Quick Change Installation and Operation Manual

Document #9620-20-B-310 Series Base Tool Changer-22

4. Maintenance
WARNING: Do not perform maintenance or repair on Tool Changer or modules unless the Tool is safely
supported or docked in the tool stand, all energized circuits (e.g. electrical, air, water, etc.) are turned off,
pressurized connections purged and power discharged from circuits in accordance with the customers
safety practices and policies. Injury or equipment damage can occur with Tool not docked and energized
circuits on. Dock the Tool safely in the tool stand, turn off and discharge all energized circuits, purge all
pressurized connections, verify all energized circuits are de-energized before performing maintenance
or repair on Tool Changer or modules.
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Changer. The dirtier the environment, the greater the need for protection against debris. Protection of the entire
EOAT, the Master, the Tool, and all of the modules may be necessary. Protective measures include the following:
1) Placement of tool stands away from debris generators.
2) Covers incorporated into the tool stands.
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4.1

Preventive Maintenance
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Table 4.1Maintenance
Application(s)

General Usage Material Handling Docking Station

Welding/Servo/Deburring, Foundry Operations (Dirty Environments)

Tool Change Frequency

Inspection Schedule

> 1 per minute

Weekly

< 1 per minute

Monthly

All

Weekly

Checklist
Mounting Fasteners

Inspect fasteners for proper torque, interferences, and wear. Tighten and correct as required. Refer to 7DEOH
)DVWHQHU6L]H&ODVVDQG7RUTXH6SHFLFDWLRQV
Ball Bearings/Alignment Pins/Bushings/Bearing Race

Inspect for wear and proper lubrication. MobilGrease XHP222 Special a NLGI #2 lithium complex grease with
PRO\EGHQXPGLVXOGHDGGLWLYHLVVXJJHVWHGIRUORFNLQJPHFKDQLVPDQGDOLJQPHQWSLQOXEULFDWLRQ2YHUWLPH
lubricants can become contaminated with debris. Therefore, it is recommended to thoroughly clean the existing
grease and replace with new as needed. See 6HFWLRQ&OHDQLQJDQG/XEULFDWLRQRIWKH/RFNLQJ0HFKDQLVPDQG
Alignment Pins.

Inspect for excessive alignment pin/bushing wear, may be an indication of poor robot position during pickup/drop-off.
Adjust robot position as needed. Check tool stand for wear and alignment problems. To replace worn alignment pins,
refer to 6HFWLRQ$OLJQPHQW3LQ5HSODFHPHQW.

Inspect for wear on the ball bearings/bearing race, may be an indication of excessive loading.
Sensors and Cables

Inspect sensor cable connectors for tightness, if loose tighten connections.

Hoses

Inspect sensor cables for any damage, cuts, and abrasion. Replace as necessary. Refer to 6HFWLRQ,QGLYLGXDO
/RFNDQG8QORFN6HQVRU$VVHPEOLHV5HSODFHPHQW and 6HFWLRQ57/6HQVRU&DEOH5HSODFHPHQW3URFHGXUH.
Inspect hose connection for tightness and leaks. If leaking or loose secure hose connection.

Inspect hoses for interferences, abrasions, cuts, and leaks. Replace as required.
Electrical Contacts/Pin Block (Modules)

Inspect for damage, debris, and stuck/burnt pins. Clean pin blocks as required, refer to 6HFWLRQ3LQ%ORFN
Inspection and Cleaning.
Seals (Modules)

Inspect for wear, abrasion, and cuts. Refer to Section 14After repair is complete, return all circuits to normal
operation (e.g. electrical, air, water, etc.).

Pinnacle Park 1031 Goodworth Drive Apex, NC 27539 Tel: 919.772.0115 Fax: 919.772.8259 www.ati-ia.com Email: info@ati-ia.com

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Quick Change Installation and Operation Manual

Document #9620-20-B-310 Series Base Tool Changer-22

4.2

Cleaning and Lubrication of the Locking Mechanism and Alignment Pins

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Figure 4.1Cleaning Ball Bearings and Outer Surfaces of Male Coupling

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Figure 4.2Cleaning Ball Bearings, Cam and Inner Surfaces of Male Coupling

Pinnacle Park 1031 Goodworth Drive Apex, NC 27539 Tel: 919.772.0115 Fax: 919.772.8259 www.ati-ia.com Email: info@ati-ia.com

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Quick Change Installation and Operation Manual

Document #9620-20-B-310 Series Base Tool Changer-22
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Figure 4.3Check Ball Bearing Movement

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DOLJQPHQWSLQV
Figure 4.4Apply Lubricant to Locking Mechanism

Apply Lubricant on Alignment Pins

and Outer Surface of Male Coupling

Apply Lubricant on Inner

Surface of Male Coupling

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EXVKLQJVIURPWKH7RROSODWH
Figure 4.5Clean Tool Plate Surfaces of locking Mechanism
Clean Bushing Surfaces

Clean Bearing Race

Surfaces

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Pinnacle Park 1031 Goodworth Drive Apex, NC 27539 Tel: 919.772.0115 Fax: 919.772.8259 www.ati-ia.com Email: info@ati-ia.com

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Quick Change Installation and Operation Manual

Document #9620-20-B-310 Series Base Tool Changer-22

4.3

Pin Block Inspection and Cleaning

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Figure 4.6Inspect Master and Tool Pin Blocks
Blackened Pins
Note: Pin blocks shown are for
illustration purposes only.

Weld Debris

Master Module Pin Block

Tool Module Pin Block

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NOTICE: Do not use an abrasive media, cleaners, or solvents to clean the contact pins. Using
abrasive media, cleaners, or solvents will cause erosion to the contact surface or pins to stick.
Clean contact surfaces with a vacuum and non-abrasive media such as a nylon brush (ATI Part
Number 3690-0000064-60)
Figure 4.7Clean Pin Blocks with a Nylon Brush

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Figure 4.8Stuck Pin and Pin Block Damage

Note: Pin blocks shown are for

illustration purposes only.

Severe Pin Block Damage

Stuck Pins

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Pinnacle Park 1031 Goodworth Drive Apex, NC 27539 Tel: 919.772.0115 Fax: 919.772.8259 www.ati-ia.com Email: info@ati-ia.com

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