Schilling Robotics

ATLAS Slave Arm

Rate-Controlled,
6.5 Km Submersible

Document No. 011-8242

Models:
199-0292-1 199-0292-4
199-0292-2 199-0322-1
199-0292-3 199-0322-2
 Copyright © 2012 by Schilling Robotics, LLC. All rights reserved.
Schilling Robotics, the FMC Technologies logo, and their frameworks are trademarks and service trademark
applications of FMC Technologies. No part of this document may be reproduced or used in any form without
the express written permission of FMC Technologies. Descriptions and specifications are subject to change
without notice.

FMC Technologies Schilling Robotics

260 Cousteau Place, Suite 200, Davis, CA 95618 • Ph: (530) 753-6718 • Fax: (530) 753-8092
Sales [email protected] • Tech Support [email protected]
Customer Service [email protected] • Web Site http://www.schilling.com

TECHNICAL MANUAL REVISION LOG

Product: Atlas, 199-0292-1, -2, -3, -4, 199-0322-1, -2
Technical Manual: 011–8242

Description Date Rev.

Cloned from 011-8228 for Gutenberg. July, 2012 A

Table of Contents
Table of Contents 3
Specifications 7
General Description 7
Slave Arm Specifications 7
Slave Arm Functions 8
Hydraulic Specifications 8
Environmental Specifications 9
Slave Arm Features & Dimensions 9
Mounting Dimensions 9
Stow Dimensions 11
Slave Arm Range of Motion 12
Installation 13
Location 13
Mounting 13
Hydraulic Connections 13
First Startup Adjustments 14
Operation 16
Pre-Start Checks 16
Troubleshooting 17
Jaw is Noisy When Operated 18
Inspection 18
Jaw Low Grip Force 19
Inspection 19
Jaw Failure T-bar Plates or Jaw Bolts 20
Inspection 20
Linear Actuator Low Force 21
Inspection 21
Linear Actuator Slow Movement 22
Inspection 22
Free Play In Joints 23
Inspection 23
Slave Arm Reduced Range of Motion 24
Inspection 24
Slave Arm Jerky Operation 25

Table of Contents — Page 3

 Inspection 25
Slave Arm Hose Failure 26
Inspection 26
Wrist Stalling 27
Inspection 27
Low Wrist Torque 28
Inspection 28
Wrist Noise when Rotating 29
Inspection 29
Periodic Maintenance 30
Service Instructions 31
Noseblock Rebuild 32
Disassembly 32
Reassembly 32
Wrist Driveshaft Replacement 34
Removal 34
Installation 34
Wrist Motor Rebuild 37
Disassembly 37
Reassembly 38
Linear Actuator Remove and Replace 42
Disassembly 42
Reassembly 44
Atlas Yaw Actuator 45
Removal 45
Changing Manipulator Direction From Left to Right 47
Disassembly 47
Pitch Actuator Replacement 51
Removal 51
Installation 52
Atlas Forearm Segment 53
Removal 53
Reassembly 53
Atlas Upper Arm Segment 55
Removal 55
Azimuth Block Remove and Replace 56

Table of Contents — Page 4

 Disassembly 56
Reassembly 57
Atlas Base Remove and Replace 59
Disassembly 59
Reassembly 61
Atlas Typical Bushing Replacement 63
Part # 010-1457 -Bushing Replacement Tool 63
Bushing Removal 63
Bushing Installation 63
Drawings, Schematics, Part Lists 65
Spares Kit 008-0506 65
Spares Kit 008-0216 (Item 1 in Spares Kit 008-0506) 66
Spares Kit 008-0509 (Item 3 in Spares Kit 008-0506) 66
Spares Kit 008-0510 (Item 4 in Spares Kit 008-0506) 67
Spares Kit 008-0096 (Item 6 in Spares Kit 008-0506) 67
Tool Kit 010-1386 68
Atlas Hydraulic Schematic 025-0132 69
Hose Routing, Left Hand Configuration 70
Hose Routing, Right Hand Configuration 71
Linear Actuators 72
Anodes and Bump Stops 73
Bushings and Inserts 74
Sensor Covers 75
Pins and Spacers 76
Major Structures 77
Linear Actuators 78
Wrist, 101-3786 79
Jaw, 101-3299 80
Jaws, 101-3569 81
Noseblock, 101-3853 82

Table of Contents — Page 5

Table of Contents — Page 6
Specifications
General Description
General
Item Specification
Control method Rate control
Input device Optional rate hand controller
Number of functions 6 plus grip
Materials of construction 6061-T6 aluminum, stainless steel, titanium

Slave Arm Specifications

All specifications are based on the standard system configuration using Shell Tellus Oil 32
hydraulic fluid, input pressure of 207 bar (3,000 psi), and available flow of 19 lpm (5 gpm).
Slave Arm Specifications
Item Specification
Depth rating 6,500 msw (21,327 fsw)
Maximum reach (from azimuth pivot to standard gripper
1,664 mm (65.5-inch)
T-bar slot)
Weight in air 73 kg (160 lb)
Weight in seawater 50 kg (109 lb)
Lift at full extension, nominal, in stowed position 250 kg (550 lb)
Maximum lift, nominal 500 kg (1,000 lb)
Maximum gripper opening (standard gripper), nominal 198 mm (7.8 inch)
Grip force, nominal 4,448 N (1,000 lbf)
Grip force, maximum xx?
Wrist torque, nominal 205 Nm (150 ft/lb)
Wrist torque, maximum xx?
Wrist rotate, nominal 360°, 6-35 rpm

Specifications — General Description Page 7

Slave Arm Functions
Slave Arm Functions
Actuator Function Type Nominal Mechanical Range
Azimuth Linear 120°
Shoulder pitch Linear 135°
Elbow pitch Linear 135°
Wrist pitch Linear 120°
Wrist yaw Linear 120°
Wrist rotate Gerotor 360°
Gripper Linear 198 mm (7.8-inch)

Hydraulic Specifications
Contact the factory about operation at other pressures and flow rates.

Hydraulic Specifications
Item Specification
Approved Fluids

All common mineral, glycol, & environmentally

Hydraulic oil
friendly fluids

Requirements

Viscosity 10 cSt to 200 cSt

Available flow 5.7 - 19.0 lpm (1.5 - 5.0 gpm)
103 bar (1,500 psi) minimum to 207 bar (3,000 psi)
Pressure maximum; slave arm performance is reduced at less
than 207 bar (3,000 psi)
Hydraulic fluid temperature, maximum 60 °C (140 °F)
Oil cleanliness less than or equal to 17/14/11, per ISO 4406-1999

Customer-Supplied Mating Fittings Required

Hose fittings -4 JIC female, 1/4 inch

Specifications — Slave Arm Functions Page 8

Environmental Specifications
Environmental Specifications
Item Specification
Operating temperature -2 °C to +54 °C (+28 °F to +130 °F)
Storage temperature -15 °C to +71 °C (+5 °F to +160 °F)
Humidity 0% to 100% condensing

Slave Arm Features & Dimensions

Models 199-0322-1 and 199-0322-2 do not have the base-mounted hose manifold.

Mounting Dimensions

Figure: Mounting dimensions

Specifications — Environmental Specifications Page 9

 Figure: Mounting holes

Specifications — Slave Arm Features & Dimensions Page 10

Stow Dimensions

Figure: Stow dimensions

Specifications — Slave Arm Features & Dimensions Page 11

Slave Arm Range of Motion

Figure: Range-of-motion dimensionsMounting

Specifications — Slave Arm Features & Dimensions Page 12

Installation
Location
The ideal mounting location maximizes the slave arm’s range of motion in the work area, while
allowing the slave arm to be stowed far enough within the vehicles protective bumpers to pre-
vent collision damage during launch and recovery.

Mounting
Install the Atlas with three 15 mm (5/8 inch) fasteners (not supplied) to a suitable flat mounting
surface (minimum 17 mm/0.67 inch thick aluminum). Use fasteners that can be locked (nylock
or safety-wired hardware, standard hardware and Loctite, etc.).
l The fasteners can be either threaded into the mounting base (minimum thickness to
equal one-bolt diameter), or pass through if there is access to the underside of the mount-
ing plate.
l Torque the bolts to 99 Nm (135 ft/lb).

Hydraulic Connections
1. Connect two user-supplied hoses from the hydraulic control manifold to each of the 7
functions on the Atlas manifold. The hoses are marked 0A 0B, 1A 1B, etc. (see Table 1).
Connect the wrist motor case drain to the same hydraulic reservoir as the controlling
manifold.

Hydraulic Connections
Actuator
Slave Arm Function Hose Code Joint Movement
Movement
0A Extend Left
Azimuth yaw
0B Retract Right
1A Extend Up
Shoulder pitch
1B Retract Down
2A Extend Up
Elbow pitch
2B Retract Down
3A Extend Up
Wrist pitch
3B Retract Down

Installation — Location Page 13

 Hydraulic Connections (continued)
Actuator
Slave Arm Function Hose Code Joint Movement
Movement
Left (left-hand Atlas mod-
els)
4A Extend
Right (right-hand Atlas
models)
Wrist yaw
Right (left-hand Atlas mod-
els)
4B Retract
Left (right-hand Atlas mod-
els)

Wrist rotate (referenced 5A Rotate CCW Continuous CCW

from behind) 5B Rotate CW Continuous CW
6A Extend Open
Jaw
6B Retract Close
Wrist drain/return C N/A N/A

2. Install over-pressure relief valves for all functions on the hydraulic manifold controlling
the slave arm. Adjust the cracking pressure as shown in the “Hydraulic Schematic, 025-
0132” on page 31.

ALWAYS install the relief valve between the restrictor valve (if used) and the actuator to
prevent over-pressurization should a joint be forced such as by a collision.

3. When operated with On/Off-type valves (solenoid or proportional valves being driven
On/Off only), install adjustable flow-restrictors to limit the maximum velocity of the joint
function. For smooth operation, the adjustable restrictors should be installed on the ports
that act as the return circuits. For example, if you pressurize port A to cause a joint to
move, restrict Port B to limit the speed of the joint.

The relief and restrictor valve arrangement is also shown on the slave arm hydraulic sche-
matic 025-0132.

Lock valves (pilot-operated check valves) should be used on most funcitons to keep them from
dropping due to control valve leakage. Do not install a lock valve on the jaw. (A lock valve is not
effective onthe wrist due to internal leakage.)

First Startup Adjustments

1. Check that the mounting fasteners are correctly torqued and locked.
2. Check that all hydraulic connections are tightened.
3. Set all adjustable restrictors to the lowest flow setting.

Installation — First Startup Adjustments Page 14

4. Have all personnel move outside the operational range of the slave arm.
5. Turn on the hydraulic supply and activate one function at a time. Open the restrictor to
obtain the desired joint velocity.
6. Operate all joints through the full range of motion to purge all air from the actuators. It
may be necessary to crack (open slightly) the hydraulic fittings at the base manifold and
actuate the functions to purge remaining air if the connection hoses to the manifold are
long or large in diameter.
7. A “soft” or “spongy” feel when pushing on the arm indicates that air remains in the actua-
tors or hoses. Continue to bleed air until each joint becomes rigid when not in operation.

It is not necessary to bleed air from the wrist motor.

Installation — First Startup Adjustments Page 15

Operation
In a typical ROV installation, Atlas hydraulic functions are controlled by a user-supplied valve
pack fitted with hydraulic solenoid valves and/or proportional valves. The operator controls the
valve pack with a set of 3-position, center-off, momentary switches on the pilots console. The
Rate Hand Controller (005-2909) can also be used in place of a standard switch set. Since the
valve pack and controls are not part of the Atlas system, consult their OEM documentation for
more information.
When used on Schilling Robotics ROV systems, Atlas slave arm functions may be controlled
through a rate hand controller or control puck, switch set, or the user-interface touch screens.
See the “System Software & Controls” volume of your ROV system technical manual for details.

Pre-Start Checks
Before operating the slave arm, check the following:
All hoses, fasteners, and fittings are connected and secure.

Air has been purged from the hydraulic system if any lines or components have been dis-
connected for maintenance or repair.

No personnel or objects are within the slave arm’s range of motion.

WARNING! Before turning on hydraulic power, move all personnel and

equipment outside the slave arm’s range of motion.

Operation — Pre-Start Checks Page 16

Troubleshooting
Jaw is Noisy When Operated 18
Jaw Low Grip Force 19
Jaw Failure T-bar Plates or Jaw Bolts 20
Linear Actuator Low Force 21
Linear Actuator Slow Movement 22
Free Play In Joints 23
Slave Arm Reduced Range of Motion 24
Slave Arm Jerky Operation 25
Slave Arm Hose Failure 26
Wrist Stalling 27
Low Wrist Torque 28
Wrist Noise when Rotating 29
Periodic Maintenance 30

Troubleshooting — Pre-Start Checks Page 17

Jaw is Noisy When Operated
Inspection

1. Is the Jaw Actuation Bearing clean and lubricated?

YES - Go to step 2.
NO - Clean and lubricate the bearing. xxLink to info on recommended lubricants?

Use minimal lubricant to prevent the accumulation of grit on rotating surfaces.

2. Is the jaw actuation bearing excessively worn?

YES - Replace the jaw actuation bearing.

NO - Go to step 3.

3. Does the actuating bearing fit snuggly in the jaw rocker?

YES - Go to step 4.
NO - Adjust the seating of the actuating bearing.

4. Is the jaw actuation bearing loose?

YES - Replace the Rocker.

NO - Check torque on jaw fittings.

Troubleshooting — Jaw is Noisy When Operated Page 18

Jaw Low Grip Force
Inspection
1. Is the hydraulic pressure correctly set?

YES - Go to step 2.
NO - Adjust the hydraulic pressure.

2. Is the jaw actuating bearing clean and lubricated?

YES - Go to step 3.
NO - Clean and lubricate the jaw actuating bearing.

NOTE: Use minimal amount of lubricant to prevent accumulation of grit on the rotating
surfaces.

3. Is the relief valve correctly set?

YES - Go to step 4.
NO - If set too low, correct the setting.

4. Has the jaw piston seal been inspected?

YES - Go to step 5.
NO - Remove and inspect the jaw piston seal. Replace if necessary.

5. Has the jaw slipring seals been inspected?

YES - Go to step 6.
NO - Remove and inspect the jaw slipring seals. Replace if necessary.

6. Has the wrist drilled bolt O-rings and seals been inspected?

NO - Remove and inspect the wrist drilled bolt O-rings and seals. Replace if nec-
essary.

Troubleshooting — Jaw Low Grip Force Page 19

Jaw Failure T-bar Plates or Jaw Bolts
Inspection

WARNING! Avoid flying the vehicle with the arm outstretched and jaw fully
opened.

1. Is the jaw rocker spread open?

YES - Replace the rocker actuation bearing and the T-bar.

NO - Go to step 2.

2. Is the relief valve correctly set?

YES - Go to step 3.
NO - If set too low, correct the setting.

3. Is the jaw bolt torqued to the specified value?

NO - Torque to specified value.

Troubleshooting — Jaw Failure T-bar Plates or Jaw Bolts Page 20

Linear Actuator Low Force
Inspection
1. Is the hydraulic pressure adequate?

YES - Go to step 2.
NO - Diagnose hydraulic system.

2. Are the relief valves adjusted properly?

YES - Go to step 3.
NO - Adjust or replace the relief valves as necessary.

3. Is there heat or a hissing sound coming from the piston seal?

YES - Replace piston seal.

NO - Replace the actuator piston seal.

Troubleshooting — Linear Actuator Low Force Page 21

Linear Actuator Slow Movement
Inspection
1. Is the hydraulic pressure adequate?

YES - Go to step 2.
NO - Make sure hose connections are tight.

2. Are the flow restrictors adjusted correctly?

YES - Go to step 3.
NO - Adjust or replace the flow restrictors as necessary.

3. Are there any pinched hoses?

YES - Adjust routing of hoses to ensure appropriate movement without pinching.

NO- Go to step 4.

4. Is there hissing or excessive heat coming from the actuator?

YES - Replace actuator seal.

Troubleshooting — Linear Actuator Slow Movement Page 22

Free Play In Joints
Inspection
1. Do bearings in the joints need replacing?

YES - Replace bearings

NO - Go to step 2.

2. Do the pins show any excessive wear?

YES - Replace the joint pin.

NO - Go to step 3.

3. Do any of the pin holes have excessive "egg" shaped wear?

YES - Replace arm segment.

Troubleshooting — Free Play In Joints Page 23

Slave Arm Reduced Range of Motion
Inspection
1. Is the arm structure straight?

YES - Go to step 2.
NO - Send in manipulator arm for repair.

2. Are joint hard stops correctly installed?

YES - Go to step 3.
NO - Inspect or replace the hard stops.

3. Are joint pins straight?

YES - Go to step 4.
NO - Replace joint bent pins.

4. Does the manipulator have foreign debris in joints or cavities?

YES - Clean debris from manipulator.

Troubleshooting — Slave Arm Reduced Range of Motion Page 24

Slave Arm Jerky Operation
Inspection
1. Are the restrictors and relief valves adjusted properly?

YES - Go to step 2.
NO - Adjust or replace the relief valves as necessary.

2. Does the manipulator show signs of a bent actuator or arm structure?

YES - Replace actuator or bent structural pieces.

Troubleshooting — Slave Arm Jerky Operation Page 25

Slave Arm Hose Failure
Inspection
1. Is the hose properly routed through manipulator?

YES - Go to step 2.
NO - Re-route hose so that it is free from pinch points and binding.

2. Are the relief valves adjusted properly?

NO - Adjust or replace the relief valves as necessary.

Troubleshooting — Slave Arm Hose Failure Page 26

Wrist Stalling
Inspection
Are the flow restrictors adjusted properly?

YES - Go to next step.

NO - Adjust flow restrictors.

Is the relief valve adjusted properly?

YES - Replace gerotor assembly if unable to hold minimum 8 RPM.

NO - Adjust relief valve.

Troubleshooting — Wrist Stalling Page 27

Low Wrist Torque
Inspection
Is the arm being supplied with at least 3,000 PSI of hydraulic pressure?

YES - Go to next step.

NO - Adjust hydraulic pressure.

Are the hoses all connected properly?

YES - Go to next step.

NO - Secure all hose connections.

Are the relief valves set properly?

YES - Go to next step.

NO - Raise the valves to the proper setting.

Are the restrictors set too low?

YES - Increase flow from restrictors.

NO - Replace gerotor assembly.

Troubleshooting — Low Wrist Torque Page 28

Wrist Noise when Rotating
Inspection
It is not unusual for a "clattering" or gear sound to come from the wrist motor during operation.
If performance is adequate, no action is required.

Troubleshooting — Wrist Noise when Rotating Page 29

Periodic Maintenance
Periodic Maintenance Table
Daily Checks

Check for loose or missing fasteners.

Check hoses for evidence of kinking or abrasion.

Check hose fittings for leaks.

Check actuator rods for damage and check actuators for signs of hydraulic leaks.

Thoroughly wash the slave arm exterior with fresh water. Remove any entrapped debris.

Weekly Checks

Perform the daily checks.

Check anodes and replace when 1/3 or less remains.

Push on the arm and check for excessive free play which may indicate worn bearings or pins.

Torque all external fasteners to specified values.

Check jaw actuation bearings and T-bar plate for damage.

Monthly Checks

Perform the daily and weekly checks.

Check all hydraulic fittings for tightness.

Remove external fasteners individually, reapply anti-seize compound, and torque to specified
values.

Every 6 Months

Replace all arm segment bushings.

Inspect pivot pins for wear. Replace if wear is more than 0.005 inch.

Replace jaw actuation bearings.

Every 2 Years

Replace seals and bearings in all linear actuators.

Replace seals and bearings in jaw actuator.

Replace wrist roller bearings, seals, bushings, and O-rings.

Replace wrist gerotor.

Troubleshooting — Periodic Maintenance Page 30

Service Instructions
Noseblock Rebuild 32
Wrist Driveshaft Replacement 34
Wrist Motor Rebuild 37
Linear Actuator Remove and Replace 42
Atlas Yaw Actuator 45
Changing Manipulator Direction From Left to Right 47
Pitch Actuator Replacement 51
Atlas Forearm Segment 53
Atlas Upper Arm Segment 55
Azimuth Block Remove and Replace 56
Atlas Base Remove and Replace 59
Atlas Typical Bushing Replacement 63

Service Instructions — Periodic Maintenance Page 31

Noseblock Rebuild
Disassembly

1. Open the jaws and loosen the jaw rod bolt. Do not
remove the bolt.

Use a lever in the opened jaws to counteract the

torque.

2. Remove the jaws.

3. Remove the 4 bolts that attach the noseblock to the

wrist, then remove the noseblock.

4. Remove the jaw rod bolt and disassemble the remaining

parts.
5. Remove the seals with a razor knife if they need to be
replaced.

Use care to not scratch the metal surfaces.

Reassembly

Service Instructions — Noseblock Rebuild Page 32

 1. Install O-rings and bearings into the noseblock as
shown.
2. Lubricate all seals and O-rings before assembly.
3. Use a sizing tool to stretch the jaw piston seal. Use resiz-
ing tools for the noseblock and piston seal.

The bearing must be installed on the piston

before the piston seal to support the resizing tool.
Failure to do so may damage to the resizing tool.

4. Use the resizing tool on the end of the jaw rod to install
the rod into the noseblock.

5. Lubricate the jaw bolt with anti-seize. Thread the bolt

through the T-bar plate and into the jaw piston. Do not
yet tighten the jaw rod bolt.

6. Install the noseblock on the wrist with 4 bolts.

7. Torque bolts to 73 lbf-ft (99 Nm)
8. Install the jaws.
9. Tighten the jaw rod bolt.
10. Torque jaw rod bolt to 160 lbf-ft (217 Nm)

Service Instructions — Noseblock Rebuild Page 33

Wrist Driveshaft Replacement
Removal

1. Loosen the clamp-nut locking screw with a 5/32-inch

Allen wrench and then use a 1 1/2-inch socket to
remove the clamp-nut.

2. Remove the thrust washers (2x) and the radial bearing

beneath the clamp-nut.

3. Push the driveshaft straight out of the wrist motor.

4. Do not rotate the driveshaft while removing it. Rotation

can cause misalignment and will prevent the wrist motor
from turning when reassembled.

5. Replace the flange seals and/or slipring seals as needed.

Installation

1. Place the driveshaft on a flat surface with the splined

shaft up.

Service Instructions — Wrist Driveshaft Replacement Page 34

 2. Install the backup seal, then the thrust washer onto the
driveshaft.

3. Lubricate the bearing and the seal.

4. Use enough lube to hold the parts in place when
inverted.

5. Install the bearing and seal. Ensure that the seal is

installed with the cup facing up.

6. Align the splines with the gerotor splines and press the
wrist motor over the driveshaft until fully seated.

7. If the splines do not align properly, the motor will not

rotate when reassembled. If this occurs, rebuild the
wrist motor according to the provided instructions.

8. Install the thrust washer, radial bearing, and second

thrust washer onto the driveshaft.

Service Instructions — Wrist Driveshaft Replacement Page 35

 9. Tighten the clamp-nut to the torque stamped on the nut
with a 1 1/2-inch socket.
A stamp of "10" = 10 lbf-ft
10. Tighten the locking screw with a 5/32-inch Allen
wrench.
11. Turn the motor over and push the flange seal into the
gap between the driveshaft and motor housing.

Service Instructions — Wrist Driveshaft Replacement Page 36

Wrist Motor Rebuild
Disassembly

1. Loosen the clamp-nut locking screw with a 5/32-inch

Allen wrench and then use a 1 1/2-inch socket to
remove the clamp-nut.

2. Remove the thrust washers (2x) and the radial bearing

beneath the clamp-nut.

3. Push the driveshaft out of the wrist motor.

4. Loosen the 8x SHCS with a 1/4-inch Allen wrench.

5. Remove the back of the wrist motor with the bolts in

place.

6. Remove the valve plate.

Service Instructions — Wrist Motor Rebuild Page 37

 7. Remove the timing plate.

8. Remove the gerotor assembly.

9. Remove the wear plate.

10. Remove and replace all seals and O-rings as required.

Reassembly

1. Place the driveshaft on a flat surface with the splined

shaft up.

Service Instructions — Wrist Motor Rebuild Page 38

 2. Install the slipring seals into the wrist housing.

3. Install the backup seal, then the thrust washer onto the
driveshaft.

4. Lubricate the bearing and the seal.

5. Use enough lube to hold the parts in place when

inverted.

6. Install the bearing and seal. Ensure that the seal is

installed with the cup facing up.

7. Press the housing over the driveshaft.

8. Place the wear plate into the wrist housing. Rotate it

until the bolt holes line up with the bolt holes in the
housing. Press down until the seal slides into the wear
plate.

Service Instructions — Wrist Motor Rebuild Page 39

 9. Install the gerotor assembly, rotating the outer ring
until it lines up with the bolt holes in the wear plate and
housing.

Install the outer ring of the gerotor with the nar-

row groove facing up.

10. Install the timing plate, making sure that you are not
able to see the rollers through the slots. If you can see
the rollers, remove the timing plate and advance it by
one spline tooth.

11. Place the shaft seal over the driveshaft with the cup
side down.
12. Place the valve plate over the shaft with the O-ring
grooves facing up. Rotate it until it aligns with the 8x
bolt holes and press it down onto the seal.
13. Install the O-rings into the grooves in the valve plate.

Service Instructions — Wrist Motor Rebuild Page 40

 14. Install a crush washer onto each of the 8x bolts.
15. There are three drilled bolts. Only two of them have O-
ring slots in the end.
16. Install O-rings onto the ends of the drilled bolts with
slots.
17. Install the 2x drilled bolts (with O-rings) on either side
of the small oil passages.
18. Install a bushing and O-ring on each of the 2x drilled
bolts.
19. Install the drilled bolt (without an O-ring) in between
the 2x O-ring bolts.
20. Install the remaining 5x bolts.
21. Install the O-ring around the outer diameter of the
manifold.
22. Align the manifold with the holes in the gerotor and
wrist housing and press it onto the driveshaft. Tighten
the 8x bolts

Torque all bolts to 15 lbf-ft (20 Nm)

Tighten all but the 2x drilled bolts with O-rings.

Torque 6x bolts to 19 lbf-ft (26 Nm)

Tighten the 5x non-drilled bolts.

Torque 5x bolts to 24 lbf-ft (33 Nm)

23. Install the thrust washer, radial bearing, and second

thrust washer onto the driveshaft.
24. Tighten the clamp-nut to the torque stamped on the
nut with a 1 1/2-inch socket.

A stamp of "10" = 10 lbf-ft

25. Tighten the locking screw with a 5/32-inch Allen

wrench.
26. Turn the motor over and push the flange seal into the
gap between the driveshaft and motor housing.

Service Instructions — Wrist Motor Rebuild Page 41

Linear Actuator Remove and Replace
1 5/8-inch modified socket tool, vice, 1/2-inch drive breaker bar or ratchet, Bear-
Tools
ing Installation & Removal tool (010-1457)

Personnel

Sub-Procedures

Parts-Kits

Safety

Consumables LOCTITE

Disassembly

1. Place the actuator base in a vise.

2. Remove the nose nut using the special 1 5/8-inch mod-

ified socket tool.

Service Instructions — Linear Actuator Remove and Replace Page 42

 3. Pull the entire assembly out of the actuator housing.

4. Place the rod end in a vise.

5. Use a 1/2-inch drive breaker bar or ratchet in the end of

the piston to unthread the piston from the rod.

6. The rod and piston are assembled with LOCTITE. Using

a heat-gun on the end that you wish to unthread will
ensure that it comes out first.
7. Slide the nose nut off the actuator rod and remove any
seals, O-rings or bearings that you will be replacing.

Service Instructions — Linear Actuator Remove and Replace Page 43

 Reassembly

1. Clean any residual LOCTITE from the rod, piston and rod
end.
2. Install new seals in the nose nut.
3. Install new bearing and seal on the piston using a sizing tool
to stretch the seal onto the piston, and a resizing tool to
shrink it to the original size.
4. Thread the resizing tool onto the rod and push the rod
through the nose nut.
5. Add spacer (if used) to rod. Put LOCTITE on the threads of
the piston and rod end and thread into the rod.

Torque to 75 lbf-ft (102 Nm).

6. Add spacer(if used) to cylinder. Push the piston into the

actuator housing and thread the nose nut into the housing.

Torque nose nut to 240lbf-ft (325 Nm).

The bearing must be installed on the piston before the

piston seal to support the resizing tool. Failure to do
so may damage to the resizing tool.

Service Instructions — Linear Actuator Remove and Replace Page 44

Atlas Yaw Actuator

Removal

1. Remove the pin keepers and rod from the yaw actuator
base with a 7/16-inch socket.

2. Remove the 2x bolts from the actuator rod end.

3. Remove the keepers and pins from the wrist base and
then slide the wrist slightly forward to allow the yaw
actuator pin and thrust washers to slide out of the wrist
base.

Service Instructions — Atlas Yaw Actuator Page 45

 4. Reinstall the wrist base pins and keepers.

5. Remove the bolts and the upper and lower yaw plates
with a 3/4-inch socket.

6. Slide actuator and actuator guard out of the arm and

remove the 2 hoses with a 9/16-inch wrench.

Service Instructions — Atlas Yaw Actuator Page 46

Changing Manipulator Direction From Left
to Right
Tools

Personnel

Sub-Procedures

Parts-Kits

Safety

Consumables LOCTITE

Disassembly

WARNING! Before performing this procedure, make sure that the Atlas
manipulator arm is on a secured surface such as a work bench. If not, the
azimuth block can fall and cause a hazard when disconnected from the
upper arm

Service Instructions — Changing Manipulator Direction From Left to Right Page 47

Service Instructions — Changing Manipulator Direction From Left to Right Page 48
 1. Remove the yaw actuator.

See the Yaw Actuator Service Instruction for more information.

2. Remove the pitch actuator pivot pin with a 7/16-inch socket.

3. Remove the keepers, pivot pin and spacers at the elbow joint pivot with a 7/16-inch
socket.
4. Remove the hose from the fitting at the base of the pitch actuator, rotate the actuator so
the fitting is on the underside of the arm, and re-install the hose with a 9/16-inch wrench.
5. Move the yaw plate that was on top to the bottom and reattach to the yaw pivot plates
with a 3/4-inch socket.
6. Place the yaw actuator guard into position, but do not attach at this time.
7. Install the remaining yaw plate on the top of the yaw assembly and attach with a 3/4-inch
socket.
8. Reinstall the pitch actuator rod end pin with a 7/16-inch socket.
9. Switch the location of all four fittings on the yaw actuator. Move both plugs to where the
90 degree fittings are located.

Service Instructions — Changing Manipulator Direction From Left to Right Page 49

 10. Attach the front yaw actuator hose only.
11. Slide the actuator into the guard.
12. Attach the rear hose.
13. Attach the pin at the base of the actuator.
14. Remove the pivot pins at the yaw pivot, and then install the yaw actuator rod pin and
attach with 2x HHCS.
15. Reinstall the yaw pivot pins.

Service Instructions — Changing Manipulator Direction From Left to Right Page 50

Pitch Actuator Replacement
Tools

Personnel

Sub-Procedures

Parts-Kits

Safety

Consumables LOCTITE

Removal

1. Remove the keeper, pivot pin, and thrust bearings at the

pitch actuator rod end with a 7/16-inch socket.

2. Remove the keepers, pivot pin, and spacers at the elbow

joint.

3. Pull the actuator out of the forearm at the elbow joint.

4. Remove the hoses with a 9/16-inch wrench

Service Instructions — Pitch Actuator Replacement Page 51

 Installation

1. Orient the fittings for left or right hand operation.

2. Place the actuator in the forearm for left or right hand

operation.

3. Reinstall the elbow pivot pin, spacers, and keepers.

4. Reinstall the rod end pivot pin, thrust bearings, and

keepers.

Service Instructions — Pitch Actuator Replacement Page 52

Atlas Forearm Segment
Tools

Personnel

Sub-Procedures

Parts-Kits

Safety

Consumables LOCTITE

Removal

1. Remove hoses C, 6A, 6B, 5A, 5B, 4A, 4B at the base

manifold.
2. Remove the pitch actuator using prior instructions.

3. Remove the keepers and pins at the pitch pivot with a

7/16-inch socket.

4. Remove the pin, thrust bearing, and keeper at the elbow

actuator rod end with a 7/16-inch socket.

5. Slide the hoses out of the upper arm and forearm.

Reassembly

Service Instructions — Atlas Forearm Segment Page 53

 1. Feed hoses C, 6A, 6B, 5A, 5B, 4A, 4B through the fore-
arm and upper arm and attach to the base manifold.
2. Install the pin, spacers and keeper for the elbow actua-
tor rod end into the forearm.
3. Install the elbow pivot pin, spacers and keepers through
the upper arm, forearm and pitch actuator base.
4. Install the pitch actuator using prior instructions.

Service Instructions — Atlas Forearm Segment Page 54

Atlas Upper Arm Segment
Tools

Personnel

Sub-Procedures

Parts-Kits

Safety

Consumables LOCTITE

Removal

1. Remove the shoulder actuator pin, thrust bearings and

keeper in the upper arm with a 7/16-inch socket.

2. Remove the elbow actuator pin, thrust bearing and

keeper in the upper arm with a 7/16-inch socket.
3. Remove hose 1A from the base of the shoulder actuator
with a 9/16-inch wrench.

4. Remove the pin, spacers, and keepers from the elbow

pivot.
5. Remove hoses 2A, 2B, 3A, 3B, 4A, 4B, 5A, 5B, 6A, 6B,
C from the base manifold.

6. Remove the pins and keepers from the shoulder pivots.

7. Slide the hoses out of the upper arm.

Service Instructions — Atlas Upper Arm Segment Page 55

Azimuth Block Remove and Replace
Tools

Personnel

Sub-Procedures

Parts-Kits

Safety

Consumables LOCTITE

WARNING! Before performing this procedure, make sure that the Atlas
manipulator arm is on a secured surface such as a work bench. If not, the
azimuth block can fall and cause a hazard when disconnected from the
upper arm.

Disassembly

1. Remove the shoulder actuator pin, thrust bearings, and

keeper in the upper arm with a 7/16-inch socket.
2. Disconnect the hydraulic hoses from the manifold.

3. Remove the 2x retaining bolts, azimuth actuator pin,

and thrust bearings in the upper arm with a 7/16-inch
socket.

Service Instructions — Azimuth Block Remove and Replace Page 56

 4. Remove the shoulder segment pivot pins and keepers
with a 7/16-inch socket.

5. Remove the 2x keepers, 2x retaining bolts, and azimuth

pivot pins with a 7/16-inch socket.

6. Remove the hose guide and hard stops with a 7/16-inch

socket to allow the hoses to come free of the azimuth.

Reassembly

1. Install the azimuth pivot pin, 2x keepers, and 2x retain-

ing bolts.

Service Instructions — Azimuth Block Remove and Replace Page 57

 2. Install the azimuth actuator pin, spacers, and bolts.

3. Install the shoulder pivot pins and keepers, and bolts.

4. Install the shoulder actuator pin, keepers, and bolts.

5. Install the hose guide and hard stops, and bolts.

6. Reconnect the hydraulic hoses to the manifold.

Service Instructions — Azimuth Block Remove and Replace Page 58

Atlas Base Remove and Replace
Tools

Personnel

Sub-Procedures

Parts-Kits

Safety

Consumables LOCTITE

WARNING! Support the Atlas manipulator arm to prevent injury or dam-

age to the manipulator.

WARNING! Before performing this procedure, make sure that the Atlas
manipulator arm is on a secured surface such as a work bench. If not, the
azimuth block can fall and cause a hazard when disconnected from the
upper arm.

Disassembly

1. Remove the azimuth actuator pin, thrust bearings, and

keeper with a 7/16-inch socket.
2. Disconnect the hydraulic hoses from the manifold.

Service Instructions — Atlas Base Remove and Replace Page 59

 3. Remove the hose manifold with a 7/16-inch socket.

4. Remove the azimuth pivot pin and keeper with a 7/16-

inch socket.

5. Remove the azimuth actuator pin from the base of the

actuator by removing the lower hidden keeper with a
3/8-inch socket. Remove the upper keeper and bolts
with a 7/16-inch socket.

6. Remove the azimuth actuator.

Service Instructions — Atlas Base Remove and Replace Page 60

 7. To completely disassemble the base, remove the 6x bolts
with a 3/4-inch socket.

Reassembly

1. Install and torque the 6x 5/8-inch fasteners with a 3/4-

inch socket.

2. Install the azimuth actuator.

Service Instructions — Atlas Base Remove and Replace Page 61

 3. Install the azimuth actuator rear pin, upper and lowers
keepers, spacers and bolts.

4. Install the azimuth pivot pin and keepers.

5. Install the azimuth actuator pin, spacers, and bolts.

(Models 199-0292-x only) Install the hose man-

ifold.

6. Reconnect the hydraulic hoses to the manifold.

Service Instructions — Atlas Base Remove and Replace Page 62

Atlas Typical Bushing Replacement
Part # 010-1457 -Bushing Replacement Tool

Bushing Removal

Use special tool 010-1457 (Bushing Removal tool) to press

out the part.

Bushing Installation

1. Clean the bushing and the bore with acetone or LOC-

TITE primer.
2. Apply LOCTITE to the bore and the bushing.

3. Use the bushing installation tool to press the bushing

into the part.

Service Instructions — Atlas Typical Bushing Replacement Page 63

Service Instructions — Atlas Typical Bushing Replacement Page 64
Drawings, Schematics, Part
Lists
Spares Kit 008-0506 65
Spares Kit 008-0216 (Item 1 in Spares Kit 008-0506) 66
Spares Kit 008-0509 (Item 3 in Spares Kit 008-0506) 66
Spares Kit 008-0510 (Item 4 in Spares Kit 008-0506) 67
Spares Kit 008-0096 (Item 6 in Spares Kit 008-0506) 67
Tool Kit 010-1386 68
Atlas Hydraulic Schematic 025-0132 69
Hose Routing, Left Hand Configuration 70
Hose Routing, Right Hand Configuration 71
Linear Actuators 72
Anodes and Bump Stops 73
Bushings and Inserts 74
Sensor Covers 75
Pins and Spacers 76
Major Structures 77
Linear Actuators 78
Wrist, 101-3786 79
Jaw, 101-3299 80
Jaws, 101-3569 81
Noseblock, 101-3853 82

Spares Kit 008-0506

SPS KIT,A7F, 008-0506, REV A
Item P/N Description Qty
1 008-0216 KIT,SOFT GOODS,LIN ACTR,T3 2
3 008-0509 SPS KIT,ATLAS,HOSES 1
4 008-0510 SPARES KIT,ATLAS,HDW 1
6 008-0096 SP KIT, RIG, WRIST 1

Drawings, Schematics, Part Lists — Spares Kit 008-0506 Page 65

Spares Kit 008-0216 (Item 1 in Spares Kit
008-0506)
KIT,SOFT GOODS,LIN ACTR,T3, 008-0216, REV A
Item P/N Description Qty
7 003-0115 BRG,PSTN,LIN ACTR,T2 GAMMA 2
8 004-0649 SEAL,PSTN,LIN ACTR,T2/3,GAMMA 1
9 004-0669 O-RING,2-031,BUNA 90 1
10 001-0893 BRG,ROD 2
11 004-0650 SEAL,ROD,LIN ACTR,GAMMA 2
12 004-0651 SCRAPER,ROD,LIN ACTR,T2 GAMMA 1
14 004-0082 O-RING,3-904 BUNA 90 2

Spares Kit 008-0509 (Item 3 in Spares Kit

008-0506)
SPS KIT,ATLAS,HOSES, 008-0509, REV A
Item P/N Description Qty
2 006-2613-1 HOSE,-4 JIC,56-DH,73.75 LG 1
3 006-2613-2 HOSE,-4 JIC,56-DH,72.75 LG 1
4 006-2613-3 HOSE,-4 JIC,56-DH,74.5O LG 1
5 006-2613-4 HOSE,-4 JIC,56-DH,73.50 LG 1
6 006-2613-5 HOSE,-4 JIC,56-DH,79.25 LG 1
7 006-2613-6 HOSE,-4 JIC,56-DH,69.25 LG 1
8 006-2613-7 HOSE,-4 JIC,56-DH,75.75 LG 1
9 006-2613-8 HOSE,-4 JIC,56-DH,62.00 LG 1
10 006-2613-9 HOSE,-4 JIC,56-DH,28.50 LG 1
11 006-2613-10 HOSE,-4 JIC,56-DH,41.75 LG 1
12 006-2613-11 HOSE,-4 JIC,56-DH,42.25 LG 1
13 006-2613-12 HOSE,-4 JIC,56-DH,32.00 LG 1
14 006-2613-13 HOSE,-4 JIC,56-DH,15.50 LG 1
15 006-2613-14 HOSE,-4 JIC,56-DH,17.00 LG 1
16 006-2613-15 HOSE,-4 JIC,56-DH,72.50 LG 1

Drawings, Schematics, Part Lists — Spares Kit 008-0216 (Item 1 in Spares

Page 66
Kit 008-0506)
Spares Kit 008-0510 (Item 4 in Spares Kit
008-0506)
SPARES KIT,ATLAS,HDW, 008-0510, REV A
Item P/N Description Qty
1 001-4342 RETAINER, PIN 3
2 002-0029P HHCS,1/4-20 X 1/2,SS,PATCH 6
3 003-0114 BRG,PVT,LIN ACTR,T2 GAMMA 2
4 002-1440 ANODE,GALVANIC 8
5 002-0229P SHCS,10-24 X 3/8,SS,PATCH 4
6 002-0195 SHCS,10-24X1-1/4,SS 4
7 003-0298 BRG,THRUST,1"IDX1.75"OD"X.0585 2
8 003-0263 BRG,DIXON,CJ16E18-5 10
9 001-10523 BRNG,TOP HAT,1.0 ID,.735 LG 4
10 003-0263-2 BEARING,DIXON,1.0X1.125X.438L 5
12 003-0263-1 BRG,DIXON,1.0 ID X .530 LG 2
13 001-10743 HARD STOP,SHOULDER,A7F 2
14 001-10492 HARD STOP,AZIMUTH,A7F 2
15 001-10538 STOP,PITCH,A7F 2
16 001-7520 BOLT,6 PT,5/8-18,STD 2
17 001-5396 PLATE,T-BAR,LOCKING 2
18 002-1925 ANTI-SIEZE,1 OZ TUBE 1
19 001-10493 SPACER,HARD STOP,AZIMUTH,A7F 2
20 002-3168 ANODE,T-20 5
21 002-0966 SHCS,1/4-20X.75,SS 2
22 002-0188 HHCS,1/4-20X1.5,SS 4
23 002-0715P HHCS,1/2-20X1.5,316SS,NLK 4

Spares Kit 008-0096 (Item 6 in Spares Kit

008-0506)
SP KIT, RIG, WRIST, 008-0096, REV B
Item P/N Description Qty
1 004-0222 O-RING,2-010 BUNA 90 5
2 003-0174 BSHG,FL.,1/4X5/16X1/4LG.,NYL 1
3 004-0617 SEAL,FLUROCARBON #AR10400-418- 1
4 002-1544 WSHR,G10,5/16X9/16X1/16 1
5 004-0803 SEAL,SHAMBAN,TGZF-S4016NA 3

Drawings, Schematics, Part Lists — Spares Kit 008-0510 (Item 4 in Spares

Page 67
Kit 008-0506)
 SP KIT, RIG, WRIST, 008-0096, REV B (continued)
Item P/N Description Qty
7 001-4454 BRG,SLYDRING,2.875IDX3.063X.25 1
8 003-0074 WSHR,THR,TRA2840,TORRINGTON 1
9 003-0013 TORRINGTON,NTA 2840 1
12 004-0575 SEAL,AR10103-214-UH,FLUROCARBO 1
15 004-0574 SEAL,AR10103-212-UH,FLUROCARBO 1
16 004-0081 O-RING,2-035 BUNA 70 1
17 004-0017 O-RING,2-031 BUNA 70 2
18 004-0413 O-RING,2-026 V75 1
19 004-0110 O-RING,2-046 BUNA 70 1
22 001-4448 BOLT,OIL SPLY,WR 2
23 001-4449 BOLT,OIL RTN,WR 1
24 004-0445 O-RING,2-006 V90 2
25 001-1984 BSHG,WR OIL SPLY TUBE 2
26 004-0698 O-RING,2-011,DISOGRIN 90 DURO 5
27 004-0576 WSHR,CRUSH,5/16 16
29 001-4577 SHCS,5/16-18X3,CADMIUM PLD,UNB 5
30 003-0092 WSHR,THR,TORRINGTON #TRC 1427 2
31 003-0091 BRG,THR,TORRINGTON #NTC 1427 1
33 002-0139 SHCS,10-32X3/4,SS 1
34 003-0078 BRG,CJ08E10-4,DIXON,.5X.625X.5 4
36 001-2946 BRG,2.25 BORE PSTN,GAMMA 2
37 004-0616 SEAL,PSTN,SHAMBAN,34G02250-A46 1
39 004-0542 O-RING,2-034 BUNA 70 1
40 004-0541 RING,BACKUP,8-034 BUNA 90 1
41 001-0893 BRG,ROD 2
42 004-0508 STEPSEAL,S48270-4203-109P 2
44 004-0619 O-RING,2-114,N90 1
48 003-0050 BRG,CJ12E144 DIXON 4
49 004-0650 SEAL,ROD,LIN ACTR,GAMMA 0

Tool Kit 010-1386

TOOL KIT,7F,ATLAS, 010-1386, REV A
Item P/N Description Qty
1 010-0173 TOOL,CLP,JAW 1
2 010-0174 TOOL,INSTALL,M,2.25 1

Drawings, Schematics, Part Lists — Tool Kit 010-1386 Page 68

 TOOL KIT,7F,ATLAS, 010-1386, REV A (continued)
Item P/N Description Qty
3 010-0175 TOOL,SIZING,F,2.25 1
4 010-0804 TOOL,PISTON ROD,JAW 1
5 010-0184 TOOL,INSTL,M,1.75 1
6 010-0185 TOOL,SIZING,F,1.75 1
7 010-0203 TOOL,SIZING,M,1.0 1
8 010-0486 SKT,MOD,NOSE NUT,LIN ACT. 1
9 010-0804-1 TOOL,PSTN ROD,JAW,SIDE SKIRT 1
10 010-1455 TOOL,CLAMP,ACTUATOR ROD,1 IN 2
11 010-1456 TOOL,PIN ALIGN ASSY 1
12 010-1457 TOOL,BEARING INSTL & RMV 1
13 010-1084 ADAPTER,SOCKET,1/2"F TO 3/4" M 1

Atlas Hydraulic Schematic 025-0132

Drawings, Schematics, Part Lists — Atlas Hydraulic Schematic 025-0132 Page 69

Hose Routing, Left Hand Configuration

Drawings, Schematics, Part Lists — Hose Routing, Left Hand Con-

Page 70
figuration
Hose Routing, Right Hand Configuration

Drawings, Schematics, Part Lists — Hose Routing, Right Hand Con-

Page 71
figuration
Linear Actuators

Drawings, Schematics, Part Lists — Linear Actuators Page 72

Anodes and Bump Stops

Drawings, Schematics, Part Lists — Anodes and Bump Stops Page 73

Bushings and Inserts

Drawings, Schematics, Part Lists — Bushings and Inserts Page 74

Sensor Covers

Drawings, Schematics, Part Lists — Sensor Covers Page 75

Pins and Spacers

Drawings, Schematics, Part Lists — Pins and Spacers Page 76

Major Structures

Drawings, Schematics, Part Lists — Major Structures Page 77

Linear Actuators

Drawings, Schematics, Part Lists — Linear Actuators Page 78

Wrist, 101-3786

Drawings, Schematics, Part Lists — Wrist, 101-3786 Page 79

Jaw, 101-3299

Drawings, Schematics, Part Lists — Jaw, 101-3299 Page 80

Jaws, 101-3569

Drawings, Schematics, Part Lists — Jaws, 101-3569 Page 81

Noseblock, 101-3853

Drawings, Schematics, Part Lists — Noseblock, 101-3853 Page 82