OPERATOR SERVICE MANUAL SAM G
Contents
1. gt HARD WA 3 8 CONCRETE MOUNTING GUIDELINES It is solely the customer s responsibility to provide the proper foundation for the manipulator and if conditions are questionable or concrete does not look adequate consult a qualified professional to inspect and make recommendations 3 8 1 SOIL CONDITION The minimum soil compaction required is 2500 lbs sq ft 0 12 MPa 3 8 2 FULLY REINFORCED CONCRETE FLOOR CONDITION 4 v e 152mm thick 4 e 3500 psi 24 1 MPa compressive strength NS T e No cracks within 48in 1 2m radius of pedestal 518 The concrete must be fully reinforced with a minimum of 3 500 psi 24 MPa compressive strength and 6 inches 152 thick with no cracks within 48 inch 1 21 m radius of the pedestal For customers that can t meet this requirement see below for alternate solutions for attaching your manipulator 3 8 3 POURED FOUNDATION CONDITION Poured foundation requirements are 48 inch 1 21 m wide x 48 inch 1 21 m long x 12 inch 0 30 m deep The top of slab must be level and the slab needs to be fully reinforced Foundation dimensions Zi x 48 X 48 X 12 a 3 8 4 PLATING ON CONCRETE If a 4 inch 101 mm reinforced concrete floor has cracks within 48 inches 1 21 m of the pedestal consult the factory for a portable base option to mount the manipulator or a foundation must be poured Whe2. Spacer Bearing Lift Cylinder Counter Weights Down Arm Box Pedestal Bearing Pedestal Option U Frame REAP RE Anchor Bolts 2 2 SERIAL TAG LOCATION AND NOMENCLATURE Model Number Serial Number Julian Date 2 digit PROVIDE FOR year amp 3 digit day SERVICE SUPPORT Capacity of Base O Machine Only SERIALNO O Electical Amps MACHINE CAPACITY LBS KG d SUPPLY VOLTAGE 2 FULL LOAD AMPS PRESSURE PSUBAR OW SCFM LM Air SCFM POSITECH LAURENS IA 50554 WWW POSITECH COM Air PSI Electrical Voltage Hertz Phase Serial Tag Location SECTION 3 SPECIFICATIONS 3 1 MECHANICAL SPECIFICATIONS Main post overturning moment capacity 40 000 in lbs 4 520 Nm Approximate system weight based on reach 1200 16 544 Kg End joint capacity 5 000 in Ibs 565 Nm Lift capacity based on reach 150 390 lbs 68 to 177 Kg Pedestal anchor hole size in concrete 625 inch 15 Pedestal anchor bolt seating torque 90 to 100 ft lbs 122 to 136 Nm Pedestal anchor bolt torque 90 ft lbs 122 Nm Spacer mounting bolts grade 5 83 ft lbs 112 Nm Main Post Bearing Bolt Torque Spacer or Pedestal 300 ft lbs 408 Nm Hoist and Lifting strap capability to lift SAM 2000 Ibs 908 Kg Lift cylinder lock nut torque 250 ft lbs 340 Nm Lift cylinder tie rod torque 35 ft los 47 Nm 3 2 PNEUMATIC SPECIFICATIONS Air supply Oil free Filtered to 40 um Air must be
3. RF AT Quality 5 Registered ag E IS 200 2006 9001 2008 The Leader in Positioning Technology Certificate 058 498 OPERATOR SERVICE MANUAL SAM G POSITECH CORPORATION 191 N RUSH LAKE ROAD LAURENS IA 50554 Phone Number 800 831 6026 24 Hour Service Phone Number 541 954 2948 Email service positech com SERIAL NO RUN NO REV A 04 14 191 N Rush Lake Road Laurens lowa 50554 712 841 4548 F 712 841 4765 www positech com Table of Contents SECTION 1 SAFETY INFORMATION READ BEFORE USING 2 A een 2 O SA DOO tee 1 EA EC ATION Mu Mu UE errr re 2 SECTION 2 NAMING CONVENTION AND SERIAL 3 anoo puc ce eee 3 2 2 SERIAL TAG LOCATION AND NOMENCLATURE 4 SECTION 5 5 3 1 MECHANICAL 6 4 04 440 00 nene 5 3 2 PNEUMATIC 6 2 2 2 0 040 ae 5 3 3 HYDRAULIC 6 124 04040 ttt tte 5 3 4 ELECTRICAL SPECIFICATIONS coccion 5 SE ula sc 5 3 6 E
4. 122 Nm according to periodic maintenance schedule Verify anchor bolts are not pulling out of the ground 25 5 8 LEVELING THE PEDESTAL SPACER AFTER INSTALLATION see SECTION 4 2 or SECTION 4 3 for close up views of the pedestal and spacer jacks and all torque specifications 2 7 Recheck the 6 Rotate the arm 90 and 180 90 and check the positions that all change in the level If 1 Rotate arm perpendicular to one set of leveling jacks to start Always keep the tooling are the same the level is not the parallel to the arm value on the same adjust the During leveling always level If not pedestal or spacer maintain the same lift repeat steps 4 until the level height Note Never move the level during leveling through 6 matches the start position 5 Rotate the arm back to the start position and recheck the level The level may not read level but the same value of level as in position 2 If the two values of level are not the same repeat step 4 2 Place a level on the base plate of the main post This is nota machined surface so the level does not need to read level 3 Check the level at this position Absolute level 1 not important but the change in level as the arm is rotated 90 and 180 from the current position is what is important 4 Rotate the arm 180 and check the change in the level If the level is not the same adjust the pedestal
5. each boss of the REAP with position while the holes in the inserting the pins down arms The factory will insert a short piece of colored hose to help show the correct location of each hose at the splice point either REAP or termination block Install the snap rings Eccentrics for in out level are set at the factory Both dots need to be in line with each other after adjustment To add more pitch up or down O will require a new set of eccentrics from the factory The tooling will be shipped split at the U Frame 16 SECTION 5 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 e 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 of normal yearly heavy semiannually or severe quarterly as explained below Normal Rating Heavy Rating Severe Ratin
6. in excess of 002 In 05 deep will require Contact the factory for parts 6 Remove the snap ring bearing and seal from head 5 Disassemble the piston from the shaft by loosening the nut Torque the locknut to 250 ft los 340 Nm with no thread lock or grease when reassembling 5 5 ADJUSTING THE FORCE LINK ROLLER Force link roller Anti Rotation pin Roller drag adjustment nut Tighten for Spanner hole to more drag hold shaft Note Excess drag may be caused by the anti rotation pin being installed too far Allow 030 to 060 inches 7 to 1 5mm of clearance between pin and side of roller If replaced pins should be lightly tapped into place and cut off flush A 24 5 6 ADJUSTING THE HOUSING ROLLER ASSEMBLIES Fixed cam 1 Center mark 2 Loosen rollers in front punch all original eccentric cam eccentric cam roller bolt and 3 8 positions hex head bolt that hold eccentric fork 3 Turn fork and eccentric equally on both sides until roller has 002 in 05 clearance Turn eccentric cam away from main post to reduce Adjustment cam clearance rollers in rear Eccentric cam roller bushing Hex against plate 4 Repeat on bottom roller 5 Torque cam roller bolt to 150 ft lbs 204 Nm amp the 3 8 bolts to 34 ft Ibs 46 Nm 5 7 TIGHTENING THE ACHOR BOLTS Torque the anchors to 90 ft lbs
7. injury Possible hazards are shown in the adjoining symbols or explained in the text Electrical hazard Contact with live parts can result in immediate death Protective covers marked with this sign may only be opened by qualified personnel only Disconnect the feed voltage before opening Suspended load overhead Do not stop or transit near suspended load Use extreme caution when moving suspended loads do not leave suspended loads unattended Do not leave load suspended above people Risk of crushing hands and or feet Do not approach mechanical parts that are moving or may start moving Do not handle the load while standing in front of the terminal arm Parts of the manipulator may come into collision with the operator Clamping Device Do not depress the gripping control button unless the correct load to be handled is between the jaws Keep body parts clear when actuating clamping devices Pinch point Indicates possible pinch point Keep extremities clear of moving parts Do not wear loose clothing or jewelry near equipment Avoid contact with areas marked with this symbol or PINCH POINT text gt gt b O Important Read and understand these warnings before operating equipment A Hook point Be sure hook is secure before lifting Do not lift people Be aware of tool sway that may occur when using a hook Hot Surface Surface temperature can exceed greater than 70 deg C during nor
8. retightened 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 manipulator is level the manipulator will not wander or wander very little See SECTION 5 8 for leveling the manipulator to eliminate drift in all operating quadrants Check for oil leaks on lost load cylinder and verify lost load is functioning properly See SECTION 5 2 for lost load test and SECTION 5 3 for replacing lost load cylinder seals 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 18 5 1 LUBRICATION SCHEDULE 1 Remove lost 2 Add hydraulic fluid under 10 Check lost load fluid load cylinder from 32 screw on lost load valve Cycle level according to manipulator and piston rod back and forth while periodic schedule by clamp vertically filling removing 10 32 screw to add fluid 3 Be sure the stat o seal is on the screw when replacing the screw 10 32 If manipulator does not lock on lost load test see SECTION 5 2 If significant oil loss is witnessed add hydraulic fluid and see SECTON 5 3 to change seals 4 Reattach lost load cylinder to manipu
9. rollers for out of adjustment D Check U frame eccentrics E Check horizontal roller assembly B C D AMO 6 release without being supported A Check GSC setting If used check 6 passage rotary manifold for leaks C Verify proper hose connections D Check bleed down speed 7 Linear movement difficult A Check horizontal roller and shelf B Check drag brake adjustment C Check pivot pins or bushings for wear D Check force link pivot pins or bushings for wear E Verify manipulator is level 8 Oil discovered near main post A Check lost load cylinder for leaks B Verify FRL lubricator is not set too high Check FRL 9 Up Down movement difficult A Check balance regulator adjustment B Verify horizontal arms are not rubbing on lift housing C Check lift cylinder and muffler D Check lost load cylinder E Check vertical cam eccentrics F Verify supply pressure and sufficient flow 10 Rotation drift at tooling A Check main post level B Check anchor bolts on main post C Check that end joint eccentrics are set equal 28 SECTION 7 DRAWINGS SECTION 8 RECOMMENDED SPARE PARTS SECTION 9
10. ION SCHEDULE nn a ee 19 5 2 ADJUSTING A DUAL LOST LOAD LOCK VAL VE 20 5 2 1 UNLOCKING A LOCKED LOST LOAD CYLINDER 20 5 2 2 CHECKING IF LOST LOAD WORKS 2 1 41 20 5 2 3 ADJUSTING A LOST LOAD VALVE THAT IS TOO 21 5 3 CHANGING SEALS IN THE DUAL LOST LOAD 22 5 4 REBUILDING A PISTON TYPE LIFT CYLINDER sessssessessesssesseessecseseseeseseneesnseseestseneesteeneesees 23 5 5 ADJUSTING THE FORCE LINK ROLLER c sscssecsesssessessseesseseeseeseesuseseesseseesseneesnseneeeneeneesees 24 5 6 ADJUSTING THE LIFT HOUSING ROLLER 8 25 5 7 TIGHTENING THE ACHOR BOLTS scesssssessssssesssessessecsessseeanssseesesenesatsaaesatesaeeaeesaeeatesaeeatesees 25 5 8 LEVELING THE PEDESTAL OR SPACER AFTER 26 5 9 AIR LINE SIZING FOR SUPPLY AIR tentent teretes 27 SECTION 6 TROUBLESHOOTING nee 28 SECTION 7 DRAWINGS 2 29 SECTION 8 RECOMMENDED SPARE 5 30 SECTION 1 SAFETY INFORMATION READ BEFORE USING 1 1 MEANING OF SYMBOLS Danger Indicates a hazardous situation which if not avoided will result in death or serious
11. NVIRONMENTAL 6 2 0 04 5 3 7 OVERTURNING MOMENT WEIGHT 8 MOUNTING 2 40 0 6 3 7 1 PEDESTAL MOUNTING PATTERN en ans ee en 7 3 7 2 OVERHEAD SPACER MOUNTING 2 0 04 1 0 0 7 3 8 CONCRETE MOUNTING GUIDELINES ocio raras 8 a o En 8 3 8 2 FULLY REINFORCED CONCRETE FLOOR 22 40 0 8 3 8 3 POURED FOUNDATION 8 3 8 4 PLATING ONCONCRETE entrada paa 8 SECTION 4 INSTALLATION INSTRUCTIONS 9 A PALE TINFORMA TON A ee 9 A PEDE STALINS TION 10 A S SPACER INSTALLATION 11 4 4 LIFTING WITH A FORK TRUCK WHEN STILL ON 122 4 040 000 12 4 5 LIFTING WITH OVERHEAD CRANE a istnd ees 13 4 6 ATTACHING MANIPULATOR TO PEDESTAL sssssessesssessesssecseseseessesecseeeseesnseneeseseneesnteneeeeee 14 4 7 ATTACHING MANIPULATOR TO SPACER Cocoon 14 4 8 DISASSEMBLING THE PAL 15 4 9 INSTALLING TOOLING U FRAME FROM 1 404 0 16 SECTION 5 MAINTENANCE ADJUSTMENTS amp INSPECTIONS 17 5 4 LUBRICAT
12. OT operate equipment in an explosive or humid environment without optional protective features offered and supplied with equipment 1 3 SAFETY PRECAUTIONS N Follow basic safety precautions to reduce the risk of damage and personal injury when using powered manipulators READ INSTRUCTIONS BEFORE OPERATING MANIPULATOR N REVIEW AND PRACTICE SAFE OPERATION OF THE MANIPULATOR Become familiar with and practice the Do s and Do Not s for safe operation of the manipulator A KEEP WORK AREA CLEAN Cluttered work areas invite injuries CONSIDER WORK ENVIRONMENT Keep work area well lit Avoid exposing the manipulator to rain or wet locations The standard manipulator is NOT designed for explosive atmospheres Special non standard designs may be required for use in extreme environments Consult Positech with performance questions related to unique environments KEEP CHILDREN AWAY All visitors and personnel not familiar with the work range of the manipulator should be kept away from the manipulator NEVER LIFT SUPPORT OR TRANSFER PEOPLE WITH MANIPULATOR OR TOOLING The manipulator is not designed as a man lift device and using the manipulator or tooling as such is ABSOLUTELY PROHIBITED A DO NOT FORCE THE MANIPULATOR OR TOOLING The manipulator will perform better and more safely at the realistic rate for which it is intended DO NOT OVERREACH OR TWIST Keep proper footing and balance at all times Use the vertical A rotation ax
13. body DO make sure that the load is free to move and will clear all obstructions DO make sure that all persons stay clear of the suspended load DO warn personnel of an approaching load DO prompily report any malfunction unusual performance or damage to the manipulator DO inspect the manipulator regularly replace any damaged or worn parts and keep appropriate records of maintenance DO replace damaged or missing labels DO use Positech parts when repairing the manipulator avoid injury THE DO NOT S DO NOT operate manipulator unless qualified to do so DO NOT modify or alter the manipulator tooling or valve settings DO NOT exceed the rated capacity for the manipulator or tooling DO NOT use a damaged unit or a unit that is not working correctly DO NOT allow your attention to be diverted while operating the manipulator DO NOT operate the manipulator by pushing or pulling that requires twisting the back DO NOT use the manipulator to lift support or transfer people DO NOT lift loads over people DO NOT lift loads higher than necessary DO NOT allow unauthorized personnel within the working area of the manipulator DO NOT leave a suspended load unattended unless safety precautions have been taken DO NOT remove or obscure any warning labels on the manipulator DO NOT adjust the manipulator unless qualified to perform such maintenance or repair DO NOT set or rest the manipulator on vacuum cups or grip jaws DO N
14. crete or at least 2 00 inches 50 80 mm below anchor Locate pedestal So air line can be routed through air supply hole 8 Torque the anchors to 90 ft lbs 122 Nm __ 7 Tighten the jam nuts on jacks against pedestal flange 2 Move pedestal and clean holes with compressed air and nylon brush 3 Add 1 flat washer between concrete and pedestal for each jack 4 Assemble anchor with washer lock washer and nut below anchor bolt chamfer and drive in with hammer r 5 Torque anchor from 90 to 100 ft lbs 122 to 136 Nm to seat anchor Then loosen 6 Level pedestal by adjusting the leveling jacks Use a machinist s level to check in two directions perpendicular to each other FINAL NOTES e No grouting is required to mount this pedestal Re torque this pedestal one week after install to 90 ft lbs 122 Re torque pedestal according to suggested maintenance schedule to 90 ft lbs 122 Nm 10 4 3 SPACER INSTALLATION LEVEL SPACER BEFORE INSTALLING MANIPULATOR ON SPACER See SECTION 5 8 for leveling the manipulator if it is already installed on spacer 1 Install jack and jam nut 6 Tighten the 5 8 bolts to 83 ft lbs 112 Nm 2 Install flat washer 5 8 7 grade 5 bolts and lock nuts if necessary 7 Tighten the jam nuts against 3 Loosen the spacer jam nut for leveling 8 Re check level of spacer to make sure it 1 sti
15. ctory 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 ie REAP nut Check for leaks Inspect condition and routing of all external hoses Replace any leaky components or cracked hoses See SECTION 5 1 for lubrication schedule 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 to 90 ft lbs 122 Nm See SECTION 4 2 for detailed views Check air supply to manipulator See profile drawing for required pressure and flow Check spacer mounting bolts if overhead mounted and torque to 83 ft lbs 112 Nm See SECTION 4 3 for detailed views Check main post mounting bolts and torque to 300 ft lbs 408 Nm See SECTION 4 6 for detailed views Inspect main post bearing Replace if a variation of 015 inch 381 mm is observed in the overall thickness of the bearing Re torque bearing mounting bolts to 300 ft lbs 408 Nm Check REAP mounting nut and set screws If set screws are loose nut and set screws need to be
16. dry enough to avoid ice formation at temperatures below 35 f 26 Air pressure required 80 psi 5 5 bar Airflow required based on reach 20 43 SCFM 566 1216 SLM 3 3 HYDRAULIC SPECIFICATIONS Hydraulic fluid used Allied AW Hydraulic Oil ISO 46 3 4 ELECTRICAL SPECIFICATIONS Supply Power 3 5 AERIAL NOISE Level of continuous acoustic pressure 80 dB A scale Aerial noise measurements are taken at the operator s work position and based on a 50th percentile operator s height 3 6 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 120 10 4 9C Relative Humidity 9596 3 7 OVERTURNING MOMENT WEIGHT amp MOUNTING PATTERN Main post overturning moment capacity 40 000 in lbs 4 520 Nm Maximum allowed deflection from mounting structure in any direction is 25 System Weight 765 lb 347 Kg 1100 lb 500 Kg 820 Ib 372 1120 lb 510 Kg 905 10 411 Kg 1155 lb 525 Kg 920 Ib 417 Kg 1155 lb 525 Kg 940 Ib 426 Kg 1155 Ib 525 Kg G66 __ G96 6112 6126 3 7 1 PEDESTAL MOUNTING PATTERN 10 63 BC x 812 THRU 21 00 EUN da 5 8 11 ANCHOR BOLTS 212 00 3 7 2 OVERHEAD SPACER MOUNTING PATTERN 0 03 11 00 Shu 21200 4x 58 1
17. es provided by the bearings of the manipulator to properly position your body to move the load USE THE CORRECT TOOL Use the tooling for what it was designed to handle Do not use a small tool or attachment to do the job of a heavy duty tool replace with Positech parts Inspect tooling and manipulator for alignment of moving parts binding of moving parts breakage of parts mounting and any other conditions that would affect operation of the manipulator Use the troubleshooting guide and routine maintenance checklist for inspecting the manipulator at regularly scheduled time periods Contact Positech for service assistance and direction N CHECK DAMAGED PARTS OR LOOSE CONNECTIONS If part of the manipulator becomes damaged USE CAUTION WHEN INSTALLING OR PERFORMING ROUTINE MAINTENANCE See the specific instructions contained in this manual for lifting and placing the manipulator Support the lift arm structure when servicing the main lift cylinder Have a second person assist with lift soeed and other adjustments Safety Data Sheets MSDS are included for proper storage handling and use of lubricants and PROPERLY STORE AND HANDLE MATERIALS USED FOR MAINTAINING THE MANIPULATOR Material other materials included with the manipulator SECTION 2 NAMING CONVENTION AND SERIAL TAG 2 1 NAMING CONVENTION Spacer Jacks Spacer Option Filter Regulator Lost Load ie Lost Load Cylinder 4 Lift Housing 4
18. ess removed the pedestal will come through the hole under the bearing 13 4 6 ATTACHING MANIPULATOR TO PEDESTAL Lift manipulator as shown in SECTION 4 4 or SECTIONA 5 Run air line Lower through hole in manipulator until pedestal and bearing mates to connect to air main post swivel Lubricate the air swivel with light grease Torque 3 4 10 grade 5 bolts to 300 ft lbs 408 Nm 4 7 ATTACHING MANIPULATOR TO SPACER Torque 3 4 10 grade 5 bolts to 300 ft lbs 408 Nm Run air line Lift manipulator through hole in 2 until bearing pedestal and mates to main connect to air post swivel Lubricate the air swivel with light grease Lift manipulator as shown in SECTION 4 4 or SECTION4 5 14 4 8 DISASSEMBLING THE PALLET After fastening manipulator to pedestal or spacer according to SECTION 4 6 or SECTION 4 7 remove pallet using the following steps 1 Remove strap holding front of manipulator to pallet 2 Remove nuts lock washers and flat washers from bolts going through boss on pallet framework Removing nuts will cause pallet to fall if not supported 5 Remove shipping restraint 6 Connect tooling See SECTION 4 9 3 Remove nuts holding angle iro to manipulator base 4 Remove side of pallet to remove pallet from around pedestal 15 4 9 INSTALLING TOOLING U FRAME FROM FACTORY Insert 2 washers per Line up the holes side on
19. g Below 65 of rated load 65 to 100 of rated load At 100 of rated load Operate in an industrial Operate in an industrial Operate in abnormal environment free of aggressive environment free of aggressive environment contaminants contaminants Life of manipulator is 2 000 000 Life of manipulator is 1 000 000 Life of manipulator is 500 000 cycles cycles 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 e Verify grip pad or vacuum cup is free of contaminant Replace if excessively worn 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 17 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 Clean and lubricate roller shelf and vertical guide rollers Check welds on structural members for cracks Look for cracked or missing paint over a weld If welds are torn from the base steel cracked or broken the manipulator should not be used until repaired or determined safe Consult fa
20. l not to disassembly rod two full cycles scratch the shaft steps 4 to 2 _ 6 Clean all parts and 3 Disassemble the replace all seals piston and shaft N Avoid over assembly by stretching seals removing the snap rings on the shaft 5 Inspect both the shaft and 4 Remove the snap cylinder case bore for scratches ring and the cap Scratches in excess of 002 in head 5 deep will require replacement 22 5 4 REBUILDING A PISTON TYPE LIFT CYLINDER 1 Support the arm onto a rigid support before starting work Also for a metering contro system depress the down lever to bleed out all air pressure or for a balance system slowly unscrew the down load regulator to bleed out the air 2 After removing the air lines and cylinder pins grip the trunion of the cylinder in a vise to support cylinder for disassembly 3 Remove tie rod When installing the U Cup the open side goes toward the head T 8 Clean all parts and lubricate all seals with light grease for assembly Replace all seals and bearing By reversing steps 6 to 2 Avoid over stretching seals nuts Torque tie rods to 35 ft lbs 47 Nm in a cross patiern A 23 4 Carefully pull out the head shaft and piston Be careful not to scratch the case 7 Inspect the shaft and cylinder case bore for scratches Scratches
21. lator Use 1 Grease on main post bearing 2 shots per periodic schedule Do not over grease Use 2 Grease on RE REAP 2 shots per periodic schedule Do not over grease 19 5 2 ADJUSTING DUAL LOST LOAD LOCK VALVE The lost load device is designed to prevent rapid upward or downward travel of the arm if a sudden change of load should occur at the end of the arm 5 2 1 UNLOCKING A LOCKED LOST LOAD CYLINDER Lower the arm slightly to lower the pressure in the cylinder and wait about 15 seconds If it is locked due to a downward travel raise it slightly If the lost load valve is locking during normal operation the valve is too sensitive and needs to be adjusted 5 2 2 CHECKING IF LOST LOAD WORKS PROPERLY e Remove any payload so that only the tooling is attached to the manipulator e Adjust the up speed flow control to full open to allow maximum travel speed upward Be sure to stand clear of the manipulator and tooling to avoid being hurt by the equipment e Depress the up button on the metering valve quickly The manipulator should only raise a few inches before locking and rising slowly e To unlock the cylinder depress the down button until the manipulator stops moving upward and wait 15 seconds Re adjust the up speed to standard speed if the lost load valve worked properly If the lost load valve did not lock properly see the adjusting the lost load valve below Re test the lost load valve and make adjustment
22. ll level 4 Loosen the 5 8 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 11 4 4 LIFTING WITH A FORK TRUCK WHEN STILL PALLET Do not remove shipping strap until N installed on pedestal or spacer Allow 13 inches between forks for pedestal clearance N Always lift from back of pallet Make sure forks N are through up to this cross member Do not cut band until ready to remove from pallet 1 Raise pallet above pedestal oee SECTION 4 2 for pedestal leveling before raising the pallet 2 Lower pallet over pedestal and install according to SECTION 4 6 Use pallet to raise manipulator to attach to spacer install according to SECTION 4 7 12 4 5 LIFTING WITH OVERHEAD CRANE Hoist and strap have to be capable of at least 2000 lbs 908 Kg Place strap A Two bolts with between cylinder X the heads cut and main post to off can make lift with hoist assembly easier when turned into e bearing Do not remove 6 N the shipping 54 CS restraint before lifting Connect air line Level and to pedestal torque the pedestal according to SECTION 4 2 before installing A Pallet can be See SECTION 4 6 for Remove tool before removed before bolts torques and lifting with a strap lifting If not proc
23. mal operation DO NOT Touch Pressurized Source Caution Contents under Pressure Do not disconnect without turning power off locking out and supporting lowered lift arms Emergency Stop Stop device activation removes power from all machine functions Warning Indicates a potentially Hazardous situation which if not avoided could result in death or serious injury Caution Indicates a potentially hazardous situation which if not avoided may result in injury Hearing Protection Recommended near sources gt 80 dbA 1 2 DO S AND DO NOT S Perform the following Do s and Do Not s for safe operation of the manipulator Following these guidelines will increase operator awareness of his her own safety and the safety of others Frequent examinations and periodic inspections of the equipment and conscientious observance of safety rules will help prevent injuries lost production time and money To avoid injury THE DO S gt gt DO read all warnings and safety information before operating unit DO become familiar with the operating controls procedures and warnings DO make sure that if the manipulator is mounted on a portable base the support surface is flat and that the leveling jacks touch the floor DO maintain firm footing while operating the manipulator DO operate the manipulator arms by pushing and pulling directly in front of the
24. n attaching plates to cracked concrete that is 6 inches 152 mm thick or more the floor anchors need to be 6 inches 152 mm from any cracks A concrete mounting plate can be made that is 36 inches 0 91 m square and uses four 0 625 inch 15 mm anchors per side located 1 50 inches 38 10 mm from the edge Contact Positech for drawings or ordering information 36 x 36 x 1 5 Concrete Mounting Plate Positech drawing 200821822 SECTION 4 INSTALLATION INSTRUCTIONS 4 1 PALLET INFORMATION A Note The SAM pallet is designed to allow installation of the SAM without removing from the pallet MANIPULATOR AS SHIPPED FROM POSITECH Shipping clamp remove after installed and before operation Fork truck pockets for lifting SAM to install on pedestal or spacer N Shipping mount 74 bolts T Hole to allow the pallet to fit over pedestal when using a fork truck Shipping pallet Inspect manipulator and pallet for any signs of damage due to shipping prior to installation Document damage and make any claims to the carrier 4 2 PEDESTAL INSTALLATION LEVEL PEDESTAL BEFORE INSTALLING MANIPULATOR See SECTION 5 8 for leveling the AN manipulator if it is already installed on pedestal Refer to SECTION 3 8 for concrete guidelines before mounting pedestal 1 Set pedestal over area and drill 0 62 inch 15 87 mm holes using pedestal for template Be sure to drill through con
25. or spacer to split the difference between the level value at positions 1 and 2 26 5 9 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 Lengthof run in feet Airline size in inches FLOW 50 75 100 200 30 SX 100 18 Yo 18 1 1 Re Ree eS ASL IE NN Dm ae ee 2 12 eae ae ae ae 28 Flow 75 35 5 30 45 60 99 150 900 27 SECTION 6 TROUBLESHOOTING 1 Machine does not move up or down A Check main air supply Verify lost load cylinder isn t locked Check main regulator If used check lift cylinder on off switch E Check pilot to lock valve Check lock valve 2 Drifts up A Check metering valve for leaks Check GSC valve for leaks If used check 6 passage rotary manifold for leaks Check balance setting Check minimum lift setting Check tool balance adjustment setting 3 Drifts down A Check metering valve B If used check 6 passage rotary manifold for leaks C Check for leaky lift cylinder seal blocking valve connection D Check white poly lines for leaks 4 Main post rotation difficult A Check for main post bearing wear B If used check drag brake adjustment C Check rails on trolley Systems 5 Linear drift A Check main post level B Verify counter weights are correct C Check vertical guide
26. s until the test is successful Re adjust the up speed to standard speed when the lost load valve worked properly to complete the test 20 5 2 3 ADJUSTING LOST LOAD VALVE THAT IS TOO SENSITIVE Loosen the chrome jam nut and back out counterclockwise the adjusting screw 1 8 turn Without tightening the jam nut check the upward travel again for over sensitivity as explained above If Repeat until upward travel does not lock at normal operating speeds Tighten the jam nut and re check at normal operating speeds to make sure the adjustment is correct To increase sensistivity follow the procedure by turning the adjusting screw in clockwise 1 8 turn at a time Adjusting screw for down direction Chrome jam nut Chrome jam nut Adjusting screw for up direction 21 5 3 CHANGING SEALS IN THE DUAL LOST LOAD CYLINDER A replacement lost load cylinder can be purchased from the factory when the lost cylinder is leaking This cylinder will be shipped less the lost load lock valve that is bolted on Lost load lock valve 8702500 Lost load cylinder 9420200 and seal kit number K200003 DY 7 Lubricate the 8 Refill with 1 Drain the oil 2 Remove the snap parts with light hydraulic fluid and out of the cylinder ring on the head and grease during install the 10 32 by removing the pull out the shaft installation and screw with the 10 32 screw and piston and head reverse stat o seal cycling the piston Be carefu
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