OPERATOR SERVICE MANUAL
Contents
1. Quality System Registered ISO 9001 2008 Q9001 2008 The Leader in Positioning Technology Senis Qno OPERATOR SERVICE MANUAL POSITECH CORPORATION 191 N RUSH LAKE ROAD LAURENS IA 50554 Phone Number 800 831 6026 Models Covered 24 Hour Service Phone Number 541 954 2948 ReactionArm 1000 Email service positech com LodeArm 3030LE RUN NO REV G 26 OCT 15 191 N Rush Lake Road Laurens lowa 50554 T 712 841 4548 F 712 841 4765 www positech com am S Table of Contents SECTION 1 NAMING CONVENTION AND SERIAL TAQGQG u uu u u 1 INAMING CONVENTION 1 2 tias 1 B SERIAL TAG LOCATION AND NOMENCLATURE 2 SECTION 2 5 re 3 A MECHANICAL SPECIFICATIONS sss eene 3 B PNEUMATIC SPECIFIGATIONS 3 titt tt tte iei tei i to cei t te te eb te toti te tee bete er 3 G HYDRAULIC SPECIFICATIONS een ae a eb ea e E HR no 3 D ELEGTRICAL SPECIEIGATIONS ii rr ER RR REED EE 3 E SABRIADINOISET pit n 3 F ENVIRONMENTAL CONDITIONS cnn conan cnn 3 PEDESTAL MOUNTING PATTERN rast te tete tete iet ete rete 4 OVERHEAD SPACER MOUNTING 4 CONCRETE MOUNTING GUIDELINES 5 J SOI CONDITIO2. Check balance setting Check minimum lift setting Check tool balance adjustment setting 3 Drifts down A B C 4 Main po A B C Check metering valve If used check 6 passage rotary manifold for leaks Check for leaky lift cylinder seal blocking valve connection Check white poly lines for leaks st rotation difficult Check for main post bearing wear If used check drag brake adjustment Check rails on trolley systems 5 Grip release without being supported A B C D Check GSC setting If used check 6 passage rotary manifold for leaks Verify proper hose connections Check bleed down speed Oil discovered on machine A B C D Check lost load cylinder for leaks Check hydraulic lines to brakes Verify FRL lubricator is not set too high Check FRL Up Down movement difficult A m Check balance regulator adjustment Verify horizontal arms are not rubbing on lift housing Check lift cylinder and muffler Check lost load cylinder Check vertical cam eccentrics Verify supply pressure and sufficient flow Rotation drift at tooling A B C Check main post level Check anchor bolts on main post Check middle joint leveling APPENDIX MACHINE OPERATION PROCEDURE APPENDIX DRAWINGS SPARE PARTS LIST
3. changes The No Load adjustment will need to be reset if the tool weight changes Use the following steps to set the Load and No Load balance regulators 1 Fully unscrew the No Load balance regulator 2 With only the tool weight carefully adjust the No Load regulator until the tool does not drift up or down 3 Fully unscrew the Load balance regulator 4 Make sure the Load or Bias switch is activated 5 Add the payload to the tool and carefully adjust the Load regulator until the tool and payload does not drift up or down LOCK OUT PROCEDURE FOR BALANCE CONTROL 1 Remove payload from tool and lower tool to lowest position 2 Set the system pressure regulator to zero 3 Lockout per factory procedure WARNING The machine is not in a zero energy state There may be pressure trapped in any cylinder with a lock valve due to the lock valve minimum locking pressure If a zero energy state is required cylinder lock valves need to be piloted by an external air source and some air lines may need to be removed See pneumatic schematic for more details and consult Positech with additional questions M METERING CONTROL ADJUSTMENTS See the pneumatic schematic for specific information regarding the pneumatic components used CONNECTING THE SUPPLY AIR 1 Set the system pressure regulator to zero 2 Connect supply air Verify pressure and flow requirements listed on prof
4. 12 MPa K FULLY REINFORCED CONCRETE FLOOR CONDITION e 6 in 152mm thick e 3500 psi 24 1 MPa compressive strength e No cracks within 48in 1 2m radius of pedestal L POURED FOUNDATION CONDITION Foundation dimensions 66 X 66 X 18 E 66 0 M PLATING ON CONCRETE A Contact Positech for drawings or ordering information SECTION 3 INSTALLATION INSTRUCTIONS A PALLET INFORMATION Inspect manipulator for any signs of damage due to shipping Document damage and make any claims to A the carrier MANIPULATOR AS SHIPPED FROM POSITECH Do not cut manipulator banding Refer to LIFTING WITH FORK TRUCK for installation instructions Shipping pallet Fork truck pockets PEDESTAL INSTALLATION LEVEL PEDESTAL BEFORE INSTALLING MANIPULATOR ON PEDESTAL See LEVELING THE A PRIMARY ARM for leveling the manipulator if it is already installed on pedestal Refer to CONCRETE MOUNTING GUIDELINES for concrete guidelines before mounting pedestal Review profile drawing for torque requirement 1 Set pedestal over area and drill holes using pedestal for template Locate pedestal so airline can be routed through air supply hole 8 Torque the anchors 2 Move pedestal and clean holes with compressed air and nylon brush A 3 Add 1 flat washer between concrete and pedestal for each jack 7 Tighten the jam nuts on jacks against pedestal
5. G F OR SUPPEY AIR u Zum nuyqa eiei e 24 SECTION 5 TROUBLESHOOTING II i i usis 25 APPENDIX A MACHINE OPERATION APPENDIX B DRAWINGS SPARE PARTS LIST u SECTION 1 NAMING CONVENTION AND SERIAL TAG A NAMING CONVENTION Primary Arm Middle Joint Brake Adjustable Rotation Stop Option Main Post Drag Brake Lift Arm Lift Cylinder Main Post Rotation Stop Option Pedestal Option Middle Joint End Joint Down Shaft Anchor Bolt 8 Leveling Jacks Option SERIAL LOCATION AND NOMENCLATURE Model Number Capacity of Base Serial Number Machine Only PROVIDE FOR SERVICE SUPPORT shown on cover Weight of Tooling Electrical MACHINE CAP LBS _________TOOL WEIGHT 185 Electical Amps Voltage Hertz Phase SUPPLY VOLTAGE V HZ PH FULL LOAD AMPS ___ PRESSURE PS SCFM AIRES DESIGN CATEGORY________ SERVICECLASS C Air POSITECH Mi 1 4 Design Category LAURENS 1A 50554 154 Pr Service Class o WWW POSITECH COM CORPORATION Serial Tag Location SECTION 2 SPECIFICATIONS A MECHANICAL SPECIFICATIONS See Profile Drawing for specification Equipment reach and load limit specifications are identified on the Profile Drawing supplied with specific projects This view will include application lift and mounting config
6. N ci HR d RR Rte e eR RE HARE dite tet tte tiere 5 K FULLY REINFORCED CONCRETE FLOOR 5 L POURED FOUNDATION 0 5 RN 5 SECTION INSTALLATION 6 1 u u u uu uu u 6 A PALLET INFORMATION 6 PEDESTAL INSTALLATION L 7 G SPACER INSTAL ATO N u ua u tete Hehe 8 D rate i 9 E ATTACHING MANIPULATOR TO 10 F ATTACHING MANIPULATOR TO 11 PREPARING THE PRIMARY ARM FOR 13 H LEVELING THE PRIMARY ARM DRIFT 14 l PREPARING THE LIFT ARM FOR 15 J LEVELING THE LIFT ARMSu u tec en ricci nee nee eere u sis 16 SETTING THE ROTATION STOPS 17 L BALANCE CONTROL ADJUSTMENTS 19 METERING CONTROL ADJUSTMENTS 20 SECTION 4 MAINTENANCE ADJUSTMENTS amp 6 1 netten 21 A AIR LINESIZIN
7. correct for drift loosen the anchor bolts at the base and extend the levelling jacks on the side of the pedestal base plate that the arm drifted toward 3 Re tighten anchor bolts and return arm back to position A and repeat steps 1 8 2 if drift still occurs 4 When all drift has been removed from position A rotate primary arm 180 degrees to position B and repeat steps 2 4 3 5 When all drifts have been removed from position B rotate primary arm 90 degrees to position C and repeat steps 2 4 6 When all drift has been removed from position C rotate primary arm 180 degrees to position and repeat steps 2 amp 3 This completes the levelling of the primary arm Position D Position B Position A I PREPARING THE ARM FOR LEVELING A Leveling adjustments to the lift arm do not affect the alignment of the primary arm 1 Tighten primary caliper brake to 3 Rotate lift arm parallel prevent primary arm from rotating to primary arm 2 Loosen middle joint brake caliper to allow lift arms to rotate freely Leveling adjustments to the lift arm are performed by loosening or tightening the adjustment bolts in the adjusting collar Adjustment bolts Primary Bearing Housing Primary Arm J LEVELING THE ARMS Select a position such as B and rotate the lift arm into that position Release arm and step back so that you can note drift of the lift arm If any drift occurs ti
8. f normal yearly heavy semiannually or severe quarterly as explained below Normal Rating Heavy Rating Severe Rating Below 65 of rated load 65 to 100 of rated load At 100 of rated load Operate in an industrial environment free of aggressive contaminants Operate in an industrial environment free of aggressive contaminants Operate in abnormal environment Life of manipulator is 2 000 000 cycles Life of manipulator is 1 000 000 cycles Life of manipulator is 500 000 cycles For a manipulator that is outside these conditions refer to the profile drawing and or consult the factory for specific instructions EVERY LIFT EVALUATIONS e Remove excess debris from surface of the load Verify grip pad or vacuum cup is free of contaminant Replace if excessively worn e e Check the condition of the operator s controls and gauges on controls e Verify the load is secure after actuation of tooling and before moving the manipulator 21 FREQUENT EVALUATIONS Move the manipulator in and out and around each axis and check for free motion Check bearing seals for leakage or damage Replace any bearings that need to be replaced Check friction devices linkages and other mechanical parts for excess wear and replace as needed Check drag brake pucks for excessive wear Check welds on structural members for cracks Look for cracked or missing paint over a weld If
9. flange 4 Assemble anchor with 5 Torque anchor to seat 6 Level pedestal by adjusting the washer lock washer and A anchor Then loosen leveling jacks Use a machinist s nut below anchor bolt level to check in two directions chamfer and drive in with perpendicular to each other hammer FINAL NOTES e grouting is required to mount this pedestal Re torque this pedestal one week after install Re torque pedestal according to suggested maintenance schedule C SPACER INSTALLATION LEVEL SPACER BEFORE INSTALLING MANIPULATOR ON SPACER See LEVELING THE PRIMARY ARM for leveling the manipulator if it is already installed on spacer Review profile drawing for torque requirement 1 Install jack and jam nut 2 Install flat washer and lock nuts if necessary 6 Tighten the bolts 3 Loosen the jam nut for leveling 7 7 Tighten the jam nuts against spacer 8 Re check levelness of spacer to make sure it is still level 4 Loosen the bolts enough to level spacer 5 Level spacer by adjusting the leveling jacks Use a machinist s level to check in two directions perpendicular to each other D LIFTING WITH FORK TRUCK The manipulator is palleted to allow for easy installation with a fork truck Raise the pallet above the pedestal and lower the manipulator onto the pedestal and install as shown in ATTACHING MANIPULATOR TO PEDESTAL For
10. ghten the adjustment bolt or bolts on the side that the arm drifted towards while at the same time loosening the adjustment bolt or bolts on the side opposite of the bolt or bolts being tightened Repeat steps 1 amp 2 to check for any additional drift After all drift has been eliminated from position B rotate lift arm 90 degrees to position C and repeat steps 1 2 amp 3 After all drift has been eliminated from position C rotate lift arm 180 degrees to position D and repeat steps 1 2 amp 3 This completes the levelling of the lift arm Re adjust the primary arm brake and middle joint brake if applicable to fit your requirements Position D Position A Position C SETTING THE ROTATION STOPS Rotation stops may be supplied for the main post and middle joint rotation axis Set the rotation stops to allow the proper working range for the manipulator 1 Rotate arm to stop position 2 Slide rotation stop onto brake disk with bumper located against caliper brake support 3 Tighten set screws to set stop location 4 Use 3 8 transfer punch to locate drill holes through center of the set screw 5 Drill 20 266 holes thru brake disk 6 Tighten bolts washers and lock nuts Main Post Rotation Stop Middle Joint Rotation Stop Shoulder bolt and washer Set screw Brake Disk Slot Lock Nut The middle joint had holes pre drilled to allow the lift arms to rotate equally in both direc
11. ile drawing 3 Adjust system pressure regulator to requirement shown on profile drawing LOCK OUT PROCEDURE FOR METERING CONTROL 1 Remove payload from tool and lower tool to lowest position 2 Set the system pressure regulator to zero 3 Lockout per factory procedure WARNING The machine is not in a zero energy state There may be pressure trapped in any cylinder with a lock valve due to the lock valve minimum locking pressure If a zero energy state is required cylinder lock valves need to be piloted by an external air source and some air lines may need to be removed See pneumatic schematic for more details and consult Positech with additional questions 20 SECTION 4 MAINTENANCE ADJUSTMENTS amp INSPECTIONS Maintenance adjustments and inspections fall into three categories every lift frequent and periodic e Every lift evaluations are visual examinations completed by operator before and during each lift e Frequent evaluations are visual examinations completed by the operator or designated persons with records not required The period to complete these evaluations is based on a service rating of normal monthly heavy weekly or severe daily as explained below Periodic evaluations are visual examinations completed by qualified personnel completing records of apparent external condition to provide a basis for continuing evaluation The period to maintain these records is based on a service rating o
12. nipulator is level the manipulator will not wander or wander very little See LEVELING THE PRIMARY ARM for leveling the manipulator to eliminate drift in all operating quadrants Inspect lift cylinder pilot check valves Inspect check valves on grip cylinder or vacuum check valves Check GSC adjustment Use empty tool and adjust GSC knob until an audible pop is heard Screw in adjustment 1 4 turn and tighten jam nut Verify adjustment using a scrap part 23 A AIR LINE SIZING FOR SUPPLY AIR Note See profile drawing for required flow and pressure SCFM Length of run in feet Air line size in inches E n nl n ln ll RES U 1 1 SLM 150 500 13 580 19 MESE 0 8 o 2500 25 IN 300 5 Cs O n Length of run in meters Air line size in mm so 7150 soo 13 ee s m 2 32 32 3 3 Css MEME EA E EA ES EA E 24 SECTION 5 TROUBLESHOOTING 1 Machine does not move up or down A UQ Y 2 Drift OWP Check main air supply Verify lost load cylinder isn t locked Check main regulator If used check lift cylinder on off switch Check pilot to lock valve Check lock valve up Check metering valve for leaks Check GSC valve for leaks If used check 6 passage rotary manifold for leaks
13. overhead mount simply raise the pallet up until the manipulator mates with the mounting surface See ATTACHING MANIPULATOR TO SPACER for installation details E ATTACHING MANIPULATOR TO PEDESTAL Lift manipulator as AAA shown in LIFTING WITH A FORK TRUCK Run air line through Lower manipulator hole in pedestal until bearing housing and connect to mates to pedestal nipple Torque machine mounting bolts See profile drawing F ATTACHING MANIPULATOR TO SPACER Lift manipulator until Torque machine bearing housing mates to mounting bolts See spacer profile drawing Run air line through _ S hole in spacer and connect to nipple Lift manipulator as shown in LIFTING WITH TRUCK PREPARING THE PRIMARY ARM FOR LEVELING All adjustments of the primary arm will be accomplished by adjusting the leveling jacks or shimming under the primary bearing housing 1 Position lift arm under primary arm If lift arm will not go under primary arm position lift arm straight out from primary arm 2 Loosen primary arm brake caliper to allow primary arm to rotate freely LEVELING THE PRIMARY ARM DRIFT METHOD 1 Select any of the four positions shown such as position A and rotate the primary arm into that position Release arm and step back so that any drift movement to the left or the right of the primary arm can be noted 2 To
14. tions The rotation stop can be moved to allow the lift arms to be stored under the primary arm operator moves the lift arms into the contact zone Use caution when relocating the middle joint rotation stop to keep the hoses routed around the middle joint from being wrapped around the joint If two rotation stops are supplied for the middle joint it may be useful to set one stop so the lift arm cannot rotate past center This is useful if the lift arms are used in one quadrant of rotation If the middle joint rotation stop is moved the lift arms may be able to contact the primary arm if the Lift Arm Rotation Direction Second Rotation Stop L BALANCE CONTROL ADJUSTMENTS See the pneumatic schematic for specific information regarding the pneumatic components used CONNECTING THE SUPPLY AIR 1 Set the system pressure regulator to zero 2 Connect supply air Verify pressure and flow requirements listed on profile drawino 3 Adjust system pressure regulator to requirement shown on profile drawing LOAD amp NO LOAD BALANCE REGULATORS If there is a bias circuit or a payload is lifted there are two balance regulators The regulators are labeled accordingly 1 Set the No Load balance regulator with the empty tool 2 Set the Load or Bias balance regulator with the tool and payload or with the bias switch actuated WARNING The Load adjustment will need to be reset if the payload weight
15. urations identified and supplied at time of sale B PNEUMATIC SPECIFICATIONS See Profile Drawing for specification C HYDRAULIC SPECIFICATIONS See Profile Drawing for specification D ELECTRICAL SPECIFICATIONS See Profile Drawing for specification E AERIAL NOISE Level of continuous acoustic pressure lt 80 dB A scale Aerial noise measurements are taken at the operator s work position and based on a 50th percentile operator s height See Profile Drawing for special notes F ENVIRONMENTAL CONDITIONS The manipulator is designed to operate inside a protected site from outside environmental conditions The operating environment needs be free of aggressive contaminants acids corrosive gases salts etc Operating Temperature 50 F 120 10 C 49 C Relative Humidity lt 95 See Profile Drawing for special notes G PEDESTAL MOUNTING PATTERN Dax 3 4 10 UNC 4 1 14 12 UN FOR LEVELING JACKS 8 00 17 50 50 OVERHEAD SPACER MOUNTING PATTERN 4X 1 1 4 12 UN FOR LEVELING JACKS 900 I CONCRETE MOUNTING GUIDELINES It is solely the customer s responsibility to provide the proper foundation for the manipulator and if A conditions are questionable or concrete does not look adequate the customer needs to consult a qualified professional to inspect and make recommendations J SOIL CONDITION The minimum soil condition that must also be achieved is 2500 Ibs sq ft 0
16. welds are torn from the base steel cracked or broken the manipulator should not be used until repaired or determined safe Consult factory for solution Check structural members for deformations Consult factory for solution Check pivoting points and hook points for excessive wear and replace as needed Replace missing guards fasteners covers stops decals warning labels or nameplates Check for loose fasteners especially set screws and retighten Check for leaks Inspect condition and routing of all external hoses Replace any leaky components or cracked hoses Operating the manipulator Check that all functions are in adjustment that all automatic mechanisms functions properly and that no functions interfere with current operation of the work cell PERIODIC EVALUATIONS Complete the frequent evaluations along with the following evaluations Check anchor bolts and re torque See PEDESTAL INSTALLATION for detailed views Check air supply to manipulator See profile drawing for required pressure and flow Check spacer mounting bolts if overhead mounted and re torque SPACER INSTALLATION for detailed views Check main post mounting bolts and re torque See 22 ATTACHING MANIPULATOR PEDESTAL for detailed views Check for worn or cracked gears pulleys sheaves sprockets bearings chains or belts and replace as needed Check manipulator for level both in out and around the main post and end joint If the ma
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