actuators into Upper Arm
10. Lubricate the anode threads (002-1440) with AquaLube and install onto upperarm (see
Figure 19).
Install Roll Base/Forearm

Roll Base
001-5093

101-3939
HHCS (2x)
002-0134
Pin
001-4711
Pin (2x)
001-4596
Pin (2x)
001-4342
HHCS (4x) Cap Plug (2x) Bearing (2x)

002-0065 002-1784 001-5368
Figure 20 Installing Roll Base/Forearm
1. Support the forearm. Apply EP grease to the pin (001-4596) and install into the roll base
(001-5093) and upper arm. Apply AquaLube to the four HHCS (002-0065) and install
with the two pins (001-4342) onto the roll base.

2. Support the forearm. Apply EP grease to the two bearings (001-5368). Apply EP grease
to the pin (001-4711) and install into the roll base and elbow linear actuator (101-3939).
Apply AquaLube to the two HHCS (002-0134) and install into the elbow linear actuator.
3. Install the two cap plugs (002-1784) onto each side of the roll base.
Install the Position Sensor and Position Sensor Wires

Refer to Figure 21, Figure 22, and Figure 23 for this procedure.
!Caution
In this procedure you will set the center position of the rotary actuator
position sensor. To do this you will need have the power to the master
controller turned on. Do not turn on the hydraulics at this time.
Slipring Manifold
101-4023
Figure 21 Installing Hydraulic Hoses onto Slipring Manifold
1. Lubricate the threads of the hydraulic hose fittings with EP grease. Loosely install the hy-
draulic hoses to the appropriate fittings on the slipring manifold (101-4023) (see Figure
21). Ensure that the hoses exit cleanly into the upper arm and will clear the manifold cov-
er (001-5088) and position sensor (101-3917) (see Figure 22). Tighten each hose fitting
finger tight, then one-sixth of a turn to tighten the hose fitting.
2. Lubricate a new o-ring (004-0130) with o-ring lube and install onto the top of the adapter
plate (001-5210) (see Figure 22).
3. Carefully install the position sensor straight down over the sensor driveshaft (not shown)
and onto the adaptor plate (see Figure 22).
Turn on the power to the master controller. Go to the diagnostics menu: Press DOWN TO
EXIT > 4 DIAGNOSE > 2 SLAVE. Locate the “ROL” column and read the "FEED
BACK" readout. Check that the "FEED BACK" readout is 0 (± 100).
If the readout is not 0 (± 100), go to step 4.
If the readout is 0 (± 100), skip to step 10.

001-5266 004-0130
SHCS (4x)
002-1550

101-4016 101-3917
Rotary Actuator
101-3781
Adapter Plate
001-5210
Figure 22 Installing Position Sensor and Wire Housing
4. Lift the position sensor off the adapter plate and set it aside. Using a flat-blade screw driv-
er, gently pry the sensor driveshaft (101-4012) up and out of the adapter plate (see Figure
23).
Sensor Driveshaft
101-4012
Gently Pry Up Here
Bearing Adapter Plate

003-0249 001-5210
Figure 23 Removing the Sensor Driveshaft
5. Grasp the forearm and turn the rotary actuator all the way to one hard stop. Note the po-
sition of the rotary actuator. Turn the rotary actuator the opposite direction to the other
hard stop. Note the position of the rotary actuator. Turn the rotary actuator back to the
center of the rotation. Do not rotate the arm away from the centered position.
6. Place the sensor driveshaft (101-4012) into the position sensor (101-3917) as shown in
Figure 24. Look at the readout and slowly rotate the driveshaft until it reads 0 (± 100).
Pull the drive shaft straight out of the sensor.
7. Lubricate the bearing (003-0249) with EP grease (see Figure 23). Align the flat on the
sensor driveshaft with the flat on the coupler inside the actuator and install the sensor
driveshaft into the rotary actuator.
8. Lubricate the o-ring (004-0130) on the top of the adapter plate (001-5210) with o-ring
lube (see Figure 22).
9. Install the position sensor onto the adapter plate (see Figure 22).

Note: Check that the "FEED BACK" readout is still at 0 (± 100). If not, repeat steps 5-
9 until the desired readout is maintained.
Sensor Driveshaft
Position Sensor 101-4012
101-3917
Figure 24 Centering the Position Sensor
10. Turn off the power to the master controller.

11. Lubricate a new o-ring (004-0130) with o-ring lube and install it into the wire housing
(001-5266) (see Figure 22).
12. Lubricate four SHCS (002-1550) with AquaLube and install the wire housing onto the
rotary actuator (see Figure 22). Torque to 28 in/lb (3.2 Nm).
13. Install the position sensor wires to the PCB assembly (101-4016) (see Figure 22). To con-
nect wires properly, match the wire colors across the connector.
Install the Wire Housing Cover and Manifold Cover

1. Lubricate a new large o-ring (004-0139) and four new smaller o-rings (004-0086) with
o-ring lube and install into the wire housing cover (001-5267) (see Figure 25).

004-0139 004-0086 001-5267

001-5266 002-0158

2. Lubricate five SHCS (002-0158) with AquaLube and install the wire housing cover (001-
5267) (see Figure 25). Torque to 28 in/lb (3.2 Nm).
3. Lubricate eight HHCS (002-1804) with AquaLube, add washers (002-1439), and install
the manifold cover (001-5088) onto the rotary actuator (see Figure 9). Torque to 35 ft/lb
(47.5 Nm).

Service Instruction
Upper Arm, Extended, 101-4064 & 101-4409

3 hours

Below is a list of required tools and materials for this Serv & ce Instruction. Look over the list and

9/64-in allen wrench Valvoline® Val-Plex EP Grease
3-32-in allen wrench AquaLube (002-0805)
9/16-in socket Dow Corning® 5 Silicone Grease

ed
!Caution

!Caution
Replace the following hydraulic hoses only with the designated pressure
diagnostic hose (PDH) spares:
Orion 7 PE Standard Orion QUEST 7PE

-4 Hose, 1B 006-1507-4 006-1507-36
-4 Hose, 1A 006-1507-3 006-1507-35
-4 Hose, 2A 006-1507-20 006-1507-37
-4 Hose, 2B 006-1507-21 006-1507-38
Replacement with hoses of other jacket types (steel, etc.) will result in
The procedures in this Service Instruction assume that the intermeshing jaw will be removed from,
and then reattached to, the azimuth. The roll (elbow) joint will need to be detached from and reat-
tached to the intermeshing jaw assembly as part of the servicing.
! WARNING
continue.

4. If power is supplied from a local, independent, source turn off the power to the slave con-
troller.
Introduction
The serviceable areas of the intermeshing jaw assembly are the:
• Hydraulic hoses
• Elbow linear actuator with its pivot pins and bearings
• Shoulder linear actuator with its pivot pins and bearings
• Shoulder joint pivot pin and bearings
• Roll (elbow) joint pivot pin and bearings

Remove the Upper Arm
Upper Arm HHCS and Washers (8x)

001-5326 002-1804 and 002-1439
Manifold Cover
001-5088
Roll Base
001-5093
Shoulder Linear Actuator Elbow Linear Actuator

101-3939 101-3939
Figure 8 Upper Arm Parts Identification
Remove Elbow Parts


002-1804 and 002-1439
Manifold Cover
001-5088
Upper Arm
001-5326

101-3781
Forearm
007-0360
er (001-5088) to the top of the forearm rotary actuator (101-3781) (see Figure 9). Remove
the manifold cover to expose the wire housing cover (001-5267) (see Figure 10).

2. Remove the five SHCS (002-0158) that hold the wire housing cover (001-5267) to the
top of the wire housing (see Figure 10). Remove the wire cover housing cover and re-
move the large o-ring (004-0139) and the four smaller o-rings (004-0086) from the wire
housing cover (see Figure 10).

004-0139 004-0086 001-5267

001-5266 002-0158
3. Using a 3/32-in flat-blade screwdriver, remove the position sensor wires from the PCB
ing.

001-5266 004-0130
SHCS (4x)
002-1550

101-4016 101-3917
Rotary Actuator
101-3781
Adapter Plate
001-5210
Figure 11 Removing Position Sensor Wires and Position Sensor
4. Remove the four SHCS (002-1550) securing the wire housing (001-5266) to the rotary
actuator (101-3781) (see Figure 11). Lift the wire housing off and remove the o-ring (004-
0130) from the bottom of the wire housing.

5. Carefully lift the position sensor (101-3917) straight up and off the rotary actuator (see
Figure 11). Try not to rotate the sensor as you lift it from the actuator. Set the sensor aside.
6. Remove the o-ring (004-0130) from the bottom of the position sensor (see Figure 11).
!Caution
Hydraulic fluid will spill out of the hydraulic hoses when you remove
them during the next step. Have a drain pan ready to catch the fluid.
7. Remove all the hydraulic hoses (8x) from the slipring manifold (101-4023) (see Figure
12).
Slipring Manifold
101-4023
Figure 12 Removing the Hydraulic Hoses from the Slipring Manifold
Remove Roll Base/Forearm

1. Remove the two cap plugs (002-1784) from each side of the roll base (001-5093).
! WARNING
After the next step, the elbow/forearm of the slave arm will not be sup-
ported. Properly support the slave arm to avoid personal injury and dam-
age to the forearm.
2. Support the forearm. Remove the two HHCS (002-0134) and slide the pin (001-4711)
out of the roll base and elbow linear actuator (101-3939).
3. Support the forearm. Remove the four HHCS (002-0065) and two pins (001-4342)
from the roll base. Remove the two pins (001-4596) from the roll base and upper arm. Set
the forearm aside.

Roll Base
001-5093

101-3939
HHCS (2x)
002-0134
Pin
001-4711
Pin (2x)
001-4596
Retainer (2x)
001-4342

002-0065 002-1784 001-5368
Figure 13 Removing Roll Base/Forearm
Remove Linear Actuators from Upper Arm

Anode Shoulder Linear Actuator Upper Arm

002-1440 101-3939 001-5326
(opposite side)
Azimuth
Pin
001-4711

101-3939
Pin (2x)
001-4594
Retainer (2x)
HHCS and Washers (2x) 001-4342
002-0134 and 002-0790
Actuator Guard HHCS (4x)
Spacer (2x) 001-4710 002-0065
001-5094
Figure 14 Removing Actuators from Upper Arm
1. Remove the anode (002-1440) from the upper arm (001-5326) (see Figure 14).
2. At the elbow linear actuator (101-3939), remove the two HHCS (002-0065) and pin (001-
4342) from the upper arm (see Figure 14). Slide the pin (001-4594) out of the upper arm
(see Figure 14).

3. Remove the four SHCS (002-0399) and washers (002-0405) from the elbow actuator
connector (see Figure 15) and the actuator. Remove the connector and push it up, and
through, the cutout in the upper arm (see Figure 15).
To service the actuator, see Orion P "Linear Actuators, 101-3938, -3939, -4328" Service
Instruction.
Shoulder Linear Actuator Cutout (2x) Connector Elbow Linear Actuator

101-3939 101-4407-2 101-3939
101-4407 (QUEST)
Connector SHCS and Washers (8x) Bearing (2x)

101-4406-1 002-0399 and 002-0405 001-5368
101-4406 (QUEST)
Figure 15 Removing Connectors from Linear Actuators
4. At the shoulder linear actuator (101-3939), remove the two HHCS (002-0065) and pin
(001-4342) from the upper arm (see Figure 14). Slide the pin (001-4594) out of the upper
arm (see Figure 14).
(001-4710) from the shoulder linear actuator (see Figure 14). Slide the pin (001-4711) out
and remove the two spacers (001-5094) (see Figure 14).
6. Remove the four SHCS (002-0399) and washers (002-0405) from the shoulder actuator
connector (see Figure 15) and the actuator. Push the connector up, and through, the cutout
in the upper arm (see Figure 15).
To service the actuator, see Orion P "Linear Actuators, 101-3938, -3939, -4328" Service
Instruction.
Remove the Upper Arm from the Azimuth

1. Remove the two HHCS (002-0065) and pin (001-4342) from the upper arm. Slide the pin
(001-4594) out of the upper arm. As you remove the upper arm (001-5326) from the az-
imuth, carefully feed all the hoses out of the upper arm.
Inspect Upper Arm Parts


1. Inspect the bearings (001-5368) for cracks, excessive wear, or other damage (see Figure
13 and Figure 15). Replace any damaged bearing.
ing, or other damage (see Figure 13, Figure 14, and Figure 16). Replace any damaged pin.
3. Inspect the upper arm (001-5326) for signs of cracking, twisting, deformation, or other
damage. Replace if damaged.
Azimuth
Pin (2x)
001-4594
Retainer (2x)
001-4342
HHCS (2x) Upper Arm
002-0065 001-5326
Figure 16 Removing Upper Arm from Azimuth
Install the Upper Arm onto the Azimuth

1. Carefully feed all the hoses into the upper arm (001-5326). The hoses should follow a
straight path through the upper arm, with no twists or sharp bends.
2. Apply EP grease to the pin (001-4594). Align the upper arm to the azimuth and insert the
pin.
3. Apply AquaLube to the threads of the two HHCS (002-0065). Install two HHCS and the
pin (001-4342) onto the upper arm. Torque to 8 ft/lb (11 Nm).
Install Linear Actuators into Upper Arm

1. Lubricate the o-ring and back-up ring (004-0062 and 004-0064) on the deep transducer
of each linear actuator (101-3939) with o-ring lube (see Figure 17).
O-ring
004-0062
Deep Transducer
101-3993
Backup Ring
004-0064
Figure 17 Lubricating Deep Transducer O-rings

2. If the linear actuators (101-3774) were serviced, reattach the hydraulic hoses. Hoses 1A
and 1B are be attached to the shoulder actuator (see Figure 18). Hoses 2A and 2B attach
to the elbow actuator (see Figure 18). Apply a thin coat of EP grease to the sealing surface
of each hose fitting. Tighten each hose fitting finger tight, then one-sixth of a turn to
tighten the hose fitting.
Hose 1B Hose 1A Hose 2A Hose 2B
Figure 18 Routing Hydraulic Hoses
3. Feed both connectors through the cutouts in the upper arm (see Figure 15). Be sure you
have the correct connector in the correct cutout and the hoses follow a straight path
through the upper arm, with no twists or sharp bends.
the shoulder actuator connector with DC5 grease. Using four SHCS and washers (002-
0405), install the connector to the shoulder linear actuator (101-3939) (see Figure 15).
5. Position the shoulder linear actuator into the azimuth (see Figure 19). Lubricate the pin
(001-4711) with EP grease and, with the two spacers (001-5094), slide into place.
the two HHCS and attach the linear actuator guard (001-4710) to the shoulder linear ac-
tuator (see Figure 19). Torque to 8 ft/lb (11 Nm).
7. Apply EP grease to the pin (001-4594). Align the shoulder linear actuator with the upper
arm and insert the pin (see Figure 19). Apply Aqua Lube to the threads of the two HHCS
the elbow actuator connector with DC5 grease. Using four SHCS and washers (002-
0405), install the connector to the elbow linear actuator (101-3939) (see Figure 15).
9. Apply EP grease to the pin (001-4342). Align the elbow linear actuator with the upper
arm and insert the pin (see Figure 19). Apply AquaLube to the threads of the two HHCS

Anode Shoulder Linear Actuator Upper Arm
002-1440 101-3939 001-5326
(opposite side)
Azimuth
Pin
001-4711

101-3939
Pin (2x)
001-4594
Pin (2x)
HHCS and Washers (2x) 001-4342
002-0134 and 002-0790
Actuator Guard HHCS (4x)
Spacer (2x) 001-4710 002-0065
001-5094
Figure 19 Installing Actuators from Upper Arm
10. Lubricate the anode threads (002-1440) with AquaLube and install onto upper arm (see
Figure 19).
Install Roll Base/Forearm

Roll Base
001-5093

101-3939
HHCS (2x)
002-0134
Pin
001-4711
Pin
001-4596
Pin Retainer2x)
001-4342

002-0065 002-1784 001-5368
Figure 20 Installing Roll Base/Forearm
1. Support the forearm. Apply EP grease to the pin (001-4596) and install into the roll base
(001-5093) and upper arm. Apply AquaLube to the four HHCS (002-0065) and install
with the two pins (001-4342) onto the roll base.

2. Support the forearm. Apply EP grease to the two bearings (001-5368). Apply EP grease
to the pin (001-4711) and install into the roll base and elbow linear actuator (101-3939).
Apply AquaLube to the two HHCS (002-0134) and install into the elbow linear actuator.
3. Install the two cap plugs (002-1784) onto each side of the roll base.
Install the Position Sensor and Position Sensor Wires

Refer to Figure 21, Figure 22 and Figure 23 for this procedure.
!Caution
Slipring Manifold
101-4023
Figure 21 Installing Hydraulic Hoses onto Slipring Manifold
1. Lubricate the threads of the hydraulic hose fittings with EP grease. Loosely install the hy-
draulic hoses to the appropriate fittings on the slipring manifold (101-4023) (see Figure
21). Ensure that the hoses exit cleanly into the upper arm and will clear the manifold cov-
er (001-5088) and position sensor (101-3917) (see Figure 22). Tighten each hose fitting
finger tight, then one-sixth of a turn to tighten the hose fitting.
2. Lubricate a new o-ring (004-0130) with o-ring lube and install onto the top of the adapter
plate (001-5210) (see Figure 22).
3. Carefully install the position sensor straight down over the sensor drive shaft (not
shown) and onto the adaptor plate (see Figure 22).
Turn on the power to the master controller. Go to the diagnostics menu: Press DOWN TO
EXIT > 4 DIAGNOSE > 2 SLAVE. Locate the “ROL” column and read the “FEED
BACK” readout. Check that the “FEED BACK” readout is 0 (± 100).
If the readout is not 0 (± 100), go to step 4.
If the readout is 0 (± 100), skip to step 10.

001-5266 004-0130
SHCS (4x)
002-1550

101-4016 101-3917
Rotary Actuator
101-3781
Adapter Plate
001-5210
Figure 22 Installing Position Sensor and Wire Housing
4. Lift the position sensor off the adapter plate and set it aside. Using a flat-blade screw driv-
er, gently pry the sensor drive shaft (101-4012) up and out of the adapter plate (see Figure
23).
Sensor Driveshaft
101-4012
Gently Pry Up Here
Bearing Adapter Plate

003-0249 001-5210
5. Grasp the forearm and turn the rotary actuator all the way to one hard stop. Note the po-
sition of the rotary actuator. Turn the rotary actuator the opposite direction to the other
hard stop. Note the position of the rotary actuator. Turn the rotary actuator back to the
center of the rotation. Do not rotate the arm away from the centered position.
6. Place the sensor driveshaft (101-4012) into the position sensor (101-3917) as shown in
sensor driveshaft with the flat on the coupler inside the actuator and install the sensor
driveshaft into the rotary actuator.
lube (see Figure 22 ).

Note: Check that the “FEED BACK” readout is still at 0 (± 100). If not, repeat steps
5-9 until the desired readout is maintained.
Sensor Driveshaft
101-3917
10. Turn off the power to the master controller.

(001-5266) (see Figure 22).
13. Install the position sensor wires to the PCB assembly (101-4016) (see Figure 22). To con-
nect wires properly, match the wire colors across the connector.
Install the Wire Housing Cover and Manifold Cover

1. Lubricate a new large o-ring (004-0139) and four new smaller o-rings (004-0086) with
o-ring lube and install into the wire housing cover (001-5267) (see Figure 25).

004-0139 004-0086 001-5267

001-5266 002-0158

the manifold cover (001-5088) onto the rotary actuator (see Figure 9). Torque to 35 ft/lb
(47.5 Nm).

Service Instruction
Forearm Rotary Actuator, 101-3781
Description
Complete service instructions for the Orion P intermeshing jaw.

4 hours


7/16-in sockets Valvoline® Val-Plex EP Grease
3/16-in hex key Loctite 271® (002-0795)
3/32-in flat-blade screwdriver Loctite 222® (002-1697)
flat blade screwdriver
rubber hammer
new razor blade or X-acto style knife
Schilling Robotics Custom Tools Need- Spares Kit(s)

ed
From Orion Tool Kit 010-0623 Seals and o-rings for rotary actuator 101-3781 are
010-0600 torquing tool available as a part of the Orion Spares Kit (P/N 008-
0100) and in two spares kits specifically for the rotary
010-0586 slipring seal installation tool actuator: the Seal Kit (P/N 101-3863) and the Slipring
010-0587 roll slipring seal resizing tool Spares Kit (P/N 101-3864)
010-0588 slipring seal resizing tool Terminology
010-0589 slipring pusher tool HHCS = Hex Head Cap Screw
010-5104 endplate pusher SHCS = Socket Head Cap Screw

!Caution
!Caution
If you are planning to replace slipring seals (004-0583), you must have
replacements on-hand. You will need to destroy the old seals to remove
them.
damage to bearings and seals.
Provide a clear workbench surface on 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.
Special Instructions
Schilling Robotics recommends that all rotary actuator seals and o-rings be replaced when the ro-
tary actuator is serviced. Seals and o-rings are available as a part of the general Orion Spares Kit
(008-0100) and in two spares kits specifically for the rotary actuator: the Seal Kit (101-3863) and
the Slipring Spares Kit (101-3864).
!Caution
If seals and o-rings must be reused, set them aside during disassembly
and carefully inspect them for damage before re-installation. All dam-
aged seals and o-rings must be replaced.
! WARNING
continue.

troller.
Detach Rotary Actuator

This procedure assumes the hydraulic power is OFF. Loosen the appropriate hose fittings to allow
the actuators to leak down and permit positioning the slave arm joints as needed to simplify disas-

sembly.
Numbers in parentheses refer to the Schilling Robotics part number of the item.
Detach Forearm Assembly From Forearm Rotary Actuator

er (001-5088) to the rotary actuator (101-3781) (see Figure 26). Remove the manifold
cover to expose the wire housing cover (001-5267) (see Figure 27).

002-1804 and 002-1439
Manifold Cover
001-5088
Forearm
Rotary Actuator 007-0360
101-3781

002-1825 and 002-0790
Figure 26 Manifold Cover and Rotary Actuator
2. Remove the wire housing cover by removing the five SHCS (002-0158) that hold the
cover to the rotary actuator (see Figure 27). Remove the large o-ring (004-0139) and the
four smaller o-rings (004-0086) from the wire housing cover (see Figure 27).

004-0139 004-0086 001-5267
SHCS (5x)
002-0158
3. Using a 3/32-in flat blade screwdriver, loosen the terminal screws and remove the fore-
arm sensor wires from the PCB assembly (101-4016) (see Figure 28).

ing.
PCB Assembly
101-4016
Forearm Sensor Wires
Figure 28 Removing Position Sensor Wires From PCB assembly
! WARNING
When you remove the ten HHCS in step 4, the forearm will be loose. The
forearm assembly, including wrist and jaw, weighs about 40 pounds (18
kg) and must be supported during removal. Read the entire step before
continuing. Be prepared by properly supporting the forearm.
4. Remove the ten HHCS (002-1825) and washers (002-0790) from the bottom of the rotary
actuator (see Figure 26). Separate the forearm from the rotary actuator and extract the po-
sition sensor wires from the rotary actuator.
5. Remove the nine o-rings (004-0222) from the bottom of the rotary actuator (101-3781)
(see Figure 29).
O-rings (9x)
004-0222
Figure 29 Bottom of Rotary Actuator
Remove Position Sensor and Manifold From Rotary Actuator


HHCS and Washer (2x) O-ring Position Sensor Wire Housing Hydraulic Hoses (6x)
002-1572 and 002-1439 004-0130 101-3917 001-5266
Adapter Plate
001-5210
Rotary Actuator
101-3781
Manifold
101-4023
Slipring
001-5053
HHCS and Washer (4x) Sensor Driveshaft

001-0182 and 002-1439 101-4012
Figure 30 Rotary Actuator Area Parts
1. Remove the four SHCS (002-1550) securing the wire housing (001-5266) to the adapter
plate (001-5210) and lay it to the side (see Figure 30 and Figure 31). Remove the o-ring
(004-0130) from the bottom of the wire housing (see Figure 30).
SHCS (4x)
002-1550
Wire Housing
001-5266
Figure 31 Removing Wire Housing from Rotary Actuator

2. Lift the position sensor (101-3917) off the adapter plate (001-5210) and lay it to the side
(see Figure 30).
3. Using a flat-blade screw driver, gently pry the sensor driveshaft (101-4012) up and out
of the adapter plate (see Figure 32).
Sensor Driveshaft
101-4012
Gently Pry Up Here
Adapter Plate
001-5210
4. Remove all the hydraulic hoses (8x) from the manifold (see Figure 30, on page 5).
5. Remove the two HHCS and washers (002-1572 and 002-1439) from the manifold (see
Figure 30, on page 5).
6. Using a rubber hammer, remove the manifold by tapping upward on the edges of the man-
ifold. Do not pry the manifold off of the actuator.
7. Remove the o-ring (004-0860) from the bottom of the manifold (see Figure 33). Note the
rotary index setting for correct reassembly. The index setting number is located on the
flange of the slipring (001-5053) (see Figure 33). Set the manifold aside for later disas-
sembly.
Note Rotary
Index Setting Here:
0-ring
004-0860
Manifold
Slipring 101-4023
001-5053
Rotary Index Setting
Figure 33 Noting Rotary Index Setting
8. Remove the two o-rings (004-0222) from the end plate (101-3779) (see Figure 33).

End Plate
101-3779
O-ring (2x)
004-0222
Figure 34 Removing O-Rings
Remove Rotary Actuator From the Roll Base

1. Before removing the rotary actuator (101-3781) from the roll base (001-5093), position
the arm as shown in Figure 35.
Rotary Actuator
101-3781
Roll Base
001-5093
Figure 35 Positioning the Arm for Removal of the Rotary Actuator
2. Remove the plugs (002-1784) from the roll base (see Figure 36). Remove the two HHCS
(002-0134) and washers (002-0790) securing the pitch pin (001-4711) to the elbow linear
actuator (see Figure 36). Support the rotary actuator and remover the pitch pin. Remove
the elbow spacers (001-5092).

Elbow Spacer(2x)
001-5092
Plug (2x)
Manifold Pitch Pin
101-4023
002-1784 001-4711
Roll Base
001-5093
Elbow Linear Actuator HHCS (2x)

101-3939 002-0134
Figure 36 Removing the Elbow Linear Actuator From the Roll Base
!Caution
When you remove the four HHCS in step 3, the rotary actuator will be
loose. Read the entire step before continuing. Be prepared by properly
supporting the rotary actuator.
3. Remove the four HHCS (002-0182) and washers (002-1439) securing the rotary actuator
to the roll base. Remove the rotary actuator from the roll base (see Figure 36).

002-0182 and 002-1439
Figure 37 Removing the Rotary Actuator
Remove Mounting Flange and Rotor Nut From Rotary Actuator


Rotor
Rotor Nut 001-5052
001-4559
Lock Washer
002-1560 End Plate
101-3779
Housing
001-5079
End Plate
101-3778
Seal
004-0816
O-ring O-ring
004-0621 004-0140
HHCS and Washers (8x) Mounting Flange O-ring (8x)

002-0062 and 002-1439 101-3777 004-0222
Figure 38 Mounting Flange and Rotor Parts
1. Stand the rotary actuator up on the mounting flange (101-3777). Hold the housing (001-
5079 in place and turn the rotor (001-5052) clockwise inside its housing until it hits at the
hard stop.Set the actuator on its mounting legs.
!Caution
Do not turn the rotor after the HHCS have been removed in step 2. Dam-
age to the end plates (101-3779 and 101-3778) could result.
2. Remove the eight HHCS and washers (002-0062 and 002-1439) from the rotary actuator.
3. Use a rubber hammer to gently tap the mounting flange (101-3777) off the rotor (001-
5052).
4. Remove the o-rings (004-0140 and 004-0621) and the seal (004-0816) from the mounting
flange.
5. Remove the eight o-rings (004-0222) from the rotor.
6. Pry the lock tab on the washer (002-1560) from the slot in the rotor nut (001-4559). Using
the torquing tool (010-0600), remove the rotor nut (001-4559) and lock washer (002-
1560).

Disassemble the Rotary Actuator
SHCS and Nut (16x) Rotor

001-5098 and 002-0058 001-5052
Washer (32x)
001-5099
End Plate
101-3779
O-ring (2x)
004-0103
Housing
001-5079
O-ring (2x)
004-0140
End Seal (2x)

001-5038
End Plate
Bearing 101-3778
003-0176
Figure 39 Rotary Actuator Parts
1. Remove both bearings (003-0176) (see Figure 39). They should drop straight out of their
bores if the edges of the endplates (101-3779 or 101-3778) are gently struck on a plastic
or wooden work surface. If a bearing becomes cocked in its bore, gently tap it back into
place and try again.
2. Remove fourteen of sixteen SHCS (001-5098), washers (001-5099), and nuts (002-0058)
from the rotary actuator assembly (see Figure 39). While removing the last two SHCS,
use care to ensure that the end plates (101-3779 and 101-3778) do not loosen and become
cocked on the housing (001-5079).
3. Stand the rotary actuator on end, with spacers under the rotary actuator so that the rotor
(001-5052) is not touching the work surface (see Figure 40). Remove the end plate (101-
3778).
Note: If the end plate is difficult to remove by hand, it may be pushed off using the four
threaded through-holes present in both end plates. Install an endplate pusher
(001-5104) into each through-hole, followed by a 3/8 x 3 in. HHCS (002-1804).
The pusher prevents scoring of the housing or the end plate by the bolt. Evenly
thread in the four HHCS until the end plate and housing are separated. Support
both assemblies so they are not damaged after separation.
!Caution
Do not damage the sharp edges of the housing (001-5079) as shown in
Figure 40. Damage will cause reduced performance and leakage.

Rotor
001-5052
O-ring (2x)
004-0140
End Seal (2x)

001-5038
Housing End Plate

001-5079 101-3779
O-ring (2x) Spacer

004-0103
End Plate
101-3778
Do Not Damage Housing Edges
Figure 40 Removing the End Plate (101-3779)
4. Remove the seal (001-5038) and o-ring (004-0140) from the rotor (001-5052) (see Figure
40).
5. Remove the housing (001-5079) from the rotor (see Figure 40).
6. Carefully remove the rotor (001-5052) from the endplate (101-3778) (see Figure 40).
7. Remove the remaining seal (001-5038) and o-ring (004-0140) from the rotor (001-5052)
(see Figure 40).
8. Remove the seal, o-ring, filler plate, and back-up plates (001-5040, 004-0130, 001-5039,
and 001-5041) from the vanes (001-5097) on the rotor, and the housing vane mount (see
Figure 41). De-grease all vane parts. Set the rotor aside for later service.
!Caution
Do not damage the sharp edges of the housing as shown in Figure 41.

Seal (2x) Filler Plate Housing
001-5040 001-5039 Vane Mount
Back-up Plate (2x)

001-5041
O-ring (2x)
004-0130
Vane (2x)
001-5097
Rotor Housing
001-5052 001-5079 Do Not Damage Housing Edges
Figure 41 Removing Vanes Parts From the Rotor and the Housing
Inspect Rotary Actuator Components

Schilling Robotics recommends that you replace all rotary actuator seals and o-rings. Seals and o-
rings are available as a part of the Orion spares kit (008-0100) and in two spares kits for the rotary
actuator: the seal kit (101-3863) and the slipring spares kit (101-3864).
Inspect other components as outlined below:
1. Inspect the roller bearings (003-0176) and endplate races (101-3779 and 101-3778) (see
Figure 39). Replace if damage is present.
2. Inspect the sharp edge of the housing (001-5079) (see Figure 40). This edge is critical to
actuator performance and must be sharp. If any damage is noted, replace the housing.
3. Inspect all other rotary actuator components. Replace damaged components.
Disassemble the Manifold


O-ring (2x)
004-0130
Bearing
003-0249
HHCS (4x) O-ring (8x)

002-1873 004-0225
Adapter Plate Manifold

001-5210 101-4023
O-ring (8x) O-ring

004-0222 004-0098
Slipring Seal (9x)

004-0583
Bearing (2x)
Slipring 003-0081
001-5053
O-ring (9x)
004-0036
Figure 42 Manifold Parts Identification
1. Remove the HHCS (002-1873) from the adaptor plate (101-5210) and remove the adap-
tor plate and slipring (001-5053) from the manifold (101-4023).
2. Remove the o-rings and bearing (004-0130, 004-0225, and 003-0249) from the adaptor
plate.
3. Remove the bearings (003-0081) from the slipring.
!Caution
If you are planning to replace slipring seals (004-0583) in step 4, you
must have replacements on-hand. You will need to destroy the old seals
to remove them.
4. Remove the slipring seals (004-0583), from the slipring, by carefully cutting across them
with a new razor blade or X-acto style knife. Using a small pick tool, remove the o-ring
(004-0036).
Note: Be very careful not to damage the finish on the slipring
5. Inspect the manifold, slipring, and bearings (003-0081) for damage. Replace damaged
components.
Replace Slipring Bearings and O-rings


1. Lubricate a bearing (003-0081) with EP grease and install into the bearing groove at the
flanged end of the slipring (004-5053).
2. Lubricate nine new o-rings (004-0036) with o-ring lube and install onto the slipring.
3. Install the slipring seal installation tool (010-0586) onto the end of the slipring. Lubricate
the tool with o-ring lube.
4. Lubricate a new slipring seal (004-0583) with o-ring lube and seal the bearing onto the
tool. Slide the seal along the tool and into the groove closest to the flange. Repeat with
all remaining seals. Remove the slipring seal installation tool.
5. Lubricate the remaining bearing (004-0081) with EP grease and install it into the remain-
ing bearing groove.
6. Lubricate the inner surface of slipring seal resizing tool (010-0587) with o-ring lube.
Slowly slide the tool onto the slipring until it touches the flange. Be sure that the slydring
bearings properly seat into their grooves. Allow the tool to remain in place at least one
hour.
Assemble the Slipring to Manifold

O-ring (2x)
004-0130
Bearing
003-0249
HHCS (4x) O-ring (4x)

002-1873 004-0225

001-5210 101-4023
O-ring (8x) O-ring

004-0222 004-0098
Slipring
001-5053
Figure 43 Assembling the Slipring and Manifold
1. Lubricate eight new o-rings (004-0222) with o-ring lube and install into the slipring
flange (see Figure 43).
2. Lubricate a new o-ring (004-0098) with o-ring lube and install into the slipring flange
(see Figure 43).
3. Lubricate two new o-rings (004-0130) with o-ring lube and install into the adapter plate
(001-5210) (see Figure 43).
4. Lubricate the bearing (003-0249) with EP grease and install into the adapter plate (see
Figure 43).

!Caution
Do not perform step 5 unless the resizing tool (010-0587) has been on the slipring for at least one
hour.
5. Place the flanged end of the slipring (001-5053) into the resizing tool stripper (010-0588)
so that the resizing tool (010-0587) is seated in the counterbore (see Figure 44). Install
the shaft of the pusher tool (010-0589) into the opposite end of the slipring. Place a socket
extension, or a suitable rod, into the recessed end of the pusher tool and drive the slipring
out of the resizing tool.
Figure 44 Removing the Resizing Tool From the Slipring
6. Lubricate four HHCS (002-1873) with EP grease and install into the adapter plate (see
Figure 43). Lubricate four new o-rings (004-0225) with o-ring lube and install onto four
HHCS (see Figure 43). Install the adapter plate onto the manifold (101-4023) (see Figure
43). Align the slipring to the correct rotary index setting (see Figure 45 and refer to Figure
33 for your rotary index setting). Torque to 24 in/lb (2.7 Nm).
0-ring
004-0860
Manifold
Slipring 101-4023
001-5053
Figure 45 Setting the Rotary Index Setting
7. Lubricate a new o-ring (004-0860) with o-ring lube and install onto the manifold (see
Figure 45). Set the manifold/slipring assembly aside for later installation.
Assemble the Rotor

1. Thread an 8/32 screw into the plug and pull the plug (001-4565) out of the rotor (see Fig-
ure 46). Leave the 8/32 screw installed in the plug.

Rotor
001-5052
Plug
001-4565
O-ring
004-0571
8/32 Screw
Figure 46 Removing the Plug From the Rotor
2. Remove the o-ring (004-0571) from the plug (see Figure 47). Lubricate a new o-ring with
o-ring lube and install it onto the plug.
Rotor
001-5052
O-ring End Seal

004-0571 001-5038
Plug
001-4565
8/32 Screw O-ring

004-0140
O-ring (8x)
004-0222
Figure 47 Assembling the Rotor
3. Lubricate the plug with o-ring lube and install it into the rotor (001-5052) (see Figure 47).
Remove the screw.
4. Lubricate a new o-ring (004-0140) with o-ring lube and install it onto the rotor (see Fig-
ure 47).
5. Lubricate a new end seal (001-5038) with o-ring lube and install it onto the rotor (see Fig-
ure 47).
6. Lubricate eight new o-rings (004-0222) with o-ring lube and install them into the rotor
(see Figure 47). Set the rotor aside for later installation.

Assemble the Mounting Flange
Refer to Figure 48 for this procedure
Seal O-ring O-ring

004-0816 004-0621 004-0140
Mounting Flange
101-3777
Figure 48 Assembling the Mounting Flange
1. Lubricate two o-rings (004-0621 and 004-0140) with o-ring lube and install onto the
mounting flange (101-3777).
2. Lubricate seal (004-0816) with o-ring lube and install onto the mounting flange.
Assemble the End Plates and Rotor

Refer to Figure 49, Figure 50, Figure 51, Figure 52, Figure 53, and Figure 54 for this procedure.
Seal (2x) Filler Plate Housing

001-5040 001-5039 Vane Mount
Back-up Plate (4x)

001-5041
O-ring (2x)
004-0130
Vane (2x)
001-5097
Rotor Housing
001-5052 001-5079
Figure 49 Installing Vanes Parts Into the Rotor and the Housing
1. Reassemble the seal, o-ring, filler plate, and back-up plate assemblies (001-5040, 004-
0130, 001-5039, and 001-5041) (see Figure 49). Lubricate the assemblies with o-ring
lube after they are assembled.

2. Install the assembly between the vanes (001-5097) on the rotor (001-5052) (see Figure
49). Repeat step 1 for the housing (001-5079) (see Figure 49). Be sure that the vane seals
are installed square.
!Caution
When performing steps 3 - 7, use extreme care not to damage the sharp
edges of the end seals, the housing, and the end plates.
3. Lubricate a new o-ring (004-0103) with o-ring lube and install into the end plate (101-
3778) (see Figure 50). Support the end plate on spacers as shown in Figure 50. Lubricate
the end plate with EP grease as shown in Figure 50.
Lubricate Along
These Surfaces
End Plate
101-3778
O-ring
004-0103
Spacer
Figure 50 Supporting and Lubricating the End Plate for Assembly
4. Lubricate the end seal (001-5038) and outer surfaces of the rotor (001-5052) with EP
grease. Carefully install the rotor into the end plate (see Figure 51).
Rotor
001-5052
End Seal
001-5038
End Plate
101-3778
Figure 51 Installing the Rotor Into the End Plate
5. Lubricate the inner surfaces of the housing as shown in Figure 52. Carefully install the
housing onto the end plate (see Figure 52). Orient the rotor as shown in Figure 52.

View Looking Down
From Above
Lubricate Along
These Surfaces
Housing
001-5079
Figure 52 Lubricating and Installing the Housing onto the Rotor and End Plate
6. Lubricate the o-ring (004-0140) and end seal (001-5038) with o-ring lube and install them
onto the rotor (see Figure 53).
End Seal
001-5038
O-ring
004-0140
Figure 53 Installing O-ring and End Seal

7. Lubricate the end plate with o-ring lube as shown in Figure 54. Carefully install the end
plate (101-3779) onto the rotor (see Figure 54).
SHCS and Nut (16x)

001-5098 and 002-0058
Washer (32x)
001-5099 End Plate
101-3779
Lubricate Along
These Surfaces
Rounded Edge of Washer
Figure 54 Installing the End Plate
!Caution
During step 8, you must place the rounded side of the washers (001-
5099) against the end plate surfaces (see Figure 54). Damage will result to
the end plates if the sharp edge of the washers are placed against the
end plates.
8. Heavily lubricate two SHCS (001-5098) with AquaLube (see Figure 54). Install on op-
posite sides of the end plates with four washers and two new locknuts (001-5099 and 002-
0058). Place the mounting legs of the assembly on a flat surface. Slowly and carefully
draw the end plates together. Damage will result to the end seals if the plates are drawn
together unevenly.
Heavily lubricate the remaining fourteen SHCS with AquaLube and install with washers
and new locknuts. Lightly tighten all locknuts.
9. Place the actuator on its mounting legs on a known flat surface or attach it to the roll base
(001-5093). Adjust the endplates so that all four mounting legs are in complete contact
with the surface. Torque all locknuts to 12 ft/lb (16.3 Nm).
Install Bearings and Mounting Flange to Rotary Actuator

Note: In step 1 you will install the bearings (003-0176) into the rotary actuator. The
bearings need to be reassembled into the proper end of the rotary actuator.
1. Pack the bearings (003-0176) with EP grease, and install them onto the rotor (001-5052)
(see Figure 55).

Rotor
001-5052
Bearing (2x)
003-0176
Figure 55 Installing Bearings
2. Lubricate the sealing surfaces of the mounting flange (101-3777) with o-ring lube. Place
the mounting flange onto the rotor (see Figure 56).

002-0062 and 002-1439
Mounting Flange
101-3777
End Plate
101-3778
Seal
004-0816
Figure 56 Installing the Mounting Flange
3. Align the rotary index number on the mounting flange to the two alignment marks on the
rotor (see Figure 57)

Note: The mounting flange/rotor interface must match the rotary index setting at the
manifold/slipring interface that you recorded in Figure 33.
HHCS and Washers (8x) Rotor Alignment Marks

002-0062 and 002-1439
Rotor
001-5052
Mounting Flange
101-3777 Rotary Index Setting
Figure 57 Aligning the Mounting Flange and Rotor
Tip: The flat inside the coupler (001-5252) should be perpendicular with the rotary in-
dex setting on the mounting flange (see Figure 58).
Coupler
001-5252
Figure 58 Noting Coupler Position
4. Lubricate eight HHCS (002-0062) with AquaLube and install, with washers (002-1439)
through the mounting flange and into the rotor (see Figure 57). Tighten in an opposing
pattern to evenly draw the mounting flange to the rotor. Make sure the seal (004-0816)
seats to the inner bore of the end plate and is not folded back between the outer face of
the end plate (101-3778) and the mounting flange (see Figure 56). Do not torque the
HHCS until the next step.
5. Lubricate the rotor nut (001-4559) with AquaLube and install, with lock washer (002-
1560), onto the rotor (see Figure 38). Use the torquing tool (010-0600) and a 1/2-in. drive
socket wrench to hold the rotor vane on the housing vane hardstop as shown in Figure 52.
Torque the HHCS, installed in step 4, to 25 ft/lb (33.9 Nm).

6. Using the torquing tool, torque the rotor nut to a minimum of 100 ft-lb (135 Nm), and
until one of the tabs on the washer lines up with a notch in the rotor nut. Bend a tab into
a notch.
Testing Operation (optional)

If test equipment is available, check that the rotary actuator meets port to port leakage and break-
away pressure specifications before it is reinstalled on the slave arm. If no equipment is available,
skip to "Reattach Forearm Rotary Actuator to Roll Base".
1. Test 1:
Perform this test in both directions. Connect a directional-controlled hydraulic power
source to the 3A and 3B hose ports. At a pressure of 300 psig (±50 psig), slowly rotate
the rotary actuator back-and-forth to expel any trapped air. Drive the rotor in either direc-
tion to the hard stop. Set the test pressure to 0 psig. Set one directional control valve to
be fully open. Slowly increase the test pressure until the forearm starts to rotate (break-
away). Record the break-away pressure:_______(250 psi or less is acceptable). Break-
away pressures above 250 psi may indicate misaligned or incorrectly installed seals/bear-
ings, a foreign object inside the actuator, or other assembly error.
2. Test 2:
Disconnect the 3B hose and case drain hose, and route into a suitable container. Pressur-
ize port 3A to 300 psig (±50 psig) to test for port to port leakage. Record the amount of
fluid coming from port B (Return) and/or the case drain:_______(57 drops/min or less
from either hose is acceptable). An unacceptable leakage rate to the case drain indicates
an end seal problem. An unacceptable leakage rate from port 3B may indicate a vane seal
or end seal problem, or damage to the edges between the face and bore of the housing
(001-5079).
Reattach Forearm Rotary Actuator to Roll Base

Rotary Actuator
101-3781 HHCS and Washers (4x)
002-0182 and 002-1439
Roll Base
001-5093
Figure 59 Installing Rotary Actuator to Roll Base
1. Place the rotary actuator (101-3781) onto the roll base (001-5093) (see Figure 59).
2. Apply a coating of Loctite 222® to the threads of four HHCS (002-0182) and install, with
washers (002-1439), through the roll base (001-5093) and into the rotary actuator (see
Figure 59). Torque to 35 ft/lb (48 Nm).

3. Lubricate the pitch pin (001-4711) and elbow spacers (001-5092) with EP grease and in-
stall into place as shown in Figure 60. Install the two HHCS (002-0134) to secure the
pitch pin (001-4711) to the elbow linear actuator (101-3939) (see Figure 60). Torque to
8 ft/lb (10.8 Nm).
Elbow Spacer(2x)
001-5092
Plug (2x)
Manifold Pitch Pin
101-4023
002-1784 001-4711
Roll Base
001-5093
Elbow Linear Actuator HHCS (2x)

101-3939 002-0134
Figure 60 Installing the Elbow Linear Actuator to the Roll Base
4. Install the plugs (002-1784) into the roll base (see Figure 60).
5. Run a 3 foot-long, 24 gauge wire (or equivalent string) through the center of the rotary
actuator. This “pull-wire” will help you get the sensor wires through the rotary actuator
when the forearm is reattached.
Install Slipring/Manifold to Rotary Actuator

1. Lubricate two new o-rings (004-0222) with o-ring lube and install onto end plate (101-
3779) (see Figure 61).
End Plate
101-3779
O-ring (2x)
004-0222
Figure 61 Installing O-Rings
2. Loosely install the hydraulic hoses to the appropriate fittings on the manifold (101-4023)
(see Figure 30).
3. Feed the pull-wire through the slipring (001-5053) and manifold (see Figure 62).

Manifold
101-4023
Pull-Wire
Slipring
001-5053
Figure 62 Installing Slipring/Manifold
4. Lubricate the slipring with o-ring lube and install into the rotary actuator (see Figure 62).
5. Lubricate two HHCS (002-1572) with AquaLube and install, with washers (002-1439),
through the manifold and into the rotor (see Figure 30). Center the manifold on the rotary
actuator by loosely installing the remaining eight HHCS (002-1804) (see Figure 26).
Torque the two HHCS (002-1572) to 35 ft/lb (47 Nm). Remove the eight HHCS (002-
1804).
Center the Position Sensor

Refer to Figure 26, Figure 30, Figure 43, Figure 63, and Figure 64 for this procedure.
!Caution
1. Place two opposing HHCS (002-1825) (see Figure 26) into the bottom of the rotary actu-
ator assembly (101-3781). Use a crossbar between these screws to turn the rotary actuator
all the way to one hard stop. Note the position of the rotary actuator. Turn the rotary ac-
tuator the opposite direction to the other hard stop. Note the position of the rotary actua-
tor. Turn the rotary actuator back to the center of the rotation. Do not rotate the arm away
from the centered position.
2. Turn on the power to the master controller. Go to the diagnostics menu: Press DOWN TO
BACK” readout.
Place the sensor driveshaft (101-4012) into the position sensor (101-3917) as shown in

Sensor Driveshaft
101-3917
sensor driveshaft with the flat on the coupler (see Figure 58) and install the sensor drive-
shaft into the rotary actuator (see Figure 30).
(001-5266) (see Figure 30).
7. Feed the pull-wire through the wire housing as shown in Figure 64. Lubricate four SHCS
(002-1550) with AquaLube and install the wire housing onto the rotary actuator (see Fig-
ure 64). Torque to 28 in/lb (3.2 Nm).
SHCS (4x)
002-1550
Pull-Wire
Wire Housing
001-5266
Figure 64 Installing the Wire Housing
Note: Check that the “FEED BACK” readout is still at 0 (± 100). If not, repeat steps
1-7 until the desired readout is maintained.
8. Remove the two screws from step 1. Turn off the master controller.

Reattach Forearm to Rotary Actuator
1. Lubricate nine o-rings (004-0222) with o-ring lube and install on the bottom of the
mounting flange (101-3777) (see Figure 65).
O-rings (9x) Pull-Wire

004-0222
Mounting Flange
101-3777
Figure 65 Installing O-rings to Bottom of the Rotary Actuator
2. Lubricate ten HHCS (002-1825) with AquaLube (see Figure 26).

3. Tie the pull-wire to the six sensor wires coming out the top of the forearm. Pull the pull-
wire through the rotary actuator as you align the mounting flange of the forearm with the
pin on the face of the mounting flange (101-3777).
4. Install HHCS from step 2, with washers (002-0790), to secure the forearm (see Figure 26,
on page 3). Torque to 8 ft/lb (10.7 Nm).
5. Align the all hydraulic hose fittings. Ensure that the hoses exit cleanly into the upper arm
and will clear the manifold cover (001-5088) (see Figure 26). Tighten the hose fittings
finger tight, then one-sixth of a turn to tighten the hose fittings.
6. Lubricate five new o-rings (004-0086 and 004-0139) with o-ring lube and install them
into the wire housing cover (001-5267) (see Figure 27).
7. Install the position sensor wires to the PCB assembly (see Figure 66). To connect wires
properly, match the wire colors across the connector.
PCB Assembly
101-4016
Position Sensor Wires

From Forearm Area
Figure 66 Connecting Sensor Wires
the manifold cover (001-5088) onto the rotary actuator (see Figure 26). Torque to 35 ft/
lb (47.5 Nm).

This page not used.

Service Instruction
Forearm, 101-3918
Description
Complete service instructions for the Orion P intermeshing jaw

3 hours


9/64 allen wrench Loctite 271® (002-0795)
1/4-in flat blade screwdriver Valvoline® Val-Plex EP Grease
3/32-in flat blade screwdriver Dow Corning 5 Silicone Grease
7/16-in wrench
9/16-in wrench
1-- 3-ft 24 gauge wire or equivalent string

ed
PHMS = Pan Head Machine Screw
!Caution

!Caution
nostic Hose) spares (P/N: 101-3835, -3836, -3837, -3838, -3839, -3840,
-3841). Replacement with hoses of other jacket types (steel, etc.) will
result in premature hose failure.
The procedures in this Service Instruction assume that the forearm assembly will be removed from
and then reattached to the slave arm. The and jaw assemblies will need to be detached from and
reattached to the forearm as part of the servicing. You will need to refer to the wrist Service Instruc-
tion for wrist removal instructions.
You must remove the wrist assembly before you can perform service on the intermeshing jaw as-
sembly. See the service instructions for the Orion Wrist Assembly.
Introduction
The serviceable areas of the forearm assembly are the:
• O-rings
• Hydraulic hoses
• Wrist pitch linear actuator with its pivot pins and bearings
• Wrist pitch joint pivot pin and bearings
• Wrist rotary position sensor
Note: Under most circumstances, the forearm should not be completely disassembled.
The routing and connection of the hydraulic hoses is complex and should not be
disturbed unless absolutely necessary for servicing. If you decide, or need, to
completely disassemble the forearm, pay special attention to the hydraulic hose
routing during reassembly.
! WARNING
continue.


troller.
Remove the Forearm

HHCS and Washers

002-1804 and 002-1439
Manifold Cover
001-5088
Anode
002-1440

101-3781 Pin
001-4342
Pin
001-4594 HHCS (2x)
002-0065
Forearm
007-0360
Wrist Pitch Linear Actuator

101-3938
Bearing
001-5368 Linear Actuator Guard
001-4710
Pin (2x)
001-4596 HHCS and Washers
002-0134 and 002-0790
Pin (2x)
101-4342 Cap Plug (2x)
002-1784
HHCS (2x)
002-0065
Wrist Base
101-3960
Rotary Position Sensor
101-3917
Figure 67 Basic Forearm Parts Identification

Remove the Forearm From the Forearm Rotary Actuator
!Caution
When you remove the ten HHCS in step 6, the forearm will be free. Read
the entire step before continuing. Be prepared by properly supporting
the forearm.
1. Remove the anode (002-1440) from the forearm (007-0360) (see Figure 68).
er (001-5088) to the top of the forearm rotary actuator (101-1781)(see Figure 68). Re-
move the manifold cover to expose the wire housing cover (001-5267) (see Figure 69).

002-1804 and 002-1439
Manifold Cover
001-5088
Anode
002-1440

101-3781
Forearm
007-0360
002-1825 and 002-0790
3. Remove the five SHCS (002-0158) that hold the wire housing cover to the top of the wire
housing (001-5266) (see Figure 69). Remove the wire cover housing cover and remove
the large o-ring (004-0139) and the four smaller o-rings (004-0086) from the wire hous-
ing cover (see Figure 69).

004-0139 004-0086 001-5267

001-5266 002-0158

4. Using a 3/32-in flat blade screwdriver, remove the forearm sensor wires from the PCB
ing.
PCB Assembly
101-4016
5. Tightly tie one end of a 3 foot-long, 24 gauge wire (or equivalent string) around all of the
wires you just removed in step 4. Tie the other end of the wire to a hydraulic fitting on
the top of the forearm rotary actuator. The “pull-wire” will trail behind when the forearm
is removed and help you get the wires back through the forearm rotary actuator when the
forearm is reattached.
!Caution
When you remove the ten HHCS in step 6, the forearm will be free. Read
the entire step before continuing. Be prepared by properly supporting
the forearm.
6. While supporting the arm, remove the ten HHCS (002-1825) and washers (002-1439)
from the bottom of the forearm rotary actuator (see Figure 68). Separate the forearm from
the forearm rotary actuator and extract the position sensor wires from the forearm rotary
actuator. Untie the pull-wire from the position sensor wires and set the forearm on a stable
work surface.
7. Remove the nine o-rings (004-0222) from the bottom of the forearm rotary actuator (101-

O-rings (9x)
004-0222
Figure 71 Bottom of Forearm Rotary Actuator
Remove Wrist from Forearm

1. Remove the two HHCS (002-0065) that hold the hose guard (001-5212) in place and re-
move the hose guard from the wrist base (101-3960) (see Figure 72).
Hose Guard
001-5212
Cap Plug (2x)
HHCS (2x)_ 002-1784
002-0065
Anode
002-1440 Wrist Base
101-3960
Figure 72 HHCS, Hose Guard, Cap Plug, and Anode Location
2. Remove the anode (002-1440) from the wrist base (101-3960) (see Figure 72).
3. Remove the two cap plugs (002-1784) from the wrist base by placing a finger on the
backside of the plug and pushing it out of the hole (see Figure 72).
(001-4710) from the linear actuator (001-3938)(see Figure 73). Slide the pin (001-4711)
out and remove the two spacers (001-4898)(see Figure 73).

Linear Actuator
001-3938
Linear Actuator Guard

001-4710
HHCS and Washers Spacer (2x)

002-0134 and 002-0790 001-4898
Wrist Base
101-3960
Pin
001-4711
Linear Actuator
101-3938
Figure 73 Removing the Linear Actuator From the Wrist Base
5. Remove the four HHCS (002-1804) and washers (002-1574) and separate the wrist motor
(101-3786) from the wrist adapter (101-3962) and wrist base (see Figure 74).

002-1804 and 002-1574
Wrist Adapter Wrist Base

101-3962 101-3960
Wrist Motor
101-3786
Figure 74 Removing the Wrist Motor From the Wrist Base
6. Remove the four small o-rings (004-0222) and one large o-ring (004-0048) from the wrist
base (see Figure 75.

O-rings (4x)
Wrist Base 004-0222
101-3960
O-ring
004-0048
Figure 75 Wrist Base O-rings
Remove Wrist Base and Wrist Position Sensor from Forearm


101-3938
Wrist Base
101-3960
Wrist Position Sensor

101-3917
PHMS (4x)
002-1841
Bearing (2x) Pin Pin (2x) HHCS (4x)

001-5368 001-4596 001-4342 002-0065
Figure 76 Wrist Base Parts Identification
1. Tightly tie one end of a 3 foot-long, 24 gauge wire (or equivalent string) around the three
wrist position sensor wires (brown, red, and black) coming out of the top of the forearm.
Tie the other end of the pull-wire to a bolt hole in the top of the forearm. When you re-
move the wrist position sensor (101-3917), in step 2, the pull-wire will trail behind and
help you get the wires back through the wrist sensor hose assembly (101-4015) when the
sensor is reattached.
2. Remove the four PHMS (002-1841) from the wrist position sensor (101-3917) and re-
move the sensor from the wrist base. Slowly pull the wires out of the wrist sensor hose
assembly (101-4015). Untie the pull-wire from the sensor wires. Set the sensor aside for
later service.
Note: Before continuing to step 3, make sure the hydraulic hose ends at the wrist base
3. Disconnect the five hydraulic hoses (101-3837, 101-3838, 101-3839, 101-3840, and 101-
3841) and the wrist sensor hose assembly (101-4015) from the wrist base (101-3960).
4. Remove the four HHCS (002-0065) and pin (001-4342) from both sides of the forearm.
Support the wrist base and slide both pins out of the wrist base to separate the wrist base
from the forearm.

Remove Wrist Pitch Linear Actuator From Forearm
HHCS and Washer(2x) Pin

002-0134 and 002-0790 001-4342
Mounting Flange
001-5244
HHCS (2x) Pin

002-0065 001-4594
Figure 77 Removing Pitch Linear Actuator From Forearm
1. Remove the two HHCS (002-0065) and pin (001-4342) from the forearm (007-0360) (see
Figure 77). Slide the pin (001-4594) out of the forearm.
2. Remove the two HHCS (002-0134) and washers (002-0790) securing the mounting
flange (001-5244) to the forearm (see Figure 77).
3. Slide the forearm off the mounting flange and wrist pitch linear actuator (101-3938). Set
the forearm aside for later inspection.
Note: Schilling Robotics recommends that you do not perform steps 4-5 unless you
have specific reasons for servicing:
• the wrist pitch linear actuator (101-3938),
• one or more hydraulic hoses, or
• the mounting flange (001-5244).
If you do not need to service any of the above parts, go to “Inspect Forearm Parts”
on page 10.
!Caution
Hydraulic fluid will spill out of the wrist pitch linear actuator when you
remove the hydraulic hoses, 4A and 4B (101-3835 and 101-3836), dur-
ing
step 4. Have a drain pan ready to catch the fluid.
4. Disconnect hydraulic hoses 4A and 4B (101-3835 and 101-3836) from the wrist pitch lin-
ear actuator (see Figure 78).

SHCS and Washer(4x) Sensor Housing Hydraulic Hose 4A
002-0399 and 002-0405 001-5207 101-3835
Hydraulic Hose 4B
101-3836
Figure 78 Wrist Pitch Linear Actuator
5. Remove the four SHCS and washers (002-0399 and 002-0405) from the sensor housing
(001-5207). Remove the sensor housing from the wrist pitch linear actuator (see Figure
78). If you need to service the wrist pitch linear actuator, see Orion "Linear Actuators,
101-3938, -3939, -4328" Service Instruction.
Inspect Forearm Parts

1. Inspect the hydraulic hoses and the connector assembly for signs of chafing, wear, kink-
ing, leakage, or other damage. Replace any damaged hose.
!Caution
nostic Hose) spares (P/N: 101-3835, -3836, -3837, -3838, -3839, -3840,
-3841). Replacing hoses of other jacket types (steel, etc.) will result in
2. Inspect the four bearings (001-5368) for cracks, excessive wear, or other damage (see
Figure 67). Replace any damaged bearing.
ing, or other damage. Replace any damaged pin.
4. Inspect the forearm (007-0360), wrist base (101-3960), and mounting flange (001-5244)
for signs of cracking, twisting, deformation, or other damage. Replace any damaged
parts.
Service the Wrist Rotary Position Sensor

See Figure 79 and Figure 80 for reference.
1. Remove the two PHMS (002-1872) from the rotary position connector (101-3961). Sep-
arate the connector from the rotary position sensor (101-3917) (see Figure 79).

Rotary Position Connector
101-3961
PHMS
002-1872
Rotary Position Sensor

101-3917
Figure 79 Rotary Position Connector and Rotary Position Sensor
2. Remove the o-ring (004-0062) and the back-up ring (004-0064) from the sensor (see Fig-
ure 80). Lubricate a new o-ring and back-up ring with o-ring lube and install onto the sen-
sor (see Figure 80).
O-ring
004-0062
Back-up Ring
004-0064
Figure 80 Rotary Position Sensor O-ring Orientation
3. Fill the connector cavity of the rotary position connector with DC 5 grease. Lubricate the
two PHMS with AquaLube and install the connector onto the sensor. Tighten the PHMS.
Set the rotary position sensor aside for later installation onto the forearm.
Reassemble Forearm
Refer to Figure 81, Figure 82, Figure 83, Figure 84, and Figure 85 for this procedure. If you did not
disconnect the hydraulic hoses from the mounting flange, or remove the wrist pitch linear actuator,
skip the steps that do not apply to you. If the wrist pitch linear actuator (101-3938) was not serviced,
skip to step 2.
1. Apply a thin film of EP grease to the sealing surfaces of the -4 hydraulic fittings (006-
0108) (see Figure 81). Attach hose 4A and 4B (101-3835 and 101-3836) (see Figure 81).
Tighten the hose fittings finger tight, then one-sixth of a turn to tighten the hose fit-
ting.
Lubricate the four SHCS (002-0399) with AquaLube (see Figure 81). Fill the connector
cavity of the connector housing with DC5 grease. Using four SHCS and washers (002-
0405), install the sensor housing (001-5207) to the wrist pitch linear actuator (see Figure
81). Torque to 10-in/lb (1.1 Nm). Wipe away excess DC5 grease.

!Caution
All hoses must be routed as shown in Figure 81, or premature hose failure
will result.
SHCS and Washer(4x) Sensor Housing Hydraulic Hose 4A

002-0399 and 002-0405 001-5207 101-3835
Hydraulic Hose 4B
101-3836
Figure 81 Hose Orientation for Wrist Pitch Linear Actuator
2. Apply a thin coat of EP grease to the sealing surface of each -4 hydraulic fitting on the
mounting flange (001-5244). Verify that the three -4 angle fittings (006-0116) are orient-
ed as shown in Figure 82.
-4 Hydraulic Fittings (3x)

004-0116
Figure 82 -4 Angle Fitting Orientation
3. Connect the -4 hydraulic hoses to the appropriate fittings. See Figure 83 for hose orien-
tation. Tighten each hose fitting finger tight, then one-sixth of a turn to tighten the
hose fitting.
Figure 83 -4 Hydraulic Hose Orientation

4. Connect the two -4 hydraulic hoses from the wrist pitch linear actuator to the mounting
flange. See Figure 84 for orientation of wrist pitch linear actuator -4 hydraulic hoses.
Drawing not to scale
Figure 84 Connecting -4 Hydraulic Hoses From Wrist Pitch Linear Actuator
5. Pass the sensor wires from the wrist pitch position sensor through the fitting marked "P"
on the mounting flange (001-5244). Connect the hydraulic fitting to the fitting marked
"P." Tighten the hose fitting finger tight, then one-sixth of a turn to tighten the hose
fitting.
6. Carefully pass the hoses and the wrist pitch linear actuator through the forearm (007-
0360). Apply AquaLube to the threads of the two HHCS (002-0134) and install, with
washers (002-0790), into the mounting flange (001-5244) (see Figure 85). Torque to 8 ft/
lb (11 Nm).
HHCS and Washer(2x)

002-0134 and 002-0790
Mounting Flange
001-5244
Figure 85 Installing the Mounting Flange
Attach Wrist Pitch Linear Actuator to Forearm

1. Apply EP grease to the pin (001-4596). Align the wrist pitch linear actuator (101-3938)
with the forearm and insert the pin.

Pin
001-4342
Pin
HHCS (2x) 001-4594
002-0065
Figure 86 Installing Body End of Wrist Pitch Linear Actuator Into Forearm
2. Apply Aqua Lube to the threads of the two HHCS (002-0065). Install two HHCS and the
pin (001-4342) onto the forearm. Torque to 8 ft/lb (11 Nm).
Attach -4 Hydraulic Hoses to Wrist Base

!Caution
All hoses must be routed as shown in Figure 87, or hose failure will result.
1. Apply a thin coat of EP grease to the sealing surface of each hydraulic fitting on the wrist
base (101-3960).
2. Attach hoses 5A and 6B to the wrist base fittings. Tighten each hose fitting finger tight,
then one-sixth of a turn to tighten the hose fitting.
Linear actuator not shown in this view for clarity
Figure 87 Wrist Base and Hose Orientation

3. Attach hoses 6A, 5B, and C to the wrist base fittings. Tighten each hose fitting finger
tight, then one-sixth of a turn to tighten the hose fitting.
4. Pass the pull-wire for the wrist position sensor wires through the wrist base at the fitting
marked “W.” Attach the wrist position sensor hose to the wrist base at the fitting marked
“W”. Tighten the hose fitting finger tight, then one-sixth of a turn to tighten the hose
fitting.
Install Wrist Base and Wrist Position Sensor to Forearm

Wrist Base
101-3960
Wrist Position Sensor

101-3917
PHMS (4x)
002-1841
Bearing Pin Pin HHCS (2x)

001-5368 001-4596 001-4342 002-0065
Figure 88 Installing Wrist Base and Wrist Position Sensor to Forearm
1. Apply EP grease to the bearings (001-5368) and pivot pins (001-4596). Align the forearm
and wrist base and insert the two pivot pins.
2. Apply AquaLube to the threads of the four HHCS (002-0065) and use them to install the
two pins (001-4342). Torque to 8 ft/lb (11 Nm).
3. Tie the pull-wire from the wrist position sensor tube to the three wires of the wrist posi-
tion sensor (101-3917). Slowly pull the wires up into the wrist position sensor tube and
out of the top of the forearm.
4. Lubricate the four PHMS (002-1841) with AquaLube and install the wrist position sensor
(101-3917) to the wrist base (101-3960). Tighten the PHMS. Untie the pull-wire from the
position sensor wires.
Install Wrist to Forearm

1. Use liberal quantities of o-ring lube to position the four small o-rings (004-0222) and one
large o-ring (004-0048) to the wrist base (101-3960) (see Figure 89).

O-rings (4x)
Wrist Base 004-0222
101-3960
O-ring
004-0048
2. Lubricate the four HHCS (002-1804) with AquaLube. Add the washers (002-1574) to the
HHCS and attach the wrist motor/wrist adapter to the wrist base (101-3960). Torque to
25 ft/lb (34 Nm) (see Figure 90).
!Caution
Be careful to line up all the oil passages correctly. The wrist and jaw will
fail to operate if the oil passages are not aligned correctly.

002-1804 and 002-1574

101-3962 101-3960
Wrist Motor
101-3786
Figure 90 Installing the Wrist Motor From the Wrist Base
3. Attach the linear actuator (001-3938) to the wrist base. Slide the pin (001-4711) and the
two spacers (001-4898) in place (see Figure 91).

Linear Actuator
001-3938

001-4710
HHCS and Washers Spacers

002-0134 and 002-0790 001-4898
Wrist Base
101-3960
Pin
001-4711
Linear Actuator
001-3938
Figure 91 Installing the Linear Actuator to the Wrist Base
the two HHCS and attach the linear actuator guard (001-4710) to the linear actuator (see
Figure 91). Torque to 8 ft/lb (11 Nm). Install two cap plugs (002-1784) onto the wrist
base (see Figure 92).
Hose Guard
001-5212
Cap Plug (2x)
HHCS (2x)_ 002-1784
002-0065
Anode
002-1440 Wrist Base
101-3960
5. Lubricate the threads of a new anode (002-1440) with AquaLube and install onto the
wrist base (see Figure 92).
6. Lubricate the two HHCS (002-0065) with AquaLube and install the hose guard onto the
wrist base (101-3960) (see Figure 92). Torque to 8 ft/lb (11 Nm).
Install Wrist Pitch Actuator to Forearm


1. Apply EP grease to the bearings (001-5368) and the pin (001-4711). Align the rod end of
the wrist pitch linear actuator (101-3938), wrist base (101-3960), and spacers (001-4898).
Insert the pivot pin so that the bolt holes are aligned with the rod end holes.

002-0134 and 002-0790
001-4710
Cap Plug (2x)
002-1784

101-3938
Bearing Wrist Base

001-5368 101-3960
Figure 93 Installing Rod End of Wrist Pitch Linear Actuator Into Wrist Base
2. Apply Aqua Lube to the threads of the two HHCS (002-0134). Attach the actuator guard
(001-4710) using the two HHCS (002-0134) and washers (002-0790). Torque to 8 ft/lb
(11 Nm).
3. Install the cap plugs (002-1784) to the wrist base.
Attach Forearm to Forearm Rotary Actuator

Refer to Figure 68, Figure 69, Figure 94 and Figure 95 for this procedure.
Pin

004-0222
Mounting Flange
101-3777

pin on the face of the mounting flange.
4. Install HHCS from step 2, with washers (002-0790), to secure the forearm (see Figure
68). Torque to 8 ft/lb (10.7 Nm).

PCB Assembly
101-4016

From Forearm Area
lb (47.5 Nm).
9. Lubricate the anode threads (002-1440) with AquaLube and install onto forearm (see Fig-
ure 68).

This page not used.

Service Instruction
Wrist, 101-3786
Description
Complete service instructions for the Orion P intermeshing jaw.

3 hours


9/16-in socket Loctite 271® (002-0795)
1-1/2-in socket Loctite 242®
5/32-in allen wrench Dow Corning 55® o-ring lube or petroleum jelly
0-1-in (0-25mm) micrometer
6-in vernier calipers
flat blade screwdriver
torque wrench capable of 5-75 ft/lb (8-102 Nm)
torque wrench capable of 0-75 in/lb (0-8.5 Nm)
new razor blade or X-acto style knife

ed
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

!Caution
!Caution
If you are planning to replace the three seals (004-0803) located in the
slipring wrist housing (101-3784), you must have replacements on-
hand. You will need to destroy the old seals to remove them.
!Caution
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 of these washers on-hand before starting this proce-
dure.
To perform the procedures in this Service Instruction, you will remove the wrist assembly from the
slave arm. The jaw will need to be detached from the wrist assembly as a step in the wrist assembly
service. Refer to the appropriate jaw Service Instruction to remove the jaw installed on your slave
arm.
! WARNING
continue.
Tip: Extend the pitch actuator to full extension. This will help you gain access to the
wrist mounting bolts.
troller.
Remove the Wrist


Remove the Jaw Assembly
Refer to the appropriate jaw Service Instruction to remove the jaw installed on your slave arm. Read
and be familiar with all the steps and requirements before you get started. Return to this point when
you have removed your jaw assembly.
Remove the Jaw Nose Block/Jaw Piston Assembly

Refer to the appropriate nose block/jaw piston Service Instruction to remove the nose block/jaw pis-
ton installed on your slave arm.
If you have a PA jaw, refer to the appropriate wrist/jaw adaptor Service Instruction to remove the
wrist/jaw adaptor installed on your slave arm.
Read and be familiar with all the steps and requirements before you get started. Return to this point
when you have removed your nose block/jaw piston assembly.
Go to "Remove Wrist from Forearm".
Remove Wrist from Forearm

1. Remove the two HHCS (002-0065) that hold the hose guard (001-5212) in place and re-
move the hose guard from the wrist base (101-3960) (see Figure 96).
Hose Guard
001-5212
Cap Plug (2x)
HHCS (2x)_ 002-1784
002-0065
Anode
002-1440 Wrist Base
101-3960
2. Remove the anode (002-1440) from the wrist base (see Figure 96).
3. Remove the two cap plugs (002-1784) from the wrist base by placing a finger on the
backside of the plug and pushing it out of the hole (see Figure 96).
(001-4710) from the linear actuator (001-3938)(see Figure 97). Slide the pin (001-4711)
out and remove the two spacers (001-4898)(see Figure 97).

Linear Actuator
001-3938

001-4710
HHCS and Washers Spacer (2x)

002-0134 and 002-0790 001-4898
Wrist Base
101-3960
Pin
001-4711
Linear Actuator
101-3938
Figure 97 Removing the Linear Actuator From the Wrist Base
5. Support the Wrist. Remove the four HHCS (002-1804) and washers (002-1574) and
separate the wrist motor (101-3786) from the wrist adapter (101-3962) and wrist base
(see Figure 98).

002-1804 and 002-1574

101-3962 101-3960
Wrist Motor
101-3786
Figure 98 Removing the Wrist Motor From the Wrist Base
6. Remove the four small o-rings (004-0222) and one large o-ring (004-0048) from the bot-
tom of the wrist base (see Figure 99).

Wrist Base Wrist Adapter
101-3960 101-3962
O-rings (5x)
004-0222
O-rings (4x)
004-0222
O-ring
004-0048
Figure 99 Removing Wrist Base O-rings
7. Remove the five small o-rings (004-0222) from the bottom of the wrist adaptor (see Fig-
ure 99).
Remove the Wrist Manifold From the Slipring Housing

!Caution
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.
HHCS Valve Plate Gerotor Drive Shaft

(5x) 001-4577, 001-1832 101-3373 001-3785
(2x) 001-4448, &
(1x) 001-4449
O-ring
004-0017
FHMS (3x)
002-1787
Clamping Nut
001-5103
Sensor Shaft
101-4008
HHCS
002-1133
Thrust Washer (2x)

003-0092 Wrist Manifold Wrist Housing
101-3782 101-3784
Thrust Bearing
003-0091
Figure 100 Basic Wrist Motor Parts Identification

1. Remove the o-ring (004-0017) from the wrist manifold (101-3782) (see Figure 100).
2. Remove the three FHMS (002-1787) from the position sensor shaft (101-4008) and re-
move the shaft.
3. Using a 5/32-in allen wrench, loosen, but do not remove the SHCS (002-1133) on the
clamping nut (001-5103) (see Figure 100). 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 100).
4. Remove the two thrust washers (003-0092) and thrust bearing (003-0091) from the drive
shaft (001-3785).
5. 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 6. 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.
6. Remove the wrist manifold from the wrist housing (101-3784) (See the "Tip" below).
Tip: Removing the wrist manifold may be difficult, but DO NOT use any tools to pry
the wrist manifold out of the wrist housing. Use the following technique to remove
the wrist manifold from the wrist slipring 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 101). Screw two HHCS (002-1804) that
held the jaw motor to the wrist base into the wrist manifold (see Figure 101).
Squeeze the screws together and evenly pull up to remove the wrist manifold (see
Figure 101).
HHCS (2x)
002-1804
Wrist Manifold
101-3782
Wrist Housing
101-3784
HHCS
002-1628
Figure 101 Removing the Wrist Manifold From the Wrist Housing

7. 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 5 (see Figure 102).
Remove both SHCS from the wrist manifold. Remove the crush washers (004-0576)
from each SCHS (see Figure 102).
Wrist Manifold
101-3782 O-ring Bushing
004-0010 001-1984
O-ring (2x)
004-0698
Washer (8x)
004-0576
SHCS (2x)
001-4448
O-ring
Bearing 004-0698
003-0011
Figure 102 Disassembling the Wrist Manifold
8. Remove the o-ring (004-0010) from the wrist manifold (see Figure 102).
9. If the bearing (003-0011)is damaged, remove it from the wrist manifold by evenly tap-
ping it out using a small brass drift or pressing it out using a suitable tool (see Figure 102).
If not damaged, the bearing may remain in the wrist manifold.
Final Wrist Motor Disassembly

1. Remove the o-rings (004-0081, 004-0017, and 004-0413) from the valve plate (001-
1832) (see Figure 103).
Valve Plate
001-1832
O-ring
004-0017
O-ring
004-0413
O-ring
004-0081
Figure 103 Removing Valve Plate O-rings
2. Using the two HHCS (001-1577) that you used to remove the wrist manifold (101-3782),
remove the valve plate by lifting it up as shown in Figure 104.

HHCS (2x) Seal
001-1577 004-0574
Driveshaft
101-3785
Valve Plate Wrist Housing

001-1832 101-3784
Figure 104 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 104).
4. Turn the slipring wrist housing face down over a flat surface and allow the gerotor assem-
bly (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 9).
5. Press down to push the drive shaft up out of the wrist housing. If necessary, tap the hous-
ing 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.
6. Remove the seal (004-0617), backup ring (001-4437), thrust washer (003-0074), and roll-
er bearing (003-0013) from the wrist housing (see Figure 105).
Driveshaft
101-3785
Back-up Ring
004-0574
Thrust Washer
003-0074
Seal
004-0617
Figure 105 Removing Parts from Wrist Housing
7. Using a small pick tool, remove the bearing (001-4454) from the wrist housing (101-
3784) (see Figure 106). Set aside bearing to inspect later.

Seal (3x)
004-0803
Bearing
001-4454
Needle Bearing
003-0031
Wrist Housing
101-3784
Figure 106 Removing Seals, Bearing, and Needle Bearing from Wrist Housing
!Caution
To remove the three seals (004-0803), in step 8, you will need to destroy the
seals. If you don’t have replacements, do not remove the seals at this
time.
8. Remove the three seals (004-0803) (see Figure 106) 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 slipring wrist housing.
9. If the needle bearing (003-0031) is damaged, remove it from the wrist housing by even-
ly tapping it out using a small brass drift (see Figure 106).
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 matched parts. If there are damaged parts, replace the en-
tire assembly.
Refer to Figure 107, for this procedure. See Figure 107 for basic identification of gerotor parts (101-
3373).

Figure 107 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 unit. All parts of
the gerotor assembly carefully are matched together at the Schilling Robotics factory and
cannot be interchanged with another gerotor assembly.
3. Inspect the inner rotor for wear. The coating on the inner rotor will flake off under ex-
treme conditions. This will show itself as jittery low speed performance and a loss of
wrist torque. Replace the gerotor assembly if all, or most of, the coating is gone.
Inspect Wrist Components

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 100, Figure 102, Figure 105, and Figure 106). Replace any
damaged bearings.
3. Inspect the thrust washers (003-0074) for wear and galling (see Figure 105). Replace
washers if they show excessive wear, galling, or other damage.
4. Inspect the bearing (001-4454) for galling or damage (see Figure 106). Using your 6-in
vernier calipers, measure the wall thickness of the bearing. Replace the bearing if the
thickness is 0.928-in (23.5 mm), 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 Slipring Wrist Housing for Assembly

1. If you removed the needle bearing (003-0031), install the bearing into the wrist housing
(101-3784) (see Figure 108). 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 108 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 109 and “Tip” below). Be very careful to place the o-ring and
seals in the correct orientation (see Figure 109). Lubricate the seal surfaces with EP
grease.
Wrist Housing
101-3784
Seal & O-ring

004-0803
Bearing
101-1154
Figure 109 Installation of O-rings, Seals, and Bearing into Wrist Housing

Tip: To aid in getting the o-ring into the groove, it may be helpful to bend it like
this: then push the o-ring down into the groove.
If the seals were not removed, lubricate the seal surfaces with EP grease.
3. Lubricate the bearing (001-4454) with EP grease and install it into the wrist housing as
shown in Figure 109.
4. Set aside the slipring wrist housing assembly for later installation.
Prepare Wrist Manifold for Assembly

Refer to Figure 110 for this procedure. See Figure 110 for wrist manifold parts identification
Crush Washer (8x) Bearing O-ring Bushing

004-0576 003-0011 004-0110 001-1984
SHCS (5x)
001-4577
SHCS (2x)
001-4448
O-ring
004-0698
SHCS (1x) O-ring (2x) Wrist Manifold

001-4449 004-0698 101-3782
Figure 110 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.
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 004-0698) 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 111 for this procedure. Stand the drive shaft (001-3785) up on end, shaft up, to pre-
pare it for installation into the wrist housing.
Drive Shaft
101-3785
Backup Ring
001-4437
Thrust Washer
003-0074
Bearing
003-0013
Seal
004-0575
Figure 111 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 and Gerotor Into Slipring Wrist Housing

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 slipring wrist
housing below the heli-coils. These bores are where the two, wrist oil supply, SHCS are
placed.
4. Carefully slide the wrist housing onto the drive shaft (see Figure 112). Seat the housing
completely onto the drive shaft.
Wrist Housing
101-3784
Drive Shaft
101-3785
Figure 112 Seating Wrist Housing on Drive Shaft Assembly

5. Lubricate the seal (004-0617) with o-ring lube, check orientation, and install it between
the slipring wrist housing and the drive shaft (see Figure 113). Check orientation and push
the seal in far enough not to damage it when you stand the housing up on that end.
Wrist Housing
101-3784
Seal
004-0617
Figure 113 Installing Seal into Wrist Housing
6. Lubricate the wear plate (001-2060) with EP grease and install it onto the drive shaft
(001-4438) (see Figure 114). 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 gero-
tor assembly. Replace the plate in the same orientation as originally installed.
Wear Plate
001-2060
Drive Shaft
101-3785
Wrist Housing
101-3784
Figure 114 Installing Wear Plate into Wrist Housing
Reassemble Gerotor Assembly

Refer to Figure 115 for this procedure. The machine tolerances are very tight in the gerotor assem-
bly, therefore you will need to be very careful handling the parts.
During assembly, lubricate all parts with petroleum jelly.

Drive Shaft
101-3785 Wear Plate
001-2060
Wrist Housing
101-3784
Figure 115 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).
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 Slipring Wrist Housing

1. Lubricate the gerotor valve plate and lower it into position onto the drive shaft (101-
3785) (see Figure 116). Carefully align the valve plate so that you cannot see rollers
through any of the slots in the plate (see Figure 116).

!Caution
Carefully align the valve plate so that you cannot see rollers through any
of the slots in the valve plate. The wrist will not function if you fail to
align the valve plate properly.
Drive Shaft
101-3785
Gerotor Assembly Valve Plate

101-3373
Slots in Valve Plate
Figure 116 Installing the Valve Plate to Gerotor Assembly
2. Install the valve plate (001-1832) onto the drive shaft (see Figure 117).
O-ring
004-0017
O-ring
Seal 004-0413
004-0574
O-ring
004-0081
Valve Plate
001-1832
Drive Shaft
101-3785
Figure 117 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 117).
4. Lubricate new o-rings (004-0081, 004-0017, and 004-0413) with o-ring lube and install
onto the valve plate (see Figure 117).

Install the Wrist Manifold Onto the Slipring Wrist Housing
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 118). Gently press the manifold into place.
Wrist Manifold
101-3782
Wrist Housing
101-3784
Pin Plug Holes
Figure 118 Positioning the Wrist Manifold Onto the Slipring Wrist Housing
3. Install new crush washers (004-0576) onto the five SHCS (001-4577) (see Figure 102).
Heavily lubricate the SHCS with EP grease and install them into the wrist manifold. Fol-
low this procedure to torque the SHCS:
Tip: To hold the slipring wrist housing steady while you torque the following SHCS, use
the same procedure you used in step 6 of “Remove the Wrist Manifold From the
Slipring Housing” on page 5.
4. Screw the two SHCS (001-4448) to finger tightness. This will center the o-rings so that
they will properly seal.
5. Tighten all the other SHCS to finger tightness.
Torque all eight of the SHCS to 15 ft/lb (20.3 Nm).
Torque only the oil-return SHCS (001-4449) and the five standard SHCS (001-4577) to
18 ft/lb (24.4 Nm).
Torque only the five standard SHCS (001-4577) to 24 ft/lb (32.5 Nm).
6. 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 119).

Clamp Nut
001-5103
Thrust Washer (2x) HHCS

101-3785 002-1133
Bearing
003-0091
Drive Shaft
101-3785
Wrist Manifold
101-3782
Figure 119 Installing Thrust Washers and Bearing
7. Install the clamp nut (001-5103) on the drive shaft with the three threaded holes facing
out (see Figure 119). Follow this procedure to torque the clamp nut:
Torque the clamp nut to 75 ft/lb (102 Nm) to seat all wrist components.
Loosen the clamp nut and retorque it to the torque stamped on the nut or to
40 ft/lb (54 Nm) to set the wrist preload.
Tighten the clamp nut SHCS (002-1133) to 5 ft/lb (7 Nm) to secure the clamp nut (see
Figure 119).
8. Install the position sensor shaft (001-4008) and the three FHMS (002-1787) that hold it
in place (see Figure 100). Use new screws, or apply Loctite 242. Tighten the FHMS.
9. Lubricate the o-ring (004-0017) with o-ring lube and install onto the wrist manifold (101-
3782) (see 7).
10. Remove the wrist housing from the vise. Remove the two HHCS (002-1628) you used to
hold the housing in the vise.
Install Wrist to Forearm

1. Use liberal quantities of o-ring lube to position the four small o-rings (004-0222) and one
large o-ring (004-0048) to the wrist base (101-3960) (see Figure 120).
O-rings (4x)
Wrist Base 004-0222
101-3960
O-ring
004-0048

2. Lubricate the four HHCS (002-1804) with AquaLube. Add the washers (002-1574) to the
HHCS and attach the wrist motor/wrist adapter to the wrist base (101-3960). Torque to
25 ft/lb (34 Nm) (see Figure 121).
!Caution
Be careful to line up all the oil passages correctly. The wrist and jaw will
fail to operate if the oil passages are not aligned correctly.

002-1804 and 002-1574

101-3962 101-3960
Wrist Motor
101-3786
Figure 121 Installing the Wrist Motor From the Wrist Base
3. Attach the linear actuator (001-3938) to the wrist base. Slide the pin (001-4711) and the
two spacers (001-4898) in place (see Figure 122).
Linear Actuator
001-3938

001-4710
HHCS and Washers Spacers

002-0134 and 002-0790 001-4898
Wrist Base
101-3960
Pin
001-4711
Linear Actuator
001-3938
Figure 122 Installing the Linear Actuator to the Wrist Base

the two HHCS and attach the linear actuator guard (001-4710) to the linear actuator (see
Figure 122). Torque to 8 ft/lb (11 Nm). Install two cap plugs (002-1784) onto the wrist
base (see Figure 123).
Hose Guard
001-5212
Cap Plug (2x)
HHCS (2x)_ 002-1784
002-0065
Anode
002-1440 Wrist Base
101-3960
5. Lubricate the threads of a new anode (002-1440) with AquaLube and install onto the
wrist base (see Figure 123).
6. Lubricate the two HHCS (002-0065) with AquaLube and install the hose guard onto the
wrist base (101-3960) (see Figure 123). Torque to 8 ft/lb (11 Nm).
Install the Jaw Nose Block/Jaw Piston Assembly

Refer to the appropriate nose block/jaw piston Service Instruction to install the nose block/jaw pis-
ton supplied with your slave arm.
If you have a PA jaw, refer to the appropriate wrist/jaw adaptor Service Instruction to remove the
wrist/jaw adaptor supplied with your slave arm.
when you have installed your nose block/jaw piston assembly. Go to "Install the Jaw Assembly".
Install the Jaw Assembly

Refer to the appropriate jaw Service Instruction to install the jaw supplied with your slave arm.
when you have installed your jaw assembly.
Test Wrist Functionality

After the wrist is reassembled, it should be tested to ensure proper functioning and to determine if
adjustment to the wrist preload is necessary.
1. Connect the slave arm to a rate control manifold or other suitable test fixture through
which 3000 psi (20000 kPa) hydraulic pressure can be applied to the arm’s 5A and 5B
supply hoses. Connect the arm’s C (compensation return) hose to a hydraulic return or
drain fitting that will not exceed 350 psi ((2400 kPa).
2. Apply hydraulic power to each supply line in turn to drive the wrist in each direction for
at least a few minutes. Closely inspect the wrist assembly (especially the wrist manifold-
pitch plate junction) for leaks.

3. Observe the wrist action as it rotates. It should turn relatively smoothly, and at a constant
rate.
Note: The gerotor drive has an inherent fluctuation in drive torque. A slight "flutter" in
wrist torque, especially under heavy load, is normal. The "flutter" may be more
noticeable at slow speeds. As long as the degree of flutter is constant, it is normal.
If a servo, or proportional control valve, is used, apply minimal pressure to each wrist
drive supply hose in turn. The wrist should start easily and turn at a constant rate as slowly
as 5-6 rpm.
If the wrist is hard to start, resisting turning until it suddenly “breaks loose,” the flutter is especially
pronounced, or if a minimum rotation speed of about 6 rpm is not obtainable, the wrist preload may
need to be adjusted. Use the following procedure to adjust the wrist preload.
Adjusting Wrist Preload

1. Remove the wrist motor from the wrist base by following the steps in “Remove Wrist
from Forearm” on page 3.
2. Loosen the clamp nut SHCS (002-1133) (see Figure 119).
3. Loosen the clamp nut (001-5103) and retorque it as follows (see Figure 119):
If the standard preload of 40 foot-pounds (54 Nm) was used, retorque the clamp nut to 30
foot-pounds (41 Nm).
If the optional preload of 30 foot-pounds does not improve wrist performance, retorque
the clamp nut to 50 foot-pounds (68 Nm).
If 30, 40, and 50 foot-pounds torque on the clamp nut do not produce the desired wrist
performance, increase the torque in 10 foot-pound (13.5 Nm) steps, up to 110 foot-
pounds (149 Nm).
4. Tighten the clamp nut SHCS (101-3786) to 5 foot-pounds (7 Nm) (see Figure 119).
5. Install the wrist following the steps in “Install Wrist to Forearm” on page 18.
6. Retest the wrist operation using the steps in “Test Wrist Functionality” on page 20 above.
7. Repeat Steps 1-6 until acceptable wrist operation is achieved.

This page not used.

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Page 2 of 2 • • 011–XXXX
Service Instruction
Jaw Piston/Nose Block for P-A Jaw, 101-3834
Estimated Time to Complete Used In:

1 hour Jaw assemblies 101-4105, 4106, 4107


11/16-in 12-point socket Anti-seize, 1 oz. tube (002-1925)
torque wrench capable of 5-100 ft/lb (8-135 AquaLube (002-0805)

Nm)
torque wrench capable of 300 ft/lb (406 Nm) Loctite 271® (002-0795)
bench vise with soft jaws Dow Corning® 55 O-ring lube or petroleum jelly
pick tool
razor blade or X-acto style knife

Needed
010-0184 male installation tool HHCS = Hex Head Cap Screw
010-0185 female sizing tool PA = Parallel-Acting (Jaws)
010-0237 sizing tool HPU = Hydraulic Power Unit

!Caution
If you are planning to replace the seals (004-0646 and 004-0039), you
must have replacements on-hand. You will need to destroy the old seals
to remove them.
!Caution
! WARNING
continue.

2. If you have a P slave arm, turn off the power switches located on the master controller
and the junction box.
4. If you have a P slave arm, and if power is supplied from a local, independent source, turn
off the power to the slave controller.
Disassemble the Nose Block


Wrist Motor
101-3786
Wrist Adaptor
101-3783
Nose Block
001-2061
Bolt
002-3109
Jaw Piston
001-5380 T-Bar Plate
001-7251
HHCS (6x)
002-0038
Figure 142 Basic Nose Block/Jaw Piston Parts Identification
Remove the PA Jaw

Refer to "Parallel-Acting Jaw 101-4106 & 101-2239 (obsolete)" Service Instruction, under “Re-
move PA Jaw From Nose Block” on page 3, for the procedure to remove the PA jaw. Read and be
familiar with all the steps and requirements before you get started. Return to this point when you
have finished removing the jaw.
Remove the Nose Block From Wrist/Jaw Adapter

HHCS (6x)
002-0038
Wrist Motor Nose Block

101-3786 001-2061
Figure 143 Removing the Nose Block
1. Remove the six HHCS (002-0038) from the nose block (001-2061).
!Caution
Hydraulic fluid will spill out of the wrist assembly when you remove the
nose block during step 2. Have a drain pan ready to catch the fluid.

2. Pull the nose block out from the wrist motor (101-3786).
Remove Jaw Piston From Nose Block

T-bar Plate
Seal and O-ring 001-7251
004-0646 & 004-0046
Bearing
003-0150
Push Jaw Piston In To

Remove Bolt
Jaw Piston
001-5380
Bolt
002-3109
Nose Block
001-2061
Figure 144 Jaw Piston, Seals, and Bearings Identification
!Caution
To remove the seal (004-0646) in step 2, you will need to destroy the
seal. If you don’t have a replacement, do not remove the seal at this
time.
1. Remove the bearing (003-0150) from the jaw piston (001-5380). Set the bearing aside to
inspect later.
2. Remove the seal (004-0646) by carefully cutting across it with a new razor blade or X-
acto style knife.
Note: Be very careful not to damage the finish on the jaw piston.
3. Place the nose block into a soft-jaw vise. Push the jaw piston all the way into the nose
block and, using a 12-point, 11/16-in socket, remove the bolt (002-3109) from the jaw
piston.
4. Slide the t-bar plate (001-7251) off of the bolt.
Remove Seals and Bearing from Nose Block

See Figure 145 for this procedure.

ARM JAW
O-ring
004-0588
Seals
004-0039
Note Orientation of Seals
Bearing
001-0903
Figure 145 Nose Block Seals and Bearings Parts Identification
!Caution
To remove the seals (004-0039), in step 2, you will need to destroy the
seals. If you don’t have replacements, do not remove the seals at this
time.
1. Using a pick tool, carefully remove the bearing (001-0903) from the nose block (001-
2061). Set the bearing aside to inspect later.
2. Remove the seals (004-0039) by carefully cutting across them with a new razor blade or
X-acto style knife. Using a pick tool, carefully remove the o-ring that sits under each of
the seals.
Note: Be very careful not to damage the finish on the nose block.
3. Using a pick tool, carefully remove the o-ring (101-0588) from the nose block.

Clean and Inspect Parts
Refer to Figure 142 for this procedure. In the following steps you will clean and check all the parts
for damage, corrosion, chipping, scuffing, and wear.
1. Clean all the parts of the nose block/jaw piston. Use a lintless rag and wipe all the surfaces
clean of dirt and hydraulic fluid.
2. Check the jaw piston (001-5380) for damage and excessive wear. Replace the jaw piston
if it is too worn or damaged.
3. Check the t-bar plate (001-7251) 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 (001-2061) 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.
!Caution
Do not attempt to repair cracks by welding. The nose block has been
heat- treated for strength and any welding will eliminate it’s strength.
Inspect Bearings
During the following procedures you will inspect the bearings (001-0903 and 003-0150). Refer to
Figure 144 and Figure 145.
1. Inspect the rod bearing (001-0903) for galling or damage (see Figure 145). Using your
calipers, measure the wall thickness of the bearing. Replace the bearing if the thickness
is 0.060-in (1.55 mm) or less at any point. After inspecting the bearings, set them aside
until you get to "Install Seals and Bearing Into Nose Block".
2. Inspect the piston bearing (003-0150) for galling or damage (see Figure 144). Using cal-
ipers, measure the wall thickness of the bearing. Replace the bearing if the thickness is
0.058-in (1.55 mm) or less at any point. After inspecting the bearings, set them aside until
you get to "Install Piston Seal And Bearings".
Install Seals and Bearing Into Nose Block

ARM JAW
Seals
004-0039
Figure 146 Installing Seals Into Nose Block

1. Lubricate the seal sets (004-0039) with o-ring lube and install them into the nose block
(001-2061) as shown in Figure 146. Be very careful to place the correct seals in the cor-
rect orientation.
Tip: : To aid in getting the o-rings and the seals into the grooves, it
may be helpful to bend them like this then push the seals down
into the grooves.
2. Lubricate the bearing (001-0903) with EP grease and install it into the nose block (see
Figure 147).
Rod Bearing
001-0903
Figure 147 Installing Rod Bearing into Nose Block
3. Lubricate the o-ring (004-0588) with o-ring lube and install it onto the nose block (see
Figure 148).
O-ring
004-0588
Figure 148 Installing O-ring onto Nose Block
Assemble Jaw Piston


Nose Block
001-2061
Jaw Piston Sizing Tool

001-5380 010-0804
Figure 149 Installing Sizing Tool and Jaw Piston Into Nose Block
1. Insert sizing tool (010-0804) in the end of the jaw piston (001-5380) (see Figure 149).
2. Lube the 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 (001-2061) until
the piston is completely inside the nose block (see Figure 149). Remove the sizing tool
from the piston.
3. Apply anti-seize (002-1925) to the threads and the underside of the bolt head (002-3109).
Insert the bolt (002-3109) through the t-bar plate (001-7251) and into the piston (see Fig-
ure 150). Place the nose block in a soft-jaw vise. Push the t-bar/piston all the way into the
nose block and torque the bolt to 300 ft/lb (402 Nm). Remove the nose block assembly
from the vise.
Note: Note that the slot in the t-bar aligns with the jaw piston.
T-bar Plate
001-7251
Nose Block
001-2061

Torque Bolt
Jaw Piston Bolt

001-5380 002-3109
Figure 150 Installing Jaw Piston into Nose Block

Install Piston Seal And Bearings
Seal & O-ring

Bearing 004-0646 & 004-0046
001-0900
Jaw Piston
001-5380
Figure 151 Orientation of Seal/O-ring on Jaw Piston
1. Slide the male installation tool (010-0184) onto the end of the jaw piston (001-5380).
Lightly lube the seal/o-ring (004-0646 & 004-0046) with o-ring lube and slide it onto the
jaw piston as shown in Figure 151.
2. Install the female sizing tool (010-0185) over the seal. Leave in place for 5-10 minutes,
then remove the tool.
3. Lubricate the bearing (003-0150) with EP grease and install it onto the jaw piston.
Install the Nose Block into the Wrist/Jaw Adapter

1. Lightly lube all surfaces of the jaw piston (001-5380) with o-ring lube.
2. Slide the nose block/jaw piston assembly into jaw/wrist adapter.
3. Lubricate six HHCS (002-0038) with AquaLube. Install and torque to 21 ft/lb (28 Nm).
Install the PA Jaw

Refer to "Parallel-Acting Jaw 101-4106 & 101-2239 (obsolete)" Service Instruction, under “Attach
Jaws to Nose Block” on page 9, for the procedure to install the PA jaw.

Page not used.

Service Instruction
Remote Systems Products Jaw Piston/Nose Block 101-3853
Description
Complete service instructions for the jaw pis-
ton/nose block 101-3853 (used in jaw assem-
blies 101-4102, 4103, 4104).
Estimated Time to Complete Reference Drawing

2 hour 101-3853
11/16-in 12-point socket Valvoline® Val-Plex EP Grease
9/16-in socket Anti-seize, 1 oz. tube (002-1925)
.7 50-in (19. 05mm) dr ill bit or drill rod
AquaLube (002-0805)
(optional)
torque wrench capable of 5-100 ft/lb (8-135
Loctite 271® (002-0795)
Nm)
torque wrench capable of 300 ft/lb (406 Nm) Loctite 7471 Primer®
Dow Corning ® 55 O-ring lube or petroleum
bench vise with soft jaws
jelly
pick tool
Needed
010-0175 female sizing tool HHCS = Hex Head Cap Screw
010-0174 male installation tool HPU = Hydraulic Power Unit
010-0214 sizing 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.
Note: If you are planning to replace the seals (004-0616 and 004-0650)
you must have replacements on-hand. You will need to destroy the old seals
to remove them.
011–5011 • Page 1
•
! 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 intermeshing jaw
assembly. See the service instructions for the jaw assembly installed on your slave arm.
slave arm components must often be performed under field conditions, the intermeshing jaw
should be disassembled and reassembled under ‘clean service’ conditions to prevent contamina-
tion 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 photo-
copy of this Service Instruction for workbench use.
! Caution
Before you can service the arm safely, you need to disable the electri-
cal and hydraulic functions of the arm. Follow the steps below before
you continue.

2. If you have a P-type (position-controlled) slave arm, turn off the power switches located on
the master controller and the junction box.
4. If you have a P-type (position-controlled) slave arm, and if power is supplied from a local,
independent source, turn off the power to the slave controller.
Disassemble the Nose Block

Disassembly of the intermeshing jaw assumes that all preparations, previously described in this
Service Instruction, have been met.
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 2 • Disable the Slave Arm 011–5011

•
Bearings(4x)
003-0050
T-bar Plate
Wrist Motor 001-5396
Nose Block
101-4108
Jaw Piston
001-5395
Bolt
001-5397
HHCS (4x)
002-1135
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 (4x)
002-1135
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 out of the wrist assembly when you
remove the nose block during the next step. Have a drain pan ready to catch
the fluid.
2. Pull the nose block out from the wrist assembly (101-3786).
Remove Jaw Piston From Nose Block

011–5011 Remove the Nose Block from the Wrist Motor • Page 3
•
T-bar Plate
Seal 001-5396
004-0616
Bearing
001-5399

Remove Bolt
Jaw Piston
001-5395
Bolt
001-5397
Nose Block
101-4108
Figure 3 Jaw Piston, Seals, and Bearings Identification
! Caution
To remove the seal (004-0616) in step 2, you will need to destroy the
seal. If you don’t have a replacement, do not remove the seal at this
time.
1. Remove the bearing (001-5399) from the jaw piston (001-5395). Set the bearing aside to
inspect later.
2. Remove the 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. Place the nose block into a soft-jaw vise. Push the jaw piston all the way into the nose block
and, using a 12-point, 11/16-in socket, remove the bolt (001-5397) from the jaw piston.
4. Slide the t-bar plate (001-5396) off of the bolt.
Remove Seals and Bearings from Nose Block

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 4 • Remove Seals and Bearings from Nose Block 011–5011

•
! Caution
To remove the seals (004-0650), in the next step, you will need to
destroy the seals. If you don’t have replacements, do not remove the
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 and Inspect Parts

In the following steps you will clean and check all the parts for damage, corrosion, chipping, scuff-
ing, 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.
011–5011 Clean and Inspect Parts • Page 5

•
! 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 the bearings (001-5399) for galling or damage. Using your calipers, measure the wall
thickness of the bearing. Replace the bearing if the thickness is 0.090-in (2.39 mm) or less at
any point. After inspecting the bearings, set them aside until you get to "Install Jaw Piston
Seal And Bearing".
2. Inspect the bearing (001-5398) for galling or damage. Using calipers, measure the wall
thickness of the bearing. Replace the bearing if the thickness is 0.058-in (1.55 mm) or less at
any point. After inspecting the bearings, set them aside until you get to "Install O-rings and
Bearings Into Nose Block".
3. Using the shaft of an 0.750-in (19.05mm) drill bit or a section of 0.750-in (19.05mm) drill
rod, check all of the bearings (003-0050) in the nose block for wear. Insert the drill shank, or
drill rod, into the bearing and check for play. One of the pivot pins (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 and Bearings Into Nose Block

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.
Page 6 • Inspect Bearings 011–5011

•
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.
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 Backup Ring

004-0542 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 8. Go to step 5 to replace the bearings.
5. Clamp the nose block securely in a soft-jaw vise. Use a 13/16-in (21mm) 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.
011–5011 Install O-rings and Bearings Into Nose Block • Page 7

•
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.
Assemble Jaw Piston

Nose Block
101-4108
Jaw Piston Sizing Tool

001-5395 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 the 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. Apply anti-seize (002-1925) to the threads and the underside of the bolt head (001-5397).
Insert the bolt (001-5397) through the t-bar plate (001-5396) and into the piston (see Figure
9). Place the nose block in a soft-jaw vise. Push the t-bar/piston all the way into the nose
block and torque the bolt to 300 ft/lb (402 Nm). Remove the nose block assembly from the
vise.
Note: Note that the slot in the t-bar aligns with the jaw piston.
Page 8 • Assemble Jaw Piston 011–5011

•
T-bar Plate
001-5396
Nose Block
101-4108

Torque Bolt
Jaw Piston Bolt

001-5395 001-5397
Figure 9 Installing Jaw Piston into Nose Block
Install Jaw Piston Seal And Bearing

Bearing Seal Set

001-5399 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 the 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

1. Lightly lube all surfaces of the jaw piston with o-ring lube.
2. Slide the nose block/jaw piston assembly into wrist assembly.
011–5011 Install Jaw Piston Seal And Bearing • Page 9

•
3. Coat the threads of the four HHCS (002-1135) with AquaLube. Install and torque to 73 ft/lb
(99 Nm).
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.
Page 10 • Install the Intermeshing Jaw 011–5011

Service Instruction
Wrist/Jaw Adapter for P-A Jaw, 101-3833
Description
Complete service instructions for the intermeshing jaw for the parallel-acting jaws (used in jaw as-
semblies 101-4105, 4106,4107).

3 hours


razor blade or X-acto style knife Dow Corning 55® o-ring lube

ed
PA = Parallel-Acting (Jaws)
!Caution
You must remove the PA jaw assembly and PA jaw piston/nose block assembly before you can per-
form service on the wrist/jaw adapter assembly. See the service instructions for the PA jaw assem-
bly and PA jaw piston/nose block assembly.

! WARNING
continue.

Remove the PA Wrist/Jaw Adapter

Numbers in parentheses refer to the SRS part number of the item. See Figure 1 for basic identifica-
tion of intermeshing jaw parts.
Wrist Motor
101-3786
HHCS (NAS) and Washer (4x)

002-1628 and 002-1439
Wrist/Jaw Adapter
101-3786
Figure 1 Basic Wrist/Jaw Adapter Parts Identification
Remove the PA Jaw Assembly

Refer to PA Jaw Service Instruction, under “Remove PA Jaw From Nose Block” on page 3, for the
procedure to remove the PA jaw. Read and be familiar with all the steps and requirements before
you get started. Return to this point when you have finished removing the PA jaw.
Remove Jaw Piston/Nose Block Assembly

Refer to "Jaw Piston/Nose Block for Parallel-Acting Jaw" Service Instruction. Follow steps 1-2 un-
der “Remove the Nose Block From Wrist/Jaw Adapter” on page 3, for the procedure to remove the
nose block/jaw piston assembly. Read and be familiar with all the steps and requirements before
you get started. Return to this point when you have finished removing the nose block/jaw piston

assembly.
Remove and Disassemble the Wrist/Jaw Adapter

1. Remove the four HHCS (002-1628) and washers (002-1439) from the wrist/jaw adapter
(101-3783) (see Figure 2).
HHCS (NAS) and Washer

002-1628 and 002-1439
Wrist/Jaw Adapter
101-3786
Figure 2 Removing HHCS from Wrist/Jaw Adapter
2. Using two 1/4x28 HHCS, evenly push the wrist/jaw adapter off of the wrist motor (101-
HHCS (2x) Wrist/Jaw Adapter

1/4x28 101-3786
Wrist Motor
101-3786
Figure 3 Removing the Wrist/jaw Adapter From the Wrist Motor
3. Remove the two o-rings (004-0840) and two back-up rings (004-0541) from the wrist/jaw
adapter (see Figure 4).

O-ring (2x)
004-0840
Back-up Ring (2x)

004-0541
Figure 4 Wrist/Adapter O-rings and Back-up Rings
4. Clean the wrist/jaw adapter with a lintless cloth.
Assemble Wrist/Jaw Adapter

Figure 5 Wrist/Adapter O-rings and Back-up Rings
1. Lubricate two new o-rings (004-0840) and two new back-up rings (004-0541) with o-ring
lube. Install as shown in Figure 4.
2. Lubricate the bore of the wrist motor assembly (101-3786) with o-ring lube.
3. Install the wrist/jaw adapter (001-3783) into the wrist motor assembly (101-3786).
Tip: Press the wrist/jaw adapter in slowly to avoid pinching the o-rings and back-up
rings. Press firmly, and evenly, to seat the adapter into place.
4. Lubricate four HHCS (002-1628) with AquaLube and install, with washers (002-1439),
into the wrist motor assembly (101-3786). Torque to 73 ft/lb (99 Nm).
Install Jaw Piston/Nose Block Assembly

Refer to "Jaw Piston/Nose Block for Parallel-Acting Jaw" Service Instruction. Follow the steps un-
der “Install the Nose Block into the Wrist/Jaw Adapter” on page 9, to install the nose block/jaw pis-
ton assembly. Return to this point when you have finished installing the nose block/jaw piston
assembly.
Install the PA Jaw Assembly

Refer to "Parallel-Acting Jaw" Service Instruction, under “Attach Jaws to Nose Block” on page 10,
for the procedure to install the PA jaw.

Service Instruction
Parallel-Acting Jaw 101-4106
& 101-2239 (obsolete)
Description
Complete service instructions for intermeshing jaw. Does not include service for the jaw piston. See
the "Jaw Piston/Nose Block for Parallel-Acting Jaw" service instruction.

2 hours


2 7/16-in socket Valvoline® Val-Plex EP Grease
0.500-in drill bit or drill rod (optional) Loctite 271® (002-0795)
9/16-in (15mm) diameter drift AquaLube (002-0805)
5-75 ft/lb (8-102Nm) torque wrench

Needed
010-0604 bearing installation tool HHCS = Hex Head Cap Screw
PA = Parallel-Acting
!Caution

!Caution
If you are planning to replace the jaw bearings (003-0113) in the rocker
link, or the idle link (101-3756), you will need to allow at least 1 hour, at
200°F (94°C), for the Loctite 271 to harden.
You can perform service to the intermeshing jaw with the wrist attached to, or separated from, the
slave arm.
Note: During this procedure, DO NOT loosen or remove the bolt (002-3109) (see Fig-
ure 6). The bolt is not involved in removing the jaws.
Bolt
002-3109
Figure 6 DO NOT Loosen or Remove Bolt 002-3109
! WARNING
continue.

4. If you have a P slave arm, and if power is supplied from a local, independent source turn

Disassemble PA Jaw
basic identification of PA jaw parts.
Rocker Links(4x)
Jaw Actuation Bearing (2x) 101-3757 HHCS and Jaw Washers (16x)
001-1851 002-0038 and 001-2071
Idle Links (4x) Jaw (2x)

101-3756 101-7196
Figure 7 Basic PA Jaw Parts Identification
Remove PA Jaw From Nose Block

1. Remove the two HHCS (002-0038) and two jaw washers (001-2071) retaining the four
jaw pins (001-2062) (see Figure 8). Remove the four jaw pins (001-2062) from the wrist/
jaw adaptor (101-3833) (see Figure 8). The HHCS, removed in step 1, may be lightly
threaded into each pin and used to pull them out.
Nose Block
001-2061
Jaw Pins(4x)
001-2062
HHCS and Jaw Washers (2X)

002-0038 and 001-2071
Figure 8 Removing Jaw Pins

2. Remove the HHCS (002-0038) and thrust washer (001-2071) from each of the pivot pins
(001-1840) holding the jaw assemblies to the nose block (001-2061) (see Figure 9). Re-
move the pivot pins and with the attached HHCS and jaw washers.
Nose Block
001-2061
HHCS and Jaw Washers

002-0038 and 001-2071
Figure 9 Removing Pivot Pins from Nose Block
3. Remove the two jaw assemblies from the nose block by pulling the assemblies out so that
the jaw actuation bearing (001-1851) slides off the t-bar plate (see Figure 10). The four
washers (001-1985) will fall out as you remove the jaw assemblies. Set them aside to in-
spect later.
Washers
101-1985
Figure 10 Removing the Jaw Assemblies
Complete Disassembly of Jaw

1. Remove the HHCS (002-0038) and jaw washer (001-2071) from each of the pivot pins
(001-1840) holding the idle links (101-3756) to the jaw (001-7196). Remove the pivot
pins and attached HHCS and jaw washers. Repeat this on the other jaw.

Idle Link HHCS and Jaw Washer
101-3756 002-0038 and 001-2071
Figure 11 Removing Rocker Links
2. Remove the HHCS (002-0038) and jaw washer (001-2071) from the pivot pin (001-1841)
holding the rocker link (101-3757) to the jaw (001-7196) (see Figure 12). Remove the
pivot pin with attached HHCS, jaw washer, and thrust washer. Repeat this on the other
jaw.
Rocker Link
101-3757
HHCS and Jaw Washer

002-0038 and 001-2071
Figure 12 Removing Idle Links
3. Remove the jaw actuation bearing (001-1851) from the each jaw (see Figure 13).
Jaw Actuation Bearing

001-1851
Figure 13 Jaw Actuation Bearing
Inspect Jaw Components

The jaw is subjected to abuse and long use. Carefully determine the amount of damage and wear
that is acceptable before the jaw no longer works properly in your application.
1. Inspect all of the pivot pins (001-1840, 001-1841, 001-2062) for signs of wear, galling or
other surface damage. Use a micrometer to measure the pins. Replace any pins that mea-
sure 0.496-in (12.6mm), or less, at any point.
2. Inspect the four idle links (101-3756) for signs of wear, cracking, twisting, or other de-
formation. Replace any link arm that shows unacceptable damage.

3. Inspect the rocker links (101-3757) and jaw actuation bearings (001-1851) for signs of
wear, cracking, twisting, or other deformation. Verify that the bearings turn smoothly in
the rocker link and that they exhibit minimal play. Replace any bearing and/or link arm
that shows unacceptable wear or damage.
Bearing
003-0113
Jaw Actuation Bearing

001-1851 Rocker Link
101-3757
Figure 14 Checking Rocker Link for Wear and Deformation
4. Inspect the eight washers (001-1985) for signs of wear or deformation. Replace any
washers that exhibit wear or damage.
Note: Schilling Robotics recommends that you replace the washers whenever you take
the jaw apart.
5. Using the shaft of an 0.500-in drill bit, or a section of 0.500-in drill rod, check all of the
bearings (003-0113) in the idle links (101-3756) and rocker links (101-3757) for wear.
Insert the drill shank, or drill rod, into the bearing and check for play. One of the long
pivot pins (001-1841) 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 permits too much play.
Replacing Idle Link Bearings

1. Using a soft jaw vise to prevent scratching the finish, clamp the idle link securely in a
vise. Use a 9/16-in (0.5625-0.60-in, or 15mm) diameter drift to drive the faulty bearing
(003-0113) out of the idle link (see Figure 15).
Tip: 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.

Bearings
003-0113
Figure 15 Identifying Bearings
2. Clean the bearing bore to remove all traces of Loctite.

3. Apply a thin coating of Loctite 271 to the outside of the jaw bearing (003-0113) and to
the inside of the bearing bore.
4. Using the bearing installation tool (010-0239), press the new bearing into the idle link
(see Figure 16). When properly installed, the bearing should protrude an equal distance
(0.025-in or 0.6mm) from each side of the idle link.
Figure 16 Pressing Jaw Bearings Into Idle Link
5. 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.
Replacing Rocker Link Bearings

Note: Replace both bearings, even if only one is worn.
1. Using a soft jaw vise to prevent scratching the finish, clamp the rocker link in a vise. Use
a 9/16-in (0.5625-0.60-in, or 15mm) diameter drift to drive the faulty bearings (003-
0113) out of the rocker link (see Figure 17).
Tip: 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.

Bearings
003-0113
Figure 17 Identifying Bearings
2. Clean the bearing bores to remove all traces of Loctite.

3. Apply a thin coating of Loctite 271 to the outside of the jaw bearing (003-0113) and to
the inside of the bearing bore.
4. Using the bearing installation tool (010-0604), press the first new bearing into the rocker
link. When properly installed, the bearing should be flush with, or slightly inside, the side
of the rocker link (see Figure 18).
Figure 18 Pressing Bearings Into Rocker Link
5. Repeat steps 3 and 4 to install the second bearing in the opposite side of the rocker link.
6. Clean off any excess Loctite. Allow the Loctite to cure for 24 hours at 72°F (22°C) or 1
hour at 200°F (94°C) before reinstalling this assembly.
Reassemble Jaw
Refer to Figure 7 and Figure 19 for this procedure. Be sure that all components are clean before
beginning this procedure.
Note: All HHCS in the jaw assembly should be torqued to 21ft/lb (28.5Nm).
1. Lubricate the idle link pivot pin (001-1841) and the bearings of two idle links (101-3756)
with EP grease. Insert the idle link pivot pin into the pivot holes of the jaw (001-7196)
closest to the gripping surface (see Figure 7). Install one idle link over each end of the
pivot pin.

2. Lubricate two HHCS (002-0038) with AquaLube. Add two jaw washers (001-2071) and
install on the ends of the idle link pivot pin (001-1841) (see Figure 7). Torque both
HHCS.
3. Apply a thin film of EP grease to a pivot pin (001-1840) and the bearings of a rocker link
(101-3757).
4. Insert the pivot pin, with screw and washer, into the jaw (001-7196) just far enough to
install a thrust washer (001-1985) onto the pin (see Figure 19, step A). Align the rocker
link (101-3757) within the jaw and push the pivot pin through the bore until it’s just flush
with the other side of the rocker link (see Figure 19, step B). Install another thrust washer
between the jaw and rocker link, and push the pivot pin in completely (see Figure 19, step
C).
HHCS and Jaw Washer

002-0038 and 001-2071
Washers
101-1985
Pivot Pin
001-1840
Jaw
101-7196
or B
Nose Block
001-2061
Rocker Link
101-3757
C
Figure 19 Installing the Rocker Link Into the Jaw or Nose Block*
5. Apply a coating of AquaLube to the threads of the HHCS and install the HHCS and jaw
washer on the end of the pivot pin. Torque the HHCS.
6. Repeat steps 1-5 with the other jaw components.
Attach Jaws to Nose Block

1. Apply a thin film of EP grease to all surfaces of a jaw actuation bearing (001-1851) and
insert it in the rocker link (101-3757).
2. Apply a thin film of EP grease to a pivot pin (001-1840) and the rocker link bearings.

3. Insert the pivot pin, with screw and washer, into the nose block (001-2061) just far
enough to install a thrust washer (001-1985) over the pin (see Figure 19, step A). Align
the rocker link within the nose block and push the pivot pin through the bore until it is
just flush with the other side of the rocker link (see Figure 19, step B). Install another
thrust washer between the rocker link and the nose block, and push the pivot pin in com-
pletely (see Figure 19, step C).
4. Apply a coating of AquaLube to the threads of the HHCS and install the HHCS and jaw
washer on the end of the pivot pin. Torque the HHCS.
5. Ensure that the snap rings are securely installed in the grooves of each of the jaw pins
(001-2062).
6. Apply a thin film of EP grease to two jaw pins and to the jaw bearings of the two idle
links (101-3756). Align the link jaw bearings with the holes in the nose block and insert
the jaw pins.
7. Apply a coating of AquaLube to the threads of two HHCS and install the HHCS and two
jaw washers on each side of the nose block so that the jaw pins are retained. Torque both
HHCS.
8. Repeat steps 1-7 with the other jaw.

Service Instruction
7.8-in Intermeshing Jaw, 101-4102 & 101-3569
Description
Complete service instructions for the Orion 7.8-in Intermeshing Jaw. Does not include servicing
of Jaw Piston—see Orion "Nose Block/Jaw Piston for Intermeshing Jaw" Service Instructions.

2 hours

2 hours

2 3/4-in sockets AquaLube (002-0805)
0.750-in (19.05mm) drill bit or drill rod (option- Dow Corning® 55 o-ring lube
al)
13/16-in (21mm) drift Valvoline Val Plex EP® grease
5-75 ft/lb (8-102 Nm) torque wrench Loctite 271® (002-0795)

Needed

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.
!Caution
You can perform the procedures in this Service Instruction with the wrist attached to, or separated
from, the slave arm.
!Caution
During this procedure DO NOT remove the bolt (001-5397) (see Figure 20).
The bolt is not involved in removing the jaws.
Bolt
001-5397
Figure 20 Do Not Loosen Bolt
! WARNING
continue.


Disassemble the Intermeshing Jaw

basic identification of jaw parts.
Jaw Actuator Bearing (2x)

001-2908
Jaw (2x)
101-3576
Nose Block HHCS and Washers (4X)

001-4465 002-0277 and 002-0071
Figure 21 Basic Intermeshing Jaw Parts Identification
Remove Interlocking Jaws from Nose Block

1. Remove the HHCS (002-0277) and washer (002-0071) from one end of each of the two
pivot pins (001-4551) holding the jaw assemblies (101-3576) to the nose block (001-
Pivot Pin (2x)

001-4451
Nose Block
001-4465
HHCS and Jaw Washers (4x)

002-0277 and 002-0071
Figure 22 Removing the Intermeshing Jaw

2. Pull out each pivot pin and with attached the HHCS and jaw washer.
3. Remove each jaw from the nose block. Lift the jaw out so that the jaw actuator bearing
(001-2908) slides off the t-bar plate. The four Dixon bearings (003-0006) will fall out as
you remove the jaws (see Figure 23). Set them aside to inspect later.
Dixon Bearings (4x)

003-0006
Pivot Pin (2x)

001-4451
Figure 23 Removing Jaws From Nose Block
Inspect Jaw Components

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 0.746-in (18.94
mm), or less at any point.
2. Inspect the jaw actuator bearings (001-2908) and jaw for signs of wear, cracking, twist-
ing, or other deformation (see Figure 24). Verify that the bearings turn smoothly in the
jaw and that they show no discernible play. Replace any bearing or jaw that shows unac-
ceptable wear or damage.
Actuator Bearing
001-2908
Check For Wear and Deformation
Figure 24 Checking Actuator Bearings and Jaw 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 jaws for wear and excessive play by inserting
a new pivot pin, an acceptable used pin, or the shaft of a .750-in (19.05mm) drill or drill
rod (see Figure 25). Using the procedure in "Replacing Jaw Bearings", replace any bear-
ing that has too much play.
Bearings
003-0050
Pivot Pin or .750-in (19.05mm)Rod
Figure 25 Checking the Bearings
Replacing Jaw Bearings

1. Clamp the jaw securely in a soft-jaw vise. Use a 13/16-in (21mm) diameter drift to drive
the bearing (003-0050) out of the jaw (101-3576).
Tip: eating 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.
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 jaw. When properly installed, the bearing should be flush,
or slightly recessed from the jaw surface.
5. Clean off any excess Loctite 271. Allow the Loctite to cure for 24 hours at 72°F (22°C),
or 1 hour at 200°F (94°C), before reinstalling this assembly.
Attach the Intermeshing Jaw to Nose Block

1. Lubricate all surfaces of a jaw actuator bearing (001-2908) with AquaLube and place the
actuator bearing into one of the jaws.
2. Lubricate the bearings (003-0006) with AquaLube.
3. Insert a pivot pin (001-4551), with HHCS (002-0277) and washer (002-0071), into the
nose block (001-4465) just far enough to install a Dixon washer (003-0006) over the pin
(see Figure 26, step A). Align the jaw (101-3757) 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 26, step
B). Install another washer between the jaw and nose block, and push the pin in completely
(see Figure 26, step C).

Nose Block
001-4465
Dixon Washers
Pivot Pin 003-0006
001-4551
Jaw
101-3576
C
Drawing is not to scale
Figure 26 Install Jaw to Nose Block
4. Apply a coating of AquaLube 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 73ft/lb (99 Nm).
5. Repeat steps 1-4 to attach the other jaw half parts.

Service Instruction
Linear Actuators, 101-3938, -3939, -4328
Assembly Number
101-3938, 2.6-in (6.6 cm) stroke
101-3939, 3.7-in (9.4 cm) stroke
101-4328, 6.0-in (15.4 cm) stroke
Description
Complete service instructions for Orion P intermeshing jaw.

1 hour


7/16-in socket Loctite 271® (002-0795)
1/8-in allen wrench Loctite 7471® Primer
3/32-in allen wrench Valvoline Val Plex EP® Grease
0-6-in (0-150mm) vernier caliper
pick tool

ed
010-0184 o-ring/seal installation tool SHCS = Socket Head Cap Screw
010-0185 female sizing tool FHMS = Flat Head Machine Screw
010-0203 linear actuator nose installation tool
010-0238 piston clamp tool
010-0486 nose nut socket tool
010-0487 1-5/8-in modified socket

!Caution
!Caution
If you are planning to replace the linear actuator seals (004-0646 and
004-0650) (see Figure 3 and Figure 4), you must have replacements on-
hand. You will need to destroy the old seals to remove them.
This Service Instruction assumes that the intermeshing jaw to be serviced has been removed from
the slave arm. See the appropriate Service Instruction for linear actuator removal and reinstallation
procedures.
ponents as the intermeshing jaw are disassembled. We recommend that you make a photocopy of
this Service Instruction for workbench use.
Disassemble Linear Actuator

Identify the intermeshing jaw you are servicing before beginning this procedure.
• Model 101-3938 is a short-stroke linear actuators, with a body about 5½-in (13.9 cm)
long (used in the azimuth and the forearm).
• Model 101-3939 is a longer version, with a body about 6½-in (16.5 cm) long (used in
the shoulder and elbow).
• Model 101-4328 is a long version used in the QUEST O7PE azimuth.
• Although service for the linear actuators is identical for all models, the housing, deep
transducer, and piston cannot be interchanged between the models.
Service Linear Actuator

The following procedures combine all linear actuators into one set of instructions. Differences in
actuators involve piece part numbers. The general instructions are the same for all linear actuators.
Refer to Figure 1 for short-stroke linear actuator parts identification.

Note: Where there are differences in part numbers, the following applies:
A = 101-3938, 2.6-in (6.6 cm) stroke
B = 101-3939, 3.7-in (9.4 cm) stroke
C = 101-4328, 6.0-in (15.3 cm) stroke
Actuator Bearing Piston Housing Nose Nut

A = 101-4598 A = 101-4238 A = 101-3772 001-3738
B = 101-4598 B = 101-4543 B = 101-3771
C = 101-5368 C = 101-5936 C = 101-4345 Rod End
001-5090
FHMS
002-0404
Deep Transducer
A = 101-4238 See Figure 4
B = 101-4543
C = 101-4353 See Figure 3
Figure 1 Linear Actuator Parts Identification
Remove Deep Transducer

1. Using a 3/32-in allen wrench, remove the two FHMS (002-0404) that hold the deep trans-
ducer in place.
2. Manually extend the piston to its full extension.
3. Plug the actuator’s “extend” port (the hydraulic fitting furthest from the nose nut and pis-
ton rod end).
Note: Hydraulic fluid will spill out of the intermeshing jaw assembly when you remove
the deep transducer during step 4. Have a drain pan ready to catch the fluid.
4. Cover the deep transducer with a heavy shop towel. Manually compress the actuator pis-
ton until the deep transducer blows out of it’s seat into the towel.
Remove the Piston Shaft


Figure 2 Holding Linear Actuator in Soft-Jawed Vise
1. Clamp the housing in a soft-jawed vise. Unscrew the nose nut using the nose nut socket
(010-0486).
!Caution
Remove the nose nut and piston assembly from the actuator body care-
fully, to avoid damaging the piston seals and bearing on the threads of
the housing
!Caution
Hydraulic fluid will spill out of the intermeshing jaw assembly when you
remove the piston assembly during step 2. Have a drain pan ready to
catch the fluid.
2. Pull the piston assembly out of the housing. Be careful not to damage the piston on the
housing/nose nut threads as you pull the piston assembly out of the housing.
3. Remove the housing from the soft-jawed vise. Drain all the hydraulic fluid from the hous-
ing. Set the housing aside for later inspection.

Remove the Nose Nut and Rod End From the Piston
Piston Nose Nut O-ring Rod End

A = 101-4238 001-3738 004-0805 001-5090
B = 101-4543
C = 101-5936
Bearing Seal O-ring

003-0150 004-0646 004-0046
Figure 3 Piston and Rod End Seals
1. Using a pick tool, carefully remove the bearing (003-0150) from the piston.
!Caution
To remove the seal (004-0646), in step 2, you will need to destroy the
seal. If you don’t have replacements, do not remove the seal at this time.
2. Remove the seal (004-0646) from the piston by carefully cutting across it with a new ra-
zor blade or X-acto style knife. Be very careful not to damage the finish on the piston.
3. Remove the o-ring (004-0046) from the piston.
4. Install the piston clamp tool (010-0238) onto the piston. Clamp the piston clamp tool in
the soft-jawed vise. Unscrew and remove the rod end (001-5090) from the piston.
5. Remove the o-ring (004-0805) from the rod end.
6. Slide the nose nut (001-3738) off the piston. Set the piston aside to inspect later.

Disassemble Nose Nut
Seals (2x) Bearing (2x) Scraper

004-0650 003-0151 004-0509
Nose Nut
001-3738
O-ring
004-0017
Figure 4 Nose Nut Parts Identification
1. Remove the o-ring (004-0017) from the nose nut (001-3738).

2. Using a pick tool, carefully remove the bearings (003-0151) from the nose nut.
!Caution
To remove the seals (004-0650), in step 3, and the scraper (004-0509),
in step 4, you will need to destroy the seals and scraper. If you don’t
have replacements, do not remove the seals and scraper at this time.
3. Remove the seals/o-ring (004-0650) from the nose nut by carefully cutting across them
with a new razor blade or X-acto style knife. Be very careful not to damage the finish on
the nose nut.
4. Remove the scraper/o-ring (004-0509) from the nose nut by carefully cutting across it
with a new razor blade or X-acto style knife. Be very careful not to damage the finish on
the nose nut.
Clean and Inspect Nose Nut and Nose Nut Bearings

1. Inspect the bearing surfaces of the nose nut (001-3738). Replace the nose nut if any gall-
ing or surface damage is found. Very small scratches and wear marks are normal.
2. Using a 6-in vernier caliper, measure the wall thickness of the bearings (003-0151). Re-
place any bearing with a wall thickness of 0.0585-in (1.49 mm) or less at any point.

Replace the Nose Nut Seals and Nose Nut Bearings
Seals (2x) Bearing (2x) Scraper

004-0650 003-0151 004-0509
Nose Nut
001-3738
O-ring
004-0017
Figure 5 Nose Nut Parts Orientation
1. Lightly lube the bearings (003-0151) with o-ring lube and install them into the nose nut
(001-3738) (see Figure 5).
2. Lightly lube the seals/o-rings (004-0650) with o-ring lube and install them into the nose
nut. See Figure 5 for proper orientation of seals/o-rings.
Tip: To aid in getting the seals/o-rings into the grooves, it may be helpful to bend them
like this: then push the seals/o-rings down into the grooves.
3. Lightly lube the scraper/o-ring (004-0509) with o-ring lube and install it into the nose nut.
See Figure 5 for proper orientation of the scraper/o-ring. Install using the “Tip” above.
4. Lubricate the linear actuator resizing tool (010-0203) with o-ring lube and install into the
nose nut (see Figure 6). This will resize the seal and scraper to the proper diameter. Leave
the tool in the nose nut until you’re ready to install the nose nut onto the piston (001-
4283).
Nose Nut
001-3738
Linear Actuator Resizing Tool

001-3738
Figure 6 Installing Linear Actuator Resizing Tool Into Nose Nut

5. Lubricate the o-ring (004-0017) with o-ring lube and install onto the nose nut (see Figure
5).
6. Set the nose nut aside to be installed onto the piston later.
Clean and Inspect Piston and Piston Bearings

1. Inspect the bearing surfaces of the piston. Replace the piston if any galling or surface
damage is found. Very small scratches and wear marks are normal.
2. Using a 6-in vernier caliper, measure the piston bearing (003-0150) wall thickness.
Note: Replace the bearing if the wall thickness is 0.0585-in (1.49 mm) or less at any
point.
Clean and Inspect Housing

Actuator Bearing Housing

A = 101-4598 A = 101-3772
B = 101-4598 B = 101-3771
C = 101-5368 C = 101-4345
Anode
002-1791
Figure 7 Servicing the Housing
1. Remove the anode (002-1791) from the side of the housing. Clean the housing. Use a lint-
less rag and wipe all the surfaces clean of dirt and hydraulic fluid.
2. Inspect the bore of the housing. Replace the housing if any galling or surface damage is
found. Very small scratches and wear marks are normal.
3. Using a new pivot pin, or a pivot pin that has been checked for correct size, check the
actuator bearings for wear. Insert the pivot pin into the bearing and check for play. Re-
place any bearing that permits too much play.
4. Lubricate the threads of a new anode with AquaLube and install onto the side of the hous-
ing.

Clean and Inspect the Deep Transducer
O-ring O-ring
004-0062 004-0190
Deep Transducer
A = 101-4238
Backup Ring B = 101-4543
004-0064 C = 101-4353
Figure 8 Deep Transducer Parts
1. Clean the deep transducer. Use a lint-less rag and wipe all the surfaces clean of dirt and
hydraulic fluid.
2. Remove the two o-rings (004-0062 and 004-0190) and the backup ring (004-0064) from
the deep transducer.
3. Inspect the deep transducer. Check for cracks and surface damage to the transducer.
4. Lubricate the two new o-rings and a new backup ring with o-ring lube and install onto the
deep transducer. See Figure 8 for proper orientation of o-rings.
Reassemble Rod End and Nose Nut onto Piston

Piston Nose Nut O-ring Rod End

A = 101-4238 001-3738 004-0805 001-5090
B = 101-4543
C = 101-5936
Bearing Seal O-ring

003-0150 004-0646 004-0046
Figure 9 Piston and Rod End Seals
1. Lubricate the outer surfaces of the piston (001-4283) and inner surfaces of the nose nut
(001-3738) with o-ring lube.

2. Align the linear actuator resizing tool (010-0203) with the piston and slide the nose nut
onto the piston, threaded-end first (see Figure 10). Remove the tool.
Piston
A = 101-4238
B = 101-4543 Nose Nut Linear Actuator Resizing Tool
C = 101-5936 001-3738 001-3738
Figure 10 Installing Nose Nut onto Piston
3. Lubricate the o-ring (004-0805) with o-ring lube and install it onto the rod end (001-
4. Clean the treads of the piston and rod end with Loctite 7471 primer.
5. Install the piston clamp tool (010-0238) onto the piston. Clamp the piston clamp tool in
the soft-jawed vise. Use two, small drops of Loctite 271 on the threads of the rod end.
Install the rod end into the piston. Torque the rod end to 60 ft/lb (81 Nm). Remove the
piston clamp tool.
6. Lubricate the o-ring (004-0046) and the seal (004-0646) with o-ring lube. Use the o-ring/
seal installation tool (010-0184) to install them onto the jaw piston as shown in Figure
11. Remove the male installation tool and install the female sizing tool (010-0185) over
the piston. This will resize the seal to the proper diameter. Leave the tool on for at least
10 minutes. After 10 minutes, remove the tool.
O-ring/seal Installation Tool

010-0184
Female Installation Tool Seal

010-0185 004-0646
Figure 11 O-ring/seal Installation and Female Sizing Tools on the Piston
7. Lubricate the bearing (003-0150) with EP grease and install it onto the piston as shown
in Figure 9.

Assemble the Short-stroke Linear Actuator
Refer to Figure 1, Figure 2, and Figure 12-Figure 18for this procedure.
1. Apply a light film of EP lube to the inner surfaces of the housing, the outer surfaces of
the piston and the threads of the housing and nose nut (001-3738) (see Figure 1). Care-
fully slide the piston into the bore of the housing and screw the nose nut into the actuator
body.
2. Clamp the housing in a soft-jawed vise as shown in Figure 2. Torque the nose nut to 100
ft/lb (135 Nm). Remove the housing from the vise.
3. Completely push the piston into the housing. Line up the mark on the top of the housing
with the mark on the deep transducer (see Figure 12). To pick up the magnet sensor that
is inside the deep transducer, slowly place the deep transducer into the housing. As you
move the deep transducer down into the housing, you will feel the magnet sensor in the
deep transducer pick up the magnet attached to the piston.
Alignment Marks
Deep Transducer Housing

A = 101-4238 A = 101-3772
B = 101-4543 B = 101-3771
C = 101-4353 C = 101-4345
Figure 12 Alignment Marks on the Deep Transducer and Housing
4. Lubricate the two FHMS (002-0404) that hold the deep transducer into place with
AquaLube and install them into the housing. Tighten the FHMS.
5. If the two plug fittings (101-4040) were removed from the housing, or if a new housing
is being used, install the plug fittings now. Inspect the o-rings to ensure they are correctly
seated. Lubricate the o-rings with o-ring lube and install the plug fittings into the housing.
Torque the plug fittings to 45-in/lb (5.1 Nm) (see Figure 13).
Hydraulic Fittings (2x)

006-1271
Plug Fitting with O-ring (2x)

101-4040
Figure 13 Installing Plug and Hydraulic Fittings

6. If the hydraulic fittings (006-1271) (see Figure 13) were removed from the housing, or if
a new housing is being used, install the hydraulic fittings now. Inspect their o-rings to en-
sure they are correctly seated. Lubricate the o-rings with o-ring lube and install the hy-
draulic fittings. Orient the fittings as described below:
Forearm linear actuator 101-3938 see Figure 14

Azimuth linear actuator 101-3938 see Figure 15
Shoulder linear actuator 101-3939 see Figure 16
Elbow linear actuator 101-3939 see Figure 17
Quest Azimuth actuator 101-4328 see Figure 18
When the fittings are oriented correctly, tighten the lock nut.
35°
4°
Figure 14 Hydraulic Fitting Orientation for Forearm Linear Actuator, 101-3938
6°
0°
Figure 15 Hydraulic Fitting Orientation for Azimuth Linear Actuator, 101-3938
S3938TP6.pdf
0° 0°
Figure 16 Hydraulic Fitting Orientation for Shoulder Linear Actuator, 101-3939

6°
0°
Figure 17 Hydraulic Fitting Orientation for Elbow Linear Actuator, 101-3939
0° 0°
Figure 18 Hydraulic Fitting Orientation for QUEST Azimuth Linear Actuator,

101-4328
7. Inspect the assembled actuator. Manually work the piston in and out of the actuator body
to be sure that it moves smoothly, without binding.
If a hydraulic test bench is available, you may test the actuator for proper action and leaks
before installing back into the slave arm.
You may also use an air hose (with a rubber tip) to force the piston back and forth. There
should be no air leaking from one port when pressure is being applied to the opposite port.
Reinstall the actuator into the slave arm.

This page not used.

Service Instruction
Changing Forearm Rotary Index Setting
Assembly Number
101-3781
Description
Complete service instructions for changing the Orion P intermeshing jaw.

2 hours


7/16-in Sockets AquaLube (002-0805)
9/16-in Socket Dow Corning® 55 O-ring lube or petroleum jelly
3/8-in Socket
3/16-in hex key
medium flat-blade screwdriver
rubber hammer
1 - 3-ft 24 gauge wire or equivalent string

ed

!Caution
Introduction to Forearm Rotary Index Settings

The Orion P slave arm’s range of motion is generally symmetrical, however the rotary actuator’s
270° range of motion is set at the factory to work as a right-hand manipulator (in a dual arm instal-
lation). As viewed from behind the slave arm (see Figure 19), rotation starts about the 3 o’clock
position rotating clockwise to about 12 o’clock (see Figure 20, position 1). There is no rotation be-
tween 12 o’clock and 3 o’clock.
Figure 19 Looking at Rotation of the Slave Arm
To accommodate differing installation requirements, the rotation can be indexed to seven other set-
tings (in 45° increments) (see Figure 20). Changing the index setting requires adjusting the orien-
tation between:
• The slipring and manifold,
• The driveshaft coupler and the forearm mounting flange,
• The rotor and forearm mounting flange.
Figure 20 Optional Rotary Orientations
Change the Rotary Actuator Index Setting

This procedure assumes the hydraulic power is OFF. Loosen the appropriate hose fittings to allow
the actuators to leak down and permit positioning the slave arm joints as needed to simplify disas-

sembly.
You must remove the Forearm assembly before you can change the forearm rotary index setting.
See the Orion P "Forearm, 101-3918" Service Instruction.
slave arm components must often be performed under field conditions, the rotary actuator should
ponents as the rotary actuator is disassembled. We recommend that you make a photocopy of this
Changing the intermeshing jaw assumes that all preparations, previously described in this Service
Instruction, have been met.
! WARNING
continue.

troller.
Detach Forearm Assembly From Forearm Rotary Actuator

er (001-5088) to the rotary actuator (101-3781) (see Figure 21). Remove the manifold
cover to expose the wire housing cover (001-5267) (see Figure 22).
Manifold Cover
001-5088

002-1804 and 002-1439
Forearm
Rotary Actuator 007-0360
101-3781

002-1825 and 002-0790
Figure 21 Manifold Cover and Rotary Actuator

2. Remove the wire housing cover by removing the five SHCS (002-0158) that hold the
cover to the wire housing (001-5266) (see Figure 22). Remove the large o-ring (004-
0139) and the four smaller o-rings (004-0086) from the wire housing cover (see Figure
22).
004-0139 004-0086 001-5267

001-5266 002-0158
3. Using a 3/32-in flat blade screwdriver, loosen the terminal screws and remove the fore-
arm sensor wires from the PCB assembly (101-4016) (see Figure 23).
ing.
PCB Assembly
101-4016
!Caution
When you remove the ten HHCS in step 4, the forearm will be loose. The
forearm assembly, including wrist and jaw, weighs about 40 pounds (18
kg) and must be supported during removal. Read the entire step before
continuing. Be prepared by properly supporting the forearm.

4. Remove the ten HHCS (002-1825) and washers (002-0790) from the bottom of the rotary
actuator (see Figure 21). Separate the forearm from the rotary actuator and extract the po-
sition sensor wires from the rotary actuator.
5. Remove the nine o-rings (004-0222) from the mounting flange (101-3777) (see Figure
24).
Mounting Flange
101-3777
O-rings (9x)
004-0222
Figure 24 Removing O-rings from Mounting Flange
Remove Wire Housing, Position Sensor, and Manifold/Slipring Assembly

O-ring O-ring (3x) Position Sensor Wire Housing

004-0098 004-0130 101-3917 001-5266
Hydraulic Fittings (6x)
HHCS and Washer (2x)

002-1572 and 002-1439
Adapter Plate
001-5210
Rotary Actuator
101-3781
Manifold
101-4023
Slipring
001-5053
Sensor Driveshaft
101-4012
Figure 25 Rotary Actuator Area Parts

1. Remove the four SHCS (001-1550) securing the wire housing (001-5266) to the adapter
plate (001-5210) and lay it to the side (see Figure 25 and Figure 26). Remove the o-ring
(004-0130) from the bottom of the wire housing (see Figure 25).
SHCS (4x)
002-1550
Wire Housing
001-5266
Figure 26 Removing Wire Housing from Rotary Actuator
2. Lift the position sensor (101-3917) off the adapter plate (001-5210) and lay it to the side
(see Figure 25).
3. Using a flat-blade screw driver, gently pry the sensor driveshaft (101-4012) up and out
of the adapter plate (see Figure 27).
Sensor Driveshaft
101-4012
Gently Pry Up Here
Adapter Plate
001-5210
4. Loosen all the hydraulic fittings (6x) on the manifold (see Figure 25).
5. Remove the two HHCS and washers (002-1572 and 002-1439) from the manifold (see
Figure 25).
6. Using a rubber hammer, remove the manifold by tapping upward on the edges of the man-
ifold. Do not pry the manifold off of the actuator.
7. Note the old rotary index setting. The rotary index setting number is located on the slip-
ring flange (001-5053) (see Figure 28). Note the new rotary index setting you wish to use
in the box below.

Note OLD Rotary
Index Setting Here:
0-ring
004-0860
Manifold
Slipring 101-4023
001-5053
Note NEW Rotary

Index Setting Here:
Figure 28 Noting Old and New Rotary Index Settings
8. Remove the o-ring (004-0860) for the manifold (see Figure 28).
9. Remove the two o-rings (004-0222) from the end plate (101-3779) (see Figure 29).
End Plate
101-3779
O-ring (2x)
004-0222
Figure 29 Removing O-Rings
Set Coupler to New Rotary Index Setting

1. Remove two SHCS (002-1861) from the coupler and rotate the coupler until the arrow
points to the keyway in the rotor (see Figure 30). The arrow and flat should now be
aligned with the new index setting number on the mounting flange (101-3777) (see Fig-
ure 30).

Keyway Arrow
Coupler
Flat 001-5252
SHCS (2x)
002-1861
Rotor
001-5052
Figure 30 Rotating Coupler To New Index Setting Number
Note: The mounting flange/coupler/rotor interface must match the new rotary index
setting at the manifold/slipring interface that you recorded in Figure 28.
New Rotary Index Setting

Flat
Mounting Flange
101-3777
Figure 31 Checking Alignment of Coupler and Mounting Flange
2. Lubricate two SHCS (002-1861) with AquaLube and install the coupler (001-5252) into
the mounting flange (101-3777) (see Figure 35). Torque to 25-in/lb (2.8 Nm).
Set Slipring to New Rotary Index Setting


HHCS (4x) O-ring
002-1873 004-0225

001-5210 101-4023
Slipring
001-5053
Figure 32 Manifold and Slipring Parts Identification
1. Remove the HHCS (002-1873) from the adaptor plate (001-5210) (see Figure 32). Leave
the adaptor plate in place.
0-ring
004-0860
Slipring Manifold
001-5053 101-4023
Figure 33 Setting the New Index Number
2. Rotate the slipring (001-5053) to the new index setting number (see Figure 33).
3. Lubricate the HHCS with EP grease. Reinstall through the slipring and adaptor plate (see
Figure 32).
If you have an aluminum slipring, torque to 24 in/lb (2.7 Nm).
If you have a stainless steel slipring, torque to 8 ft/lb (10.8 Nm).
4. Lubricate the o-ring (004-0860) with o-ring lube and install onto the manifold (see Figure
33).
5. Lubricate the slipring with o-ring lube and install into the rotary actuator (see Figure 34).

Manifold
101-4023
Slipring
001-5053
Figure 34 Installing Slipring/Manifold
6. Lubricate two HHCS (002-1572) with AquaLube and install, with washers (002-1439),
through the manifold and into the rotor (see Figure 25). Center the manifold on the rotary
actuator by loosely installing the remaining eight HHCS (002-1804) (see Figure 21).
Torque the two HHCS (002-1572) to 35 ft/lb (47 Nm). Remove the eight HHCS (002-
1804).
Set Mounting Flange to New Rotary Index Setting

1. Remove the eight HHCS (002-0062) on the mounting flange (101-3777) (see Figure 35).
Mounting Flange
101-3777

002-0062 and 002-1439
Figure 35 Removing the HHCS from the Mounting Flange
2. Install two HHCS (002-1825) into the mounting flange. Use a crossbar between these
screws to turn the mounting flange and align the rotor (001-5052) alignment marks to the
new index setting number (see Figure 36).
HHCS (2x)
002-1825 Rotor
001-5052
Alignment Mark (2x)
Figure 36 Aligning the Mounting Flange and Rotor to New Index Setting Number

3. Lubricate eight HHCS (002-0062) with AquaLube and install, with washers (002-1439),
into the rotor (see Figure 35). Torque to 25 ft/lb (33.9 Nm). Leave the HHCS you in-
stalled in step 2 in place until “Center the Position Sensor” on page 11.
Center the Position Sensor

!Caution
1. Use a crossbar between these screws you installed in step 2 of “Set Mounting Flange to
New Rotary Index Setting” on page 10 to turn the rotary actuator all the way to one hard
stop. Note the rotary actuator position. Turn the rotary actuator the opposite direction to
the other hard stop. Note the rotary actuator position. Turn the rotary actuator back to the
center of rotation. Do not rotate the arm away from the centered position.
2. Turn on the power to the master controller. Go to the diagnostics menu: Press DOWN TO
BACK” readout.
Place the sensor driveshaft (101-4012) into the position sensor (101-3917) as shown in
Sensor Driveshaft
101-3917
3. Lubricate the sensor driveshaft with EP grease (see Figure 37). Align the flat on the sen-
sor driveshaft with the flat on the coupler and install the sensor driveshaft into the rotary
actuator (see Figure 25).
5. Install the position sensor onto the rotary actuator (see Figure 25).
6. Ensure that the hydraulic hoses exit cleanly into the upper arm and will clear the manifold
cover (001-5088) (see Figure 21). Tighten the hose fittings finger tight, then one-sixth
of a turn to tighten the hose fittings.

(001-5266) (see Figure 25).
SHCS (4x)
002-1550
Pull-Wire
Wire Housing
001-5266
Figure 38 Installing the Wire Housing
9. Check that the “FEED BACK” readout is still at 0 (± 100). If not, repeat steps 1-8 until
the desired readout is maintained.
10. Remove the two screws from step 1. Turn off the master controller.
11. Tie one end of a 3 foot-long, 24 gauge wire (or equivalent string) to a hydraulic fitting on
the top of the rotary actuator. Feed a the “pull-wire” through the wire housing and down
through the rotary actuator (see Figure 38). The “pull-wire” will help you get the sensor
wires back through the forearm rotary actuator when the forearm is reattached.
Reattach Forearm to Rotary Actuator

Pin

004-0222
Mounting Flange
101-3777

pin on the face of the mounting flange.

4. Install HHCS from step 2, with washers (002-0790), to secure the forearm (see Figure
21). Torque to 8 ft/lb (10.7 Nm).
Final Reassembly of Forearm

Refer to Figure 21, Figure 22, and Figure 40 for this procedure
PCB Assembly
101-4016

From Forearm Area
lb (47.5 Nm).

This page not used.

Service Instruction
Compensator, 101-4470
Description Document No.: 011-5041

This service instruction describes how to
replace the compensator diaphragm. Other
internal components are NOT serviceable.
Estimated Time to Complete Reference Drawing

1/2 hour 101-4470 (see “Drawing & Part List” chapter)

10 mm socket Diaphragm 004-0895
Phillips-head screwdriver O-ring 004-0015
M12 x 180 mm (minimum) HHCS and locknut, Dow Corning® 55 O-ring lube or petroleum
or M12 x 20 HHCS (2x) jelly
Duct tape or equivalent
Custom Tools Needed Special Terminology

N/A HHCS = Hex Head Cap Screw

Look over the list above and make sure you have all the required tools and 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 warnings, cautions, and notes.
START INSTRUCTION
Compensator parts referred to in this instruction are shown in Figure 13 on page 3.
1. Remove and drain the compensator.
! Caution
Release of the compensator spring can cause serious personal injury and dam-
age to surrounding equipment. It is not necessary to release the spring to
replace the diaphragm. The spring, piston, and spring guide assembly is NOT
user-serviceable. Return to the factory for repair.
2. To restrain the piston and spring, insert an M12 x 180 mm or 1/2 x 7-in (minimum) HHCS
through the housing and piston skirt holes and install a locknut (see Figure 11).
011–5041 • Page 1
•
Oil-side Housing
V-Stamp Clamp
002-2245
M12x180mm HHCS &

locknut
or
M12x20mm HHCS (2x)
Water-side Housing
Figure 11 Securing the Piston with M12 or 1/2-in Hardware
If a long HHCS is not available, insert two short M12 x 20 mm or 1/2 x 1-in (minimum) HHCS
through the holes in the opposite sides of the housing and piston. Keep the HHCS in place by wrap-
ping the housing and bolt heads with two layers of duct tape or equivalent (see Figure 12).
Figure 12 Securing the Short M12 HHCS with Tape
! Caution
Confirm that the piston is secure before loosening the v-stamp clamp nut.
3. Slowly loosen v-stamp clamp nut and remove the clamp.
NOTE:
It is normal for spring pressure to separate the oil- and water-side housing flanges by
2-3mm (.062-.125-in) when the v-stamp clamp is removed.
4. Separate the oil- and water-side housings.

5. Remove the M6x25 Sealing Screw and separate the diaphragm guide and o-ring from the
diaphragm and piston.
6. Remove the damaged diaphragm from the piston and housing.
Page 2 • 011–5041
•
7. Install the replacement diaphragm, seat the D-profile lip into the flange of the water-side
housing (flat side facing to the flange of the oil-side housing). Form and smooth the diaphragm
over the piston.
— - Diaphragm 004-0895
Oil-side Housing
V-stamp Clamp
002-2245
D-profile Lip
Diaphragm
(004-0895)
Top Diaphragm Guide

(001-5631)
O-ring
(004-0015)
M6x25mm Sealing Screw

(002-2272)
3.4 Nm (35-in/lb)
Water-side Housing
Spring Guide
Figure 13 Internal Components (shown with piston compressed)
8. Apply o-ring lubricant to the mating surfaces of the sealing screw and guide o-ring. Install the
top guide and o-ring to the diaphragm and piston.
— - O-ring 004-0015
9. Install the M6x25 sealing screw.
— - Torque: 3.4 Nm (35-in/lb)
! Caution
Use ONLY the M6x25 sealing screw (002-2272). In this application, the use of
a different screw will cause leaks.
10. Install the oil-side housing to the water-side housing, aligning marks, and making sure the D-
profile bead on the diaphragm is correctly seated in the flange of the water-side housing.
11. Install the v-stamp clamp. The assistance of another person may be required to press the
housing flanges together while the v-clamp is installed. The two housing faces may also be
pressed together using large C- or pipe clamps. When the flanges are mated, tighten the v-
clamp nut.
011–5041 • Page 3
•
— Torque: 7.3 Nm (65-in/lb)
z Confirm that the housings are correctly seated to each other and the v-clamp correctly torqued.
Remove the tape and M12 HHCS from the compensator.
Dry-Testing the Compensation system

If compensation system fittings or components have been opened or replaced, you may want to dry-
test the compensation system for leaks before charging it with fluid. Two test methods are outlined
below:
12. Fill the compensation system with air to 1 atmosphere (15 psi). Check for leaks by spraying all
connections and compensated components with a mild detergent or window cleaner. Watch for
the active bubbles or foam that indicate a leak.
or, when some connections are not accessible:
13. Install a pressure gauge on the compensation system. Fill the system with air to 1 atmosphere
(15 psi). Allow the air pressure to stabilize and monitor the pressure gauge over a period of at
least 2 hours. If any pressure drop occurs, check for leaks using the method described in step 1,
above.
Charging Guidelines
Charge and bleed the compensation system only after verifying that all compensated components
are functioning correctly and can be safely positioned for access to the bleed fittings.
Damage may occur to compensated components or enclosures if components are submerged while
large amounts of air remain in the compensation system. Verify that the compensator is correctly
installed and air has been bled from all compensated components.
1. Charge the compensator through one of its unused fittings. Temporarily disconnect any other
lines that may become filled with air during the charging process.
NOTE:
Charging pressures above 20 psig (1.4 bar) will cause the discharge of compensation
fluid or vapor from the relief valve.
2. Pump fluid into the compensator until the yellow band on the piston approaches the “full” band
on the housing - do not overfill. Crack the fitting seal at the top of the compensator and bleed
off any air in the accumulator.
3. Re-connect compensation lines disconnected in step1.
4. Starting with the lowest, open each compensated component’s bleed plug or relief valve poppet
and bleed off all air. Reseal when compensation fluid emerges. Continue adding fluid to the
compensator as needed.
NOTE:
For specific details about each component’s bleed port locations and procedures, see
the component manual.
Page 4 • 011–5041
•
z Bleed any remaining air from the compensator and fill the compensator.
NOTE:
DO NOT fill completely. Leave a small amount of diaphragm travel to allow for ther-
mal expansion
5. Inspect compensation system components, hoses, and connections for leaks and correct all
leaks.
011–5041 • Page 5
•
Page 6 • 011–5041
Drawings & Part Lists
1 Organization
The drawings and part lists in this chapter are in numerical order, starting with the
prefix, then the number. Note:
z The drawings and part lists for assembled components (with a 101- prefix) are
grouped together, with the drawing following the part list.
z Electrical and wiring diagrams (drawing prefix 035-) and hydraulic schematics
(drawing prefix 025-) do not have part lists.
z Individual parts of a component are cross-referenced between the drawing and
part list using their item numbers. On the drawing, item numbers appear in a cir-
cle with a line drawn to the individual part.
Note: To get the right part when ordering, use the identification number pro-
vided in the P/N column.
2 Index
Use the list below to find the number of the drawing that you need. Components are
grouped by major assemblies. Where the page number is followed by an asterisk (*), a
larger paper copy of the drawing is provided under the “Oversize Drawings” tab in the
binder.
Manipulator Systems 199-0229 and 199-0230

Slave Arm Hydraulic Schematic, 025-0060............................page 6
Orion System Wiring Diagram, 035-0564 .......................... page 16*
Power & Telemetry Cable, 101 4018 ................................... page 40
Orion Manipulator System, Short, 199-0229, Rev G ............ page 98
Orion Manipulator System, Long, 199-0230, Rev G ........... page 100
Master Controller 101-4198-2

Master Switch Schematic, 035-0028 .....................................page 7
Master Controller Opto-Iso PC Board, 035-0310 ................. page 8*
Master Controller CPU Board, 035-0320.............................. page 9*
011–0569 1 Organization • Page 1

• Drawings & Part Lists
Master Controller Analog Board, 035-0321 ....................... page 10*
Actuator Controller Board Schematic, 035-0522................. page 11
Display Transition Board, 035-0526 ................................... page 12
Master Controller Mother Board, 035-0527....................... page 13*
Master Arm Wiring Diagram, 035-0537 .............................. page 14
Master Controller Wiring Diagram, 035-0540 ................... page 15*
Face Plate, Master Controller, 101-3796, Rev B .................. page 28
Master Controller, 101-4198, Rev G, & 101-4198-2, Rev C) page 93

J-Box, 07P, 85-265 VAC, AC/DC Supply, 101-4017, Rev C .. page 37
Slave Controller 101-3912

Base Module Schematics, 005-3600, Sheets 3, 4, 5, Rev F.. page 3*
Actuator Controller Board Schematic, 035-0522............... page 11*
Slave Controller, 101-3912, Rev D .................................... page 30*
Slave Arms 101-4116 and 101-4117

Actuator, Rotary, Forearm, 101-3781, Rev C .................... page 19*
Wrist Motor, 101-3786, Rev E............................................. page 22
Actuator, Lin., 1.75-in. X 2.6 in. Stroke, 101-3938, Rev C ... page 33
Actuator, Lin., 1.75 in. X 3.7 in. Stroke, 101-3939, Rev C ... page 35
Orion Slave Arm, Short, 101-4116 ...................................... page 67
Orion Slave Arm, Long, 101-4117 ....................................... page 80
Jaws
Jaw Kit, 4-Finger Intermeshing, 101-4102, Rev B .............. page 41
Jaw Kit, 6-in, Parallel-Acting, 101-4103, Rev A .................. page 44
Jaw Kit, Intermeshing, 11.5-in, 101-4104, Rev B ............... page 48
Jaw Kit, 3-Finger Intermeshing, 101-4105, Rev A .............. page 52
Jaw Kit, Parallel-Acting, 4-in, 101-4106, Rev B .................. page 57
Jaw Kit, Parallel-Acting, 6-in, 101-4107, Rev A .................. page 62
Compensator
Compensator, 101-4470, Rev E .......................................... page 96
1:1 Mounting/Clearance Templates

Slave Arm Mounting Template, 050-0711 ......................... page 17*
Slave Controller Mounting Template, 050-0755 ................ page 18*
*
Indicates that a larger, paper reproduction of the drawing is located under the
“Oversize Drawings” tab.
– PAGE BREAK –
Page 2 • 2 Index 011–0569

Base Module Schematics, 005-3600, Sheets 3, 4, 5, Rev F
UL
Page 3 - Drawings & Part Lists

Slave Arm Hydraulic Schematic, 025-0060

Master Switch Schematic, 035-0028

Master Controller Opto-Iso PC Board, 035-0310

Master Controller CPU Board, 035-0320

Master Controller Analog Board, 035-0321

Actuator Controller Board Schematic, 035-0522

Display Transition Board, 035-0526

Master Controller Mother Board, 035-0527

Master Arm Wiring Diagram, 035-0537

Master Controller Wiring Diagram, 035-0540

Orion System Wiring Diagram, 035-0564

Slave Arm Mounting Template, 050-0711

Slave Controller Mounting Template, 050-0755

Actuator, Rotary, Forearm, 101-3781, Rev C
Item P/N Part Description Qty. Unit
1 101-3779 PLATE, END, ORION, BEARING, SUBASSEMBLY 1

2 001-5079 HOUSING, ROLL 1
3 101-3777 MOUNTING FLANGE, SUBASSEMBLY 1
5 001-5052 ROTOR, ROLL 1
6 001-4559 ROTOR NUT 1
7 002-1560 WASHER, LOCK, SHAFT 1
8 001-5098 SHCS, 1/4-28 x 4.0 CAD PLATING, HIGH STRENGTH 16
9 001-5099 WASHER, .484 OD x .257 ID .078 THICK 32
10 002-0058 NUT, MS-21043-4 16
11 003-0176 BEARING, TAPERED, CONE, 2.5 2
12 101-3778 PLATE, END, ORION, PLUGGED, SUBASSEMBLY 1
14 004-0103 O-RING, 2-044 BUNA 70 2
15 001-5038 SEAL, END, ROLL 2
16 004-0140 O-RING, 2-037 BUNA 90 3
17 004-0222 O-RING, 2-010 BUNA 90 8
18 004-0816 SEAL, UCUP 3 1/2 OD X 1/8 HIGH, POLYURETHA 1
19 002-0062 NAS 6406U12 8
20 002-1562 SHCS, 1/4-28 X 1/2, GR.8 STEEL 8
21 001-5040 SEAL, VANE, INVERTED RADIUS, ROLL 2
22 004-0130 O-RING, 2-022 BUNA 70 2
23 001-5039 PLATE, FILLER, VANE SEAL, ROLL 2
24 001-5041 PLATE, BACKUP, VANE SEAL, ROLL 4
25 001-5097 VANE, ROLL, 2 PIECE 2
29 001-4565 PLUG, BOLT PASSAGE 1
30 004-0571 O-RING, 2-007 BUNA 90 1
34 004-0621 O-RING, 2-028, BUNA 90 1
35 101-4040 FITTING, PLUG, -2 W/ URETHANE O-RING 4
36 001-5252 COUPLER, ROLL DRIVESHAFT 1
37 002-1861 SCREW, SHOULDER 8-32 X 0.5 SS, SOCKET HD 2
52 002-1439 WASHER, 3/8 ID, 5/8 OD 8
– PAGE BREAK –

Wrist Motor, 101-3786, Rev E
Item P/N Description Qty

No.
1 101-3785 SHAFT, DRIVE, WRIST, ORION, SUBASSEMBLY 1

2 101-3784 HOUSING, ALUMINUM, SLIPRING, SUBASSEMBLY 1
3 004-0617 SEAL, FLUROCARBON #AR10400-418-UH 1
4 003-0031 BEARING, NEEDLE, TORRINGTON B-5612 1
5 004-0803 SEAL, SHAMBAN, TGZF-S4016NA 3
7 001-4454 BEARING, SLYDRING, 2.875 ID, 3.063 x .25 1
8 003-0074 WASHER, THRUST, TRA2840, TORRINGTON 1
9 003-0013 TORRINGTON, NTA 2840 1
10 001-4437 RING, SEAL BACKUP 1
11 001-2060 PLATE, WEAR 1
12 004-0575 SEAL, AR10103-214-UH, FLUROCARBON 1
13 101-3373 GEROTOR W/O WRIST RING 1
14 001-1832 VALVE PLATE 1
15 004-0574 SEAL, AR10103-212-UH, FLUROCARBON 1
16 004-0081 O-RING, 2-035 BUNA 70 1
17 004-0017 O-RING, 2-031 BUNA 70 1
18 004-0413 O-RING, 2-026 V75 1
19 004-0110 O-RING, 2-046 BUNA 70 1
20 101-3782 MANIFOLD, WRIST, ORION, SUBASSEMBLY 1
21 003-0011 TORRINGTON, B148 1
22 001-4448 BOLT, OIL SUPPLY, CONAN WRIST 2
23 001-4449 BOLT, OIL RETURN 1
24 004-0445 O-RING, 2-006 V90 2
25 001-1984 BUSHING, WRIST 2
26 004-0698 O-RING, 2-011, URETHANE 2
27 004-0576 WASHER, CRUSH, SLAVE ARM 8
29 001-4577 SHCS, 5/16-18 x 3.0, UNBRAKO 5
30 003-0092 WASHER, THRUST, TORRINGTON #TRC 1427 2
31 003-0091 BEARING, THRUST, TORRINGTON #NTC 1427 1
32 001-5103 NUT, CLAMPING, 7/8-20, 1.5 HEX 1
33 002-1133 SHCS, 10-32 X 5/8, UNBRAKO ONLY, ALLOY STEEL 1
– PAGE BREAK –

Face Plate, Master Controller, 101-3796, Rev B
Item
No. P/N Part Description Qty. Units
2 005-0038 BOOT, SWITCH, TITAN, MASTER, POWER 1

3 101-1819 POWER SWITCH ASSY, MASTER CONTROL UNIT 1
4 001-2670 FACEPLATE 1
5 004-0113 O-RING 2-047, BUNA 70 2
6 001-0367 LENS, DISPLAY, CONSOLETTE, MASTER 1
8 005-0033 PCB, MASTER SWITCH 1
11 002-1025 STANDOFF, 1/4 HEX X 5/8, M-F, 6-32,SS 2
12 002-1783 STANDOFF, 1/4 HEX, 6-32 X 9/16, MALE- 4
FEMALE
13 101-3821 LCD DISPLAY, ASSEMBLY 1
14 001-0366 KEY, CONSOLETTE, MASTER 12
15 001-0365 PLATE, BACK-UP, KEY, MCA 12
16 005-0185 KEYPAD, SINGLE, RUBBER 12
17 002-0124 FHMS, 6-32 X 1/4, SS, HEX DRIVE 1
18 005-0136 CONN, 32 PIN SIP(SS-132-G-2 SAMTEC) 1
20 001-5057 ADAPTOR, LCD 1
21 005-0135 CONN, 32 PIN SIP BBL-132-G-F, SAMTEC 1
22 002-0006 BHCS, 4-40 X 1/4, SS 4
23 002-0429 FHMS, PH, 6-32 X 3/8, 100DEG, C’SINK, SS 4

Slave Controller, 101-3912, Rev D
1 001-5178 MANIFOLD, POSITION, ORION 1

2 007-0372 LID, MANIFOLD, ORION 7P 1
3 001-5180 BLOCK, FILTER SOLENOID 1
4 101-4011 CAP, FILTER, SOLENOID, SUB-ASSEMBLY 1
5 006-1554 FIT, HYD, -4 ST MALE, 1/4 TUBE FEM, SWAGELOK, 1
316S
6 002-0136 PIN, DOWEL, 1/8 x 1/4, SS 2
7 002-1163 WASHER, FLAT, #10, .438 OD, SS 12
8 101-3965 RELIEF VALVE, UNIVERSAL 5
9 101-4086 VALVE, LOCK, ORION 5
10 001-2637 ADAPTER, MOOG 30-780 PORT CIRCLE 6
11 101-3100 VALVE, SERVO, MOOG 30-389 7
12 006-0108 FITTING, HYD, -4, JIC, -4 ST, ELBOW, MALE(4- 17
C5OX-SS)PARKER
13 101-3297 WIRING HARNESS, POWER/TELEMETRY, CONAN 1
BASE MODEL
14 005-3600 PCB ASSEMBLY, BASE MODULE AND SLAVE CON- 1
TROL UNIT
15 101-3656 PCB ASSEMBLY, ACTUATOR CONTROLLER BOARD 7
16 101-3258 LOCKVALVE ASSEMBLY, KEPNER CARTRIDGE, 150 1
PSI
17 001-1463 I.D. PLATE, 3.75 x 1.0 1
18 002-0933 SHCS, 6-32, 5/16 LONG, ALLOY STEEL 28
19 002-0198 SHCS, 10-24 X 2, SS 26
20 004-0665 O-RING, .326 X .039, BUNA 90 24
21 004-0222 O-RING, 2-010 BUNA 90 51
23 006-0015 FITTING, HYD, -4 JIC, -4 ST, 4F50X-SS 6
24 001-5268 MANIFOLD, P TO C2, R TO C1 1
25 002-0020 SHCS, 10-24 X 3/4, SS 4
26 002-0156 SHCS, 10-24 X 1/2, SS 11
27 002-0197 SHCS, 10-24 X 1-1/2, SS 6
28 002-1853 STANDOFF, HINGED, 5/8 LONG, KEYSTONE #335 3
29 002-1025 STANDOFF, 1/4 HEX X 5/8, M-F, 6-32, SS 6
30 002-0119 NUT, 6-32, SS, NYLOCK 5
31 004-0695 O-RING, 2-021, BUNA 70 1
33 006-0362 FILTER ELEMENT 10 MIC. NOM, 25MIC ABS, -6SS 1
34 001-5243 STANDOFF, MOTHERBOARD, ORION, MANIFOLD 3
35 006-0042 CARTRIDGE, SOLENOID, WATERMAN 12C1S-000-00 1
36 006-0432 COIL ASSY, 24 VDC, WATERMAN #704108-24 1
37 002-1487 STANDOFF, #10 X 3/8 LONG 1
38 002-0114 SHCS, 6-32 X 1/4, SS 8

Slave Controller, 101-3912, Rev D (cont.)
39 002-0196 SHCS, 10-24 X 1, SS 12

40 002-0860 SHCS, 10-32 X 5/16, SS 3
42 101-4026 CABLE ASSEMBLY, SERVO EXTENSION 7
43 002-1860 SPRING, COMPRESSION, 31/32~L, .09LBS/INSS 1
44 001-5202 SEAT, RELIEF VALVE, 316 SS 1
45 001-5067 SLEEVE, RELIEF VALVE 1
46 001-4581 SEAT, SPRING, RELIEF VALVE 1
47 002-1805 BALL, CHROME STEEL, .125 1
48 004-0225 O-RING, 2-008 BUNA 90 1
49 001-5111 SHSS, 7/16-20 x .25, SS, VENTED 1
50 006-0025 FITTING, HYD, -6, ST, PLUG, HOLLOW HEX- 2
SS(6HP50N-SS)
51 006-0029 FITTING, HYD, PLUG, 4-HP50N-SS 8
52 101-3942 PCB ASSEMBLY, MOTHERBOARD, SCU, ORION 1
53 101-3924 VALVE, BYPASS 1
56 002-1867 STANDOFF, 10-32, M-F, 1~ 7
– PAGE BREAK –

Actuator, Lin., 1.75-in. X 2.6 in. Stroke, 101-3938, Rev C
1 101-3772 HOUSING, ACTUATOR, 1.75 DIA x 2.6 STROKE, 1

SUBASSEMBLY
2 001-4283 PISTON 1
3 001-3738 NOSE NUT, 1.75 DIA 1
4 001-5090 ROD END 1
5 101-3992 DEEP TRANSDUCER, 2.6 IN. 1
10 001-4598 BEARING, ACTUATOR 2
11 003-0150 BEARING, PISTON, LINEAR ACTUATOR 1
12 004-0046 O-RING, 2-127 BUNA 70 1
13 004-0646 GLYD RING, PISTON, GAMMA 1
14 004-0650 SEAL, ROD, LINEAR ACTUATOR, GAMMA 2
15 003-0151 BEARING, SHAFT, LINEAR ACTUATOR 2
16 004-0509 SCRAPER, S48302-0108A-56 1
17 004-0966 O-RING, 2-031 URETHANE 70 1
18 004-0805 O-RING, 2-113, B90 1
21 006-1271 FIT, HYD, -4, ST, PLUG, PLASTIC 2
26 002-1791 ANODE, GALVANIC, ZINC ONLY 1
– PAGE BREAK –

Actuator, Lin., 1.75 in. X 3.7 in. Stroke, 101-3939, Rev C
1 101-3771 HOUSING, ACTUATOR, 1.75 DIA x 3.7 STROKE, 1

SUBASSEMBLY
2 001-4543 PISTON, 1.75 DIA x 3.7 INCH STROKE 1
3 001-3738 NOSE NUT, 1.75 DIA 1
4 001-5090 ROD END 1
5 101-3993 DEEP TRANSDUCER, 3.7 IN. 1
10 001-4598 BEARING, ACTUATOR 2
11 003-0150 BEARING, PISTON, LINEAR ACTUATOR 1
12 004-0046 O-RING, 2-127 BUNA 70 1
13 004-0646 GLYD RING, PISTON, GAMMA 1
14 004-0650 SEAL, ROD, LINEAR ACTUATOR, GAMMA 2
15 003-0151 BEARING, SHAFT, LINEAR ACTUATOR 2
16 004-0509 SCRAPER, S48302-0108A-56 1
17 004-0966 O-RING, 2-031 URETHANE 70 1
18 004-0805 O-RING, 2-113, B90 1
21 006-1271 FIT, HYD, -4, ST, PLUG, PLASTIC 2
26 002-1791 ANODE, GALVANIC, ZINC ONLY 1
– PAGE BREAK –

J-Box, 07P, 85-265 VAC, AC/DC Supply, 101-4017, Rev C
1 005-0554 CONN, RECP, DB25(SOCKETS)205207-11, AMP 1

2 005-3135 J-BOX, 14PIN, 9 PIN, DB-25, GROUND 1
3 003-0007 FEET, RUBBER, STICK ON MASTER CONTROL HOUSING 4
4 005-2513 RING, TERMINAL, 16-22 AWG, 1/4 IN. STUD 1
5 005-1839 CONN, CPC, 17-14, REVERSE SEX RECEPTACLE 1
6 005-0263 SWITCH, PWR MODULE WTH SWITCH & FUSE, 06A2D, DELTA 1
7 005-1627 TUBING, SHRINK, 3/16~, SURFACE IRRADIATED POLYOLEFIN 0.15
8 002-0159 BHCS, 6-32 X 3/8, SS 8
9 005-0555 CONN, PIN FEMALE, D-SUB(66682-4 AMP) 4
10 005-0239 CONN, SOCKET, CPC, 66594-2, AMP 15
12 005-3134 CONN, CPC 17-9, REVERSE SEX, SQUARE FLANGE, RECP 1
13 005-0587 FUSE, 6A, 5x20mm(21806.3) 2
15 005-1760 WIRE, 18 AWG, BLACK TEFLON 3.5
16 005-0603 CONN, SCREWLOCK FOR DB CONNECTORS 2
17 005-0264 CABLE, POWER CORDSET(86537030 PANEL COMPTS CORP) 1
18 005-0219 WIRE, 22 AWG., 7/32 TEFLON, BLACK, .10 INSULATION 4
19 001-1463 I.D. PLATE, 3.75 x 1.0 0
20 002-0524 CABLE TIE 4
21 002-1876 FHMS, 4-40-X1, 82 DEGREE, COUNTERSINK, SS, P 4
22 002-0226 NUT, 4-40, SS 4
23 005-0448 TUBING, SHRINK, 1/4, SURFACE IRRADIATED 0.15
24 005-2810 POWER SUPPLY, +/-12VDC, AC INPUT, SCR 1
– PAGE BREAK –

Power & Telemetry Cable, 101 4018
Note: Drawing Only

Jaw Kit, 4-Finger Intermeshing, 101-4102, Rev B
Jaw Kit, 4-Finger Intermeshing, 7.8-in, 101-4102, Rev B
1- 101-3569 KIT, INTERMESHING JAWS, Rev B 1

1 101-3576 6 INCH INTERMESHING JAW 2
5 001-4551 PIN, PIVOT, INTERMESHING JAWS 2
7 001-2908 BEARING, ACTUATOR, BRONZE 2
11 002-0277 HHCS, 1/2-20 X 3/4"LG, 316SS 4
15 003-0006 BEARING, DIXON, CWW12E24-3 4
28 002-0071 WASHER, 1/2, 316SS 4
2- 101-3853 NOSE BLOCK, CONAN/RIGMASTER, KIT, Rev M 1
2 001-5395 PISTON, 1-PIECE 1
3 001-5399 BEARING, PISTON 2.25,ORKOT 1
4 004-0616 SEAL, PISTON, SHAMBAN, 34G02250-A46 1
5 101-4108 BLOCK,NOSE,CONAN,W/BRG 1
6 004-0542 O-RING,2-034 BUNA 70 1
7 004-0541 RING,BACKUP,8-034 BUNA 90 1
8 001-5398 BEARING,1.0 DIA. ROD, ORKOT 2
9 004-0650 SEAL,ROD,LINEAR ACTUATOR,GAMMA 2
11 002-1925 ANTISIEZE, 1 OX TUBE 0
12 001-5396 PLATE,T-BAR,LOCKING 1
13 001-5397 BOLT, 12-POINT, FUSE, 30,000 LBS. TENSILE LOAD 1
14 002-1135 NAS 6406U4 4
15 011-5011 SERVICE INSTRUCTION, INTERMESHING JAW NOSE- 0
BLOCK

Jaw Kit, 6-in, Parallel-Acting, 101-4103, Rev A
1- 101-3853 NOSE BLOCK, CONAN/RIGMASTER, KIT, Rev 1
M
2 001-5395 PISTON, 1-PIECE 1
6 004-0542 O-RING,2-034 BUNA 70 1
7 004-0541 RING,BACKUP,8-034 BUNA 90 1
14 002-1135 NAS 6406U4 4
15 011-5011 SERVICE INSTRUCTION, INTERMESHING JAW 0
NOSEBLOCK
2- 101-4114 KIT, JAW, PA, 6", W/BRG, Rev B 1
1 101-4111 JAW, PA, W/BRG 2
2 101-4110 LINK, IDLER, W/BRG 4
3 101-4109 LINK, ROCKER, W/BRG 2
4 007-0308 WELDMENT, IDLER PLATE 2
5 001-4491 SPACER, DELRIN 4
6 001-4492 PIN, .749 DIA. 2
7 001-4493 PIN, .499 DIA. X 3.030 2
8 001-4494 PIN, .499 DIA. X 4.148 LG. 2
9 002-0277 HHCS, 1/2-20 X 3/4"LG, 316SS 4
10 002-0071 WASHER, 1/2, 316SS 4
11 002-0050 NAS 6404U2 4
12 001-2071 WASHER, T2 JAW 4
15 001-1985 WASHER, THRUST JAW 16
17 002-1427 PIN, SPRING, .125 DIA. X 1IN., SS 2

Jaw Kit, Intermeshing, 11.5-in, 101-4104, Rev B
1- 101-3853 NOSE BLOCK, CONAN/RIGMASTER, KIT, Rev 1
M
2 001-5395 PISTON, 1-PIECE 1
6 004-0542 O-RING,2-034 BUNA 70 1
7 004-0541 RING,BACKUP,8-034 BUNA 90 1
14 002-1135 NAS 6406U4 4
15 011-5011 SERVICE INSTRUCTION, INTERMESHING JAW 0
NOSEBLOCK
2- 101-3586 JAW KIT, RIGMASTER, Rev B 1
1 101-4113 BASE, JAW, W/BRG 2
4 002-0277 HHCS, 1/2-20 X 3/4"LG, 316SS 4
5 002-0063 NUT, MS-21043-6 8
6 001-2099 JAW, TINE 4
8 001-2122 ROD, TIE, JAW, 3.4 2
9 001-2121 ROD, TIE, JAW, 5.2 2
10 001-2100 JAW, SPACER 2
11 002-0071 WASHER, 1/2, 316SS 4
12 001-4551 PIN, PIVOT, INTERMESHING JAWS 2

Jaw Kit, 3-Finger Intermeshing, 101-4105, Rev A
1- 101-3833 ADAPTER, WRIST/JAW CONAN/T 3, KIT, Rev C 1
1 101-3783 ADAPTER, JAW, ORION, SUB ASSY 1
2 004-0541 RING, BACKUP, 8-034 BUNA 90 2
3 004-0840 O-RING, 2-034, N90 2
4 002-1628 NAS6406U3 4
5 002-1439 WASHER, 3/8 ID, 5/8 OD 4
2- 101-3834 NOSE BLOCK, PISTON, T2/T3, K IT, Rev B 1
1 001-5380 PISTON, 1-PIECE, 1.75DIA, .75 X 2.2 ROD 1
2 001-0900 BEARING, PISTON 1
3 001-2061 BLOCK, NOSE, WRIST, T2 1
4 004-0588 O-RING, 2-129 BUNA 90 1
5 001-0903 BEARING, ROD 1
6 004-0039 SEAL, ROD STEP RSW100750-Z48NA, 3/4 ROD 2
9 001-7251 PLATE, T-BAR, LOCKING, INCONEL 1
10 0023109 BOLT, NAS1275-22 1
11 002-0038P NAS 6404U1, NLK 6
12 004-0646 SEAL, JAW PISTON, GAMMA 1
13 004-0046 O-RING, 2-127 BUNA 70 1
3- 101-3125 JAW KIT, INTERMESHING, 3 FINGER, T3, Rev B 1
1 101-3760 JAW, 1FINGER, 2/BEARING T2/3 1
2 101-3761 JAW, 2FINGER, W/BEARING T2/3 1
3 001-1851 BEARING, JAW ACTUATION, T2 2
4 001-1840 PIN, .5 X 2.0, JAW, T2 2
6 002-0038P NAS 6404U1, NLK 4
7 001-2071 WASHER, T2 JAW 4

Jaw Kit, Parallel-Acting, 4-in, 101-4106, Rev B
1- 101-3833 ADAPTER, WRIST/JAW CONAN/T 3, KIT, Rev C 1
1 101-3783 ADAPTER, JAW, ORION, SUB ASSY 1
2 004-0541 RING, BACKUP, 8-034 BUNA 90 2
3 004-0840 O-RING, 2-034, N90 2
4 002-1628 NAS6406U3 4
5 002-1439 WASHER, 3/8 ID, 5/8 OD 4
2- 101-3834 NOSE BLOCK, PISTON, T2/T3, K IT, 101-3834, 1
Rev B
1 001-5380 PISTON, 1-PIECE, 1.75DIA, .75 X 2.2 ROD 1
2 001-0900 BEARING, PISTON 1
3 001-2061 BLOCK, NOSE, WRIST, T2 1
4 004-0588 O-RING, 2-129 BUNA 90 1
5 001-0903 BEARING, ROD 1
6 004-0039 SEAL, ROD STEP RSW100750-Z48NA, 3/4 ROD 2
9 001-7251 PLATE, T-BAR, LOCKING, INCONEL 1
10 002-3109 BOLT, NAS1275-22 1
11 002-0038P NAS 6404U1, NLK 6
12 004-0646 SEAL, JAW PISTON, GAMMA 1
13 004-0046 O-RING, 2-127 BUNA 70 1
3- 101-2239 JAW KIT, T3, PA, 4 IN., Rev D 1
11 101-3757 LINK, ROCKER, W/BEARINGS CX 2
12 101-3756 LINK, IDLE, W/BEARINGS 4
13 001-7196 JAW, .75 - 1,00 CROSS BAR, T4 2
14 001-1840 PIN, .5 X 2.0, JAW, T2 4
15 001-1841 PIN, .5 X 3.0, JAW, T2 2
16 001-2062 PIN, .5 X 1.0, JAW, T2 4
25 001-1851 BEARING, JAW ACTUATION, T2 2
30 002-0710 RING, RETAINING, EXTERNAL, SMALLEY #VS50-S16 4
77 002-0038P NAS 6404U1, NLK 14
78 001-2071 WASHER, T2 JAW 14

Jaw Kit, Parallel-Acting, 6-in, 101-4107, Rev A
1- 101-3833 ADAPTER, WRIST/JAW CONAN/T 3, KIT, Rev C 1 EA
1 101-3783 ADAPTER, JAW, ORION, SUB ASSY 1 EA
2 004-0541 RING, BACKUP, 8-034 BUNA 90 2 EA
3 004-0840 O-RING, 2-034, N90 2 EA
4 002-1628 NAS6406U3 4 EA
5 002-1439 WASHER, 3/8 ID, 5/8 OD 4 EA
2- 101-3834 NOSE BLOCK, PISTON, T2/T3, K IT, Rev B 1 EA
1 001-5380 PISTON, 1-PIECE, 1.75DIA, .75 X 2.2 ROD 1 EA
2 001-0900 BEARING, PISTON 1 EA
3 001-2061 BLOCK, NOSE, WRIST, T2 1 EA
4 004-0588 O-RING, 2-129 BUNA 90 1 EA
5 001-0903 BEARING, ROD 1 EA
6 004-0039 SEAL, ROD STEP RSW100750-Z48NA, 3/4 ROD 2 EA
9 001-7251 PLATE, T-BAR, LOCKING, INCONEL 1 EA
10 002-3109 BOLT, NAS1275-22 1 EA
11 002-0038 NAS 6404U1 6 EA
12 004-0646 SEAL, JAW PISTON, GAMMA 1 EA
13 004-0046 O-RING, 2-127 BUNA 70 1 EA
3- 101-2958 JAW KIT, T3, PA, 6 IN., Rev C 1 EA
11 101-3758 LINK, ROCKER, 6 INCH JAW, WITH BEARINGS 2 EA
12 101-3759 LINK, IDLE, 6 INCH JAW, WITH BEARINGS 4 EA
13 001-7196 JAW, .75-1-IN, CROSS-BAR 2 EA
14 001-1840 PIN .5 x 2.0 4 EA
15 001-1841 PIN .500 X 2.770 2 EA
16 001-2062 PIN, .5 x 1 4 EA
25 001-1851 BEARING, JAW ACTUATOR 2 EA
30 002-0710 RING, RETAINING, EXTERNAL, SMALLEY #VS50-S16 4 EA
74 001-1985 WASHER 8 EA
77 002-0038 HHMS, 1/4-28 UNF-2A x .432 LONG 14 EA
78 001-2071 WASHER, JAW 14 EA

Orion Slave Arm, Short, 101-4116
Notes on the slave arm part list:

The part list for the slave arm shows the major assemblies in BOLD type. Parts within those
assemblies follow in PLAIN type.
Some serviceable subassemblies or parts within the major subassemblies have drawings and
part lists provided under their own part number (For example, see part list/drawing 101-3781
for Item 3 (in bold), ACTUATOR, ROTARY, FOREARM, ORION). The drawing list at the
beginning of the chapter identifies these components.
Slave Arm, O7P, Short, 101-4116 Rev B

1- 101-3915 KIT, AZIMUTH, POSITION, ORION, Rev D 1
1 001-5086 AZIMUTH BASE, ORION 1
2 001-5096 AZIMUTH, ORION 1
3 001-4594 PIN, SLOTTED, 1 x 4.8 2
4 001-4711 PIN, ROD END 1
5 001-4342 RETAINER, PIN 2
6 101-3938 ACTUATOR, LINEAR, DIAMETER 1.75 X 2.6 STROKE, POSITION 1
8 001-5094 SPACER, SH/AZ ACTUATOR ROD END, ORION 2
9 001-5368 BEARING, TOP HAT, ORION 8
10 002-0134 HHCS, 1/4-20 X 1, SS 2
11 001-5095 BUMPER, AZIMUTH HARDSTOP 2
12 001-5087 HOSE GUARD 1
13 002-0109 PIN, SPIROL, 3/16 X .5, SS 2
14 002-0065 HHCS, 1/4-20 X 5/8, SS 11
17 001-4647 HOSE GUARD 1
18 001-4646 BUMPER, SHOULDER 2
19 006-1964-1 HOSE, -4, JIC, CRMP/REUSE, 123L, 0A 1
20 006-1964-2 HOSE, -4, JIC, CRMP/REUSE, 126L, 0B 1
21 006-0108 FITTING, HYD, -4, JIC, -4 ST, ELBOW, MALE(4-C5OX-SS)PARKER 2
22 002-0790 WASHER, 1/4 ID X .5 OD, SS .032 THK 3
27 101-4408-1 CONN ASSY, LIN ACTR, AZ, 121L 1
2- 101-3916 KIT, UPPER ARM, POSTION, ORI ON, Rev D 1
1 001-4600 UPPER ARM 1
3 001-4594 PIN, SLOTTED, 1 x 4.8 2
5 002-0065 HHCS, 1/4-20 X 5/8, SS 4

12 002-0846 CABLE TIE, 8 IN. X .14 WIDE 2
13 101-4406-1 CONN ASSY, LIN ACTR, SHLDR, 145L 1
14 101-4407-1 CONN ASSY, LIN ACTR, ELB, 148L 1
3 101-3781 ACTUATOR, ROTARY, FOREARM, ORION, Rev C 1
4- 101-3918 KIT, FOREARM, POSITION, ORION, Rev C 1
1 007-0360 FOREARM 1
2 001-5244 FLANGE, MOUNTING, FOREARM 1
3 101-3960 WRIST BASE, ORION 1
5 001-4711 PIN, ROD END 1
6 001-4594 PIN, SLOTTED, 1 x 4.8 1
7 001-4596 PIN, PIVOT, 1 x 1.8 2
9 002-0065 HHCS, 1/4-20 X 5/8, SS 6
11 001-4710 GUARD, PITCH 1
12 001-4638 BUMPER, STEM 2
16 006-0116 FITTING, HYD, -4, JIC, -4, ST, EL, MALE, 45, SS(4V50XSS) 3
18 101-3835 HOSE ASSEMBLY, FOREARM, 4A 1
19 101-3836 HOSE ASSEMBLY, FOREARM, 4B 1
24 101-3841 HOSE ASSEMBLY, FOREARM, C 1
26 002-0134 HHCS, 1/4-20 X 1, SS 4
27 002-1784 PLUG, CAPLUG BPF-1-1/8-6 2
29 001-5376 SPACER, HOSE ORION FOREARM 1

34 002-1789 SPRING, COMPRESSION, CENTURY S-1500, SS 1
35 001-5068 SPACER, RELIEF VALVE 1
36 001-5111 SHSS, 7/16-20 x .25, SS, VENTED 1
37 004-0225 O-RING, 2-008 BUNA 90 1
38 002-0407 WASHER, FLAT, #6, SS 1
39 001-4898 SPACER, PITCH ACTUATOR ROD END, ORION 2
40 101-3961 CONNECTOR, ROTARY POSITION SENSOR 1
41 101-3917 POSITION SENSOR, ROTARY 1
43 004-0062 O-RING, 2-013 BUNA 70 1
44 004-0064 RING, BACKUP, 8-013 BUNA 90 1
45 002-1872 PHMS, 8-32 X 3/4, SS 2
46 002-1841 PHMS, 8-32 X 1, SS 4
47 101-4015 HOSE ASSEMBLY, WRIST SENSOR 1
48 101-3980 CONNECTOR ASSEMBLY, LINEAR ACTUATOR, PITCH 1
5 101-3786 WRIST MOTOR, ORION, Rev E 1
9- 101-3842 SHOULDER KIT, ORION, Rev B 1
1 001-4711 PIN, ROD END 1
2 001-4710 GUARD, PITCH 1
3 001-4594 PIN, SLOTTED, 1 x 4.8 1
5 002-0065 HHCS, 1/4-20 X 5/8, SS 2
6 002-0134 HHCS, 1/4-20 X 1, SS 2
8 001-4638 BUMPER, STEM 2
10- 101-3920 KIT, ELBOW POSITION, ORION, Rev D 1
1 004-0583 SEAL, SLIP RING 9
2 004-0036 O-RING, 2-027 BUNA 70 9
3 003-0081 BEARING, SLYD RING 2
4 001-5053 SLIP RING 1
6 101-4023 MANIFOLD, ORION7P, SLIPRING, SUBASSEMBLY 1
7 001-5210 ADAPTER PLATE, ROLL SENSOR 1
8 001-5088 COVER, MANIFOLD 1
9 002-1873 NAS 6403U7 4
10 004-0225 O-RING, 2-008 BUNA 90 4
11 002-0795 ADHESIVE, #271 RED LOCTITE 50ML 0
12 004-0222 O-RING, 2-010 BUNA 90 10

13 004-0860 O-RING, URETHANE, 2-044 90 DUROMETER 1
14 004-0130 O-RING, 2-022 BUNA 70 3
15 004-0098 O-RING, 2-030 BUNA 70 1
16 001-4575 BUMPER, ELBOW 2
17 002-1804 HHCS, 3/8-16 X 3.0, 316SS 8
18 001-5093 BASE, ELBOW 1
19 002-0182 HHCS, 3/8-16 X 1, SS 4
21 002-0065 HHCS, 1/4-20 X 5/8, SS 6
22 002-1439 WASHER, 3/8 ID, 5/8 OD 14
25 001-4596 PIN, PIVOT, 1 x 1.8 2
26 001-4711 PIN, ROD END 1
27 001-5092 SPACER, ELBOW ACTUATOR ROD END, ORION 2
30 002-0134 HHCS, 1/4-20 X 1, SS 2
31 002-1784 PLUG, CAPLUG BPF-1-1/8-6 2
40 006-1964-15 HOSE, -4, JIC, CRMP/REUSE, 159L, C 1
44 002-1572 HHCS, 3/8-16 X 1.75, 316 SS 2
45 101-4012 DRIVESHAFT ASSEMBLY ROLL SENSOR ORION 7P 1
46 001-5271 BEARING, THRUST, .694 OD x .441 ID x .032 THK 1
47 003-0249 BEARING, FLANGE, .875 OD X .50 ID X .25 LG 1
49 001-5266 WIRE HOUSING, ORION ROLL 1
50 001-5267 WIRE HOUSING COVER, ORION ROLL 1
51 101-4016 PCB ASSEMBLY, ROLL CONNECTOR 1

54 002-1485 CABLE, TIE, .10 X 4.5 LG, #4 SCREW EYE 2
55 002-0358 SHCS, 4-40 X .18, SS 3
57 002-1550 SHCS, 8-32 X 1.25, 316SS 4
58 002-0158 SHCS, 8-32X1/2 5
59 101-4518 HOSE, ELEC, WRIST/PITCH, 159.0 LG 1
60 101-4478-1 CABLE, SNSR, ROLL ACTR, 159L 1
61 004-0086 O-RING, 2-011 BUNA 70 4
62 004-0139 O-RING, 2-040 BUNA 70 1
63 002-1875 SHCS 4-40 X .3125 SS 2
64 004-0064 RING, BACKUP, 8-013 BUNA 90 1
11- 101-3963 FOREARM, MOUNTING HARDWARE, KIT., Rev B 1
1 002-1825 HHCS, 1/4-20X2.0, 316SS 10
3 002-1804 HHCS, 3/8-16 X 3.0, 316SS 4
5 002-1574 WASHER, .625 OD X .385 ID X .125 THK, 316SS 4
7 004-0222 O-RING, 2-010 BUNA 90 18
8 004-0017 O-RING, 2-031 BUNA 70 1
9 002-0109 PIN, SPIROL, 3/16 X .5, SS 5
10 004-0130 O-RING, 2-022 BUNA 70 1
11 101-3962 ADAPTER, WRIST, ORION 1
12 101-4008 SHAFT, POSITION SENSOR, WRIST, CONAN 1
13 002-1787 FHMS, 4-40 X .25 LG, 82DEG, 18-8, NYLON LOCKING 3
15 004-0048 O-RING, 2-041 BUNA 70 1
16 001-5212 HOSE GUARD, WRIST BASE 1
17 002-0065 HHCS, 1/4-20 X 5/8, SS 2
12 002-1440 ANODE, GALVANIC 5

Orion Slave Arm, Long, 101-4117
Notes on the slave arm part list:

The part list for the slave arm shows the major subassemblies in BOLD type. Parts within
those subassemblies follow in PLAIN type.
Some serviceable subassemblies or parts within the major subassemblies have drawings and
part lists provided under their own part number (For example, see part list/drawing 101-3781
for Item 3 (in bold), ACTUATOR, ROTARY, FOREARM, ORION). The drawing list at the
beginning of the chapter identifies these components.
Slave Arm, O7P, Long, 101-4117, Rev B

1- 101-3915 KIT, AZIMUTH, POSITION, ORION, Rev D 1
1 001-5086 AZIMUTH BASE, ORION 1
2 001-5096 AZIMUTH, ORION 1
3 001-4594 PIN, SLOTTED, 1 x 4.8 2
4 001-4711 PIN, ROD END 1
10 002-0134 HHCS, 1/4-20 X 1, SS 2
11 001-5095 BUMPER, AZIMUTH HARDSTOP 2
12 001-5087 HOSE GUARD 1
13 002-0109 PIN, SPIROL, 3/16 X .5, SS 2
14 002-0065 HHCS, 1/4-20 X 5/8, SS 11
17 001-4647 HOSE GUARD 1
18 001-4646 BUMPER, SHOULDER 2
27 101-4408-1 CONN ASSY, LIN ACTR, AZ, 121L 1
2- 101-4064 KIT, UPPER ARM, POSTION, ORI ON, Rev D 1
1 001-5326 UPPERARM, ORION, LONG 1
3 001-4594 PIN, SLOTTED, 1 x 4.8 2
5 002-0065 HHCS, 1/4-20 X 5/8, SS 4

12 002-0846 CABLE TIE, 8 IN. X .14 WIDE 2
13 101-4406-1 CONN ASSY, LIN ACTR, SHLDR, 145L 1
14 101-4407-2 CONN ASSY, LIN ACTR, ELB, 166L 1
3 101-3781 ACTUATOR, ROTARY, FOREARM, ORION, Rev C 1
4- 101-3918 KIT, FOREARM, POSITION, ORION, Rev C 1
1 007-0360 FOREARM 1
2 001-5244 FLANGE, MOUNTING, FOREARM 1
3 101-3960 WRIST BASE, ORION 1
5 001-4711 PIN, ROD END 1
6 001-4594 PIN, SLOTTED, 1 x 4.8 1
7 001-4596 PIN, PIVOT, 1 x 1.8 2
9 002-0065 HHCS, 1/4-20 X 5/8, SS 6
11 001-4710 GUARD, PITCH 1
12 001-4638 BUMPER, STEM 2
16 006-0116 FITTING, HYD, -4, JIC, -4, ST, EL, MALE, 45, SS(4V50XSS) 3
24 101-3841 HOSE ASSEMBLY, FOREARM, C 1
26 002-0134 HHCS, 1/4-20 X 1, SS 4
27 002-1784 PLUG, CAPLUG BPF-1-1/8-6 2
29 001-5376 SPACER, HOSE ORION FOREARM 1

34 002-1789 SPRING, COMPRESSION, CENTURY S-1500, SS 1
35 001-5068 SPACER, RELIEF VALVE 1
36 001-5111 SHSS, 7/16-20 x .25, SS, VENTED 1
37 004-0225 O-RING, 2-008 BUNA 90 1
38 002-0407 WASHER, FLAT, #6, SS 1
39 001-4898 SPACER, PITCH ACTUATOR ROD END, ORION 2
40 101-3961 CONNECTOR, ROTARY POSITION SENSOR 1
43 004-0062 O-RING, 2-013 BUNA 70 1
44 004-0064 RING, BACKUP, 8-013 BUNA 90 1
45 002-1872 PHMS, 8-32 X 3/4, SS 2
46 002-1841 PHMS, 8-32 X 1, SS 4
47 101-4015 HOSE ASSEMBLY, WRIST SENSOR 1
48 101-3980 CONNECTOR ASSEMBLY, LINEAR ACTUATOR, PITCH 1
5 101-3786 WRIST MOTOR, ORION, Rev E 1
9- 101-3842 SHOULDER KIT, ORION, Rev A 1
1 001-4711 PIN, ROD END 1
2 001-4710 GUARD, PITCH 1
3 001-4594 PIN, SLOTTED, 1 x 4.8 1
5 002-0065 HHCS, 1/4-20 X 5/8, SS 2
6 002-0134 HHCS, 1/4-20 X 1, SS 2
8 001-4638 BUMPER, STEM 1
10- 101-4065 KIT, ELBOW POSITION, ORION, Rev D 1
1 004-0583 SEAL, SLIP RING 9
2 004-0036 O-RING, 2-027 BUNA 70 9
3 003-0081 BEARING, SLYD RING 2
4 001-5053 SLIP RING 1
6 101-4023 MANIFOLD, ORION7P, SLIPRING, SUBASSEMBLY 1
7 001-5210 ADAPTER PLATE, ROLL SENSOR 1
8 001-5088 COVER, MANIFOLD 1
9 002-1873 NAS 6403U7 4
10 004-0225 O-RING, 2-008 BUNA 90 4
12 004-0222 O-RING, 2-010 BUNA 90 10
13 004-0860 O-RING, URETHANE, 2-044 90 DUROMETER 1

14 004-0130 O-RING, 2-022 BUNA 70 3
15 004-0098 O-RING, 2-030 BUNA 70 1
16 001-4575 BUMPER, ELBOW 2
17 002-1804 HHCS, 3/8-16 X 3.0, 316SS 8
18 001-5093 BASE, ELBOW 1
19 002-0182 HHCS, 3/8-16 X 1, SS 4
21 002-0065 HHCS, 1/4-20 X 5/8, SS 6
22 002-1439 WASHER, 3/8 ID, 5/8 OD 14
25 001-4596 PIN, PIVOT, 1 x 1.8 2
26 001-4711 PIN, ROD END 1
27 001-5092 SPACER, ELBOW ACTUATOR ROD END, ORION 2
30 002-0134 HHCS, 1/4-20 X 1, SS 2
31 002-1784 PLUG, CAPLUG BPF-1-1/8-6 2
40 006-1964-28 HOSE, -4, JIC, CRMP/REUSE, 172L, C 1
44 002-1572 HHCS, 3/8-16 X 1.75, 316 SS 2
45 101-4012 DRIVESHAFT ASSEMBLY ROLL SENSOR ORION 7P 1
46 001-5271 BEARING, THRUST, .694 OD x .441 ID x .032 THK 1
47 003-0249 BEARING, FLANGE, .875 OD X .50 ID X .25 LG 1
49 001-5266 WIRE HOUSING, ORION ROLL 1
50 001-5267 WIRE HOUSING COVER, ORION ROLL 1
51 101-4016 PCB ASSEMBLY, ROLL CONNECTOR 1

54 002-1485 CABLE, TIE, .10 X 4.5 LG, #4 SCREW EYE 2
55 002-0358 SHCS, 4-40 X .18, SS 3
57 002-1550 SHCS, 8-32 X 1.25, 316SS 4
58 002-0158 SHCS, 8-32X1/2 5
59 101-4518-1 HOSE, ELEC, WRIST/PITCH, 172.0 LG 1
60 101-4478-2 CABLE, SNSR, ROLL ACTR, 172L 1
61 004-0086 O-RING, 2-011 BUNA 70 4
62 004-0139 O-RING, 2-040 BUNA 70 1
63 002-1875 SHCS 4-40 X .3125 SS 2
64 004-0064 RING, BACKUP, 8-013 BUNA 90 1
65 004-0062 O-RING, 2-013 BUNA 70 1
11- 101-3963 FOREARM, MOUNTING HARDWARE, KIT., Rev B 1
1 002-1825 HHCS, 1/4-20X2.0, 316SS 10
3 002-1804 HHCS, 3/8-16 X 3.0, 316SS 4
5 002-1574 WASHER, .625 OD X .385 ID X .125 THK, 316SS 4
7 004-0222 O-RING, 2-010 BUNA 90 18
8 004-0017 O-RING, 2-031 BUNA 70 1
9 002-0109 PIN, SPIROL, 3/16 X .5, SS 5
10 004-0130 O-RING, 2-022 BUNA 70 1
11 101-3962 ADAPTER, WRIST, ORION 1
12 101-4008 SHAFT, POSITION SENSOR, WRIST, CONAN 1
13 002-1787 FHMS, 4-40 X .25 LG, 82DEG, 18-8, NYLON LOCKING 3
15 004-0048 O-RING, 2-041 BUNA 70 1
16 001-5212 HOSE GUARD, WRIST BASE 1
17 002-0065 HHCS, 1/4-20 X 5/8, SS 2
12 002-1440 ANODE, GALVANIC 5

Master Controller, 101-4198-2
Master Controller, 101-4198, Rev G, & 101-4198-2, Rev C)

Titan III/Conan (101-4198) & Orion (101-4198-2)
Item No. P/N Part Description Qty. Unit

1 101-3796 FACEPLATE ASSEMBLY, MASTER CONTROLLER 1
2 101-3824 MOTHERBOARD ASSEMBLY, 115VAC 1
101-1645 MASTER CONTROL ARM, CONAN, TITAN 3 1
3 OR
101-3816 MASTER CONTROL ARM, ORION 1
5 101-1774 PCB ASSY, OPTO/ISO, RS422HD/FD, RS232 1
6 101-1840 PCB ASSEMBLY, ANALOG MASTER, GROUNDED 1
7 101-1839 PCB ASSEMBLY, 8088 CPU, MASTER, GROUNDED 1
8 002-0137 SHCS, 6-32 X 3/8, SS 4
9 002-0011 BHCS, 6-32 X 1/4, 18-8, SS 6
10 002-0161 CLAMP, CABLE, 1/8 1
11 002-0082 SHCS, 10-24 X 5/8, SS 3
12 001-0205 SPACER, ELECTRONICS BOTTLE 2
13 101-4196 AUX JAW SWITCH ASSY, MOMENTARY TOGGLE 1
15 002-0115 STANDOFF, RICHCO MSP-4N, 2
16 001-2663 HOUSING, MASTER, TITAN 1
17 003-0007 FEET, RUBBER, STICK ON MASTER CONTROL HOUSING 4
18 101-1782 CABLE ASSY, MCU-TO-J-BOX, GND MSTR, 15’ 1
19 001-3893 NAMEPLATE 1
23 002-0862 WASHER, #8 LOCK INTERNAL TOOTH, SS 1
24 002-0403 SHCS, 8-32 X 1/4, SS 1
035-0529 WIRING DIAG., MASTER CONSOLETTE, 85-264VAC, CONAN, 0
TITAN 3
25 OR
035-0540 WIRING DIAG., MASTER CONSOLETTE, 85-264VAC, ORION 0
26 001-4838 CLAMP, SIP CONNECTOR, MASTER CONTROLLER 2
27 004-0843 O-RING, .930 ID X .040, N70 1
32 002-0020 SHCS, 10-24 X 3/4, SS 1
33 001-1463 I.D. PLATE, 3.75 x 1.0 1
50 002-0279 CASE, SHIPPING, MASTER CONTROLLER 1
52 001-5387 LABEL, INPUT VOLT, 90/260 VAC 1

Compensator, 101-4470, Rev E
Compensator, 101-4470, Rev E
Item No. P/N Description Qty
1 101-4163 COMPENSATOR, 2 LITER, 8-10 PSI 1

2 006-1651 VALVE, RELIEF, CIRCLE SEAL, 559T1-2M-20 1
4 006-1680 FITTING, HYD, -4 JIC, 1/2 NPT, SS 1
5 006-0027 FITTING, HYDRAULIC, -4, JIC, CAP-S(4FNTX-S) 1
6 006-1625 FITTING, HYDRAULIC, 1/2 PIPE PLUG, HEX HEAD 1
7 006-0225 FITTING, HYD, 1/4, PIPE, PLUG, HOLLOW HEX-SS(1/4 HHP-SS) 1
8 001-6315 BRACKET, COMP SINGLE, QUICK RELEASE 1
9 002-8007-20P HHCS, M10 X 20, FULL THREAD, 316 SS, NYLOCK 2
10 002-9029 WASHER, FLAT, M10, REGULAR OD, 316 SS 2
11 002-2448 LABEL, COMPENSATOR 1
Note: Part numbers for serviceable components within Item No. 1 (Compensator 101-
4163) are located in the Compensator Kit 101-4470 Service Instruction.
! WARNING
The compensator 101-4163 (Item 1) contains a powerful spring under high
compression. Release of the spring can cause serious injury and damage to
nearby equipment.
See the Compensator Ass’y 101-4470 Service Instruction for safe service of
the compensator.
– PAGE BREAK –

Orion Manipulator System, Short, 199-0229, Rev G
1 101-4116 SLAVE ARM, O7P, SHORT 1

2 101-3912 SLAVE CONTROLLER ASSY, O7P 1
3 101-4198- MA CONT, UNIV INPUT, JAW SW, ORP 1
2
4 101-4017 J-BOX, O7P, 115V, GNEED, AC/DC SPL 1
5 101-4018 CA ASSY, PWR/TELEM, CPC/BURTON 1
6 101-4470 COMP, 2 LITER, 8-10 PSI, MANIP 1
7 101-4090 HOSE ASSY, COMP TO SCU, 1/4 TUBE 1
8 101-3913 SOFTWARE GROUP, O7P 1
9 011-9182 TECHNICAL MANUAL, ORION 7P, STD & EXTENDED 2
REACH
10 008-0143 SPARES KIT, ORION POSITION STD 0
12 002-2429 CASE, SHIPPING, 46X29X15 ID 1
13 025-0060 HYDRAULIC SCHEMATIC, ORION, POSITION 0
14 035-0564 WRG, DIAG, SYS, O7P, 90-260VAC 0
16 006-0028 FITTING, HYD, -6, JIC, CAP-S(6FNTX-S) 1
17 001-5076 LOGO, PLATE, HERCULES 2
18 002-0814 ADHESIVE, LOCTITE, BLACK MAX, #38050, 1OZ. 0
19 005-3133 CONNECTOR, CPC 17-9, REVERSE SEX PLUG 1
20 005-1794 PIN, CONN, CPC, AMP #66587-2 9
21 005-1850 CONN, STRAIN RELIEF CPC 17 SHELL LARGE 1
24 006-0096 FITTING, HYD, -4, JIC, CAP-SS(4-FNTX-SS) 1
25 005-2810 POWER SUPPLY, +/-12VDC, AC INPUT, SCREW TER- 1
MINAL
27 101-4102 KIT, JAW, 4FNGINTMESH, 7.8~ 0
28 101-4103 KIT, JAW, 6~, PA, CON 0
29 101-4104 KIT, JAW, INTMESH, 11.5~ 0
30 101-4105 KIT, JAW, 3FNG, INTMESH, T3 0
31 101-4106 KIT, JAW, PA, 4~, T3 0
32 101-4107 KIT, JAW, PA, 6~, T3 0
35 001-5006 LABEL, SERIAL 1
36 002-1926 RIVET, 1/8, SS 2

Orion Manipulator System, Long, 199-0230, Rev G
1 101-4117 SLAVE ARM, O7P, LONG 1

2 101-3912 SLAVE CONTROLLER ASSY, O7P 1
3 101-4198- MA CONT, UNIV INPUT, JAW SW, ORP 1
2
4 101-4017 J-BOX, O7P, 115V, GNEED, AC/DC SPL 1
5 101-4018 CA ASSY, PWR/TELEM, CPC/BURTON 1
6 101-4470 COMP, 2 LITER, 8-10 PSI, MANIP 1
7 101-4090 HOSE ASSY, COMP TO SCU, 1/4 TUBE 1
8 101-3913 SOFTWARE GROUP, O7P 1
9 011-9182 TECHNICAL MANUAL, ORION 7P, STD & EXTENDED 2
REACH
10 008-0143 SPARES KIT, ORION POSITION STD 0
12 002-2429 CASE, SHIPPING, 46X29X15 ID 1
13 025-0060 HYDRAULIC SCHEMATIC, ORION, POSITION 0
14 035-0564 WRG, DIAG, SYS, O7P, 90-260VAC 0
16 006-0028 FITTING, HYD, -6, JIC, CAP-S(6FNTX-S) 1
17 001-5076 LOGO, PLATE, HERCULES 2
18 002-0814 ADHESIVE, LOCTITE, BLACK MAX, #38050, 1OZ. 0
19 005-3133 CONNECTOR, CPC 17-9, REVERSE SEX PLUG 1
20 005-1794 PIN, CONN, CPC, AMP #66587-2 9
21 005-1850 CONN, STRAIN RELIEF CPC 17 SHELL LARGE 1
24 006-0096 FITTING, HYD, -4, JIC, CAP-SS(4-FNTX-SS) 1
25 005-2810 POWER SUPPLY, +/-12VDC, AC INPUT, SCREW TER- 1
MINAL
27 101-4102 KIT, JAW, 4FNGINTMESH, 7.8~ 0
28 101-4103 KIT, JAW, 6~, PA, CON 0
29 101-4104 KIT, JAW, INTMESH, 11.5~ 0
30 101-4105 KIT, JAW, 3FNG, INTMESH, T3 0
31 101-4106 KIT, JAW, PA, 4~, T3 0
32 101-4107 KIT, JAW, PA, 6~, T3 0
35 001-5006 LABEL, SERIAL 1
36 002-1926 RIVET, 1/8, SS 2
– PAGE BREAK –

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Remote Systems Products

Orion Manipulator System

TECHNICAL MANUAL REVISION LOG

Sec. Page Description Rev Date

1.2 Ranges of Motion . . . . . . . . . . . . . . . . . . . . . . . . . 2

3.2 Dual Arm Systems 199-0232, 199-0233, 199-0250 . . . . . . . . . 7

3.3 Systems 199-0251, 199-0252 . . . . . . . . . . . . . . . . . . . 7

3.4 System 199-0254 . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.5 Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . 8

3 Slave Arm Configuration Options . . . . . . . . . . . . . . . . . 3

4 Installing the Slave Arm . . . . . . . . . . . . . . . . . . . . . . 4

5 Installing the Slave Controller. . . . . . . . . . . . . . . . . . . 5

6 Installing the Compensator . . . . . . . . . . . . . . . . . . . . 7

7 Power and Telemetry Connections . . . . . . . . . . . . . . . . 9

7.2 Remote Operation Connections . . . . . . . . . . . . . . . . . . 10

8 Installing the Master Controller . . . . . . . . . . . . . . . . . 11

8.2 For Remote Operation . . . . . . . . . . . . . . . . . . . . . . 12

9 Installing the Junction Box . . . . . . . . . . . . . . . . . . . 13

9.2 For Remote Operation . . . . . . . . . . . . . . . . . . . . . . 14

10 Slave Controller Connections . . . . . . . . . . . . . . . . . 14

10.2 For Remote Operation . . . . . . . . . . . . . . . . . . . . . . 15

10.3 Telemetry Configuration . . . . . . . . . . . . . . . . . . . . . 15

11 Completing the Installation . . . . . . . . . . . . . . . . . . 15

11.2 Repeat Installations . . . . . . . . . . . . . . . . . . . . . . . 16

12 Charging and Bleeding the Compensation Circuit . . . . . . . 17

13 First Startup Tutorial . . . . . . . . . . . . . . . . . . . . . . 20

13.2 Master Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

13.3 First Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

13.4 The Startup Process . . . . . . . . . . . . . . . . . . . . . . . 24

13.5 The DEPLOY Menu . . . . . . . . . . . . . . . . . . . . . . . . 27

13.6 The MAIN menu . . . . . . . . . . . . . . . . . . . . . . . . . 27

14.2 Operating the Slave Arm . . . . . . . . . . . . . . . . . . . . . 30

15 The SET LIMITS and SET STOW Menus . . . . . . . . . . . . . 31

15.2 Setting Slave Arm Movement Limits . . . . . . . . . . . . . . . . 32

15.3 Setting the Stow and Deploy Sequence . . . . . . . . . . . . . . 34

15.4 Testing the Movement Limits and Stow Sequence . . . . . . . . . 36

16 Submersible System Options . . . . . . . . . . . . . . . . . . 37

1.2 The Control Process . . . . . . . . . . . . . . . . . . . . . . . . 5

1.3 Menu Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.4 Factors Affecting Slave Arm Performance . . . . . . . . . . . . . . 10

1.5 Avoiding Slave Arm Damage . . . . . . . . . . . . . . . . . . . . 11

2.2 Startup Sequence . . . . . . . . . . . . . . . . . . . . . . . . . 13

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2.4 Using the MAIN Menu. . . . . . . . . . . . . . . . . . . . . . . 16

2.5 Operation and Shutdown of the Slave Arm . . . . . . . . . . . . . 17

2.6 System Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 20

3.2 SETUP Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4 System Fault and Error Diagnosis . . . . . . . . . . . . . . . . 33

5 Adjusting the LCD Screen Viewing Angle . . . . . . . . . . . . 40

2.2 Master Arm Symptoms . . . . . . . . . . . . . . . . . . . . . . . 3

2.3 Slave Arm Behavior Defined . . . . . . . . . . . . . . . . . . . . 4

2.4 Entire Slave Arm Symptoms . . . . . . . . . . . . . . . . . . . . 5

2.5 Slave Arm Joint Symptoms . . . . . . . . . . . . . . . . . . . . . 6

3 System Fault and Error Diagnosis . . . . . . . . . . . . . . . . . 9

3.2 Using the DIAGNOSTICS Menus . . . . . . . . . . . . . . . . . . 11

3.3 Diagnosing Problems . . . . . . . . . . . . . . . . . . . . . . . 11

3.4 Enabling and Disabling System Error Checking . . . . . . . . . . . 16

4 Electrical Component Diagnosis . . . . . . . . . . . . . . . . . 18

4.2 Wireway Short and Open Circuits . . . . . . . . . . . . . . . . . 18

4.3 Diagnosing Servo Valve Failures. . . . . . . . . . . . . . . . . . 18

4.5 Diagnosing Potentiometer Failure . . . . . . . . . . . . . . . . . 19

4.6 Master Controller PC Board Diagnosis. . . . . . . . . . . . . . . . 20

4.7 Slave Controller PC Board Diagnosis . . . . . . . . . . . . . . . . 22