Contents - Savant Automation
Contents
1. 1 5 2 DC60 Drive Lubrication and Maintenance srarnnnnnnvrrrnnnnnnnnrrrnnnnnr 9 1 5 3 Drive Assembly Turntable Bearing rrrrrrrrnnnnnnornnnnnrrrrnnnnnnnrrrrnnnnnn 9 1 5 4 Chain kevlar annidee 9 1 5 5 Rear Linkage Arm Lubrication wxorrrnnnvrrrnnnnrnnnrvnnnnrrrrnnnnnnnrrrrnnnnnn 9 1 5 6 EINE 9 1 6 Safety Laser Scanner Bumper Care rnnnrrnnnnnnnnnnnnnnnnrnnnnnrrnnnnnnnennr 9 1 6 1 Daly CH skont uarreundisemumnenenivbemnmjedmeh in 10 gt savant l ran 2012 March 15 Project 1683 i DC60 AGV System Cummins Engine Preventive Maintenance Operation and Maintenance Manual 7 automation A P savant il Project 1683 2012 March 15 gt Cummins Engine DC60 AGV System Operation and Maintenance Manual Preventive Maintenance 1 Preventive Maintenance 1 1 Introduction Preventive maintenance is a systematic approach to vehicle maintenance designed to prevent equipment down time by identifying potential problems before they occur An effective preventive maintenance program will not necessarily prevent the need for corrective maintenance but it will allow you the time necessary to plan a corrective maintenance procedure before the need becomes immediate This allows time for scheduling equipment down time and parts procurement An effective preventive maintenance system should include a schedule of all maintenance actions to be completed and a method to record or keep track of the maintenance actions2. 1683 2012 March 15 U automation Cummins Engine DC60 AGV System Operation and Maintenance Manual Preventive Maintenance Table 3 Recommended Vehicle Maintenance nm Semi Annual Checks EN Inspect the brake rotor thickness and air gap See the Lenze Operating Instructions in the Vendor 2 3 mn ME 0 1 2 3 1 Information chapter Lenze Brake type BRK458 10E 2 Check the motor brushes See the Sauer Danfoss Maintenance Instructions inthe Verdor chapier a Perorm the Quarter Checks 17 Lubricate the drive assembly turntable bearing using general purpose gresse Check the ground track sensor urethane wheel for wear or cracks Replace when diameter of wheel measures below 4 7 8 2 3 Change the grease per the Sauer Danfoss Maintenance Instructions located in the Vendor chapter of this manual 4 5 1 Perform every 3000 hours or every 3 years Replace all sealing elements See the Sauer Danfoss Maintenance Instructions in the Vendor chapter Perform every 6000 hours or 6 years 2 4 Change the oil in the steer motor gear reducer See the Alpha Gear Reducer Operating Instructions in the Vendor Information chapter Every 10 000 hours or 5 years whichever comes first 5 Replace oil in deck gear reducer Every 5 years See the Grove Gear Reducer Installation Instructions in the Vendor Information chapter lt BE a HON orner checks greaternanoneye o O S amp av
3. completed 1 2 Schedule According To Use Maintenance must be planned otherwise hit or miss servicing could easily result This eventually leads to extensive repairs and unit failures usually at a critical time Your vehicle maintenance should be based upon the calendar or number of hours the vehicle operates whichever comes first and the environment it is used in Aoi Preventive maintenance is a preventive measure Non compliance with the instructions and maintenance intervals can result in impaired use and damage to the vehicle Maintenance supervisors should ensure periodic maintenance is performed on a regular basis They should follow the recommended vehicle maintenance until situations require change in maintenance interval They should never increase the time between a recommended maintenance action They have the authority to shorten it when the need becomes evident 1 2 1 Maintenance Schedule A master maintenance schedule listing all maintenance to be performed during the year should be maintained by the maintenance supervisor A partial copy of the master schedule showing only the maintenance actions scheduled in the immediate future should be posted in the maintenance area so that all maintenance personnel are able to refer to it The schedules should prescribe maintenance actions at specific intervals The recommended interval codes for K savant 7 automation 2012 March 15 Project 1683 i DC60 AGV System Preve
4. the correct laser configuration zones are loaded and set Verify the operation of the front and rear Safety Laser Scanner Zones 5 Check to ensure the brake immediately sets in an emergency stop condition laser scanner actuation or E stop button Vehicle is to stop within the collapsible distance of the laser scanner protection zone 6 Verify communications COM OK is displayed in the status line of the CDU Make sure the vehicle is on the guidepath 7 Verify ON Path is displayed in the status line of the CDU Make sure the vehicle has been initialized and is on the guidepath See the operator s guide 8 Verify the vehicle navigates the path in automatic mode without losing ON PATH COM OK and with little or no steering assembly oscillations 9 Verify the opportunity charge mechanism is operating Manually lower and raise the charge shoes using the correct output function code via the CDU See the software section Look for binding and proper raised and lowered positions 10 Check the charge on battery and charge as necessary prior to putting the AGV back into service Check battery cables and connectors 11 Verify the operation of the powered roller deck using the manual deck switch JE AX Savant gt automation 2012 March 15 Project 1683 5 DC60 AGV System Cummins Engine Preventive Maintenance Operation and Maintenance Manual Table 3 Recommended Vehicle Maintenance
5. use Safety devices must never be altered or modified by anyone other than Savant Automation service and repair personnel Use only Savant Automation replacement parts See Spare Parts Drawing in the Parts section for lists provided as part of this service As part of the procedure to replace the laser scanner unit a Savant Automation approved configuration file is downloaded into the new unit For specific details see the Repair section of the Laser Scanner User Manual located in the Vendor Information chapter of this manual savant kj automation 1 1 2012 March 15 Project 1683 DC60 AGV System Cummins Engine Preventive Maintenance Operation and Maintenance Manual 7 automation A savant 12 Project 1683 2012 March 15 gt
6. 4 Perform the AGV Guidance Navigation Performance Testing See the Troubleshooting chapter Check the Opportunity Charge mechanism Operate the mechanism using the diagnostic output function See the Repairs Chapter Verify proper operation and that no stress exists at the power ring terminals 1 2 4 7 ZZ Ea i zm 6 Quarterly Checks 1 Check drive tire for excessive wear Replace as necessary Check hex bolts used to secure the drive tire to the drive assembly for proper torque Hex bolts shall be tightened to 75 foot pounds using a torque wrench and the normal torquing sequence star pattern Lubricate the rear steer linkage arms using general purpose grease Lubricate rear casters using general purpose grease Check caster tire and mechanical parts for excessive wear Replace as necessary Lubricate steering chains front rear using an aerosol lubricant Inspect the AGV travel areas guidepath Verify that no excessive holes bumps or other floor defects are noted If any are found repair immediately to avoid AGV drive train damage Clean contactor contacts using suitable contactor cleaning solvent Aelia Do not use emery cloth sandpaper or files to clean pitted or damaged contactors Replace them using recommended Savant Automation parts See Vehicle Spare Parts Drawing in the Parts section Verify RF modem antenna and its cable are securely mounted using recommended mounting hardware i savant 6 Project
7. Cummins Engine DC60 AGV System Operation and Maintenance Manual Preventive Maintenance Contents 1 Preventive Maintenance rrnnnnnnvnnnnnnnnnnnnnnnnnvnnnnnnnnnnnnnnnnnnnennnnenennr 1 1 1 040760 0 REE REN 1 1 2 Schedule According To USe rannnnnnnnnnnnnnvnnnnnnnnnnnnnnnnnrnnnnnrnnnnnnnennnr 1 1 2 1 Maintenance SCHOdUI iiscicsicsccsescsercnsrectexcoresssesnersenserersaveenceteeneneentes 1 1 2 2 Use a Record Keeping System rannrrnnnnnrnnnnnnnnnnnrnnnnnrnnnnnnnnnnnrnnnnnn 2 1 2 3 Required 0 ER 2 1 3 DC60 Preventive Maintenance Sequence rrarrrnnnnvrrrnnnnnnnnrrrnnnnnr 3 1 3 1 Visual NS pecho Mkirira e E E E E ER 3 1 3 2 Perform an Operational Test rrrrarrnnnvrrrnnnnnnnnrnnnnnvrrrnnnnnnnnrrrnnnnnn 3 1 3 3 Perform Maintenance annnnnnnnnnannnnnnnnnnnnnnnnnnnnrnannnrnnnnnnnnnntennrrnnnnn 3 1 3 4 Repeat Operational Test eennnnannrnnnnnnrnnnnnnnnnrrnnnnnrnnnnnnennnrnnrrnnnnnn 3 1 3 5 Record Completed Actions sssccerctitccerassicescotieeressiarcbinroneieieentian 4 1 4 Corrective Maintenance rarrrrnnnnnrnnnnnnnannnrnnnnnrnnnnnnnannnrnannnrnnnnnnnnne 4 1 4 1 Troubleshoot the Vehicle rrrrrrrnnnnrrnnnnnnnnnrnnnnnrnnnnnnnnnnrnnannnnnnnnnnnne 4 1 4 2 Repair the VEE Gaspar kes nstemarudise 4 1 4 3 M ke AdjUsStments iira sisese iE 4 1 5 Vehicle LUDNGAVOM 22 5 gis cacrethccessgcasdusestateecegsarsensvenaseieceaiaacacsadatsectace 8 1 5 1 Caster Lubrication EE nnn neserrnnn ennn 8
8. Monthly Checks 1 Clean battery as necessary to remove any acid or residue from outside surfaces See the Operator Guide chapter for further information 2 Blow dust out of motor and brake with low pressure low moisture and static free air Check to ensure all electrical connections are tight on the motor encoder brake and temperature switch 4 Check to ensure connectors and ribbon cables are secure on all Printed Circuit Boards Check to ensure printed circuit board assemblies are securely mounted using recommended mounting hardware Clean all vehicle and electrical compartments using low pressure moisture and static free air anda soft non conductive brush 7 Clean the lenses on all optics on the vehicle deck Check all lights replace bulbs as required Clean the front and rear laser scanner screens with a lint free cloth using lens cleaner or equivalent Check magnet sensors for damage and make sure that their electrical connections are tight i e they must be level with floor and centered in the middle of the vehicle 1 16 Check the MAG Sensor Calibration See Magnet Sensor Diagnostics in the Troubleshooting section of this manual 2 Check the GTS assembly for obvious mechanical damage especially the track wheel surface Perform the Ground Track Sensor Diagnostic Test for the DME and Angle Encoder Refer to Ground Track Sensor Diagnostics in the Troubleshooting section for procedures
9. Turntable Bearing Use a general purpose grease Mobil AW2 or equivalent to lubricate the turntable bearing The bearing has four 4 grease zerks that require grease Remove the steer stop bolt and rotate the drive assembly to access the grease zerks Squirt each zerk until grease emerges from the inside of the bearing Chain Lubrication Use an aerosol lubricant to lubricate steer chains and deck chains if installed Rear Linkage Arm Lubrication Lubricate the four linkage arm rod ends using general purpose grease Deck Lubrication 1 Use 10w30 weight oil to lubricate pivot joints 2 Use 90 weight gear lubricant to lubricate gears and chains 3 Use a good quality general purpose grease to lubricate bearings and drive shafts 4 Use Mobil 634 synthetic gear lube or equivalent filling to the recommended fill level of 3 4 pint See the Grove Gear installation manual for instructions Safety Laser Scanner Bumper Care The safety laser scanner bumpers installed on your automatic guided vehicle AGV are used as primary safety devices The emitted laser light senses fixed obstacles and if the obstacle infringes on the long range detection zone the AGV slows down When the object infringes on the short range detection zone the AGV immediately sets its brake and stops The laser scanner bumpers are designed to be as fail safe as possible however like any electromechanical device they can fail or be inactivated Therefore they need
10. ailures To effectively troubleshoot the vehicle the technician should 1 Understand the operational characteristics of the vehicle 2 Know the capacity of the vehicle and the limits the vehicle is designed to operate within 3 Understand the designed operation of the system The vehicle may be operating correctly but show an apparent error due to a change in the way that the vehicle is being used 4 Be certain that the battery is fully charged Electronic failures may be caused by operating on a low battery Repair the Vehicle Make the necessary repairs to return the vehicle to normal use Use Savant Automation parts See Spare Parts Drawing in Parts section for part numbers Make Adjustments When repairs are made the technician must be aware of any necessary adjustment which might be required to ensure normal vehicle operation See the Repairs chapter for information on specific repairs amp Savant Project 1683 2012 March 15 Cummins Engine DC60 AGV System Operation and Maintenance Manual Preventive Maintenance Table 2 Operational Test Test Test 1 Verify manual operation The AGV drives and steers using the pendant Verify the pendant brake switch releases and sets the brake 2 Verify the operation of all start stop and emergency stop switches 3 Verify the operation of all signal devices including motion alarms horn warning lights and turn signals 4 Check to ensure that
11. ant 2012 March 15 Project 1683 7 DC60 AGV System Cummins Engine Preventive Maintenance Operation and Maintenance Manual 1 5 Vehicle Lubrication Periodic lubrication is required to keep the DC60 AGV fully operational The specific points that require lubrication are listed below Maintenance personnel shall use a quality general purpose grease or machine oil when performing lubrication 1 5 1 Caster Lubrication Lubricate casters at the locations shown in Figure 1 A DANGER The lubricants recommended within this service manual may be dangerous to your health Always follow the manufacturer s precautions and recommendations as provided on the label of the container No Synthetic and mineral type lubricants should not be mixed Figure 1 Typical Lubrication Point Diagram l J L T f Mi ao E We GREASE ZERK 7 nr GREASE ZERK 1000475A CGM S amp avant 8 Project 1683 2012 March 15 Cummins Engine DC60 AGV System Operation and Maintenance Manual Preventive Maintenance 1 5 2 1 5 3 1 5 4 1 5 5 1 5 6 1 6 amp savant automation DC60 Drive Lubrication and Maintenance See the Sauer Danfoss Maintenance Instructions for the Drive Assembly in the Vendor Information chapter of this manual Drive Assembly
12. erational test See table 1 Perform the test before all maintenance actions to ensure that the vehicle operates correctly If the vehicle is inoperative first correct the malfunction then start the operational test 1 3 3 Perform Maintenance Perform the scheduled maintenance Do the procedure exactly as described on the maintenance schedule 1 3 4 Repeat Operational Test Completed maintenance actions should be followed by an operational test to ensure that the vehicle remains operational If the vehicle is inoperative retrace your steps SA Ssavant 7 automation 2012 March 15 Project 1683 a DC60 AGV System Cummins Engine Preventive Maintenance Operation and Maintenance Manual 1 3 5 1 4 1 4 1 1 4 2 1 4 3 Record Completed Actions Using the system prescribed by the maintenance supervisor record the completed maintenance action Corrective Maintenance Corrective Maintenance is maintenance designed to place the vehicle back into service by repairing a known problem In most cases the maintenance is not scheduled Arrange the corrective maintenance task into some logical beginning and ending See the Troubleshooting chapter for details The steps required for corrective maintenance include troubleshooting repairing and adjusting the vehicle Troubleshoot the Vehicle Using the information gained in the visual inspection the operational test and as provided in this service manual locate the f
13. ical maintenance on Savant Automation vehicles can be performed using standard hand tools and a torque wrench When using compressed air ensure that the air is low pressure moisture and static free and properly filtered Most electronic maintenance can be performed using a digital multi meter Ssavant Project 1683 2012 March 15 Cummins Engine DC60 AGV System Operation and Maintenance Manual Preventive Maintenance 1 3 DC60 Preventive Maintenance Sequence The recommended DC60 maintenance items and their intervals are listed in Table 3 Arrange your preventive maintenance tasks into logical beginnings and endings stopping if necessary at a point that would not render the vehicle totally useless for possible entry into emergency service 1 3 1 Visual Inspection Preventive maintenance should begin with a visual inspection of the vehicle If the vehicle is inoperative first repair the malfunction then start the preventive maintenance process Visually check and ensure that e Bent or otherwise damaged parts are repaired or replaced using Savant Automation recommended replacement parts e Mechanical parts operate freely e Mounting hardware such as lock washers spacers nuts and bolts are present and properly secured e The vehicle is reasonably clean especially the compartments containing electronics and moving or rotating parts 1 3 2 Perform an Operational Test The visual inspection should be followed by an op
14. ntive Maintenance Cummins Engine Operation and Maintenance Manual the DC60 are listed in Table 1 These maintenance intervals should be completed by which ever comes first the calendar interval or the time interval The time interval refers to the AGV s hour meter reading which increments only when the AGV is moving In a 24 hour operating system the time interval hour meter reading will probably occur first Table 1 Interval Codes Calendar Interval Time Interval Monthly 200 Hours Q Quarterly 500 Hours Semi Annually 1000 Hours Annually 2000 Hours Bi Annually Once Every Two Years 5000 Hours Prescribed maintenance actions should be adequately described This ensures that the action is performed in the same manner each time it is accomplished The schedules should enable the personnel involved to keep track of those actions completed and those which are still pending A good maintenance practice would be to mount a schedule behind Plexiglas so that the maintenance person can mark off completed actions with a grease pencil or erasable marker 1 2 2 Use a Record Keeping System The Maintenance supervisor should maintain a master maintenance record of all completed maintenance actions both preventive and corrective for each vehicle This is necessary to ensure that the maintenance schedule remains flexible and helps the supervisor to predict system failures before they actually occur 1 2 3 Required Tools Most mechan
15. to be checked daily to ensure the laser scanners are operating properly See the Vehicle Outline Drawing in the Drawings chapter for the defined protection zones 2012 March 15 Project 1683 9 DC60 AGV System Cummins Engine Preventive Maintenance Operation and Maintenance Manual i DANGER Do not disable or alter any safety devices installed on vehicle Injury to the vehicle operator personnel in the area or damage to the vehicle and the materials it handles may result dr 6 1 Daily Checkout i DANGER Do not place any vehicle into service with a known safety failure Injury to the vehicle operator personnel in the area or damage to the vehicle and the materials it handles may result Laser scanner bumpers and all other installed safety devices should be checked daily before the vehicle is placed into normal operation Repair any known problems before placing the vehicle into operation i DANGER Do not expose the scanner to fog rain snow vapors smoke or dust Clean the screens monthly as required 6 1 1 Laser Scanner Bumper Testing i DANGER Only properly trained personnel should operate the automatic vehicle system and automatic guided vehicles Use the following procedure to test safety laser scanner bumpers on a daily basis 1 Program the loaded vehicle for automatic operation Select proper path for the section of guidepath on which the vehicle is to be tested i DANGER DO NOT use yo
16. ur body to perform the next test 2 Place an inanimate test object in the vehicle s path of travel The object must be large enough and properly positioned to cause infringement on the protection zones 3 Start the vehicle and observe its operation as it travels the guidepath 4 Verify the vehicle Emergency Stops once the laser scanner bumper senses the object 5 Repeat this test procedure to test each laser scanner bumper installed on the vehicle 6 If a safety laser scanner bumper fails to function as designed make repairs to the device before returning the vehicle to normal use The vehicle MUST be removed from normal use until the safety device has been repaired Ssavant ba automation 0 Project 1683 2012 March 15 Cummins Engine DC60 AGV System Operation and Maintenance Manual Preventive Maintenance 1 6 1 2 Manual Mode A WARNING Safety laser scanner bumpers are NOT operational in manual mode When a vehicle is manually operated the safety laser scanner bumpers are not operational and will not stop the vehicle This allows vehicle movement after a collision or when the laser scanner is damaged and needs repair Safe operation of the vehicle in manual mode is the responsibility of the operator Only trained operators should manually operate the vehicle 1 6 1 3 Replacement Parts The safety devices on Savant Automation automatic guided vehicles are specifically designed and extensively tested for AGV
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