1 InnoSys Quick Connect End Effecter Service and Maintenance Procedures Shreveport Assembly 14 MAY, 2008

2 InnoSys Quick Connect End Effecter Maintenance Table of Contents 3 Bill of Material 4 – 5End Effecter Exploded Views Nose/Bearing Maintenance. Perform once per day Replace Float Sleeves every 20,000 cycles Crowsfoot Attachment Lubrication Lubricate vis the grease zerk every 5,000 Cycles Dissemble Clean and Lube every 20,000 Cycles 14 – 19 Replacing the Drive Adapter Every 20,000 Cycles as needed 20 – 22 Replacing Internal Components – Perform every 20,000 cycles Backing Block Thrust Bearings and Races Spring Retainer Cleaning and lubricating the Release Mechanism. Perform every 40,000 cycles 28 –30 Replacing a Load Cell Perform as needed 31 – 34 Process Overview

InnoSys Quick Connect End Effecter

Exploded View Rear Section of End Effecter 4

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InnoSys QC Service Procedure Nose/Bearing Maintenance 1)With End Effecter in returned position as shown Return Sleeve is back Wire Boss is Forward Return Sleeve will remain in this returned (back) position. Do not push in Input Shaft during this procedure 2) Unscrew and remove Nose 6

InnoSys QC Service Procedure Nose/Bearing Maintenance 3) Slide O- Ring and Float Sleeve off input shaft to expose input shaft balls. Do not push in on input shaft during this procedure. 4) Remove Balls, there are six in all. A magnet can be used to remove the balls. 7

InnoSys QC Service Procedure Nose/Bearing Maintenance 5) After removing Balls, slide the Nose Bearing off the Input Shaft. Clean Input Shaft and ID and OD of Nose Bearing. Do not use solvents on Nose Bearing. 6)Clean bearing holes and shaft. Use a magnet to remove metallic particles from holes. Apply super lube to holes and outside of shaft. 8

InnoSys QC Service Procedure Nose/Bearing Maintenance 7) Slide Nose Bearing back on to Input Shaft. 8) Re-lubricate outside of Input Shaft and place balls back into holes. (Use Super Lube). 9) Slide Float Sleeve and o-ring back onto Input Shaft. DO NOT APPLY GREASE TO OUTSIDE OF FLOAT SLEEVE or INSIDE OF NOSE. 9

InnoSys QC Service Procedure Nose/Bearing Maintenance 10) Screw Nose of End Effecter back on to Cylinder, hand tighten. 10

11 InnoSys QC Service Procedure Crows Foot Lubrication Crows Foot Attachment Nut Runner

InnoSys QC Service Procedure Crows Foot Lubrication 12 1)Unscrew cap screws and remove front plate to expose gears.

InnoSys QC Service Procedure Crows Foot Lubrication 13 Roller Bearing 2)Clean gears and reapply super lube to gears, bearing and inside of back plate. Back plate

InnoSys QC Service Procedure Replacing the Drive Adapter 1) Remove end plate, crows foot, and return spring from cylinder of end effecter. Return SpringCrows Foot Attachment End Plate 14

InnoSys QC Service Procedure Replacing the Drive Adapter 2) Remove spirol ring, drive keys and drive adapter from input shaft. Drive Adapter Drive Keys Spirol Ring 15

InnoSys QC Service Procedure Replacing the Drive Adapter 3) Install new Drive Adapter and reinstall the Drive Keys, aligned with slots of Input Shaft. 16

InnoSys QC Service Procedure Replacing the Drive Adapter 17 This two piece tool is required for installing the Spirol Ring at the end of the input shaft.

InnoSys QC Service Procedure Replacing the Drive Adapter 18 4) Place Spirol Ring onto tapered mandrel of installation tool. Place driver over top of mandrel.

19 InnoSys QC Service Procedure Replacing the Drive Adapter 5) Push the driver down expanding the ring until the ring snaps into the groove at the end of the input shaft.

Replacing Internal Components, Spring Retainer, Thrust Bearings and Backing Block 1) After removing Drive Adapter (previous section) remove Dowel retainer to expose Dowel Pins. Dowel Retainer 20

Replacing Internal Components, Spring Retainer, Thrust Bearings and Backing Block 2) Unscrew M5 cap screw and slide Wire Boss a short distance from cylinder of end effecter. Wire Boss M5 Cap Screw3)Push Dowel Pins down through slots of input shaft and out bottom of cylinder. Dowel Pins 21

Prevent Input Shaft from sliding out the nose of the tool. 22

InnoSys QC Service Procedure Quick Connect/Bearing Maintenance 1) After removing all Nose components, push the Input Shaft in. This action will unlock the Release Sleeve and allow it to be removed. Wire Boss locks back 23

24 InnoSys QC Service Procedure Quick Connect/Bearing Maintenance 2) The Release Sleeve and Sleeve Spring can now be removed to expose the Quick Connect Balls. 3) After removing the Release Sleeve the Input Shaft will spring back to the extended or “return” position.

25 InnoSys QC Service Procedure Quick Connect/Bearing Maintenance 5) Replace the Balls and reinstall the alignment Dowel Pin. The Balls and Pin should be lubricated with Super Lube. 4) Balls and aligning Dowel Pin can now be removed and the holes of the Cylinder can be cleaned.

26 InnoSys QC Service Procedure Quick Connect/Bearing Maintenance 6) Place Release Sleeve Spring back on face of Cylinder

27 InnoSys QC Service Procedure Quick Connect/Bearing Maintenance 7) Push and hold Wire Boss down while sliding Release Sleeve all the way down to it’s stop. Once the Release Sleeve is all the way down release the Wire Boss. The Wire Boss and Input Shaft will spring back to the extended “return” position and the Return Sleeve will be locked in place. Then, reinstall all Nose components.

InnoSys QC Service Procedure Replacing a Load Cell First Break Electrical Connection at Load Cell Connecter. 1) Unscrew Cap Screws and Remove End Plate, Crows Foot and Release Spring. 2) Remove entire End Effecter from Crows Foot of Nut Runner. Push Wire Boss back to lock into retracted position. This will enable easier access to the Drive Adapter. 28

29 InnoSys QC Service Procedure Replacing a Load Cell 3) Remove all of the following components Prevent the Input Shaft from sliding out the nose of the tool. If it does, be sure the Interium Gap Washer is on the shaft and slide it back in.

InnoSys QC Service Procedure Replacing a Load Cell 4) Remove entire assembly of Load Cell, Wire Boss, Hose Connecter and Hose from Cylinder of End Effecter. Reverse this procedure to install new Load Cell Assembly. 30

Process Overview 31 STEP1 Nut is installed on threaded rod and operator aligns end effecter with nut. STEP 2 Operator slides nut into barrel of input shaft.

Process Overview 32 STEP 3 Operator cocks tool by pushing the threaded rod into the nose of the end effecter. The nut is now positioned away from the equalizer and locked in place. Balls cam in to lock in nut Release Ring springs forward to lock in piston balls

Process Overview 33 STEP 4 Operator presses start button and nut is run up threaded rod at fast forward speed until a percentage of the final tension target is achieved. Load cell detects tension. STEP 5 After achieving the fast run tension target, the nut runner runs forward at slow speed until the final tension target is achieved. The cable tends to relax so the tool will jog forward to maintain target tension until tension stabilizes.

Process Overview 34 STEP 6 Tool runs reverse a specified angle to achieve the proper residual tension when the tool is removed from the job. STEP 7 When the cycle is complete operator gets green light and audible tone. The operator then slides the release ring back to release the nut from the nose of the tool and removes the tool from the job. Release Ring