Open 8204rigmaster

Schilling Robotics
RigMaster 2 Slave Arm

Rate-Controlled,
6.5 Km Submersible
Document No. 011-8204

Models:
199-0274
199-0287
Copyright © 2014 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.fmctechnologies.com/schillingrobotics.aspx
TECHNICAL MANUAL REVISION LOG
PRODUCT: RigMaster Slave Arm, 199-0274 & 199-0287

TECHNICAL MANUAL: 011–8204
Description Date Rev.
Manual release 11/29/05 Ø
Production revision 10/30/06 A
Production revision 10/29/07 B
Production revision (add model 199-0287) 04/17/08 C
Removed incorrect Orion references. Fixed vari- 5/6/2014 D
ous cosmetic changes, removed rate controlled
references, updated spec info, changed relief
valve pressure data for wrist drain (p.16),
refortted trouble shooting tables, removed ref-
erences to P-type slave arm.
Table of Contents
Specifications
1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Manipulator Arm Specifications. . . . . . . . . . . . . . . . . . . . . . 7
3 Hydraulic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Fluid Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . 8
Installation
1 RigMaster Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 User-supplied Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Installing the Slave Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Preparing the Slave Arm Mounting Platform. . . . . . . . . . . . . .. 9
3.2 Installing the Control & Drain Hoses . . . . . . . . . . . . . . . . . . . 11
3.3 Installing Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.4 Installing Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4 Installation Startup & Test . . . . . . . . . . . . . . . . . . . . . . . . 13
4.1 Confirm Before First Startup . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 First Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3 Testing Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Operation
1 Operation Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.1 RigMaster Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Factors Affecting Slave Arm Performance. . . . . . . . . . . . . 15
3 Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1 Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4 Controlling System Functions . . . . . . . . . . . . . . . . . . . . . . 17
Troubleshooting
Page 3
1 Troubleshooting the Slave Arm . . . . . . . . . . . . . . . . . . . . . 19
2 Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.1 Whole-Arm Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . 20
2.2 Single Joint Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . 22
Maintenance & Service

1 Organization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2 Safety First! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.1 Worksite Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2 Maintenance & Service Safety. . . . . . . . . . . . . . . . . . . . . . . . 26
2.3 Deck Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3 Important Service Practices & Procedures . . . . . . . . . . . . 27
3.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4 Basic Service Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1 Base Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2 Shoulder Block Assembly Replacement . . . . . . . . . . . . . . . . . 31
4.3 Arm Segment Assembly Replacement . . . . . . . . . . . . . . . . . . 31
4.4 Boom Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.5 Wrist/Jaw Assembly Replacement . . . . . . . . . . . . . . . . . . . . . 33
4.6 Linear Actuator Assembly Replacement . . . . . . . . . . . . . . . . . 34
4.7 Hydraulic Hose Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 36
4.8 Part Lists & Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5 Special Service Instructions. . . . . . . . . . . . . . . . . . . . . . . . 50
5.1 Using the Service Instructions . . . . . . . . . . . . . . . . . . . . . . . 50
5.2 Start-up Following Service . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.3 Service Instruction List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Drawings & Part Lists

1 Organization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.1 Spares Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Page 4 Table of Contents

Safety & Service Summary
Precautionary Notices
This manual provides precautionary notices which carry important information about
safety risks to personnel and damage to equipment while installing, operating, servic-
ing, or maintaining this equipment.
The form and significance of the notices are shown below.
! WARNING
A WARNING alerts you to a risk of injury or loss of life. It
may also include instructions to help minimize or eliminate
the risk.
! Caution
A CAUTION alerts you to a risk of equipment damage or loss.
It may also include instructions to help minimize or elimi-
nate the risk.
NOTE: The absence of WARNING and CAUTION notices does not mean
that risk is absent. Always use appropriate safety procedures, equipment,
and personal protective equipment (PPE) when operating and servicing this
equipment.
Service Assumption
This manual assumes that service personnel are familiar with the general operating
principles, safety guidelines, and service practices associated with the types of equip-
ment represented in this manual.
Table of Contents Page 5

Page 6 Table of Contents
Specifications
1 General Description
Control method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rate control
Control input device. . . . . . . . . . . . . . . . . . . . . . . . . . . Optional rate hand controller
Number of functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Four plus grip
Materials of construction. . . . . Titanium, anodized aluminum, 17-4 stainless steel
2 Manipulator Arm Specifications

All specifications are based on the standard configuration using Shell Tellus Oil 32 hydraulic
fluid, input pressure of 207 bar (3,000 psi) and available flow of 19 lpm (5 gsm).
Depth rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,500 msw (21, 327)
Reach (from shoulder pivot to tip of standard gripper):
Retracted boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1067 mm (42.0-in.)
Extended boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,372 mm (54.0-in.)
Weight in air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 kg (142 lbs)
Weight in seawater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 kg (105 lbs)
Lift at full extension, nominal:
Retracted boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 kg (595 lbs)
Extended boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 kg (400 lbs)
Maximum standard gripper opening, nominal. . . . . . . . . . . . . 289 mm (11.377-in.)
Grip force, nominal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,448 N (1,000 lbf)
Wrist torque, nominal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 Nm (150 ft/lbs)
Wrist rotate, continuous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360°, 6-35 rpm
Actuator functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see table below
Actuator Functions
Actuator Function Type Nominal Mechanical Range
Base yaw Linear 105°
Shoulder pitch Linear 105°
Boom extend/retract Linear 305 mm (12-in.)
011–0753 Page 7
• Specifications
Actuator Functions (cont.)

Wrist rotate Gerotor 360°
Gripper, standard Linear 284 mm (11.2-in.)
3 Hydraulic Specifications
Viscosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 cSt to 200 cSt
Available flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 - 19.0 l/min (1.5 - 5.0 gpm)
Pressure . . . . . . . 103 bar (1,500 psi) minimum to 207 bar (3,000 psi) maximum
Note: Contact the factory about operation with other pressures and flow rates.
Rotary actuator return pressure, maximum . . . . . . . . . . . . . . . . . . 24 bar (350 psi)

Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 microns (25 microns absolute)
Hydraulic control hose length extending from base,
nominal, all functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-in. (4.6 ft)
Control hoses:
Working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 bar (3,000 psi)
Proof pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 bar (4,500 psi)
Burst pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621 bar (9,000 psi)
Customer-supplied mating fittings reguired:
Control hose fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -4 JIC male, ¼-in.
3.1 Fluid Selection

Select a hydraulic fluid based on its maximum temperature during normal operations.
 Lower than 54°C (130°F): Use 22 grade oil.
 Higher than54°C (130°F): Use 32 grade oil.
 For temperatures above 71°C (160°F), below 0°C (32°F), or when in doubt about
which fluid to use, contact your regional technical support representative.
 Do not use water-based fluids.
 If a fluid has been specified for this system to meet special environmental or oper-
ational requirements, use it and disregard the parameters listed above.
Approved hydraulic fluids . . . . . . .Shell Tellus, Royal Purple Marine Hydraulic Oil
4 Environmental Specifications
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
Page 8 • 3 Hydraulic Specifications 011–0753

Installation
In This Chapter:
• 1 RigMaster Overview ...............................................page 9
• 2 User-supplied Equipment .................................................page 9
• 3 Installing the Slave Arm ..................................................page 9
• 4 Installation Startup & Test ............................................. page 13
1 RigMaster Overview
The RigMaster's five functions are base yaw, shoulder pitch, boom extend and retract, wrist
rotate, and jaw open and close. Movement of each joint is achieved using a linear or rotary actua-
tor. RigMaster hydraulic hose connections consist of ten control lines which are connected to the
base, shoulder, boom, wrist, and jaw actuators, and one line for the wrist case drain.
2 User-supplied Equipment
The following equipment, if not ordered as options from the factory, is required to complete the
installation of the slave arm and provide for its control and operation:
 A hydraulic power source.
 A hydraulic control manifold.
 Two relief valves each for all arm functions.
 Cross-port check valves
 All hardware, hoses, and fittings for connecting to the slave arm’s hydraulic hose
fittings.
3 Installing the Slave Arm

3.1 Preparing the Slave Arm Mounting Platform
1. Determine a suitable mounting location for the slave arm guided by the dimensional requirements
of the following drawings:
 “Rigmaster Slave Arm, Range of Motion” on page 115, sheet 3 of the RigMaster
slave arm drawing in the “Drawings & Part Lists” chapter.
 Figure 1, Stow dimensions on page 10.
 Figure 2, Minimum distance to bulkhead hose fittings on page 10.
011–0756 Page 9
• Installation
Figure 1 Stow dimensions
Figure 2 Minimum distance to bulkhead hose fittings

2. Create a sturdy mounting platform that will provide a flat surface for the three mounting holes in
the base as shown in Figure 3.
3. Move the slave arm to the mounting platform. Lower the base onto the platform and align the
mounting holes in the base and mounting platform.
Page 10 • Installing the Slave Arm 011–0756

Installation •
Figure 3 Slave arm mounting dimensions

4. A minimum of three 1/2-20 UNF-2B hex-head cap screws and lockwashers are required to attach
the base to the mounting platform. The installation of a fourth fastener, at the rear of the base, is
optional (see Figure 3).
! Caution
Mounting fasteners must be long enough to engage a minimum of 1.2
cm (0.5-in) of the base.
Lubricate the threads of the fasteners with AquaShield (Aqualube) and add the lock
washers. Install the fasteners through the mounting platform and into the RigMaster
base. Torque the fasteners to 102 Nm (75 ft/lbs).
3.2 Installing the Control & Drain Hoses

Ten hoses are supplied for connecting RigMaster functions to your control manifold or interme-
diate bulkhead fittings. The eleventh hose provides case drain from, and compensation to, the
wrist assembly. This line must be connected to the return system.
Note: IMPORTANT INSTALLATION DIMENSIONS:
1. Bulkhead hose fittings must be located no closer than 610 mm (24-in.) from the slave arm as
shown in Figure 2.
2. Minimum bend radius for slave arm hoses is 51 mm (2-in.).
3. If control hose lengths exceed 6 meters (20 ft), consult Customer Service for information about
increasing the hose diameter to maintain adequate pressure and flow.
A hydraulic schematic diagram of the RigMaster manipulator system can be found in the “Draw-
ings & Part Lists” chapter.
The table below lists the control and drain hose connections at the slave arm, and identifies actu-
ator functions, hose codes, and actuator movements. The slave arm hydraulic hoses are fitted
with female -4 JIC fittings for connecting all user-supplied hydraulics.
011–0756 Installing the Slave Arm • Page 11

• Installation
Slave Arm Actuator/ Joint Travel Hose Actuator

Function Code Movement
Left 1A Extend
Azimuth yaw
Right 1B Retract
Up 2A Extend
Shoulder pitch
Down 2B Retract
Out 3A Extend
Boom
In 3B Retract
N/A 4A Rotate CCW
Wrist rotatea
N/A 4B Rotate CW
Open 5A Extend
Jaw
Close 5B Retract
b
Wrist Drain N/A C N/A
a. Forearm and wrist roll CW/CCW movements are referenced from behind the slave
arm.
b. The maximum wrist drain/return pressure is 350 psi. If the wrist drain/return line
passes through a filter or is manifolded with other equipment returns, check the
return pressure when all equipment is running to be sure it does not exceed the
maximum.
! Caution
The wrist drain/return relief valve cracking pressure range is 350-600
psi. If pressure exceeds 350-600 psi above ambient, the relief valve
will crack and release hydraulic fluid into the environment.
For a description of how the supplied hydraulic hoses are connected to the manipulator, see the
section entitled “Hydraulic Hose Replacement” of the “Maintenance & Service” chapter.
3.3 Installing Relief Valves

Pressure relief valves must be installed on all control lines to protect slave arm components from
the abnormally high pressures generated by overloads or collisions. The fluid release relieves
excessive pressure on seals, and reduces stress on mechanical and hydraulic components. When
normal working pressures return, the affected relief valves close and allow normal operation to
resume. Without relief valves, slave arm components and seals are forced to
directly absorb pressures and stresses above their rated working capacity; the
result can be damage or breakdown.
! Caution
Operating the slave arm without relief valves on all control lines can
result in damage to components.
1. Adjust the cracking pressure of the A and B line relief valves to the figures shown on the
slave arm hydraulic schematic (with 025- prefix) in the “Drawings & Part Lists” chapter.
The cracking pressure may be set closer to the operating pressure of the system, if
desired, but be sure the reseal pressure is also above the normal operating pressure range
of the system. If it is not, the valve may not reseal during normal operation and the
actuator will respond erratically.
Page 12 • Installing the Slave Arm 011–0756

Installation •
Note: Do not set the cracking pressure higher than 4500 psi.
2. Connect the relief valves at any point between the hydraulic control manifold and the slave arm
hose connections.
Note: If a circuit has a restrictor, throttle, or flow control valve, install the relief valve between the actu-
ator and the flow control valve.
An illustration of relief valve connections is found on Sheet 1 of the RigMaster slave arm drawing
(upper right-hand corner) and the hydraulic schematic in the “Drawings & Part Lists” chapter.
The “to tank” port on each relief valve allows relieved fluid to be returned to the hydraulic power
unit reservoir.
3.4 Installing Check Valves

Adding cross-port check valves to the azimuth, shoulder, and boom functions is recommended. A
check valve can be installed to the wrist function but may not be effective due to internal leakage
of the wrist motor. Do not install a check valve to the jaw function as a hydraulic failure will leave
the jaw locked in place (if the jaw is clamped on structure it cannot be disengaged).
4 Installation Startup & Test

This section describes procedures for initially checking, starting up, and testing the slave arm
after all system components have been installed and interconnected.
4.1 Confirm Before First Startup

Before you operate the slave arm, confirm the following:
 Installation instructions have been completed for the slave arm and all other system compo-
nents.
 Individual control valves and hoses are securely connected to the appropriate slave arm hoses
for each actuator function.
 Control hoses are routed and supported/secured to eliminate snagging, kinking, and damage
during slave arm operation.
 A relief valve is installed on the base yaw, shoulder pitch, and boom extend/retract control
hose lines.
 The wrist drain hose is connected to the hydraulic system return.
 Hydraulic supply and return hoses/fittings are correctly connected and securely tightened to
the user’s control manifold.
 Submersible models only. Compensator hoses/fittings for user’s hydraulic system are cor-
rectly connected and securely tightened. (The slave arm does not require compensation.)
4.2 First Startup
! Caution
If the wrist drain/return line exceeds 600 psi above ambient, hydrau-
lic fluid will be released into the environment from the relief valve.
1. Clear all personnel or equipment from within the slave arm’s range of motion.
011–0756 Installation Startup & Test • Page 13

• Installation
2. Remove any installation supports from the slave arm.
3. Activate the hydraulic power unit (HPU).
4. Check and confirm:
 Hydraulic supply pressure is within the range listed in the System Specifications chapter.
 Hydraulic return or tank pressure is 350 psi or less. If the hydraulic return passes through a
filter or is manifolded with other equipment returns before returning to the tank, check the
return pressure when all equipment is running to be sure it does not exceed the maximum.
 No leaks from hoses, fittings, components.
5. Following the manufacturers’ recommendations, bleed air from the HPU and manifold
components.
4.3 Testing Functions

1. Briefly operate control valves and verify that they are correctly matched to slave arm
functions. Correct any misconnected hoses. Label the hydraulic controls to match the
slave arm’s functions and movements.
Note: Air in hydraulic lines or components may cause very rapid or jerky slave arm movement.
2. Adjust the restrictor valves, if present, to produce the maximum rate of travel desired for each
slave arm function.
3. Purge the slave arm’s hydraulic system of air by driving each linear actuator through its full range
of travel several times.
Installation of your RigMaster Slave Arm is finished. Proceed to the “Operation” chapter.
Page 14 • Installation Startup & Test 011–0756

Operation
In This Chapter:
• 1 Operation Overview ............................................. page 15
• 2 Factors Affecting Slave Arm Performance ......................... page 15
• 3 Normal Operation ......................................................... page 16
• 4 Controlling System Functions ......................................... page 17
1 Operation Overview
1.1 RigMaster Overview
The RigMaster is a hydraulically powered, rate-controlled slave arm with five functions: azimuth
yaw, shoulder pitch, boom extend, wrist rotate, and jaw open/close. Movement of each function
is achieved using a linear actuator, except the wrist, which uses a rotary actuator.
The base, shoulder block, extension boom, and wrist/jaw are the major structural components of
the slave arm. Linear actuators control movement of the azimuth, shoulder, boom-extend func-
tions. The actuator body is pinned to one structural member and the actuator rod is pinned to
the adjacent structural member. Extending or retracting the actuator rod causes one structural
member to pivot or extend in relation to the other. A rotary actuator (gerotor) provides wrist
rotation and a small linear actuator, inside the wrist, opens and closes the jaws.
2 Factors Affecting Slave Arm Performance

RigMaster's performance specifications for lift, wrist torque and speed, and jaw grip force are
based on the use of water-glycol (or an equivalent fluid type) at 3000 psi with an available flow
of 5 gpm. At lesser pressures and flow rates, lifting capacity, wrist torque and speed, and jaw grip
force will be reduced. Even with an adequately sized HPU, other conditions can reduce the pres-
sure, viscosity, and flow of fluid delivered to the slave arm and diminish performance. These con-
ditions include:
 extremely high or low fluid temperature
 fluid contamination
 plugged filters
 extreme hose lengths
 inadequate hose diameters
 improperly adjusted flow restrictors
011-0757 Page 15
• Operation
With a consistent hydraulic input, the ability of the slave arm to lift loads also varies with the
changing leverage available within each joint and the position and distance of the load from the
active joint. For example, the slave arm can lift 181 kg (400 lbs) when the boom is fully extended
and up to 270 kg (595 lbs) when the boom is fully retracted.
The wrist rotate function is affected by loads in a similar way, most noticeably when the axis of
rotation is at or near horizontal: loads closer to the axis of rotation are more easily rotated than
loads farther from the axis of rotation. Likewise, a balanced load of any size can be rotated easier
than an unbalanced load. A severely unbalanced load can also cause an active actuator to stall
and an inactive actuator to drift.
The RigMaster slave arm is designed with safety factors well above of its specified load-handling
capacity. If possible, avoid operational situations where the safety factors may be exceeded.
These situations include:
 Collisions.
 Collisions while managing extreme loads.
 Collisions while managing extreme loads at the slave arm’s mechanical limits.
 Managing extreme loads at the slave arm’s mechanical limits.
The best protection is anticipating risky situations and planning slave arm operations to
minimize risks before manipulating any substantial load.
3 Normal Operation
3.1 Pre-Start Checks
Before operating the slave arm, check the following:
 No personnel or objects are within the slave arm’s range of motion.
 All hoses, fasteners, and fittings are connected and secure.
 Air has been purged from the hydraulic system if any lines or components have been discon-
nected for maintenance or repair.
3.2 Startup Procedure
! WARNING
Air in the hydraulic lines or components may cause very rapid or jerky
movement of the slave arm. Before turning on hydraulic power, be
sure that no personnel or equipment are within the slave arm’s range
of motion.
! Caution
If system pressure on the wrist drain (return) exceeds 350-600 psi
above ambient, hydraulic fluid will be released into the environment
from the relief valve.
1. Activate the hydraulic power unit.
2. Verify the following conditions:
Page 16 • 3 Normal Operation 011-0757

Operation •
 The hydraulic supply pressure is 207 bar (3,000 psi).
 The hydraulic system return or tank pressure does not exceed 350 psi.
 No hydraulic fluid leaks from hoses, fittings, or components.
Correct unsatisfactory conditions before proceeding.
3. Purge the slave arm’s hydraulic system of air by driving each linear actuator through its full range
of travel several times.
The slave arm is now ready for normal operation.
4 Controlling System Functions

The RigMaster’s base yaw, shoulder pitch, boom extend/retract, wrist rotate, and jaw grip are all
controlled by the user’s hydraulic control manifold. The rate and direction of hydraulic fluid flow
determine the function performed. The table below lists each specific slave arm joint/actuator
function and the movements that result from the application of hydraulic pressure. Label the
hydraulic controls to match slave arm’s functions and movements.
To terminate operation, turn off or disable hydraulic power to the control manifold and slave
arm.

Base yaw Linear 105°
Shoulder pitch Linear 105°
Boom extend/retract Linear 305 mm (12-in.)
Wrist rotate Gerotor 360°
Gripper, standard Linear 284 mm (11.2-in.)
011-0757 4 Controlling System Functions • Page 17

• Operation
This page not used.
Page 18 • 4 Controlling System Functions 011-0757

Troubleshooting
In This Chapter:
• 1 Troubleshooting the Slave Arm .............................. page 19
• 2 Troubleshooting Tables .................................................. page 20
1 Troubleshooting the Slave Arm

Whole arm symptoms:
If all slave arm actuators are unresponsive, sluggish, sagging, erratic, or hard-over, the cause will
be found either in the HPU (hydraulic power unit) and equipment supplying hydraulic pressure
or the manifold and equipment providing function control. Check supply and return pressures
and the supply solenoid (if present) to quickly eliminate the HPU group of causes. Consult the
appropriate OEM manual and the tables in this chapter for more specific troubleshooting infor-
mation on the remaining group of causes.
Single function symptoms:
When a single function is unresponsive, sluggish, sagging, erratic, or hard-over, the cause will
usually be either a single control component failure, including controller, manifold, control
cabling, hoses, valves (lock, restrictor, relief), or in a faulty component directly associated with
the function (such as actuator, fittings, seals). To eliminate the control component group of pos-
sible causes, determine whether or not controlled pressures are reaching the slave arm hoses for
the affected function. The tables in this chapter provide more specific troubleshooting informa-
tion about the function group.
Multiple causes:
Sometimes a symptom is the result of a group of causes. For example, a sluggish slave arm could
be caused by one or more of the following causes: a marginal supply pressure, a faulty solenoid
valve, a pinched supply hose, inadequately-sized control hoses, high return pressure, etc. Diag-
nosing all causes can be difficult: one cause may be intermittent or vary with temperature or
time, one cause may initiate another, or no one cause alone may be sufficient to produce a recog-
nizable symptom. If you correct one obvious cause, but the symptom doesn’t change or there is
only a marginal improvement, more detective work is in order.
Start by inspecting the entire slave arm system for clues; get an accurate overall picture of its
present condition:
 Is the HPU extra noisy or running hot?
 Are the supply and return pressures within specifications?
 Does the operation of other hydraulic equipment have an effect?
011-0784 Page 19
• Troubleshooting
 Are all hoses clear and functional?
 Are the symptoms better or worse at startup? At shutdown?
 Is anything leaking?
This is the time when familiarity with the look, feel, sound, and smell of correctly functioning
components will help you spot something wrong. Test electrical and hydraulic outputs to elimi-
nate functional components from suspicion. Replace or repair all marginal components and cor-
rect all questionable conditions as you go. The ultimate result will be a fully functional and
reliable slave arm system.
To help prevent the reoccurrence of multiple causes, maintain system components on a regular
schedule and take corrective action at the first sign of a symptom.
2 Troubleshooting Tables
The following tables are keyed to whole-arm troubleshooting and single-joint troubleshooting. In
both these groups are individual tables for troubleshooting slave arm components exhibiting
unresponsive, sluggish, erratic, sagging, or hard-over misbehavior. Each table describes a differ-
ent symptom. Within each table are columns listing the possible causes and corrective actions.
“Symptoms” Column
The following terms are used in the “Symptoms” column to describe behavior of the entire
manipulator Arm or a specific functions:
 Unresponsive: Does not respond to control input.
 Sluggish: Responds predictably but slowly to control input.
 Erratic: Responds jerkily or unpredictably to control input.
 Sagging: Fails to remain in position in absence of control input.
 Hard Over: Locked firmly against limit of mechanical travel.
From the whole-arm or single-joint table collections select the specific symptom the slave arm or
function is exhibiting.
2.1 Whole-Arm Troubleshooting Tables

These tables are for troubleshooting when the entire slave arm exhibits a specific symptom.
Note: A symptom may be the result of more than one cause or the cumulative affect of several marginal
causes. For example, a sluggish slave arm may result from clogged filters, a pinched supply hose, inade-
quate pressure from HPU.
SYMPTOM: Entire Slave Arm Unresponsive

Possible Causes Corrective Action
Very low or no hydraulic pressure and/or Restore electrical power to HPU.
flow. Adjust or repair HPU.
Adjust or repair supply restrictor valve.
Hydraulic fluid low or below pump intake. Add hydraulic fluid.
Page 20 • 2 Troubleshooting Tables 011-0784

Troubleshooting •
SYMPTOM: Entire Slave Arm Unresponsive (continued)

Faulty supply or manifold solenoid valve. Adjust or repair solenoid valve.
Blocked, pinched, or kinked supply hose. Clear blocked hose/reposition or protect hose to ensure
free flow.
Pinched or kinked manifold control hoses. Reposition or protect hoses to ensure free flow.
Electrical power failure to manifold control- Restore electrical power.
ler
Manifold controller, controller cabling, or Replace or repair controller, cable, or termination.
termination failure.
Load exceeds slave arm capacity. Reduce load.
Clogged hydraulic filters. Check visually-inspectable filters. Replace if clogged or
approaching contaminant saturation. Replace all canis-
ter-type filters.
SYMPTOM: Entire Slave Arm is Sluggish

Low hydraulic pressure and/or flow. Adjust or repair HPU.
Adjust or repair supply restrictor valve.
Hydraulic fluid low Add hydraulic fluid.
Partially blocked, pinched, or kinked sup- Unblock supply hose/reposition or protect hose to ensure
ply hose. free flow.
Excessive demand on HPU Turn off other hydraulic equipment, reduce or stage HPU
demand, or increase HPU capacity.
Pinched or kinked control hoses. Reposition or protect hoses to ensure free flow.
Control or supply hoses not sized for dis- Increase hose diameter to provide adequate pressure
tance from manifold. and flow to slave arm.
Hydraulic fluid dirty, contaminated or Replace fluid if dirty, contaminated, or incorrect type or
incorrect type or viscosity, temperature viscosity. Install heater or cooler to keep viscosity within
too high or too low to maintain viscosity. specification.
Clogged hydraulic filters. Check visually-inspectable filters. Replace if clogged or
approaching contaminant saturation. Replace all canister-
type filters.
Load at or near slave arm capacity. Reduce load.
Use shoulder joint to lift heavy loads.
Severe hydraulic leak. Repair leak source.
SYMPTOM: Entire Slave Arm is Operating Erratically

Air in hydraulic lines. Purge hydraulic system.
Load exceeds slave arm capacity. Reduce slave arm loading.
011-0784 2 Troubleshooting Tables • Page 21

• Troubleshooting
SYMPTOM: Entire Slave Arm is Operating Erratically (continued)

Hydraulic fluid dirty, contaminated or Replace fluid if dirty, contaminated, or incorrect type or
incorrect type or viscosity, temperature viscosity. Install heater or cooler to keep viscosity within
too high or too low to maintain viscosity. specification.
Clogged hydraulic filters. Visually inspect filters. Replace if clogged. Replace all
canister-type filters on a regular schedule.
Low hydraulic fluid level (possibly inter- Add hydraulic fluid. Increase HPU fluid capacity.
mittent).
High HPU demand (steady or intermit- Reduce or stage HPU demand, or increase HPU capacity.
tent).
Partially blocked, pinched, or kinked man- Clear hose/reposition or protect hose to ensure free flow.
ifold supply hose.
Pinched or kinked control hoses. Reposition or protect hoses to ensure free flow.
Intermittent electrical power to HPU or Correct power supply problem.
manifold controller.
Intermittent wiring fault in controller, Correct wiring fault.
cable, or manifold.
SYMPTOM: Entire Slave Arm Hard Over.

Manifold controller or controller cable Repair/replace controller or cable.
failure.
SYMPTOM: Entire Slave Arm Sagging

Low hydraulic pressure. Adjust/repair HPU or supply restrictor valve. Add hydraulic fluid.
Reduce or stage HPU demand, or increase HPU capacity.
Low hydraulic fluid level. Add hydraulic fluid. Increase HPU fluid capacity.
Severe hydraulic leak. Repair leak source.
2.2 Single Joint Troubleshooting Tables
SYMPTOM: Single Joint/Actuator Sluggish

Joint load capacity near limit. Reduce slave arm loading. Use combination of joints
to manipulate load.
Air in control line. Purge hydraulic system.
Control hose pinched, kinked, or leaking. Reroute, protect, replace, or repair control hose.
Partial failure of actuator seal or component. Repair or replace seal or component.
Stuck or faulty relief valve. Repair or replace relief valve.

Troubleshooting •
SYMPTOM: Single Joint/Actuator Sluggish (continued)

(Wrist only) Incorrect wrist motor preload. Service wrist joint and set correct motor preload.
(Wrist only) Excessive return/drain pressure. Check and clear return line. Check for internal leak in
wrist and correct.
SYMPTOM: Single Joint/Actuator Unresponsive

Load capacity exceeded. Reduce joint load. Use combination of joints to
manipulate load.
Pinched, kinked, or leaking control hose. Reroute, protect, replace, or repair control hose.
Faulty, stuck, or frozen relief valve. Repair or replace relief valve
Faulty control switch, wiring, cable, or cable ter- Repair or replace rate control switch, wiring,
mination. cable or cable termination.
Actuator failure. Repair or replace actuator.
(Jaw only) Blocked wrist joint slip ring. Repair or replace wrist joint slip ring.
(Wrist only) Faulty seal. Replace seal.
(Wrist only) Excessive return/drain pressure. Check and clear return line/check for internal
leak in wrist and correct.
SYMPTOM: Single Joint/Actuator Sagging or Drifting

Faulty actuator seal or component. Repair or replace actuator seal or component.
Faulty relief valve. Repair or replace relief valve.
Faulty lock valve. Repair or replace lock valve.
Hydraulic leak. Repair leak source.
Extreme load on actuator. Reduce load or balance load. Sagging linear actuator-driven
joints or drifting roll joints are normal with extreme loads or
unbalanced loads.
SYMPTOM: Single Joint/Actuator Hard Over

Controller or controller cable failure. Repair/replace controller or cable.
Faulty actuator seal or component. Repair or replace actuator seal or component.
011-0784 2 Troubleshooting Tables • Page 23

• Troubleshooting
SYMPTOM: Single Joint/actuator Operating Erratically

Air in control line. Purge hydraulic system.
Partial actuator failure. Repair or replace actuator.
Control hose being pinched or kinked by Reroute or protect hose to ensure free flow.
operation.
(Jaw only) Blocked wrist joint slip ring Clear wrist joint slip ring port.
port.
(Wrist only) Low hydraulic pressure. Provide 1500-3000 psi nominal pressure. Wrist torque
and breakaway RPM may become erratic as supply pres-
sure drops.

Maintenance & Service
In This Chapter:
• 1 Organization ................................................................ page 25
• 2 Safety First!................................................................. page 26
• 3 Important Service Practices & Procedures ............... page 27
• 4 Basic Service Instructions..................................... page 29
• 5 Special Service Instructions .................................. page 50
1 Organization
This chapter contains information on general maintenance and service instructions for compo-
nents and assemblies of the RigMaster Slave Arm. Two types of service instructions are pro-
vided:
Basic Service
The “Basic Service Instructions” section on page 29, cover the less complex procedures shown
below. They are followed by part lists and illustrations supporting the instructions.
 “Base Assembly Replacement” section on page 30
 “Shoulder Block Assembly Replacement” section on page 31
 “Arm Segment Assembly Replacement” section on page 31
 “Boom Replacement” section on page 32
 “Wrist/Jaw Assembly Replacement” section on page 33
 “Linear Actuator Assembly Replacement” section on page 34
— Linear actuator (6-in., base/shoulder) replacement
— Linear actuator (6-in., shoulder/arm segment) replacement
— Linear actuator (12-in.) replacement
— Linear actuator seal, bearing and o-ring replacement
— “Hydraulic Hose Replacement” section on page 36
Special Service Information
The detailed “Special Service Instructions” section on page 50 cover the following components:
 Jaw Piston/Nose Block, 101-3853
 Intermeshing Jaw, 101-3586
 Wrist, 101-3587
011-0754 Page 25
• Maintenance & Service
2 Safety First!
Note: The following information is presented as a reminder of the safety issues present when maintain-
ing or servicing a slave arm or manipulator system. It does not cover every possible safety risk and is
not meant to replace existing worksite policies, standards, processes, and practices for protecting the
safety of personnel working on or around this equipment.
2.1 Worksite Safety
! WARNING
HYDRAULIC AND MECHANICAL HAZARDS! Before any starting any ser-
vice, maintenance, configuration, or testing of this equipment:
• Notify the appropriate personnel of your activities.
• Be sure you have a safe electrical, hydraulic, and mechanical work-
ing environment. Turn off, lock out/tag out, and/or isolate surround-
ing equipment that could be a safety hazard to you.
• Observe all safety regulations and procedures in effect at the work-
site.
• Wear personal protective equipment (PPE) appropriate for the task.
2.2 Maintenance & Service Safety

Protect yourself! Before you perform any maintenance or service, read the following safety
warnings.
2.2.1 Mechanical Safety
! WARNING
Slave arm components are heavy and can move, drop, shift, or col-
lapse when hydraulic pressure is removed or relieved.
• Support the slave arm at the elbow and jaw when relieving hydrau-
lic pressure or opening any hydraulic connection.
2.2.2 Hydraulic Safety
! WARNING
Failure to follow safety procedures for working with high-pressure
hydraulic equipment can result in serious injury or death. ALWAYS
assume that hydraulic equipment is energized until you have CON-
FIRMED that it is isolated, locked out, and tagged out as directed by
applicable hydraulic safety regulations and procedures, that all pres-
sure gauges indicate zero pressure, and that all stored and residual
pressures have been isolated or relieved.
Common causes of serious injury and death from high-pressure hydraulic equipment include:
 Injection of pressurized hydraulic fluid into the body.
 Blunt force trauma to the body from flailing, pressurized hoses and forcefully
ejected fittings.
Page 26 • 2 Safety First! 011-0754

Maintenance & Service •
 Bodily contact with hot hydraulic fluids and sprays or ignited fluids, sprays, or
mists.
 Falls caused by slipping on spilled fluids.
To prevent injury or death while working with high-pressure hydraulic equipment, always follow
all applicable hydraulic safety regulations and procedures. The instructions listed below provide
general guidelines and are not meant to replace or modify existing safety regulations and proce-
dures.
 Always lock out and tag out hydraulic equipment before it is serviced so that it
cannot be accidentally energized.
 Provide support for equipment and components that can move, drop, shift, or col-
lapse when hydraulic pressure is removed or relieved.
 Always wear safety glasses and other required personal protective equipment
(PPE).
 Confirm that equipment pressure gauges indicate zero pressure.
 Before loosening any fittings, isolate or relieve any stored or residual pressure
that remains in components even when the hydraulic system is de-energized.
 Never use any part of your hand or body to check for hydraulic fluid leaks, even if
you are wearing personal protective equipment. High-pressure hydraulic fluid
injects easily into any body part, and an injection wound, regardless of size, must
be evaluated immediately by a physician as a surgical emergency.
 Service hydraulic equipment away from sparks or open flame.
 Immediately clean up spilled hydraulic fluid from floors or other surfaces.
 Before returning the equipment to service, tighten all fittings and connections as
specified by the equipment manufacturer.
 Move all personnel away from serviced hydraulic equipment before pressurizing
it and testing for safe operation.
Only qualified and authorized personnel should perform hydraulic work on this equipment. A
qualified person is one who has the required skills and knowledge to perform hydraulic work
safely, even under adverse environmental conditions, and who knows the hazards associated
with hydraulic work and the methods for reducing the risk of accidents from those hazards.
2.3 Deck Testing
! WARNING
When testing a slave arm on deck:
• Move all personnel outside the slave arm's range of motion when
hydraulic pressure is applied and functions are tested.
• Direct the slave arm to point away from personnel and critical or
sensitive areas while testing jaw functions.
3 Important Service Practices & Procedures

Important practices and procedures for successful manipulator system service:
011-0754 3 Important Service Practices & Procedures • Page 27

 Clean, degrease, and inspect disassembled parts. Replace damaged, worn, or bro-
ken parts before reassembling.
 Replace o-rings that are broken, damaged, or shows signs of wear.
 Lubricate all o-rings with o-ring lubricant (Dow Corning® 55 or petroleum jelly).
Note: Do not use lubricants that contain suspended particles, such as molybdenum or graphite, on com-
ponents exposed to the hydraulic system—the particles can be drawn into the hydraulic fluid and clog fil-
ters.
 Apply Aqua Lube (or equivalent) to all fastener threads, EXCEPT:

— when threads are exposed to the hydraulic system.
— when you are directed otherwise by the work instruction or engineering draw-
ing.
 Torque all fasteners as specified. Torque specifications on engineering drawings
take precedence over all other text references.
! Caution
Excessive torque to 1/4-20 exterior fasteners (above 8 ft-lbs) can
strip the hole threads in aluminum components. Follow torque specifi-
cations on engineering drawings and service instructions.
3.1 Maintenance
Maintenance keeps your slave arm functioning safely and efficiently, helps reduce downtime and
service expenses, and extends its service life. This section provides information on recommended
maintenance practices and schedules.
3.1.1 Daily Maintenance and Inspections

Daily inspections pinpoint real, potential, and emerging problems before they become cata-
strophic. Complete the following steps daily, or after every duty cycle, to keep your slave arm sys-
tem in good operating condition:
1. (Submersible models) Thoroughly wash the exterior of the slave arm with fresh water.
Remove any entrapped debris. If the slave arm will be out of service for more than a few
days, coat exposed actuator rods with a film of hydraulic oil.
2. Inspect the slave arm for loose or missing fasteners (vibration and temperature cycles can
cause fasteners to loosen). Replace or retighten fasteners, as needed.
3. Inspect the hydraulic hoses for abrasions or cuts. Repair or replace damaged hoses.
Install hose protection or reroute hoses, if practical, to prevent future damage.
4. Inspect the slave arm for hydraulic leaks. Repair any leaks, replace lost fluid, and bleed
air as needed.
5. If the slave arm has been subjected to severe service or collision, carefully inspect slave
arm components. Verify that the slave arm joints, actuator rod pins, and pivot pins are
intact and secure. Inspect the base and arm segments for bends, fractures or cracks,
especially around the pin mounts. Inspect linear actuator bodies and shafts for dents,
bends, or damaged components. Repair or replace damaged components.
Page 28 • 3 Important Service Practices & Procedures 011-0754

3.1.2 Scheduled Maintenance
Regularly scheduled maintenance helps maintain the performance, efficiency, and service life of
your slave arm.
1. Develop schedules of inspection, maintenance, and service that fit your slave arm's
operating environment and duty cycles. Harsh service environments require more
frequent intervals of attention.
2. Perform the inspections, maintenance, or service as scheduled.
3. Keep a log of all inspections, maintenance, and service.
4. Inspect components and observe performance frequently, starting with the first use of
the slave arm. This will allow you to note initial conditions, track changes and wear, and
set up maintenance and service schedules appropriate to your slave arm's operating
environment and duty cycles.
The table below contains a minimum maintenance schedule for your slave arm and should be
used along with schedules supplied with your HPU and control manifold.
Minimum Maintenance Schedule

Schedule Period Maintenance Task
After daily operation See Daily Maintenance and Inspections section.
Every 100 operating hours Re-torque all external slave arm fasteners.
Take a sample of hydraulic fluid and test for water and partic-
ulate contamination. Replace if contaminated.
(seawater operation) Coat pivot pins and pivot pin bores with
silicone grease such as DC-5.
Every 500 operating hours or per HPU Check hydraulic tank fluid level. Clean/replace HPU suction
documentation strainers, fluid and breather filters.
Every 2000 operating hours Replace worn or damaged actuator pins and bushings.
Every 2000 operating hours or per Drain and replace hydraulic fluid (filter replacement fluid).
HPU documentation
Every 2000 operating hours or every Replace all actuator o-rings and seals. Lubricate with Dow
3 years (whichever comes first) Corning® DC-4. Clean all o-ring grooves and surfaces.
4 Basic Service Instructions

The “Basic Service Instructions” cover the procedures shown below. These instructions are sup-
ported by the “Part Lists & Illustrations” on page 14.
 Base assembly replacement
— “Base Assembly Replacement” section on page 30
 Shoulder block assembly replacement
— “Shoulder Block Assembly Replacement” section on page 31
 Arm segment assembly replacement
— “Arm Segment Assembly Replacement” section on page 31
 Boom replacement
011-0754 4 Basic Service Instructions • Page 29

— “Boom Replacement” section on page 32
 Wrist/jaw assembly replacement
— “Wrist/Jaw Assembly Replacement” section on page 33
 Linear actuator replacement
— “Linear Actuator Assembly Replacement” section on page 34
— Linear actuator (6-inch, base/shoulder) replacement
— Linear actuator (6-inch, shoulder/arm segment) replacement
— Linear actuator (12-inch) replacement
— Linear actuator seal, bearing and o-ring replacement
 Hydraulic hose replacement
— “Hydraulic Hose Replacement” section on page 36
Each individual part identified in a service instruction step is followed by an item number in
parentheses. This number corresponds to the item number of the part on the related part list. On
the adjacent drawing, this same item number is placed in a circle, with a line drawn to the spe-
cific part.
Note: The item numbers in this section are provided only for convenient reference between the service
procedures that follow and their respective drawings and part lists. They do NOT match the item num-
bers in the part lists and engineering drawings provided in the “Drawings & Part Lists” chapter.
Note: To get the right part when ordering, use the identification number shown in the Part No. column
of the part list.
Reference engineering drawings and part lists for the RigMaster slave arm and other sub-assem-
blies are located in the “Drawings & Part Lists” chapter.
4.1 Base Assembly Replacement

For the base assembly replacement procedure, item numbers in parentheses refer to parts in
Figure 1 and Figure 2.
4.1.1 Removing the Base Assembly

Refer to Figure 1 for the following steps:
1. Disconnect RigMaster from its hydraulic power source.
2. Remove retaining rings (7), thrust bearings (9), and the extend pin (8) that hold the
linear actuator (10) onto the base (3).
3. Remove the retaining rings (7), the thrust bearings (9), and the extend pin (8) that secure
the linear actuator (10) to the shoulder block (5).
Refer to Figure 2 for the following steps:
4. Remove the retaining ring (7), the thrust bearings (4), and the pivot pin (16) from the
base (15) and shoulder block (8). The bearings (5) are not removable.
Page 30 • 4 Basic Service Instructions 011-0754

5. Remove the two screws (18) and the bracket (17) securing the hoses (not shown) to the
base (15).
4.1.2 Installing the Base Assembly

To install the base assembly, reverse the removal procedure.
4.2 Shoulder Block Assembly Replacement

For the shoulder block assembly replacement procedure, item numbers in parentheses refer to
parts in Figure 2 on page 40.
4.2.1 Removing the Shoulder Block Assembly

2. Perform steps 3, 4, and 5 in the section on removing the base assembly.
3. Remove the retaining rings (7), the two bearings (4), the pivot pin (6), and the cable
guide (19) from the shoulder block (8). The bearings (5) are not removable.
4. Remove the retaining rings (14), the thrust bearings (9), and the wrist extend pin (13)
securing the linear actuator (11) to the shoulder block (8).
4.2.2 Installing the Shoulder Block Assembly

To install the shoulder block assembly, reverse the removal procedure.
4.3 Arm Segment Assembly Replacement

For the arm segment assembly replacement procedure, item numbers in parentheses refer to
4.3.1 Removing the Arm Segment Assembly

2. Remove the retaining rings (13), the thrust bearings (14), and the extend pin (27)
3. Remove the retaining rings (3), the thrust bearings (1), the cable guide (Figure 2 on page
40, item 19), and the shoulder pivot pin (4) securing the arm segment to the shoulder
block (5). The bearings (2) are not removable.
4. Remove the eighteen bolts and washers (9, 28) securing the arm segment to the wrist/jaw
(11).
5. Push out the wrist extend pin (12) securing the linear actuator (10) to the wrist/jaw (11).
! Caution
1. Loosening or disconnecting any hydraulic hose may release hydrau-
lic fluid under residual pressure.
2. Tag hydraulic fittings as you remove them in this procedure. Match

tags when reconnecting.
6. Disconnect the five wrist hoses (16) from the base of the wrist/jaw (11).

4.3.2 Installing the Arm Segment Assembly
To install the arm segment, reverse the removal procedure.
Torque the bolts in step 4 to 28.5 Nm (21 ft-lbs).
4.4 Boom Replacement

For the boom replacement procedure, item numbers in parentheses refer to parts in Figure 4 on
page 43 and Figure 5 on page 45.
4.4.1 Removing the Boom

For the following steps, item numbers in parentheses refer to parts in Figure 4.
2. Support the wrist/jaw assembly (5).
3. Manually extend the boom (2) enough to provide access to the wrist-attaching hardware.
4. Remove the eighteen bolts and washers (3, 8) securing the wrist/jaw assembly (5) to the
boom (2).
5. Push out the wrist extend pin (7) securing the linear actuator (4) to the wrist/jaw
assembly (5).
! Caution

6. Disconnect the five wrist hydraulic hoses (6) attached to the bottom of the wrist base (5).
For the following steps, item numbers in parentheses refer to parts in Figure 5 on page
45.
7. Remove the two bolts (14), the retainer (26), the base extend pin (13), and the two
actuator spacers (12) from the linear actuator (6).
8. Remove the two bolts (14), their washers (26), the base extend pin (13), and the two
actuator spacers (12) from the linear actuator (11).
9. Remove the retaining rings (Figure 3 on page 42, item 3), the thrust bearings (Figure 3,
item 1), and the shoulder pivot pin (Figure 3, item 4) from the arm segment and shoulder
block (Figure 3, item 5).
10. Remove bolts (15) and their washers (27) around the perimeter of the side plate (1).
Remove the side plate.
11. Carefully pull the boom (4) out of the arm segment.
4.4.2 Installing the Boom

For the boom installation procedure, item numbers in parentheses refer to parts in Figure 5 on
page 45.

1. Place one of the two short strip bearings (24) into the groove in the top plate (2), and the
other into the groove in the bottom plate (2).
2. Place one of the long strip bearings (23) into the groove in the left side plate (3).
3. Place the scraper (22) over the end of the boom (4). Estimate the distance the scraper
should be from the end of the boom by noting the location of the scraper grooves in the
top, bottom, and side plates (1, 2, 3).
4. Place two of the corner bearings (25) into their grooves on the opposite end of the boom
(4).
5. Holding the boom (4) and the corner bearings (25), line up the scraper (22) with the
grooves in the top, bottom and left side plates (1, 2, 3), and carefully place the boom into
the arm segment.
6. Place the remaining two corner bearings (25) into their slots at the end of the boom (4).
7. Place the remaining long strip bearing (23) into its groove in the right side plate (1).
Secure it in place with Aqua Lube™ or a similar factory-approved lubricant.
8. Replace the shoulder pivot pin (Figure 3 on page 42, item 4) and the two thrust bearings
(Figure 3, item 1) into the shoulder block (Figure 3, item 5) and arm segment.
9. Replace the two actuator spacers (12) and the extend pin (13) at the upper end of the
linear actuator (6).
10. Install the fitting guide (74) and BHCS (75) to the rear hose fitting (15) of the 12 in linear
actuator as shown in Detail B of Figure 5 on page 45.
11. Replace the two actuator spacers (12) and the extend pin (13) at the end of linear actuator
(11) that is nearest the wrist (7).
12. Replace the right side plate (1), carefully inserting the scraper (22) into the plate’s scraper
groove.
13. Replace the two retaining rings (Figure 3 on page 42, item 3) onto the shoulder pivot pin
(Figure 3, item 4).
14. Replace the four bolts (14) and the retainers (26) securing linear actuators (6, 11) in place.
15. Replace bolts (15) and washers (27) securing the right plate (1). Torque the bolts to 11 Nm
(8 ft-lbs).
4.5 Wrist/Jaw Assembly Replacement

Wrist and jaw components are most easily serviced or repaired when the wrist/jaw assembly has
been removed from the slave arm. Detailed wrist, jaw, and noseblock service instructions are
provided. See “Special Service Instructions” section on page 50.
For the wrist/jaw assembly replacement procedure, item numbers in parentheses refer to parts
in Figure 4 on page 43.
4.5.1 Removing the Wrist/Jaw Assembly
! Caution

Note: Tag hydraulic fittings as you remove them in this procedure. Match tags when reconnecting.

boom (2).
5. Push out the wrist pin (7) securing the wrist/jaw assembly (5) to the linear actuator (4).
6. Disconnect the five wrist hoses (6) at their fittings where they are connected to the
bottom of the wrist base (5).
4.5.2 Installing the Wrist/Jaw Assembly

To install the wrist/jaw, reverse the removal instructions.
4.6 Linear Actuator Assembly Replacement
! Caution
The linear actuators can be removed from the RigMaster without unbolting the arm segment
from its mounting. However, since linear actuators provide part of the support skeleton for the
arm, support the slave arm when you perform the following procedure.
Note: Tag hydraulic fittings as you remove them in this procedure. Match tags to reconnect the appro-
priate fittings.
4.6.1 Removing the 6-Inch Base/Shoulder Linear Actuator

For the base/shoulder linear actuator replacement procedure, item numbers in parentheses refer
to parts in Figure 1 on page 38.
1. Disconnect the RigMaster from its hydraulic power source.
2. Remove azimuth hydraulic hoses (11, 12) from the side and bottom of the linear actuator
(10).
3. Remove the retaining rings (7), the thrust bearings (9), and the extend pins (8) from the
base and shoulder ends of the linear actuator (10).
4. Remove the linear actuator (10).
4.6.2 Installing the 6-Inch Base/Shoulder Linear Actuator

To install the 6-inch base/shoulder linear actuator, reverse the removal procedure.
4.6.3 Removing the 6-Inch Shoulder/Arm Segment Linear Actuator

For the shoulder/arm segment linear actuator replacement procedure, item numbers in paren-
theses refer to parts in Figure 5 on page 45.

1. Disconnect the RigMaster from its hydraulic power source.
2. Disconnect the shoulder hose (18) from the linear actuator (11).
3. Remove the retaining rings (9), thrust bearings (10), and the extend pin (28) from the
shoulder end of the linear actuator (11).
4. Disconnect the shoulder hydraulic hose (19) from the linear actuator (11).
5. Remove the bolts (14) and the retainer (26), the extend pin (13), and actuator spacers (12)
from the linear actuator (11).
6. Remove the linear actuator (11).
4.6.4 Installing the 6-Inch Shoulder/Arm Segment Linear Actuator

To install the 6-inch shoulder/arm linear actuator, reverse the removal procedure.
Torque the bolts in step 5 to 217 Nm (160 ft-lbs).
4.6.5 Removing the 12-Inch Linear Actuator from the Arm Segment
For the 12-inch linear actuator replacement procedure, item numbers in parentheses refer to
1. Disconnect the RigMaster from its hydraulic power.
2. Manually extend the boom (4) enough to provide access to the bolts (5) and the wrist pin
(8).
boom (4).
4. Push out the wrist pin (8) securing the linear actuator (6) to the wrist (7).
! Caution
5. Disconnect the five wrist hoses (17).
6. Remove bolts (15) and their washers (27) securing the bottom plate (2). Loosen bolts (16)
securing the side and top plates (1, 2) of the arm segment just enough to remove the
bottom plate (2).
7. Disconnect the extend hose (21) from the wrist end of the linear actuator (6).
8. Remove the bolts (14) and the retainer (26) securing the base extend pin (13) and the
actuator spacers (12) to the arm. Carefully pull down the linear actuator (6), disconnect
the extend hose (20), and then remove the linear actuator.
4.6.6 Installing the Linear Actuator on the Arm Segment

To install the linear actuator, reverse the removal procedure.
Torque the bolts in step 6 to 11 Nm (8 ft-lbs).

4.6.7 Linear Actuator Seal, Bearing, & O-Ring Replacement
For the linear actuator disassembly procedure, item numbers in parentheses refer to parts in Fig-
ure 6 on page 47 for the 6-inch linear actuator, and Figure 7 on page 49 for the 12-inch linear
actuator.
Disassembling the Linear Actuator
! Caution
1. After removing the linear actuator from the arm segment, drain the fluid out of the linear
actuator by pushing and pulling the actuator shaft (2) in and out of actuator body (13)
several times.
2. Using some force, fully extend the actuator shaft (2).
3. Secure the end of the linear actuator body (13) in a vise, and using a modified 1 5/8-inch
deep socket head wrench fitted over the rod end (3), loosen and remove the nose gland
(4).
4. To separate the piston (1) from the shaft (2), insert a 1/2-inch ratchet wrench into the
hole in the piston and unscrew the piston from the shaft.
5. Remove and replace the seals, bearings, and o-rings (9, 10, 11) on the nose gland (4) and
the seals, fittings, and bearings (7, 8) on the piston (1).
Assembling the Linear Actuator
To assemble the linear actuator, replace all seals, bearings, and o-rings in the nose gland, and
then reverse the disassembly procedure.
Also install the fitting guide (74) and BHCS (75) to the rear hose fitting (15) of the 12 in linear
actuator as shown in Figure 7 on page 49.
4.7 Hydraulic Hose Replacement

For the hydraulic hose replacement, item numbers in parentheses refer to parts shown on Figure
4 on page 43 and sheet 1 of the RigMaster slave arm drawing 101-4991 located in the “Drawings
& Part Lists” chapter.
4.7.1 Removing the Hydraulic Hoses
! Caution
See the slave arm drawing 101-4991 in the “Drawings & Part Lists” chapter for the following
steps:
1. Disconnect the RigMaster from its hydraulic power source. Support the arm while
disconnecting the hoses.
2. Remove azimuth hoses (9, 10) by unscrewing them from the linear actuator (48).

3. Remove the retaining rings (29), thrust bearings (40), and the wrist extend pin (27)
4. Remove the shoulder hoses (7, 8) by unscrewing them from the linear actuator (48).
5. Loosen the bolts (33), securing the side, top, and bottom plates (12, 13, 14) in place, just
enough to remove the bottom plate (14). If the bottom plate cannot be removed by
loosening these bolts, it may be necessary to loosen the four large bolts (30).
6. Remove the extend hoses (5, 6) by unscrewing them from the linear actuator (2).
See Figure 4 on page 43 for the following steps:
boom (2).
10. Remove the five wrist hydraulic hoses (6) by unscrewing them from the wrist/jaw
assembly (5).
4.7.2 Installing the Hydraulic Hoses

To install the hydraulic hoses, reverse the removal procedure.
1. Torque the bolts (item 33) in step 5 to 8 ft-lbs, and the bolts (item 30) in step 5 to 160 ft-
lbs (See sheet 1 of the slave arm drawing 101-4991 located in the “Drawings & Part Lists”
chapter.
2. Torque the bolts in step 9 to 21 ft-lbs (see Figure 4 on page 43).
4.8 Part Lists & Illustrations

This section contains the part lists and illustrations for all “Basic Service Instructions” section on
page 29.
Note: The illustration and part list item numbers in this section (“Part Lists & Illustrations”) are provid-
ed only for convenient reference to the item numbers in the preceding service instructions. They do NOT
match the item numbers in the part lists and engineering drawings found in the “Drawings & Part
Lists”chapter.

Table 1 Also see Figure 1
Legend for Base Assembly Replacement

Item Part
Part Description Qty.
No. Number
3 007-0181 BASE 1
5 007-0180 SHOULDER BLOCK 1
7 002-1042 RING, RETAINING, EXTERNAL 4
8 001-3030 PIN, EXTEND, WRIST 2
9 003-0099 THRUST BEARING, DIXON CWW16E24-3 4
10 101-1908 LINEAR ACTUATOR, 6" 1
11 006-0834 AZIMUTH HOSE C2 1
12 006-0833 AZIMUTH HOSE C1 1
Base assembly replacement drawing
Figure 1 Base assembly replacement

Legend for Shoulder Block Replacement

Item Part
No. Number
4 003-0100 BEARING, THRUST, DIXON #CWW24E42-3 4
5 003-0025 BEARING, DIXON #CJ24E26-8 4
6 001-7288 PIN, PIVOT, SHOULDER 1
8 007-0180 BLOCK, SHOULDER 1
14 002-1042 RING RETAINING, EXTERNAL 4
15 007-0181 BASE 1
16 001-3035 PIN, PIVOT, AZIMUTH 1
17 001-3116 HOSE GUIDE 1
18 002-1057 SHCS, 1/4-28 X 2-1/2, SS 2
19 001-3117 BRACKET 1

Shoulder block replacement drawing
Figure 2 Shoulder block replacement

Legend for Arm Segment Replacement

Item Part
No. Number
1 003-0100 BEARING, THRUST, DIXON #CWW24E42-3 2
2 003-0025 BEARING, DIXON #CJ24E26-8 2
4 001-7288 PIN, PIVOT SHOULDER 1
5 007-0180 SHOULDER BLOCK 1
6 002-0065 HHCS, 1/4-20 X 5/8, SS 2
7 001-7287 PIN, ACTUATOR, SLOTTED, 5.47 LONG 2
8 001-2119 SPACER, ACTUATOR 2
9 002-0052 NAS 6404U3 18
10 101-1909 LINEAR ACTUATOR 12" 1
11 101-3587 WRIST 1
14 003-0099 BEARING, THRUST DIXON CWW16E24-3 2
16 006-1594 HOSE ASSY, -4 JIC, 93-IN, 5
17 001-4342 RETAINER, PIN 1
28 002-2151 WASHER, 1/2 OD X 9/32 ID, .078 THK, SS 18

Arm segment replacement drawing
Figure 3 Arm segment replacement

Legend for Wrist/Jaw & Boom Replacement

Item Part
No. Number
1 No part number ARM SEGMENT 1
2 001-3029 SPAR (BOOM), 12" 1
3 002-0052 NAS6404U3 18
5 101-3587 WRIST 1
6 006-1594 HOSE ASSY, -4 JIC, 93-IN 5
Wrist/jaw and boom replacement drawing
Figure 4 Wrist/jaw and boom replacement

Legend for Shoulder & Arm Linear Actuator Disassembly

Item Part
No. Number
1 001-7285 RIGHT SIDE PLATE 1
2 001-2110 TOP/BOTTOM PLATE 2
3 001-7286 LEFT SIDE PLATE 1
4 001-3029 SPAR (BOOM) 1
5 002-0052 NAS 6404U3 18
7 101-3587 WRIST 1
8 001-2117 WRIST EXTEND PIN 1
9 002-1042 RETAINING RING, EXTERNAL 2
12 001-2119 ACTUATOR SPACER 4
13 001-7287 BASE EXTEND PIN 2
14 002-1043 HHCS, 1/4-20 X 5/8, SS 4
15 002-0188 HHCS, 1/4-20 X 1.5, SS 13
17 006-1594 HOSE ASSY, -4 JIC, 93-IN 5
18 006-0832 SHOULDER HOSE 2A 1
19 006-0831 SHOULDER HOSE 2B 1
20 006-0829 BOOM HOSE C1 1
21 006-0830 BOOM HOSE C2 1
22 001-2588 SCRAPER, BOOM 1
23 003-0098 LONG STRIP BEARING 2
24 003-0097 SHORT STRIP BEARING 2
25 003-0096 CORNER BEARING 4
27 002-0790 WASHER, 1/4 ID X .50 OD, SS, .032 THK 26

Shoulder and arm linear actuator disassembly drawing
Figure 5 Shoulder and arm linear actuator disassembly

Legend for 6-Inch Linear Actuator Assembly
Linear Actuator, 6-in Stroke, 101-6361
Rev. B
Item P/N Description Qty
1 001-1777 PSTN,LIN ACTR 1.75 1
2 001-2105 SFT,LIN ACTR,6 IN 1
3 001-1779 ROD END,LIN ACTR 1
4 001-2703 GLAND,NOSE,LIN ACTR 1
6 003-0114 BRG,PVT,LIN ACTR,T2 GAMMA 2
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
13 007-0797 BODY,LINEAR,ACTUATOR,6 INCHES 1
14 004-0082 O-RING,3-904 BUNA 90 0
15 006-0108 FIT,HYD,-4,JIC,-4 ST,ELB,MALE 2
16 006-0841 FIT,HYD,-4 JIC BHD,4WTX-SS 1
17 001-9632 TUBE,EXTEND,ACTUATOR,LINEAR 1
18 006-0842 NUT,FIT,JAM,-4,7/16-20,4WLN-SS 1
40 101-6361-WI WORK INSTRUCTIONS 0
46 010-0184 TOOL,INSTL,M,1.75 0
47 010-0185 TOOL,SIZING,F,1.75 0
48 010-0203 TOOL,SIZING,M,1.0 0
49 010-0759 CROWSFOOT,OPEN END,1 5/8 0

REV ZONE DESCRIPTION DATE BY APPR
A - RELEASED FOR PRODUCTION 7/27/07 PK SLW

NOTES:
ADDED BALLOON 18, AND NUT IN MODEL AND
B - UPDATE TUBE 17 WITH DIMENSION 11/16/07 VDM AL
1. ITEMS LISTED BELOW TO BE TORQUED AS INDICATED:
ITEMS: TORQUE:
1, 3 75 FOOT LBS.
011-0754
4 240 FOOT LBS.
15 21 FOOT LBS.
2 SERIALIZE IN LOCATION SHOWN.
15
6-Inch Linear Actuator Assembly drawing
Figure 6
15
16
17
A 18
1
2
9 4
6
14
2 REF
6-Inch Linear Actuator Assembly

3
6 13 10 11 10 11 12
7 8 7
A
SECTION A-A
4 Basic Service Instructions

GENERAL NOTES NEXT ASSEMBLY
INTERPRET DIMENSIONING AND TOLERANCING
A
101-3582
PER ASME Y14.5M-1994. IN ADDITION, S
DENOTES REGARDLESS OF FEATURE SIZE.
•
101-4991
REMOVE ALL BURRS AND BREAK ALL SHARP
EDGES
ALL MACHINED SURFACES TO BE 63 RMS PROJECT RIGMASTER
FINISH UNLESS OTHERWISE NOTED. SIGNATURE DATE
TITLE
DIMENSIONS ARE IN INCHES UNLESS
OTHERWISE NOTED. DRAWN SLW 7/19/07 LINEAR, ACTUATOR,
TOLERANCES DESIGNED
PROPRIETARY AL 7/19/07 6 INCH WITH HARD LINE BRACKET
RELEASED FOR DECIMALS FRACTIONS ANGLES
THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO CHECKED SCALE: DRAWING NUMBER SIZE SHEET REV
SCHILLING ROBOTICS. ANY REPRODUCTION, DISCLOSURE, OR .X ±.1 .X ±30'
USE OF THIS DOCUMENT IS EXPRESSLY PROHIBITED EXCEPT .XX ±.02 ±1/16 .XX ±15' LEAD SLW OF
AS SCHILLING ROBOTICS MAY OTHERWISE AGREE TO IN WRITING. PRODUCTION .XXX ±.005 1:1 101-6361 C 1 1 B
Page 47
Legend for 12-inch lInear Actuator Assembly
Rev. A
1 001-1777 PSTN,LIN ACTR 1.75 1
2 001-2103 SFT,LIN ACTR,12 IN 1
9 004-0669 O-RING,2-031,BUNA 90 1
10 001-0893 BRG,ROD 2
13 007-0173 BODY,LIN ACTR,12IN,RIG 1
14 004-0082 O-RING,3-904 BUNA 90 0
46 010-0184 TOOL,INSTL,M,1.75 0
47 010-0185 TOOL,SIZING,F,1.75 0
48 010-0203 TOOL,SIZING,M,1.0 0

12-inch linear actuator assembly drawing
Figure 7 12-inch linear actuator assembly

5 Special Service Instructions
This section consists of detailed service instructions for the wrist and jaw assemblies.
5.1 Using the Service Instructions

The first page of each Service Instruction provides information about the affected assembly,
preparations that should be completed before beginning the service steps, and any materials,
chemicals, standard and custom tools that will be needed. Special warnings, tips, and notes are
included to help you perform the steps safely, correctly, and quickly.
Within the instruction steps, part numbers are placed in parenthesis. Use these numbers to
select parts from spares kits or stock, and to order parts from the factory. To reference the part
number to the equivalent part on an engineering drawing (in the “Drawings & Part Lists” chap-
ter), match up the part number on the accompanying part list. Then note the Item number. On
the related engineering drawing the item number is placed in a circle, with a line drawn to the
specific part.
Before beginning any service, review the “Safety First!” section on page 26 and the “Important
Service Practices & Procedures” section on page 27 of this chapter.
5.2 Start-up Following Service

After Minor Service:
Follow the pre-start checkout and start-up procedures in the “Operation” chapter. Be sure to
replace any hydraulic fluid lost during maintenance or service and bleed air from the system.
After Major Service:
Follow “Installation Checkout & Test” in the “Installation” chapter before resuming normal oper-
ation. If it is likely that fluid has been contaminated, flush the hydraulic system, replace with
fresh, filtered fluid, and bleed air from the system.
5.3 Service Instruction List

• Jaw Piston/Nose Block, 101-3853. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 51
• Intermeshing Jaw, 11.5-in, 101-3586 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 61
• Wrist, 101-3587 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 69
Page 50 • 5 Special Service Instructions 011-0754

Service Instruction
Jaw Piston/Nose Block, 101-3853
Description
Complete service instructions for the jaw
piston/nose block 101-3853. Used in jaw
assemblies:
101-4102, 4-Finger Intermeshing
101-4103, 6-in. Parallel-Acting
101-4104), 11.5-in. Intermeshing
Estimated Time to Complete Reference Drawing

2 hour 101-3853
Preparation for Service
Below is a list of required tools and materials for this Service Instruction. Look over the list
and make sure you have all the materials before you get started. Read through the entire
procedure to make sure you understand, and are capable of performing, the service. Take
special notice of all notes, warnings, and the terminology section.
Tools Needed Materials Needed
11/16-in. 12-point socket Valvoline® Val-Plex EP Grease
9/16-in. socket Anti-seize, 1 oz. tube (002-1925)
19.05 mm (.750-in.) drill bit or drill rod Aqua Lube (002-0805)
(optional)
torque wrench capable of 8-135 Nm (5-100 Loctite 271® (002-0795)
ft/lbs)
torque wrench capable of 406 Nm (300 ft/ Loctite 7471 Primer®
lbs)
bench vise with soft jaws Dow Corning® 55 O-ring lube or petroleum
jelly
pick tool
razor blade or X-acto style knife
Custom Tools Needed Terminology
010-0175 female sizing tool HHCS = hex head cap screw
010-0174 male installation tool HPU = hydraulic power unit
010-0214 sizing tool
Note: If you intend to change bearings (003-0050) in the nose block

(101-4108), you will need to allow at least 1 hour for the Loctite 271 to
harden.
SERVICE INSTRUCTION 011–5011 Page 51

Note: If you are planning to replace the seals (004-0616 and 004-
0650) you must have replacements on-hand. You must destroy the old
seals to remove them.
! Caution
Some components have protective coatings such as anodiz-
ing. Take care not to scratch any protective coatings. Corro-
sion damage will result.
You must remove the jaw assembly before you can perform service on the jaw piston/nose
block assembly. See the service instructions for the jaw assembly installed on your slave
arm.
You can perform the procedures in this Service Instruction with the wrist attached to, or
separated from, the slave arm. If possible, perform all assembly work in a clean, dry envi-
ronment to prevent contamination and damage to bearing surfaces. We recommend that
you make a photocopy of this Service Instruction for workbench use.
Disable the Slave Arm
! Caution
Before you can service the arm safely, you must disable
electrical and hydraulic functions of the arm. Follow steps
below before continuing.
1. Raise the arm to a comfortable working position.

2. Turn off the power to the hydraulic power unit (HPU).
Disassemble the Nose Block

Disassembly of the intermeshing jaw assumes that all preparations, previously described
in this Service Instruction, have been met.
Numbers in parentheses refer to the part number of the item. See Figure 1 for basic iden-
tification of intermeshing jaw parts.
Remove the Jaw

Determine the type of jaw installed on your slave arm. Refer to the proper jaw service in-
struction for the procedure to remove the jaw. Read and be familiar with all the steps and
requirements before you get started. Return to this point when you have finished removing
the jaw.
Page 52 011–5011 SERVICE INSTRUCTION

T-bar Plate Bearings(4x)
001-5396 003-0050
Wrist Motor
Nose Block
101-4108
Jaw Piston
001-5395 Bolt
001-7520 or 001-
5397 (fused)
HHCS/Washers (4x)
002-1135/002-1439
Figure 1 Basic nose block/jaw piston parts identification
Remove the Nose Block from the Wrist Motor

Refer Figure 1 and Figure 2 for this procedure.
HHCS/Washers (4x)
002-1135/002-1439
Wrist Motor
Nose Block
101-4108
Figure 2 Removing nose block
1. Remove the four HHCS (002-1135) from the nose block (101-4108) (see Figure 2).
Note: Hydraulic fluid will spill from the wrist assembly as you remove
the nose block during the next step. Have a drain pan ready to catch
fluid.
2. Pull the nose block out from the wrist assembly (101-3786).
Remove Jaw Piston From Nose Block

Refer to Figure 3 for this procedure.

T-bar Plate
Seal 001-5396
004-0616
Bearing
001-5399
Push Jaw Piston In To

Remove Bolt
Jaw Piston
001-5395 Bolt 001-7520 or
001-5397 (fused)
Nose Block
101-4108
Figure 3 Jaw piston, seals, and bearings identification
! Caution
To remove seal (004-0616) in step 2, you must destroy the
seal. If you don’t have a replacement, do not remove the
seal at this time.
1. Remove bearing (001-5399) from jaw piston (001-5395). Set aside to inspect later.
2. Remove seal (004-0616) by carefully cutting across it with a new razor blade or X-
acto style knife.
Note: Be very careful not to damage the finish on the jaw piston.
3. Place the nose block into a soft-jaw vise. Push the jaw piston all the way into the
nose block and, using a 12-point, 11/16-in. socket, remove the bolt (001-7520 or
001-5397 [fused]) from the jaw piston.
4. Slide the t-bar plate (001-5396) off of the bolt.
Remove Seals & Bearings from Nose Block

1. Using a pick tool, carefully remove both bearings (001-5398) from the nose block
(101-4108). Set the bearings aside to inspect later.

! Caution
To remove seals (004-0650), in the next step, must destroy
the seals. If you don’t have replacements, do not remove
seals at this time.
2. Remove the seals (004-0650) by carefully cutting across them with a new razor
blade or X-acto style knife. Using a pick tool, carefully remove the O-rings that sit
under each of the seals.
O-ring and Backup Ring

004-0542 and 004-0541
Bearing (2x)
001-5398
Seal (2x)
004-0650
Figure 4 Nose block seals and bearings parts identification
! Caution
Be very careful not to damage the finish on the nose block.
3. Remove the O-ring (004-0542) and the backup ring (004-0541) from the nose
block.
Clean & Inspect Parts

In the following steps you will clean and check all parts for damage, corrosion, chipping,
scuffing, and wear.
1. Clean all the parts of the nose block/jaw piston. Use a lintless rag and wipe all the
surfaces clean of dirt and hydraulic fluid.
2. Check the jaw piston (001-5395) for damage and excessive wear. Replace the jaw
piston if it is too worn or damaged.
3. Check the t-bar plate (001-5396) for damage and excessive wear. Replace the t-bar
plate if it is too worn or damaged.
4. Check the inner bore surfaces of the nose block (101-4108) for damage and
excessive wear. Check all the outer surfaces on the nose block for damage or
cracks. Replace the nose block if you find any unacceptable damage, or cracks.

! Caution
Do not attempt to repair cracks by welding. The nose block
has been heat- treated for strength and any welding will
eliminate its strength.
Inspect Bearings
During the following procedures you will inspect the piston bore bearings and the rod
bearings.
1. Inspect bearings (001-5399) for galling or damage. Using calipers, measure
bearing wall thickness. Replace the bearing if thickness is 2.39 mm (0.090-in.) or
less at any point. After inspecting the bearings, set them aside until you get to
“Install Jaw Piston Seal & Bearing”.
2. Inspect bearing (001-5398) for galling or damage. Using calipers, measure bearing
wall thickness. Replace the bearing if thickness is 1.55 mm (0.058-in.) or less at
any point. After inspecting bearings, set aside until you get to “Install O-rings &
Bearings Into Nose Block”.
3. Using the shaft of an 19.05 mm (0.750-in.) drill bit or a section of 19.05 mm
(0.750-in.) drill rod, check all bearings (003-0050) in the nose block for wear.
Insert the drill shank, or drill rod, into the bearing and check for play. A pivot pin
(001-4551) may be substituted for the drill bit or drill rod if it is first checked, as in
step 1, to verify that it does not exhibit excessive wear. You may also use a new
pivot pin. Replace any bearing that has too much play.
Install O-rings & Bearings Into Nose Block

Refer to Figure 1, Figure 5, Figure 6, and Figure 7 for this procedure.
ARM JAW
Seal Set (2x)

004-0650
Figure 5 Installing seals into nose block
1. Lightly lube the O-ring/seal sets (004-0650) with O-ring lube and install them into
the nose block (101-4108) (see Figure 5). Be very careful to place the correct O-
ring/seal in the correct location and orientation.
Note: To aid in getting the O-ring and seals into the

groove, it may be helpful to bend them as shown at right.
Then push them down into the grooves.

2. Lubricate the bearings (001-5398) with EP grease and install them into the nose
block (see Figure 6).
Bearings
001-5398
Figure 6 Installing bearings into nose block
3. Lightly lube the O-ring (004-0542) and backup ring (004-0541) with O-ring lube
and install them onto the nose block (see Figure 7).
ARM JAW
O-ring Backup Ring

004-0542 004-0541
Figure 7 Installing O-ring and back-up ring onto nose block
4. If you are not replacing the bearings (003-0050) in the nose block (see Figure 1),
skip to “Assemble Jaw Piston” on page 58. Go to step 5 to replace the bearings.
5. Clamp the nose block securely in a soft-jaw vise. Use a 13/16-in. (21 mm) diameter
drift to drive the bearing out of the jaw.
Note: Heating the jaw assembly with a heat gun, or in an oven, at

approximately 280-300°F (140-150°C), will help soften the adhesive and
remove the bearings.
6. Using Loctite 7471 primer, clean the bearing bore to remove all traces of Loctite.
7. Apply a thin coating of Loctite 271 to the outside of the bearing and to the inside of
the bearing bore.
8. Press the new bearings into the jaw. When properly installed, the bearing should
be flush, or slightly recessed from the jaw surface.
9. Clean off any excess Loctite. Allow the Loctite to cure for 24 hours at 72°F (22°C),
or 1 hour at 200°F (94°C), before reinstalling this assembly.

Assemble Jaw Piston
Refer to Figure 8 and Figure 9 for this procedure.
Nose Block
101-4108
Jaw Piston Sizing Tool

001-5395 010-0214
Figure 8 Installing sizing tool and jaw piston into nose block
1. Insert sizing tool (010-0214) in the end of the jaw piston (001-5395) (see Figure 8).
2. Lube surfaces of the tool/piston combination and the inner surfaces of the nose
block with O-ring lube. Push the tool/piston combination into the nose block (101-
4108) until the piston is completely inside the nose block (see Figure 8). Remove
the sizing tool from the piston.
3. Apply anti-seize (002-1925) to threads and the underside of the bolt head (001-
7520 or 001-5397 [fused]). Insert the bolt through the t-bar plate (001-5396) and
into the piston (Figure 9). Place the nose block in a soft-jaw vise. Push the t-bar/
piston all the way into the nose block and torque the bolt to 402 Nm (300 ft/lbs).
Remove nose block assembly from the vise.
Note: Note that the slot in the t-bar aligns with the jaw piston.
T-bar Plate
001-5396
Nose Block
101-4108
Push Jaw Piston In To

Torque Bolt
Bolt 001-7520 or
001-5397 (fused)
Jaw Piston
001-5395
Figure 9 Installing jaw piston into nose block

Install Jaw Piston Seal & Bearing
Bearing Seal Set

001-5399 004-0616
Jaw Piston
001-5395
Figure 10 Orientation of seal/O-ring on jaw piston
1. Slide the male installation tool (010-0174) onto the end of the jaw piston (001-
5395). Lightly lube the seal/O-ring (004-0616) with O-ring lube and slide it onto
the jaw piston as shown in Figure 10.
2. Install female sizing tool (010-0175) over the seal. Leave in place for 5-10 minutes,
then remove the tool.
3. Lubricate the bearing (001-5399) with EP grease and install it onto the jaw piston.
Install the Nose Block Into the Wrist Assembly

1. Lightly lube all surfaces of the jaw piston with O-ring lube.
2. Slide the nose block/jaw piston assembly into wrist assembly.
3. Coat threads of the four HHCS (002-1135) with Aqua Lube. Install and torque to
99 Nm (73 ft/lbs).
Install the Intermeshing Jaw

Refer to the “Interrmeshing Jaw” Service Instruction under “Attach the Intermeshing Jaw
to Nose Block” Service Instruction, for the procedure to install the intermeshing jaw.
END OF SERVICE INSTRUCTION

This page not used.

Service Instruction
Intermeshing Jaw, 11.5-in, 101-3586
Description
Complete service instructions for the intermeshing jaw. Does not include servicing of
jaw piston—see “Jaw Piston/Nose Block 101-3774” Service Instruction. Used in Jaw
101-4104.
Estimated Time to Complete

2 hour
Below is a list of required tools and materials for this Service Instruction. Look over
the list and make sure you have all the materials before you get started. Read through
the entire procedure to make sure you understand, and are capable of performing, the
service. Take special notice of all notes, warnings, and the terminology section.
2 3/4-in. sockets Aqua Lube (002-0805)
19.05 mm (0.750-in.) drill bit or drill
Dow Corning® 55 o-ring lube
rod (optional)
21 mm (13/16-in.) drift Valvoline Val Plex EP® grease
8-102 Nm (5-75 ft/lb) torque wrench Loctite 271® (002-0795)
bench vise with soft jaws
0-25 mm (0-1-in.) micrometer
Terminology
HHCS = hex head cap screw
HPU = hydraulic power unit
Note: If you intend to replace the bearings (003-0050), you

will need to allow at least one hour for the Loctite 271 to harden.
Service Instruction 011–5025 Page 61

! WARNING
Take care not to scratch any protective coatings such as anodiz-
ing. Corrosion damage will result.
You can perform the procedures in this Service Instruction with the wrist attached to,
or separated from, the slave arm.
Perform all assembly work in a clean, dry environment if possible. Although assembly
of major slave arm components must often be performed under field conditions, the
intermeshing jaw should be disassembled and reassembled under ‘clean service’ condi-
tions to prevent contamination and damage to bearing surfaces. Prepare a clear area on
the work surface in which to arrange the components as the intermeshing jaw is disas-
sembled. We recommend that you make a photocopy of this Service Instruction for
workbench use
Note: During this procedure DO NOT attempt to remove the

bolt (001-7520 or 001-5397 [fused]) (see Figure 1). The bolt is not
involved in removing the jaws.
Bolt 001-7520 or 001

5397 [fused]
Figure 1 DO NOT loosen bolt
! WARNING
Before you can service the arm safely, you need to disable the
electrical and hydraulic functions of the arm. Follow the steps
below before you continue.
1. Raise the arm to a comfortable working position.

3. If your arm is equipped with a hydraulic compensation unit, isolate the unit from
the arm.
Page 62 011–5025 Service Instruction

Disassemble the Intermeshing Jaw
Disassembly of the intermeshing jaw assumes that all preparations, previously
described in this Service Instruction, have been met.
Numbers in parentheses refer to the part number of the item. See Figure 2 for basic
identification of jaw parts.
Jaw Actuator Bearing (2x)

001-2908
Base (2x)
101-4113
Jaw (4x)
001-2099
Nose Block
101-3853
HHCS and Washers (4X)

002-0277 and 002-0071
Figure 2 Basic intermeshing jaw parts identification
Remove Interlocking Jaws from Nose Block

1. Remove the HHCS (002-0277) and washer (002-0071) from one end of each of
the two pivot pins (001-4551) holding the base assemblies (101-4113) to the nose
block (101-3853) (see Figure 3).
Pivot Pin (2x)

001-4551
Nose Block
101-3853
HHCS and Washers (4x)

002-0277 and 002-0071
Figure 3 Removing the intermeshing jaw
2. Pull out each pivot pin and with attached the HHCS and jaw washer.

3. Remove each jaw and base assembly (001-2099 and 101-4113) from the nose
block. Lift the jaw and base assemblies out so that the jaw actuator bearing (001-
2908) slides off the t-bar plate (see Figure 2, on page 3). The four bearings (003-
0006) will fall out as you remove the jaw and base assemblies (see Figure 4). Set
them aside to inspect later.
Jaw and Base Assembly (2x)
Bearings (4x)
003-0006
Figure 4 Removing jaws from nose block
Remove the Jaws From the Base

If you are not going to remove the jaws, go to “Inspect Jaw Components” on page
65.
Jaw (4x)
001-2099
Tie Rod (2x)
Nut (8x) 001-2122
002-0063
Spacer (2x)
001-2100
Base (2x) Tie Rod (2x)

101-4113 001-2121
Figure 5 Removing the jaws from the base
1. Remove one nut (002-0063) from one of the tie rods (001-2121 or 001-2122,
whichever is applicable) and pull the tie rod out of the jaws (001-2099), spacers
(001-2100, if applicable), and base (101-4011). Repeat for the other jaws.

Install the Jaws to the Base
If you did not remove the jaws from the bases, go to "Inspect Jaw Components".
1. Lubricate the tie rod body (001-2121 or 001-2122, whichever is applicable) and
threads with Aqua Lube. Install into the jaws (001-2099), spacers (001-2100, if
applicable), and base (101-4011). Torque to 28 Nm (21 ft/lbs). Repeat for the
other jaws.
Inspect Jaw Components

Often the jaw is subjected to long use, severe service, and abuse. Carefully determine
the amount of damage and wear that is acceptable before the jaw no longer works prop-
erly for your application.
1. Inspect the pivot pins (001-4551) for signs of wear, galling, or other surface
damage. Use a micrometer to measure any suspect pins and replace any that
measure 18.94 mm (0.746-in.), or less at any point.
2. Inspect the actuator bearings (001-2908) and jaw for signs of wear, cracking,
twisting, or other deformation (see Figure 6). Verify that the bearings turn
smoothly in the base and that they show no discernible play. Replace any bearing
or base that shows unacceptable wear or damage.
Check For Wear and Deformation
Actuator Bearing
001-2908
Bearing (2x)
003-0006
Base (2x)
Jaw Not Shown For Clarity 101-4113
Figure 6 Checking actuator bearing and base for wear and deformation
3. Inspect the four bearings (003-0006) for signs of wear or damage. Replace any
bearings that show wear or damage.
4. Check all of the bearings (003-0050) in the bases for wear and excessive play by
inserting a new pivot pin, an acceptable used pin, or the shaft of a 19.05 mm
(0.750-in.) drill or drill rod (see Figure 7). Using the procedure in “Replacing Jaw
Bearings” on page 66, replace any bearing that has too much play.

Bearings (2x)
003-0050
Pivot Pin or .750-in (19.05mm)Rod
Figure 7 Checking bearings
Replacing Jaw Bearings

1. Clamp the base securely in a soft-jaw vise. Use a 21 mm (13/16-in.) diameter drift
to drive the bearing (003-0050) out of the base (101-4113).
Note: Heating the base assembly with a heat gun, or in an

oven, at approximately 140-150°C (280-300°F), will help soften
the adhesive and remove the bearings.
2. Clean the bearing bore to remove all traces of Loctite 271.

3. Apply a thin coating of Loctite 271 to the outside of the bearing and to the inside of
the bearing bore.
4. Press the new bearings into the base. When properly installed, the bearing should
be flush, or slightly recessed from the base surface.
5. Clean off any excess Loctite 271. Allow the Loctite to cure for 24 hours at 22°C
(72°F), or 1 hour at 94°C (200°F), before reinstalling this assembly.
Attach the Intermeshing Jaw to Nose Block

1. Lubricate all surfaces of a actuator bearing (001-2908) with Aqua Lube and place
the actuator bearing into one of the bases.
2. Lubricate the bearings (003-0006) with Aqua Lube.
3. Insert a pivot pin (001-4551), with HHCS (002-0277) and washer (002-0071),
into the nose block (101-3853) just far enough to install a bearing (003-0006)
over the pin (see Figure 8, step A). Align the base (101-4113) in the nose block and
push the pivot pin (001-1840) in until it is just flush with the other side of the jaw
(see Figure 8, step B). Install another bearing between the jaw and nose block,
and push the pin in completely (see Figure 8, step C).

Nose Block
101-3853
Bearings
003-0006
Pivot Pin
001-4551
S3586TP
A
Base
101-4113
C
Drawing is not to scale
Figure 8 Install jaw to nose block
4. Apply a coating of Aqua Lube to the threads of the HHCS (002-0277) and install
the HHCS and washer (002-0071) to the end of the pivot pin (001-4551). Torque
the HHCS to 99 Nm (73ft/lb).
5. Repeat steps 4 to attach the other base.

This page not used.

Service Instruction
Wrist, 101-3587
Description
Complete service instructions for the RigMaster wrist.
Estimated Time to Complete Reference Drawing

3 hour 101-3587
Below is a list of required tools and materials for this Service Instruction. Look over the
list and make sure you have all the materials before you get started. Read through the en-
tire procedure to make sure you understand, and are capable of performing, the service.
Take special notice of all notes, warnings, and the terminology section.
7/16-in. socket Valvoline® Val-Plex EP Grease
9/16-in. socket Loctite 271® (002-0795)
1-1/2-in. socket Loctite 242®
5/32-in. allen wrench Aqua Lube (002-0805)
1/4-in. socket Dow Corning 55® o-ring lube or petro-
leum jelly
0-25 mm (0-1-in.) micrometer
6-in. vernier calipers
flat blade screwdriver
torque wrench capable of 8-102 Nm (5-75
ft/lb)
torque wrench capable of 0-8.5 Nm (0-75-
in./lb)
new razor blade or X-acto style knife
Custom Tools Needed Terminology

010-0237 jaw rod sleeve installation tool HHCS = hex head cap screw
010-0480 clamp nut tool SHCS = socket head cap screw
010-0236 bearing installation tool FHMS = flat head machine screw
010-0238 piston clamp tool PA=parallel-acting
010-0525 lip seal installation tool

Read and be familiar with all the steps and requirements of this
service instruction before you start.
! Caution
Avoid damaging protective coatings or surface treatments.
Corrosion can result.
! Caution
Some slave arm components may retain hydraulic pressure,
even when the HPU has been disabled. Bleed off residual
pressure to the components being serviced by slowly loosen-
ing hydraulic hoses and/or other hydraulic fittings.
Be Prepared!
In this Service Instruction, the wrist assembly is removed from the slave arm, and the jaw
and noseblock assemblies are detached from the wrist assembly (other Service Instruc-
tions describe how to remove the jaw and noseblock assemblies).
Note: The three seals (004-0803) located in the slip ring wrist housing
(101-3784) are destroyed during removal. Be sure you have replace-
ments on-hand.
Note: The wrist motor cannot be reassembled without new crush

washers (004-0576). These components are “one use only” items. Be sure
that you have eight of these washers on-hand before starting this proce-
dure.

1. Raise the arm to a comfortable working position and support non-locking
functions.
Note: Extend the boom fully for easy access to the wrist mounting
bolts.

3. If your system is equipped with a compensation unit, isolate it from the slave arm.
Remove Wrist From Slave Arm


Linear Actuator
Boom 101-1909
001-3029
Wrist
101-3587
Wrist Base
001-3033
Wrist Pin
001-2117
Hydraulic Hose (5x)

HHCS (18x) 006-1594
Washer (18x) 002-0052
002-2151
Figure 1 Removing wrist from boom
! Caution
When you remove the eighteen HHCS in step 1, the wrist will
separate from the slave arm. Support the wrist before pro-
ceeding.
1. Support the Wrist. Remove the eighteen HHCS and washers (002-0052 and
002-2151) that secure the wrist (101-3587) to the boom (001-3029).
2. Push the wrist pin (001-2117) out of the wrist base (001-3033) and linear actuator
(101-1909).
Note: Before performing step 3, make sure the hydraulic hoses con-
nected to the wrist base are identified. If the hoses are unmarked, label
them with a permanent marker (see Figure 2).
Figure 2 Hose designations
3. Disconnect the five hydraulic hoses (006-1594) from the wrist base.

Remove the Jaw Assembly
Refer to Service Instruction 011-5025 to remove the jaw installed on your slave arm. Read
and be familiar with all the steps and requirements before you get started. Return to this
point when you have removed your jaw assembly.
Remove the Jaw Nose Block/Jaw Piston Assembly

Refer to Service Instruction 011-5011 to remove the nose block/jaw piston installed on
your slave arm.
Remove Wrist Base From Wrist

HHCS (4x) Wrist

001-4697 O-ring 101-3372
004-0017
Wrist Base
001-3033
O-ring (5x)
004-0222
Figure 3 Removing wrist base from wrist
1. Remove the four HHCS (001-4697) that hold the wrist base (001-3033) to the
wrist (101-3372). Pull the wrist base off the wrist and remove the o-rings (004-
0222 (5x) and 004-0017 (1x).
Remove the Wrist Manifold From the Slip Ring Housing

Refer to Figure 4, Figure 5, and Figure 6 for this procedure.
Note: The wrist motor cannot be reassembled without new crush

washers (004-0576). These components are “one installation only” items.
Be sure that you have eight new washers on-hand before starting this
procedure.
1. Remove the o-ring (004-0017) from the wrist manifold (101-3782) (see Figure 4).
2. Using a 5/32-in. allen wrench, loosen, but do not remove the SHCS (002-1133)
on the clamping nut (001-5103) (see Figure 4). Using a 1-1/2-in. socket, or the
clamping nut torque tool (010-0480), remove the clamping nut (001-5103) from
the drive shaft (001-4438) (see Figure 4).
3. Remove the two thrust washers (003-0092) and thrust bearing (003-0091) from
the drive shaft (001-3785).

Valve Plate Gerotor Wrist Drive Shaft
HHCS 101-3373
5 x 001-4557, 001-1832 001-4438
2 x 001-4448, &
1 x 001-4449
Clamping Nut
001-5103
HHCS
002-1133
Wrist Manifold Slip Ring Wrist Housing

101-3782 101-3784
Figure 4 Basic wrist motor parts identification
4. Using a 1/4-in. allen wrench, remove the eight SHCS (001-4577, 001-4448, and
001-4449) from the wrist manifold. You will find that two SHCS (001-4448) may
not come out. You may leave them in, for now. They will come out when you
remove the wrist manifold (101-4759) in step 5. Remove the crush washer (004-
0576) from each SCHS.
Note: The three different SHCS types must be reinstalled according to

the assembly drawing. The SHCS are not interchangeable.
5. Remove the wrist manifold from the wrist housing (101-3784) (See the “Tip”
below).
Note: Removing the wrist manifold may be difficult. Do not use any
tools to pry the wrist manifold out of the wrist housing. Use the following
technique to remove the wrist manifold from the wrist slip ring housing:
Using two HHCS (002-1628) that hold the nose block to the wrist motor,
hold the wrist motor in a soft-jaw vise (see Figure 5). Screw two HHCS
(001-4697) that held the jaw motor to the wrist base into the wrist mani-
fold (see Figure 5). Squeeze the screws together and evenly pull up to
remove the wrist manifold (see Figure 5).

HHCS (2x)
001-4697 or longer
(for disassembly Wrist Manifold
purposes only) 101-3782
Wrist Housing
101-3784
HHCS
002-1628
Figure 5 Removing the wrist manifold from the wrist housing
6. Remove the o-rings (004-0445 and 004-0698) and the bushing (001-1984) from
both of the SHCS (001-4448) that remained in the wrist manifold during step 4
(see Figure 6). Remove both SHCS from the wrist manifold. Remove the crush
washers (004-0576) from each SCHS (see Figure 6).
Wrist Manifold
101-3782 O-ring Bushing
004-0110 001-1984
O-ring (2x)
004-0698
Washer (8x)
004-0576
SHCS (2x)
001-4448
O-ring
Bearing 004-0698
003-0011
Figure 6 Disassembling the wrist manifold
7. Remove the o-ring (004-0110) from the wrist manifold (see Figure 6).
8. If the bearing (003-0011)is damaged, remove it from the wrist manifold by evenly
tapping it out using a small brass drift or pressing it out using a suitable tool (see
Figure 6). If not damaged, the bearing may remain in the wrist manifold.
Final Wrist Motor Disassembly

1. Remove the o-rings (004-0081, 004-0017, and 004-0413) from the valve plate
(001-1832) (see Figure 7).

Valve Plate
001-1832
O-ring
004-0017
O-ring
004-0413
O-ring
004-0081
Figure 7 Removing valve plate o-rings
2. Using the two HHCS (001-4557) (used to secure the wrist manifold to the wrist
housing - see Figure 4), remove the valve plate by lifting it up as shown in Figure
8.
HHCS (2x) Seal

001-4557 (for 004-0574
disassembly
purposes only)
Driveshaft
101-3785
Valve Plate Wrist Housing

001-1832 101-3784
Figure 8 Removing the valve plate
3. Remove the seal (004-0574) from the valve plate (001-1832), or the drive shaft
(101-4438), depending on where the seal is when you remove the valve plate (see
Figure 8).
4. Turn the slip ring wrist housing face down over a flat surface and allow the gerotor
assembly (101-3373) and wear plate (001-2060) to fall out of the wrist housing.
Set the gerotor assembly aside for later inspection (see “Inspect the Gerotor
Assembly” on page 77).
5. Press down to push the drive shaft up out of the wrist housing. If necessary, tap
the housing gently against a plastic or wood work surface to dislodge these parts.
! Caution
The gerotor assembly (101-3373) is made up of precision
parts. Handle these parts carefully. Do not damage the
edges of any of the parts.

6. Remove the seal (004-0617), backup ring (001-4437), thrust washer (003-0074),
and roller bearing (003-0013) from the wrist housing (see Figure 9).
Driveshaft
101-3785
Back-up Ring
004-0574
Thrust Washer
003-0074
Seal
004-0617
Figure 9 Removing parts from wrist housing
7. Using a small pick tool, remove the bearing (001-4454) from the wrist housing
(101-3784) (see Figure 10). Set aside bearing to inspect later.
Seal (3x)
004-0803
Bearing
001-4454
Needle Bearing
003-0031
Wrist Housing
101-3784
Figure 10 Removing seals, bearing, and needle bearing from wrist

housing
! Caution
The three seals (004-0803) will be destroyed during removal
in step 8. If you don’t have replacements, do not remove the
seals.
8. Remove the three seals (004-0803) (see Figure 10) by carefully cutting across
them with a new razor blade or X-acto style knife. Using a small pick tool, remove
the o-ring that sits under each seal.
Note: Be very careful not to damage the finish on the slip ring wrist
housing.
9. If the needle bearing (003-0031) is damaged, remove it from the wrist

housing by evenly tapping it out using a small brass drift (see Figure 10).

If not damaged, the bearing may remain in the wrist housing.
Inspect the Gerotor Assembly

In the following steps you will clean, and then check, all the parts for corrosion, chipping,
scuffing, and wear. The gerotor is assembled with factory-matched parts. If any part is
damaged, you must replace the entire assembly.
Refer to Figure 11 for this procedure. See Figure 11 for basic identification of gerotor parts
(101-3373).
Figure 11 Gerotor components
! Caution
The gerotor assembly (101-3373) is made up of precision
matched parts. Handle these parts carefully. Do not damage
the edges of any of the parts. Damaging the edges of the
parts will cause a lack of torque and power in the wrist
assembly.
1. Clean, degrease, and dry all parts.

2. Carefully check all surfaces for wears, nicks, or other damage. Any obvious high
spots caused by nicks, or other damage, may be carefully lapped down. If a lapping
machine is not available you will have to replace the gerotor assembly as a whole

unit. All parts of the gerotor assembly are factory-matched and cannot be
interchanged with parts from other gerotors.
3. Inspect the inner rotor for wear. The coating on the inner rotor will degrade under
extreme conditions and exhibit jittery low speed performance and a loss of wrist
torque. Replace the gerotor assembly if all, or most of, the coating is gone.
Inspect Wrist Components

1. Clean, degrease, and dry all parts.
2. Inspect the four bearings (003-0031, 003-0013, 003-0011, and 003-0091) for
signs of wear or damage (see Figure 4 on page 73, Figure 6 on page 74, Figure 9 on
page 76, and Figure 10 on page 76). Replace any damaged bearings.
3. Inspect the thrust washers (003-0074) for wear and galling (see Figure 9 on page
76). Replace washers if they show excessive wear, galling, or other damage.
4. Inspect the bearing (001-4454) for galling or damage (see Figure 10 on page 76).
Using your 6-in vernier calipers, measure the wall thickness of the bearing.
Replace the bearing if the thickness is 23.5 mm (0.928-in.), or less, at any point.
5. Inspect the wear surfaces of all major parts for excessive wear, galling, or other
damage. Replace any parts that show excessive wear, galling, or other damage.
Prepare slip ring Wrist Housing for Assembly

1. If you removed the needle bearing (003-0031), install the bearing into the
wrist housing (101-3784) (see Figure 12). The printed edge of the bearing should
show out the bottom of the wrist housing. Pack the needle bearing with EP grease.
If you didn’t remove the needle bearing, pack the bearing with EP grease.
Seal (3x)
004-0803
Bearing
001-4454
Needle Bearing
003-0031
Wrist Housing
101-3784
Figure 12 Installing bearings and seals into wrist housing
2. If the three seals (004-0803) were removed, install three new o-rings and
seals in the wrist housing (see Figure 13 and “Tip” below). Be very careful to place
the o-ring and seals in the correct orientation (see Figure 13). Lubricate the seal
surfaces with EP grease.

Note: To aid in getting the o-ring into the groove, it
may be helpful to bend it as shown at right. Then push
the o-ring down into the groove.
3. If the seals were not removed, lubricate the seal surfaces

with EP grease.
Wrist Housing
101-3784
Seal & O-ring

004-0803
Bearing
001-4454
Figure 13 Installation of o-rings, seals, and bearing into wrist hous-

ing
4. Lubricate the bearing (001-4454) with EP grease and install it into the wrist
housing as shown in Figure 13.
5. Set aside the slip ring wrist housing assembly for later installation.
Prepare Wrist Manifold for Assembly

Refer to Figure 14 for this procedure. See Figure 14 for wrist manifold parts identification.
Crush Washer (8x) Bearing O-ring Bushing

004-0576 003-0011 004-0110 001-1984
SHCS (5x)
001-4577
SHCS (2x)
001-4448
O-ring
004-0698
SHCS (1x) O-ring (2x) Wrist Manifold

001-4449 004-0698 101-3782
Figure 14 Position of wrist manifold parts
1. If you removed the bearing (003-0011), install the bearing into the wrist
manifold (101-4759). The printed edge of the bearing should show out the bottom
of the wrist manifold. Pack the bearing with EP grease.

— If you didn’t remove the bearing, pack the bearing with EP grease.
2. Install new crush washers (004-0576) onto both SHCS (001-4448). Heavily
lubricate the SHCS with EP grease and install both SHCS into the wrist manifold.
3. Lubricate the o-rings (004-0445 and 004-0698004-0698) and bushing (001-
1984) with o-ring lube and install onto the two SHCS (001-4448) that you just
installed in step 2.
4. Install a new crush washer (004-0576) onto the SHCS (001-4449). Lubricate the
SHCS with EP grease and install into the wrist manifold (101-3782). Each of the
three SHCS types must be placed in the correct wrist manifold bores.
5. Lubricate the o-ring (004-0110) with o-ring lube and install it into the groove of
the wrist manifold (101-4759). Set the wrist manifold aside for later installation.
Prepare Drive Shaft for Assembly

Refer to Figure 15 for this procedure. Stand the drive shaft (001-3785) up on end, shaft up,
to prepare it for installation into the wrist housing.
Drive Shaft
101-3785
Backup Ring
001-4437
Thrust Washer
003-0074
Bearing
003-0013
Seal
004-0575
Figure 15 Wrist drive shaft parts
1. Lubricate the backup ring (001-4437) with o-ring grease and install onto the drive
shaft.
2. Lubricate the seal (004-0575) with EP grease and install it onto the drive shaft.
3. Lubricate the thrust washer (003-0074) and the bearing (003-0013) with EP
grease and install onto the drive shaft.
Install Drive Shaft & Gerotor Into Slip Ring Wrist Housing
1. Lubricate all the inner surfaces of the wrist housing (101-3784) with EP grease.
2. Lubricate all outer surfaces of the drive shaft (101-3785) with EP grease.
3. Use o-ring lube to generously lubricate the bores of the bolt holes in the slip ring
wrist housing below the heli-coils. These bores are where the two, wrist oil supply,
SHCS are placed.

4. Carefully slide the wrist housing onto the drive shaft (see Figure 16A). Seat the
housing completely onto the drive shaft.
A B
Wrist Housing
101-3784
Drive Shaft
101-3785 Seal
004-0617
Figure 16 Instancing drive shaft assembly & seal to wrist housing
5. Lubricate the seal (004-0617) with o-ring lube, check orientation, and install it
between the slip ring wrist housing and the drive shaft (see Figure 16B). Check
orientation and push the seal in far enough not to damage it when you stand the
housing up on that end.
6. Lubricate the wear plate (001-2060) with EP grease and install it onto the drive
shaft (001-4438) (see Figure 17). You may need an arbor press to fully seat the
wear plate over the seal and onto the bearing.
Note: Note the wear marks on the wear plate. Circular wears marks
go toward the gerotor assembly. Replace the plate in the same orienta-
tion as originally installed.
Wear Plate
001-2060
Drive Shaft
101-3785
Wrist Housing
101-3784
Figure 17 Installing wear plate into wrist housing
Reassemble Gerotor Assembly

Refer to Figure 18 for this procedure. The machine tolerances are very tight in the gerotor
assembly, therefore you will need to be very careful handling the parts.
During assembly, lubricate all parts with petroleum jelly.

Drive Shaft
101-3785 Wear Plate
001-2060
Wrist Housing
101-3784
Figure 18 Assembling gerotor into wrist housing
1. Install the locating ring into the wrist housing (101-3784). Align the holes in the
locating ring with the holes in the wear plate (001-2060). Be sure to install with
the narrow groove facing up and the large groove facing down.
2. Install the inner rotor. Notice that the inner ring has a chamfer. The chamfer may
be placed either side up.
3. Install the outer element.
4. Install the sharp-edged sealing rollers between the outer element and the inner
rotor. Be careful not to damage an edge when sliding them into position.
5. Install the anti-rotation rollers between the outer element and the locating ring.
Install Gerotor Into Slip Ring Wrist Housing

1. Lubricate the gerotor valve plate and lower it into position onto the drive shaft
(101-3785) (see Figure 19). Carefully align the valve plate so that you cannot see
rollers through any of the slots in the plate (see Figure 19).

! Caution
Carefully align the valve plate so that you cannot see rollers
through any of the slots in the valve plate. The wrist will not
function if you fail to align the valve plate correctly.
Drive Shaft
101-3785
Gerotor Assembly Valve Plate

101-3373
Slots in Valve Plate
Figure 19 Installing the valve plate to gerotor assembly
2. Install the valve plate (001-1832) onto the drive shaft (see Figure 20)
.
O-ring
004-0017
O-ring
Seal 004-0413
004-0574
O-ring
004-0081
Valve Plate
001-1832
Drive Shaft
101-3785
Figure 20 Installing valve plate o-rings
3. Lubricate the seal (004-0574) with EP grease. Check seal orientation and, using
the seal installation tool (010-0525), install it onto the drive shaft (see Figure 20).
4. Lubricate new o-rings (004-0081, 004-0017, and 004-0413) with o-ring lube and
install onto the valve plate (see Figure 20).

Install the Wrist Manifold Onto the Slip Ring Wrist Housing
1. Lubricate the upper edge of the wrist housing (101-3784) with o-ring lube.
2. Install the wrist manifold (101-3782) onto the wrist housing (101-3784). Orient
the two corresponding pin plug holes on the manifold to the two corresponding
pin plug holes on the outside of the wrist housing (see Figure 21). Gently press the
manifold into place.
.
Wrist Manifold
101-3782
Wrist Housing
101-3784
Pin Plug Holes
Figure 21 Positioning the wrist manifold onto the slip ring wrist
housing
3. Install new crush washers (004-0576) onto the five SHCS (001-4577) (see Figure 6
on page 74). Heavily lubricate the SHCS with EP grease and install them into the
wrist manifold. Follow this procedure to torque the SHCS:
Note: To hold the slip ring wrist housing steady while you torque the
following SHCS, use the same procedure you used in step 5 of “Remove
the Wrist Manifold From the Slip Ring Housing” on page 72.
a. Screw the two SHCS (001-4448) to finger tightness. This will center the o-rings
so that they will properly seal.
b. Tighten all the other SHCS to finger tightness.
c. Torque all eight of the SHCS to 15 ft/lb (20.3 Nm).
d. Torque only the oil-return SHCS (001-4449) and the five standard SHCS
(001-4577) to 24.4 Nm (18 ft/lb).
e. Torque only the five standard SHCS (001-4577) to 32.5 Nm (24 ft/lb).
4. Lubricate the two thrust washers (003-0092) and bearing (003-0091) with EP
grease and install them onto the wrist drive shaft (101-3785) (see Figure 22).

Clamp Nut
001-5103
Thrust Washer (2x) HHCS

101-3785 002-1133
Bearing
003-0091
Drive Shaft
101-3785
Wrist Manifold
101-3782
Figure 22 Installing thrust washers and bearing
5. Install the clamp nut (001-5103) on the drive shaft with the three threaded holes
facing out (see Figure 22). Follow this procedure to torque the clamp nut:
a. Torque the clamp nut to 102 Nm (75 ft/lbs) to seat all wrist components.
b. Loosen the clamp nut and re-torque it to the torque stamped on the nut
or to
54 Nm (40 ft/lb) to set the wrist preload.
c. Tighten the clamp nut SHCS (002-1133) to 7 Nm (5 ft/lbs) to secure the
clamp nut (see Figure 22).
6. Lubricate the o-ring (004-0017) with o-ring lube and install onto the wrist
manifold (101-3782) (see Figure 4 on page 73).
7. Remove the wrist housing from the vise. Remove the two HHCS (002-1628) you
used to hold the housing in the vise.
Install Wrist Base onto Wrist

HHCS (4x) Wrist

001-4697 O-ring 101-3372
004-0017
Wrist Base
001-3033
O-ring (5x)
004-0222
Figure 23 Installing wrist base onto wrist

1. Lubricate the six o-rings (004-0222 (5x) and 004-0017) with o-ring lube and
place into position on the wrist base (101-3033).
2. Install wrist base to the wrist (101-3587). Lubricate the four HHCS (001-4697)
with Aqua Lube and install. Torque to 34 Nm (25 ft/lbs).
! Caution
Be careful to line up all the oil passages correctly. The wrist
and jaw will fail to operate if the oil passages are not aligned
correctly.
Install Wrist onto Slave Arm

Linear Actuator
Boom 101-1909
001-3029
Wrist
101-3587
Wrist Base
001-3033
Wrist Pin
001-2117
Hydraulic Hose (5x)

HHCS (18x) 006-1594
002-0052
Washer (18x)
002-2151
Figure 24 Installing wrist onto boom
1. Support the Wrist. Apply a thin film of EP grease to the sealing surfaces of the five
hydraulic fittings (006-0015). Attach the five hoses (006-1594) to the appropriate
fittings on the wrist base (101-3033). Tighten the hose fittings finger tight, then
one-sixth of a turn to tighten the hose fitting.
2. Align the wrist base with the linear actuator (101-1909). Lubricate the wrist pin
(001-2117) with EP grease and install.
3. Align the wrist base with the boom (001-3029. Lubricate the eighteen HHCS
(002-0052) with Aqua Lube and install with washers (002-2151). Torque to 28
Nm (21 ft/lbs).

Install the Jaw Nose Block/Jaw Piston Assembly
Refer to the appropriate nose block/jaw piston Service Instruction to install the nose
block/jaw piston supplied with your slave arm.
If you have a PA jaw, refer to the appropriate wrist/jaw adaptor Service Instruction to
remove the wrist/jaw adaptor supplied with your slave arm.
Read and be familiar with all the steps and requirements before you get started. Return to
this point when you have installed your nose block/jaw piston assembly. Go to "Install the
Jaw Assembly".
Install the Jaw Assembly

Refer to the appropriate jaw Service Instruction to install the jaw supplied with your slave
arm. Read and be familiar with all the steps and requirements before you get started. Re-
turn to this point when you have installed your jaw assembly.
Test Wrist Functionality

After the wrist is reassembled, it should be tested to ensure proper functioning and to de-
termine if adjustment to the wrist preload is necessary.
1. Connect the slave arm to a rate control manifold or other suitable test fixture
through which 3000 psi (20000 kPa) hydraulic pressure can be applied to the
arm’s 4A and 4B supply hoses. Connect the arm’s C (compensation return) hose
to a hydraulic return or drain fitting that will not exceed 350 psi (2400 kPa).
2. Apply hydraulic power to each supply line in turn to drive the wrist in each
direction for at least a few minutes. Closely inspect the wrist assembly (especially
the wrist manifold-pitch plate junction) for leaks.
3. Observe the wrist action as it rotates. It should turn relatively smoothly, and at a
constant rate.
Note: The gerotor drive has an inherent fluctuation in drive torque. A

slight “flutter” in wrist torque, especially under heavy load, is normal.
The “flutter” may be more noticeable at slow speeds. As long as the
degree of flutter is constant, it is normal.
— If a servo, or proportional control valve, is used, apply minimal pressure to

each wrist drive supply hose in turn. The wrist should start easily and turn at
a constant rate as slowly as 5-6 rpm.
— If the wrist is hard to start, resisting turning until it suddenly “breaks loose,”
the flutter is especially pronounced, or if a minimum rotation speed of about
6 rpm is not obtainable, the wrist preload may need to be adjusted. Use the
following procedure to adjust the wrist preload.
Adjusting Wrist Preload

Refer to Figure 22 on page 85 for this procedure.
1. Remove the wrist motor from the wrist base by following the steps in “Remove
Wrist From Slave Arm” on page 70.
2. Loosen the clamp nut SHCS (002-1133).

3. Loosen the clamp nut (001-5103) and retorque it as follows:
— If the standard preload of 40 foot-pounds (54 Nm) was used, re-torque the
clamp nut to 41 Nm (30 ft/lbs).
— If the optional preload of 30 foot-pounds does not improve wrist perfor-
mance, retorque the clamp nut to 68 Nm (50 ft/lbs).
— If 30, 40, and 50 foot-pounds torque on the clamp nut do not produce the
desired wrist performance, increase the torque in 13.5 Nm (10 ft/lbs) steps,
up to 149 Nm (110 ft/lbs).
4. Tighten the clamp nut SHCS (101-3786) to 7 Nm (5 ft/lbs).
5. Install the wrist following the steps in “Install Wrist onto Slave Arm” on page 86.
6. Retest the wrist operation using the steps in "Test Wrist Functionality" above.
7. Repeat Steps 1-6 until acceptable wrist operation is achieved.

1 Organization
The drawings and part lists in this chapter are in numerical order, ordered first by the three digit
prefix, then by the following dashed numbers.
 The drawing and part list for a component are located together.
 Drawing and part list revisions (“Rev X”) are not linked and can differ.
 Parts identified in a bubble on a drawing are referenced to their “Item” number
on the part list.
 Electrical schematics (prefix 035-) and hydraulic schematics (prefix 025-) do not
have part lists.
Note: To get the right part when ordering, use the identification number provided in the P/N column.
2 Index
Major Assembly Drawings
Base assembly replacement drawing ...................................... page 38
Shoulder block replacement drawing ...................................... page 40
Arm segment replacement drawing ........................................ page 42
Wrist/jaw and boom replacement drawing ............................... page 43
Shoulder and arm linear actuator disassembly drawing ............. page 45
6-Inch Linear Actuator Assembly drawing................................ page 47
12-inch linear actuator assembly drawing................................ page 49
Sub-Assembly Drawings
Hydraulic Schematic, 025-0028 ............................................. page 91
RigMaster 1:1 Mounting Template, 050-0692.................. page 92
Linear Actuator, 12-in Stroke, 101-1909 ................................. page 93
Wrist Assembly, 101-3372 .................................................... page 95
Jaw, 11.5-in Intermeshing, 101-3586 ..................................... page 99
Wrist Assembly, 101-3587 .................................................. page 101
Wrist Motor, 101-3786 ........................................................ page 104
Nose Block Kit, 101-3853.................................................... page 110
RigMaster Slave Arm, 101-4991........................................... page 112
Linear Actuator, 6-in Stroke, 101-6361 ................................. page 116
RigMaster System, 199-0274 .............................................. page 118
RigMaster System, 199-0287 .............................................. page 118
011–0755 Page 89
• Drawings & Part Lists
2.1 Spares Kit
Spares Kit, w/Anodized Wrist, 008-0104 ............................... page 120
Item 1: Spares Kit, Wrist, Gamma, 008-0096 ................ page 121
Item 2: Spares Kit, Hoses, 008-0105............................ page 122
Item 3: Rebuild Kit, Actuator, 008-0106 ........................ page 122
Item 4: Spares Kit, Hardware, 008-0107....................... page 122
Item 5: Spares Kit, Boom, 008-0108 ............................ page 123
Item 6: Tool Kit, 010-0689 .......................................... page 123
Page 90 • 2 Index 011–0755

Hydraulic Schematic, 025-0028
011–0755 • Drawings & Part Lists • Page 91

RigMaster 1:1 Mounting Template, 050-0692

Rev. A
1 001-1777 PSTN,LIN ACTR 1.75 1
2 001-2103 SFT,LIN ACTR,12 IN 1
9 004-0669 O-RING,2-031,BUNA 90 1
10 001-0893 BRG,ROD 2
13 007-0173 BODY,LIN ACTR,12IN,RIG 1
14 004-0082 O-RING,3-904 BUNA 90 0
46 010-0184 TOOL,INSTL,M,1.75 0
47 010-0185 TOOL,SIZING,F,1.75 0
48 010-0203 TOOL,SIZING,M,1.0 0

Wrist Assembly, 101-3372

Rev. B
2 101-3786 WRIST MOTOR,ALUM,2.25IN BORE 1
7 101-3853 NOSE BLOCK KIT,CONAN/RIGMASTER 1
12 010-0174 TOOL,INSTALL,M,2.25 0
13 010-0175 TOOL,SIZING,F,2.25 0
Note:
• Item 2 (101-3786) has a drawing and part list under its own part number (for location see the draw-
ings and part lists index at the beginning of this chapter).
• Item 7 (101-3853) parts are shown on drawing 101-3372 as 7-x items. The 101-3853 part list is located
below.
Item 7: Nose Block

,
Kit, 101-3853
,
Rev. V
2 001-5395 PISTON,1 PIECE,2.25 DIA,JAW 1
3 001-5399 BRG,PSTN,2.25DIA,ORKOT 1
4 004-0616 SEAL,PSTN,SHAMBAN,34G02250-A46 1
5 001-4465 BLOCK,NOSE,CONAN/RIGMASTER 1
6 004-0542 O-RING,2-034 BUNA 70 1
7 004-0541 RING,BACKUP,8-034 BUNA 90 1
8 001-5398 BRG,ROD,1.0DIA,ORKOT 2
10 003-0113 BEARING,JAW,GAMMA 4
11 003-0050 BRG,CJ12E144 DIXON 4
12 001-5396 PLATE,T-BAR,LOCKING 1
13 001-7520 BOLT,6 PT,5/8-18,STD 1
14 002-1135 NAS 6406U4 4
15 011-5011 SVCE INSTR,ITMSHG JAW NOSE BLK 0
16 002-1439 WSHR,3/8ID,5/8OD 4
18 010-0991 TOOL,CONAN JAW BOLT 0
19 002-0795 ADH,#271 RED LOCTITE 50ML 0
23 002-1925 ANTI-SIEZE,1 OZ TUBE 0

Jaw, 11.5-in Intermeshing, 101-3586
Rev. B
1 101-4113 BASE,JAW,W/BRG 2
3 003-0006 BRG,THR,0.75X1.50X0.078 4
4 002-0277 HHCS,1/2-20X3/4~L,316SS 4
5 002-0063 NUT,MS-21043-6 8
6 001-2099 JAW,TINE 4
7 001-2908 BRG,ACTR,BRZ 2
8 001-2122 TIE ROD,JAW,SHORT 2
9 001-2121 TIE ROD,JAW,LONG 2
10 001-2100 SPACER,JAW 2
11 002-0071 WSHR,1/2,316SS 4
12 001-4551 PIN,PVT,INTMSHG JAWS 2

Rev. B
1 001-3033 BASE,WR,18 SCR MT 1
2 101-3372 WRIST,CON/RIG 1
12 001-4697 HHCS,3/8-16X.930,SS 4
44 101-3586 JAW KIT,RIG 1
48 004-0222 O-RING,2-010 BUNA 90 5
49 004-0017 O-RING,2-031 BUNA 70 1
50 006-0015 FTG,HYD,-4 JIC,-4 ST,4F50X-SS 5
51 006-0612 VALVE,RL,RLF,NUPRO 350-600 PSI 1
110 101-3587-WI WORK INSTRUCTONS 0
111 011-5030 SVCE INSTR,WR,RIG 0
113 011-5025 SVCE INSTR,INTMSHG JAW,11.5 0

Wrist Motor, 101-3786
Rev. H
1 101-3785 SFT,WR,SUB-ASSY 1
2 101-3784 HSG,AL,SR WR,GAMMA 1
3 004-0617 SEAL,FLUROCARBON #AR10400-418- 1
4 003-0031 BRG,NEEDLE,TORRINGTON B-5612 1
5 004-0803 SEAL,SHAMBAN,TGZF-S4016NA 3
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
10 001-4437 RING,SEAL BACKUP 1
11 001-2060 PL,WEAR,WR MOTOR 1
12 004-0575 SEAL,AR10103-214-UH,FLUROCARBO 1
13 101-3373 GEROTOR,W/O WR RING 1
14 001-1832 VALVE,PL,WR MOTOR 1
16 004-0081 O-RING,2-035 BUNA 70 1
17 004-0017 O-RING,2-031 BUNA 70 1
18 004-0413 O-RING,2-026 V75 1
19 004-0110 O-RING,2-046 BUNA 70 1
20 001-4759 MANF,WR 1
21 003-0011 TORRINGTON,B148 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 2
27 004-0576 WSHR,CRUSH,5/16 8
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
32 001-5103 NUT,CLPING,7/8-20,1.5HEX 1
33 002-1133 SHCS 10-32 X 5/8,UNBRAKO 1
64 010-0236 TOOL,BRG PUSHER,T2/3 0
69 010-0525 TOOL,SEALINSTL 0
70 010-0556 INSTL TOOL,RIG/CON,O-RING 0
72 010-0613 PL,TEST,WR,ORION 0
73 002-1628 NAS6406U3 0
111 011-5014 SVCE INSTR,O7P,WRIST 0
112 011-5002 SVCE INSTR,O7R,WRIST 0
113 011-5030 SVCE INSTR,WR,RIG 0

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6 2 B A @ ? > =
Nose Block Kit, 101-3853
Rev. V
2 001-5395 PISTON,1 PIECE,2.25 DIA,JAW 1
3 001-5399 BRG,PSTN,2.25DIA,ORKOT 1
5 001-4465 BLOCK,NOSE,CONAN/RIGMASTER 1
6 004-0542 O-RING,2-034 BUNA 70 1
7 004-0541 RING,BACKUP,8-034 BUNA 90 1
8 001-5398 BRG,ROD,1.0DIA,ORKOT 2
10 003-0113 BEARING,JAW,GAMMA 4
11 003-0050 BRG,CJ12E144 DIXON 4
13 001-7520 BOLT,6 PT,5/8-18,STD 1
14 002-1135 NAS 6406U4 4
16 002-1439 WSHR,3/8ID,5/8OD 4
19 002-0795 ADH,#271 RED LOCTITE 50ML 0

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RigMaster Slave Arm, 101-4991
Rev. D
1 101-3587 WRIST,ANODIZED,RIG 1
2 101-1909 LIN ACTR,12IN 1
4 006-1594 HOSE ASSY,-4JIC,93 IN O.A.L. 5
5 006-0829 HOSE,BOOM,3A,MACHINED NUT 1
6 006-0830 HOSE, BOOM, 3B, RIG 1
7 006-0831 HOSE,SHLDR,2B,RIG 2
9 006-0833 HOSE,AZ,1A,RIG 1
10 006-0834 HOSE,AZ,1B,RIG 1
11 001-3029 SPAR,RIG 1
12 001-7286 PLATE,LEFT SIDE,.95 THK,RIG 1
13 001-7285 PLATE,RIGHT SIDE,.95 THK,RIG 1
14 001-2110 PL,TOP,RIG 2
15 101-7920 BLOCK, AZIMUTH , W/BRGS 1
16 007-0181 BASE,RIG 1
21 001-2117 PIN,EXTEND,WR RIG 1
22 001-7287 PIN,ACTUATOR,SLOTTED,5.47 LONG 2
23 001-2119 SPR,ACTR,RIG 4
24 001-7288 PIN,PIVOT SHOULDER,5.412 LONG 1
25 001-3035 PIN,PVT,AZ 1
27 001-3030 PIN,EXTEND,WR,RIG 3
28 002-1041 RING,RTNG,EXTERNAL 4
33 002-0188 HHCS,1/4-20X1.5,SS 26
34 002-0052 NAS 6404U3 18
37 003-0096 BRG,CORNER SPAR,RIG 4
38 003-0097 BRG, STRIP, LONG, SPAR, RIG 2
39 003-0098 BRG, STRIP, SHORT, SPAR, RIG 2
40 003-0099 BRG,THR,1.00X1.50X0.078 6
41 003-0100 BRG,THR,1.50x2.63X0.078 4
44 001-2588 SCRAPER,BOOM,RIG 1
45 002-0790 WSHR,1/4IDX.5OD,SS .032THK 26
48 101-1908 LIN ACTR,6IN 1
49 005-3166 HOSE LABEL KIT,RIG 1
57 006-0121 FIT,HYD,-4,JIC,PLUG,HEX-S(4-PN 0
65 001-3116 GDE,HOSE 1
66 002-1057 SHCS,1/4-28X2 1/2,SS 2
67 001-3117 BRACKET,HOSE GUIDE 1
70 002-1440 ANODE,GALVANIC 2
71 002-2151 WSHR,1/2OD X9/32ID,.078 THK,SS 18
72 101-6361 LIN ACTR,6IN,W/HRD LINE BRKT 1
73 025-0028 SCHEM,HYD 0
74 002-0065 HHCS,1/4-20X5/8,SS 4

Rigmaster Slave Arm, Range of Motion

Rev. B
1 001-1777 PSTN,LIN ACTR 1.75 1
2 001-2105 SFT,LIN ACTR,6 IN 1
9 004-0669 O-RING,2-031,BUNA 90 1
10 001-0893 BRG,ROD 2
13 007-0797 BODY,LINEAR,ACTUATOR,6 INCHES 1
14 004-0082 O-RING,3-904 BUNA 90 0
16 006-0841 FIT,HYD,-4 JIC BHD,4WTX-SS 1
17 001-9632 TUBE,EXTEND,ACTUATOR,LINEAR 1
18 006-0842 NUT,FIT,JAM,-4,7/16-20,4WLN-SS 1
46 010-0184 TOOL,INSTL,M,1.75 0
47 010-0185 TOOL,SIZING,F,1.75 0
48 010-0203 TOOL,SIZING,M,1.0 0

REV ZONE DESCRIPTION DATE BY APPR
A - RELEASED FOR PRODUCTION 7/27/07 PK SLW

NOTES:
ADDED BALLOON 18, AND NUT IN MODEL AND
B - UPDATE TUBE 17 WITH DIMENSION 11/16/07 VDM AL
1. ITEMS LISTED BELOW TO BE TORQUED AS INDICATED:
ITEMS: TORQUE:
1, 3 75 FOOT LBS.
4 240 FOOT LBS.
15 21 FOOT LBS.
D 2 SERIALIZE IN LOCATION SHOWN. D
15
011–0755
15
C C
•
16
17
A 18
1
2
9 4
6

B 14 B
2 REF
• Page 117
3
6 13 10 11 10 11 12
7 8 7
A
SECTION A-A
GENERAL NOTES NEXT ASSEMBLY

A INTERPRET DIMENSIONING AND TOLERANCING
A
101-3582
PER ASME Y14.5M-1994. IN ADDITION, S
DENOTES REGARDLESS OF FEATURE SIZE. 101-4991
REMOVE ALL BURRS AND BREAK ALL SHARP
EDGES
ALL MACHINED SURFACES TO BE 63 RMS PROJECT RIGMASTER
FINISH UNLESS OTHERWISE NOTED. SIGNATURE DATE
TITLE
DIMENSIONS ARE IN INCHES UNLESS
OTHERWISE NOTED. DRAWN SLW 7/19/07 LINEAR, ACTUATOR,
TOLERANCES DESIGNED
PROPRIETARY AL 7/19/07 6 INCH WITH HARD LINE BRACKET
RELEASED FOR DECIMALS FRACTIONS ANGLES
THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO CHECKED SCALE: DRAWING NUMBER SIZE SHEET REV
SCHILLING ROBOTICS. ANY REPRODUCTION, DISCLOSURE, OR .X ±.1 .X ±30'
USE OF THIS DOCUMENT IS EXPRESSLY PROHIBITED EXCEPT .XX ±.02 ±1/16 .XX ±15' LEAD SLW OF
AS SCHILLING ROBOTICS MAY OTHERWISE AGREE TO IN WRITING. PRODUCTION .XXX ±.005 1:1 101-6361 C 1 1 B
RigMaster System, 199-0274
Rev. B
1 101-4991 SLAVE ARM, RIGMASTER 1
2 002-2430 CASE,SHIPPING,60X12X13 ID 1
3 011-8204 MNL,RIGMASTER 199-0274/0287 2
5 008-0104 SPS KIT,RIG,W/ANODIZED WR 0
11 001-5006 LABEL,SERIAL NUMBER 1
12 002-1527 SCR,DRIVE,SS,#6X3/8LONG,.120IN 2
Note: Part list only. See drawing 199-0274.
RigMaster System, 199-0287

Rev. D
1 101-4991 SLAVE ARM, RIGMASTER 1
3 011-8204 MNL,RIGMASTER 199-0274/0287 2
5 008-0104 SPS KIT,RIG,W/ANODIZED WR 0
11 001-5006 LABEL,SERIAL NUMBER 1
12 002-1527 SCR,DRIVE,SS,#6X3/8LONG,.120IN 2

hh

Spares Kit, w/Anodized Wrist, 008-0104
Rev. F
1 008-0096 SP KIT, RIG, WRIST 1
2 008-0105 SPS KIT,RIG HOSES 1
3 008-0106 REBUILD KIT,RIG ACTR 1
4 008-0107 SPS KIT,RIG HDW 1
5 008-0108 SPS KIT,RIG,BOOM 1
6 010-0689 TOOL KIT,CON/RIG 1
8 001-7520 BOLT,6 PT,5/8-18,STD 2
NOTE: Part lists for 008- and 010- kits in the “Item” column begin on the follow-
ing page.
008-0104 Item Part Lists index

Item 1: Spares Kit, Wrist, Gamma, 008-0096 ................... page 121
Item 2: Spares Kit, Hoses, 008-0105 ............................... page 122
Item 3: Rebuild Kit, Actuator, 008-0106 ........................... page 122
Item 4: Spares Kit, Hardware, 008-0107 .......................... page 122
Item 5: Spares Kit, Boom, 008-0108 ............................... page 123
Item 6: Tool Kit, 010-0689 ............................................. page 123

Item 1: Spares Kit, Wrist, Gamma, 008-0096
Rev. B
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
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
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
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

Item 2: Spares Kit, Hoses, 008-0105
Rev. B
4 006-1594 HOSE ASSY,-4JIC,93 IN O.A.L. 5
5 006-0829 HOSE,BOOM,3A,MACHINED NUT 1
6 006-0830 HOSE, BOOM, 3B, RIG 1
7 006-0831 HOSE,SHLDR,2B,RIG 1
8 006-0832 HOSE, SHLDR, 2A, RIG 1
9 006-0833 HOSE,AZ,1A,RIG 1
10 006-0834 HOSE,AZ,1B,RIG 1
Item 3: Rebuild Kit, Actuator, 008-0106

Rev. B
9 004-0669 O-RING,2-031,BUNA 90 1
10 001-0893 BRG,ROD 2
14 004-0082 O-RING,3-904 BUNA 90 2
Item 4: Spares Kit, Hardware, 008-0107

Rev. D
1 002-1135 NAS 6406U4 2
2 002-1439 WSHR,3/8ID,5/8OD 4
3 003-0006 BRG,THR,0.75X1.50X0.078 2
4 002-0277 HHCS,1/2-20X3/4~L,316SS 2
5 002-0063 NUT,MS-21043-6 2
11 002-0071 WSHR,1/2,316SS 2
33 002-0188 HHCS,1/4-20X1.5,SS 10
34 002-0052 NAS 6404U3 4
40 003-0099 BRG,THR,1.00X1.50X0.078 4
41 003-0100 BRG,THR,1.50x2.63X0.078 2
42 003-0406 BRG,DIXON# CJ24E26-7 4
45 002-0790 WSHR,1/4IDX.5OD,SS .032THK 10
66 002-1057 SHCS,1/4-28X2 1/2,SS 2
70 002-1440 ANODE,GALVANIC 4
71 002-2151 WSHR,1/2OD X9/32ID,.078 THK,SS 4
74 002-0065 HHCS,1/4-20X5/8,SS 4

Item 5: Spares Kit, Boom, 008-0108
Rev. A
37 003-0096 BRG,CORNER SPAR,RIG 4
38 003-0097 BRG, STRIP, LONG, SPAR, RIG 2
39 003-0098 BRG, STRIP, SHORT, SPAR, RIG 2
44 001-2588 SCRAPER,BOOM,RIG 2
Item 6: Tool Kit, 010-0689

Rev. E
1 010-0099 SKT,MOD,7/16,6PT.,1/4 DRIVE(SN 1
2 010-0173 TOOL,CLP,JAW 1
3 010-0174 TOOL,INSTALL,M,2.25 1
4 010-0175 TOOL,SIZING,F,2.25 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
8 010-0804 TOOL,PISTON ROD,JAW 1
9 010-0237 TOOL,RESIZING 1
10 010-0238 CLR,JAW PSTN 1
12 010-0525 TOOL,SEALINSTL 1
13 010-0480 NUT,CLPING,WR,PIN 0
14 010-0760 CROWSFOOT,OPEN END,1 1/4~ 1
16 010-1117 WRIST CLAMP TOOL 2
17 010-1202 TOOL,CONAN,RELIEF VALVE 1
18 010-0239 TOOL,BRGINSTL 1
19 010-0240 TOOL,JAW ROD SL 1

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Schilling Robotics

RigMaster 2 Slave Arm

Document No. 011-8204

FMC Technologies Schilling Robotics

TECHNICAL MANUAL REVISION LOG

PRODUCT: RigMaster Slave Arm, 199-0274 & 199-0287

Maintenance & Service

Drawings & Part Lists

Page 4 Table of Contents

Table of Contents Page 5

2 Manipulator Arm Specifications

Actuator Functions (cont.)

Rotary actuator return pressure, maximum . . . . . . . . . . . . . . . . . . 24 bar (350 psi)

3.1 Fluid Selection

Page 8 • 3 Hydraulic Specifications 011–0753

3 Installing the Slave Arm

Figure 1 Stow dimensions

Figure 2 Minimum distance to bulkhead hose fittings

Page 10 • Installing the Slave Arm 011–0756

Figure 3 Slave arm mounting dimensions

3.2 Installing the Control & Drain Hoses

Note: IMPORTANT INSTALLATION DIMENSIONS:

011–0756 Installing the Slave Arm • Page 11

Slave Arm Actuator/ Joint Travel Hose Actuator

3.3 Installing Relief Valves

Page 12 • Installing the Slave Arm 011–0756

3.4 Installing Check Valves

4 Installation Startup & Test

4.1 Confirm Before First Startup

4.2 First Startup

011–0756 Installation Startup & Test • Page 13

4.3 Testing Functions

Page 14 • Installation Startup & Test 011–0756

2 Factors Affecting Slave Arm Performance

3.2 Startup Procedure

Page 16 • 3 Normal Operation 011-0757

4 Controlling System Functions

Actuator Function Type Nominal Mechanical Range

011-0757 4 Controlling System Functions • Page 17

This page not used.

Page 18 • 4 Controlling System Functions 011-0757

1 Troubleshooting the Slave Arm

2.1 Whole-Arm Troubleshooting Tables

SYMPTOM: Entire Slave Arm Unresponsive

Hydraulic fluid low or below pump intake. Add hydraulic fluid.

Page 20 • 2 Troubleshooting Tables 011-0784

SYMPTOM: Entire Slave Arm Unresponsive (continued)

SYMPTOM: Entire Slave Arm is Sluggish

SYMPTOM: Entire Slave Arm is Operating Erratically

011-0784 2 Troubleshooting Tables • Page 21

SYMPTOM: Entire Slave Arm is Operating Erratically (continued)

SYMPTOM: Entire Slave Arm Hard Over.

SYMPTOM: Entire Slave Arm Sagging

2.2 Single Joint Troubleshooting Tables

SYMPTOM: Single Joint/Actuator Sluggish

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SYMPTOM: Single Joint/Actuator Sluggish (continued)

SYMPTOM: Single Joint/Actuator Unresponsive

SYMPTOM: Single Joint/Actuator Sagging or Drifting

SYMPTOM: Single Joint/Actuator Hard Over