Service Bulletins,: For Manipulator Systems, Slave Arms, & Accessories

Service Bulletins,
Volume 2
For Manipulator Systems, Slave Arms, &
Accessories
Bulletins 011-7151 (September 2005)

through the present
DOCUMENT NO. 0117233

Copyright 2009 by Schilling Robotics, LLC. All rights reserved.
Schilling Robotics, the Schilling Robotics logo, and their frameworks are trademarks and service
trademark applications of Schilling Robotics. No part of this document may be reproduced or
used in any form without the express written permission of Schilling Robotics. Descriptions and
specifications are subject to change without notice.
We invite your comments about our products and technical manuals. Please contact:
Schilling Robotics, LLC
260 Cousteau Place, Ste 200, Davis, CA 95618 Ph: (530) 753-6718 Fax: (530) 753-8092
E-mail: [email protected] [email protected] [email protected]
Web Site: http://www.schilling.com
TECHNICAL MANUAL REVISION LOG

PRODUCT: Manipulator Systems, Slave Arms, and Accessories
TECHNICAL MANUAL: Service Bulletins, Volume 2, 011-7233
Description
Manual release
Manual update (bulletins added
Date
Rev.
January 2009
December 2009
PAGE BREAK
Service Bulletin 0117233
Page ii

Upgrading Titan Master & Slave
Controller EPROMs
Compliance:
Recommended*
ISSUE DATE
September 8, 2005
AFFECTED PRODUCTS
Titan 2, 3, and 4 Manipulator Systems
AFFECTED COMPONENTS
Master controller and slave controller EPROMs
SERVICE INFORMATION
If you operate any combination of standard Titan 2, Titan 3 and Titan 4 manipulator
systems, upgrading the EPROMs in all Titan master controllers and Titan 2 and 3 slave
controllers is recommended.
With the newest EPROMS installed, any Titan master controller can operate any standard Titan 2,
3, and 4 manipulator systems without error messages or the need to overwrite existing software and
settings. The operator sees only the normal startup, operation, and configuration screens, and, existing settings for joint travel limits, stow sequence, error checks, and servo valve offsets are retained.
! Caution
Never connect a T3 slave arm to a T2 slave controller. The voltage difference
(24VDC versus 120/240 VAC) will cause damage to slave arm components.
FIELD ACTION
1.
Inspect all master controller EPROMs and Titan 2 and 3 slave controller EPROMS.
2.
Install master controller EPROM 014-0695, Rev D if not present.
3.
(Titan 2 and 3 only) Install slave controller EPROM 014-0594, Rev C (introduced mid-1999) if
not present.
NOTE: No EPROM change is necessary for Titan 4 in-arm slave controllers.

*BULLETIN COMPLIANCE LEVELS
REQUIRED Field action is REQUIRED to ensure personnel safety, equipment functionality, and/or continuation of warranty coverage.
RECOMMENDED Field action is not required but is highly RECOMMENDED and will result in significantly
increased levels of personnel safety and/or equipment functionality.
OPTIONAL Field action may be useful under certain circumstances. Compliance is OPTIONAL and left to
the discretion of the owner/operator.
ADVISORY Bulletin contains advisory information to assist the owner/operator in more effective operation or service of the product. Compliance is not rated.
If you have any questions about this service bulletin, contact the Schilling Customer Service Department at:
Tel: +1 530 753 6718 (USA) or +44 (0) 1224 560 900 (UK)
Fax: +1 530-753-1534 (USA) or +44 (0) 1224 560 901 (UK)
e-mail: [email protected] For bulletins & manuals online, go to: http://www.schilling.com
Page 1
Other Features of Master Controller EPROM 014-0695, Rev D

The new EPROM also provides clear options when it is installed in a master controller with incompatible software (previously used with an incompatible system) or it is used to control an incompatible system.
If the master controller was previously used to operate a non-standard/custom Titan system, the
new software will detect an incompatibility with the software code on the master controller CPU
board EEPROM and display the alert screen below. You then have two options.
1.
2.
If you want to implement operation,

press the 4> Yes key to overwrite the
EEPROM with software appropriate
for the Titan slave arm that is detected
(T4 in the sample screen at right)
and proceed with normal startup and
operation of the Titan slave arm.
Overwriting installs factory default
settings. Joint travel limits, stow
sequence, error checks, and servo
valve offsets must be reset as
necessary.
SCHILLING ROBOTICS, LLC

TITAN MANIPULATOR SYSTEM
-------------------------------The ID Code indicates that
this Master Controller may
have been configured for a
non-Titan manipulator.
Select [Yes] only if you would
like to change ID Code to T4
and to overwrite saved values
for joint limits and stow.
4> Yes
--------------------------------
If you dont want to lose existing joint travel limits, stow sequences, error checks, and servo
valve offsets, replace the original EPROM and install the new EPROM in a different master
controller where it is OK to overwrite existing values.
When the master controller is connected to an incompatible Titan slave controller/slave arm, such
as a Titan 7F or a non-standard/custom Titan, you will see the alert screen below. You then have two
options.
1.
Recommended option: Do not use the

master controller. Connect a
compatible model instead.
2.
Use the 4> Yes option only if

emergency operation is absolutely
necessary as the slave arm may
display uncontrolled or inconsistent
operation.
SCHILLING ROBOTICS, LLC

TITAN MANIPULATOR SYSTEM
-------------------------------The Master Controller software
is not compatible with the
slave arm. Further operation
may risk damage to equipment.
Select [Yes] only if you would
like to proceed anyway.
4> Yes
--------------------------------
Non-Titan Systems
A Titan master controller/EPROM cannot communicate with a NON-TITAN slave arm and, if connected, will display a Fatal Telemetry Error screen at startup.
Page 2

New Potentiometer Expands Master
Controller Display Adjustability
Compliance:
OPTIONAL*
ISSUE DATE
September 2, 2005
AFFECTED PRODUCT(S)
Titan 3, Titan 4, Conan P, and Orion P Manipulator Systems
AFFECTED COMPONENT
Newer Master Controllers with a blue gray LCD. Older master controllers with a
greenish yellow LCD are NOT affected by this bulletin.
SERVICE ISSUE
Newer Titan 3, Titan 4, Conan P and Orion P master controllers (with the blue-gray
LCD) have automatic and manual adjustments for keeping the viewing angle consistent under varying temperature conditions. However, the range of temperature in
some environments may be greater than the range of adjustability.
This condition can be corrected with a new adjustment potentiometer (005-0705) that extends the
adjustment range to approximately 0 to 100F (-18c to +40c). Field replacement of the potentiometer (Figure 1, arrow) requires PCB-level soldering and mechanical skills.
Figure 1 Display adjustment potentiometer on the display transition PCB

Potentiometer 005-0705 is available upon request at no charge for field installation and will be
installed at no charge on master controllers returned to the factory for other service.
OPTIONAL Field action may be useful under certain circumstances. Compliance is OPTIONAL and left
to the discretion of the owner/operator.
Tel: +1 530 753 6718 (USA) or +44 (0) 1224 560 900 (UK)
Fax: +1 530-753-1534 (USA) or +44 (0) 1224 560 901 (UK)
Page 1
FIELD ACTION
To replace the adjustable potentiometer:
1.
Confirm the master controller has a blue gray display, with raised black bars to the left and
right sides of the LCD (see Figure 2). Do not continue if the display has no bars or is greenish
yellow.
BARS
Figure 2 Blue/gray display with bars

2.
Open the master controller and remove the display transition PCB from the master controller
(see the master controller drawing in your manipulator technical manual for hardware details).
3.
Remove the existing adjustable potentiometer.
4.
Install the new adjustable potentiometer (005-0705).
5.
If necessary, adjust the viewing angle of the display as directed in the Maintenance and
Service chapter of your manipulator technical manual.
Page 2

New Non-Fuse Jaw Bolt for
Manipulator Systems & Slave Arms
Compliance:
Advisory*
ISSUE DATE
December 12, 2005
AFFECTED PRODUCTS
Titan 4, Orion, Conan, and RigMaster manipulator systems and slave arms
AFFECTED COMPONENTS
Jaw bolts and T-bar plates
SERVICE INFORMATION
Because a number of customers have found the failure-rate of the fuse-type jaw
bolts unacceptable, all new manipulator systems and slave arms are configured with
non-fuse bolts. In addition, the material of the t-bar plate has been changed from
Titanium to Inconel to increase it's strength.
Customers purchasing replacement parts can select the fuse or non-fuse jaw bolt. Jaw bolt and
T-bar plate part numbers for common models are listed in the table below.
Manipulator or Slave Arm Models
Non-Fuse
Jaw Bolt
Fuse Jaw
Bolt
Inconel
T-Bar PLate
Std. Titan 3 and 4 Manipulator Systems
001-7519
001-5382
001-5381
Orion and custom Titan 3 models using

Nose Block Kit 101-3834 (jaw kits 1014105, 4106, 4107)
001-7519
001-5382
001-5381
Orion, Conan, and Rigmaster models

using Nose Block Kit 101-3853 (jaw kits
101-4102, 4103, 4104
001-7520
001-5397
001-5396

Tel: +1 530 753 6718 (USA) or +44 (0) 1224 560 900 (UK)
Fax: +1 530-753-1534 (USA) or +44 (0) 1224 560 901 (UK)
Page 1

Replacement of Titanium Azimuth
Block on RigMaster Slave Arms
Compliance:
Recommended*
ISSUE DATE
August 22, 2006
AFFECTED PRODUCTS
RigMaster slave arms
AFFECTED COMPONENTS
Azimuth block 001-3043
SERVICE INFORMATION
The cast titanium azimuth block supplied on RigMaster slave arms delivered between
May 2005 and March 2006 may experience failure. A replacement part will be provided at no charge.
RigMaster slave arms delivered before May 2005 and after March 2006 have azimuth blocks made
of 17-4 stainless steel and are not subject to failure.
ACTION
The titanium azimuth block 001-3043 should be replaced. To determine if the azimuth block is titanium, look at the section that holds the azimuth pivot pin. The titanium part has a gap and has a
more sculptured finish (figure below, left) . The stainless steel part has no gap (figure, right).
REPLACE!
OK
If you have a titanium part, contact the Customer Service Department and provide the serial number
of the slave arm, along with a contact name and shipping address. A replacement part will be sent
immediately.
Tel: +1 530 753 6718 (USA) or +44 (0) 1224 560 900 (UK)
Fax: +1 530-753-1534 (USA) or +44 (0) 1224 560 901 (UK)
Page 1

Remote Systems Products
Changes to the Titan 4 Upper Arm

Assembly & Spares Kits
Status:
Advisory*
ISSUE DATE
February 12, 2007
AFFECTED PRODUCTS
Titan 4 Manipulator Systems 199-0269, 199-0269PAL, 199-0276, 199-0278, & 1990284
AFFECTED COMPONENTS
Slave Arm and Upper Arm Assemblies
SERVICE INFORMATION
To enhance reliability and improve access to the filter element in the upper arm, Titan
4 Manipulator Systems shipped after February 1, 2007 include stainless steel hydraulic pressure lines and a new isolation valve assembly (see Figure 1).
Figure 1 New hard lines (left) and isolation valve assembly (right) in the upper arm.
The changes have resulted in new part numbers for the upper arm assembly (now 101-5977), the
slave arm (now 101-5976), and Titan 4 standard and enhanced spares kits. The top level model numbers for Titan 4 manipulator systems (199-xxxx) have not changed.
The new spares kits include the hard lines, new isolation valve, solenoid, and associated parts. They
apply only to Titan 4 models built after February 1, 2007 with upper arm part number 101-5977
stamped into the underside of the upper arm assembly near the elbow (see Figure 2).
*BULLETIN STATUS LEVELS

Required
Recommended
Field action is REQUIRED to ensure personnel safety, equipment functionality, and/or continuation of warranty coverage.
Field action is not required but is highly RECOMMENDED and will result in significantly
Optional
Field action may be useful under certain circumstances. Compliance is OPTIONAL and left to
Advisory
Bulletin contains advisory information to assist the owner/operator in more effective operation or service of the product. Compliance is not rated.
Tel: +1 530 753 6718 (US) or +44 (0) 1224 560 900 (UK)
Fax: +1 530-753-1534 (US) or +44 (0) 1224 560 901 (UK)
Page 1
ELBOW
UPPER ARM
Figure 2 Part number of upper arm (arrow)

The new spares kit part numbers are shown in Table 1.
NOTE:
The new spares kits are NOT interchangable with spares kits for Titan 4 models built before February 1, 2007 and/or with upper arm part number 101-4841. Consult your existing service documentation for the correct spares kit part numbers.
Table 1
New Titan 4 Spares Kits

Model (with upper
arm 101-5977)
Standard
Spares Kit
Enhanced
Spares Kit
199-0269
008-0321
008-0322
199-0269PAL
008-0321
008-0322
199-0276
008-0323
008-0324
199-0278
008-0325
008-0326
199-0284
008-0325
008-0326
0117171
Page 2

Changes to the Titan 4 Forearm

Assembly
Status:
Advisory*
ISSUE DATE
March 19, 2007
AFFECTED PRODUCTS
Titan 4 Manipulator Systems 199-0269, 199-0269PAL, 199-0276, 199-0278, &
199-0284
AFFECTED COMPONENTS
Forearm Assembly 101-5723
SERVICE INFORMATION
A relief valve has been added to prevent ambient pressure from locking the shoulder
actuator if the manipulator hydraulics are turned off when operating at depth. The
new parts are shown in Figure 1.
Figure 1 Titan 4 Forearm Assembly

Field action is REQUIRED to ensure personnel safety, equipment functionality, and/or continRequired
uation of warranty coverage.
Recommended
Optional
Advisory
Tel: +1 530 753 6718 (US) or +44 (0) 1224 560 900 (UK)
Fax: +1 530-753-1534 (US) or +44 (0) 1224 560 901 (UK)
Page 1
To minimize this risk, enable the hydraulic power when surfacing the slave arm or install relief valve
kit 101-5555. The relief valve will be factory installed on Titan 4 models built after February 1, 2007.
Relief Valve Kit, 101-5555

Rev. 2
Item
P/N
Description
Qty
101-3965
RLF V,UNIV
002-0330P
SHCS,10-32X1.25,316SST,NLK
004-0222
O-RING,2-010 BUNA 90
0117172
Page 2

Changes to the Titan 4 Forearm

Assembly
Status:
Advisory*
ISSUE DATE
August 31, 2007
AFFECTED PRODUCTS
Titan 4 Manipulator Systems 199-0269, 199-0269PAL, 199-0276, 199-0278, &
199-0284
AFFECTED COMPONENTS
Forearm Assembly 101-5723
SERVICE INFORMATION
The T4 Lock Valve has been modified for serviceability. The new Lock Valve is factory
installed on Titan 4 models with serial number 68418 and higher built starting on September 1, 2007. The new Lock Valve assembly, part number 101-6190, is shown as item
10 in Figure 1. The new, longer screws, part number 002-0341P, are shown as item 11
in Figure 1.
Figure 1 New Titan 4 Forearm Assembly

Required
Recommended
Field action is REQUIRED to ensure personnel safety, equipment functionality, and/or continuation of warranty coverage.
Optional
Advisory
Tel: +1 530 753 6718 (US) or +44 (0) 1224 560 900 (UK)
Fax: +1 530-753-1534 (US) or +44 (0) 1224 560 901 (UK)
Page 1
The previous Lock Valve assembly, part number 101-0838, is shown as item 4 in Figure 2. The previously used, shorter screws, part number 002-0330P, are shown as item 2 in Figure 2
Figure 2 Previous Titan 4 Forearm Assembly

To service a Titan 4 Lock Valve built after September 1, 2007, kit 008-0347 should be used.
Titan 4 Lock Valve

Kit, 008-0347
e
0
Item
P/N
Description
Qty
001-1923
PSTN,LOCK V
001-1924
VALVE,LOCK
002-0728
SPR,LC-029B-3 MW,LEE
004-0587
010-0627
TOOL,LOCKV TEST
10
004-0571
11
004-0087
13
002-3661
SHCS,6-32 X 1/4 ALLOY, ST
14
002-0795
ADH,#271 RED LOCTITE 50ML
20
101-6190-WI
WORK INSTRUCTIONS
To replace a Titan 4 Lock Valve built prior to September 1, 2007, kit 101-6459 should be used.
0117188
Page 2
Titan 4 Lock Valve Kit, 101-6459

Item
P/N
Description
Qty
101-6190
LOCK VALVE ASSY,3000 PSI,T4
002-3708P
SHCS,10-32 X 1.125,SS,NLK
004-0222
004-0114
002-0341P
New Titan 4 Lock Valve Assembly, 101-6190

Rev. C
Item
P/N
Description
Qty
001-9345
BLOCK,LOCK VALVE,3000 PSI,74
001-1923
PSTN,LOCK V
001-1924
VALVE,LOCK
002-0728
SPR,LC-029B-3 MW,LEE
001-9346
PLATE,COVER,LOCK VALVE,T4
001-9347
PLUG,LOCK VALVE,3000 PSI,T4
004-0587
010-0627
TOOL,LOCKV TEST
10
004-0571
11
004-0087
12
002-9043
WSHR,FLAT,M4,FENDER,316 SS
13
002-0114
SHCS,6-32X1/4,SS
14
002-0795
ADH,#271 RED LOCTITE 50ML
20
101-6190-WI
WORK INSTRUCTIONS
0117188
Page 3
0117188
18
INCH LBS.
PROPRIETARY
5
2
13
8
14
REF
ADD SERIAL NUMBER IN APPROXIMATE LOCATION SHOWN PER

WORK INSTRUCTIONS.
13
ITEMS LISTED BELOW TO BE TORQUED AS INDICATED:

ITEMS:
TORQUE:
THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO

SCHILLING ROBOTICS. ANY REPRODUCTION, DISCLOSURE, OR
USE OF THIS DOCUMENT IS EXPRESSLY PROHIBITED EXCEPT
AS SCHILLING ROBOTICS MAY OTHERWISE AGREE TO IN WRITING.
1.
NOTES:
2
2
3
2
7
2
6
2
SECTION A-A
7
2
14
REF
12 13
10
4
2
11
4
1
-
PRODUCTION
RELEASED FOR
ZONE
REV
DESCRIPTION
2:1
SCALE:
TITLE
.X
.XX
30'
15'
ANGLES
DATE
LEAD
CHECKED
DESIGNED
SLW
SLW
PK
101-5723
101-2326
DRAWN
101-6190
DRAWING NUMBER
OF
SHEET
APPR
DATE
SLW
SLW
REV
6/5/07
6/5/07
NLH
SIGNATURE
B 1
SIZE
BY
PK
NEXT ASSEMBLY
8/20/07
6/5/07
LOCK VALVE, 3000 PSI,

T4
T4
1/16
PROJECT
FRACTIONS
DECIMALS
.X .1
.XX .02
.XXX .005
TOLERANCES
DIMENSIONS ARE IN INCHES UNLESS

OTHERWISE NOTED.
ALL MACHINED SURFACES TO BE 63 RMS

FINISH UNLESS OTHERWISE NOTED.
REMOVE ALL BURRS AND BREAK ALL SHARP

EDGES
INTERPRET DIMENSIONING AND TOLERANCING

PER ASME Y14.5M-1994. IN ADDITION, S
DENOTES REGARDLESS OF FEATURE SIZE.
GENERAL NOTES
SCALE 1.5:1
ISOMETRIC VIEW
UPDATED MODEL AND DRAWING DUE TO PART

MODEL ECO'S
RELEASED FOR PRODUCTION
Page 4

Correct hardware essential to safely
mounting RigMaster Slave Arm
Compliance:
Mandatory*
ISSUE DATE
February 20, 2008
AFFECTED PRODUCT(S)
RigMaster Slave Arm 199-0184 and earlier models
SERVICE INFORMATION
RigMaster Technical manual 011-9137 incorrectly lists M12 hex-head cap screws as a
mounting hardware option. M12 hardware will NOT secure the slave arm and it will
come loose from the vehicle.
CORRECTIVE ACTION
If M12 hardware is currently used to mount the slave arm, do not operate the slave arm. Replace the
M12 hardware as soon as possible with 1/2-20 UNF-2B hardware ONLY. Refer to Figure 1, below.
The mounting base should engage a minimum .5-in or 1.2 cm of the fastener threads.
Replacement pages for the RigMaster technical manual 011-9137 are provided on the following page.
Print as many as needed to correct all existing manuals.
Figure 1 Correct Slave Arm Mounting Hardware (arrow)

MANDATORY Field action is MANDATORY to ensure personnel safety, equipment functionality, and/or
continuation of warranty coverage.
Tel: +1 530 753 6718 (USA) or +44 (0) 1224 560 900 (UK)
Fax: +1 530-753-1534 (USA) or +44 (0) 1224 560 901 (UK)
Page 1
4 Installing the Slave Arm
2. Create a sturdy mounting platform that will provide a flat surface for the three mount-
ing holes in the base as shown in Figure 2-5.

NOTE: A full-size 1:1 drilling template, drawing 050-0692, is
located in a plastic sleeve at the back of this manual.
Figure 2-5 Slave Arm Mounting Dimensions

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.

4. Three 1/2-20 UNF-2B hex-head cap screws and lockwashers are required to attach the
base to the mounting platform.
CAUTION! Mounting fasteners must be long enough to engage a

minimum of .5-in or 1.2 cm 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 75 ft/lb (102 Nm).
4.2
Installing the Control and Drain Hoses

Ten hoses are supplied for connecting RigMaster functions to your control manifold or intermediate bulkhead fittings. The eleventh hose provides case drain from, and compensation to,
05841
Installation
Page 5 of 10
4 Installing the Slave Arm
the wrist assembly. This line must be connected to the return system. The wrist actuator also
has a drain pressure relief valve.
NOTE: IMPORTANT INSTALLATION DIMENSIONS:
1. Bulkhead hose fittings must be located no closer than 24 in

(610 mm) from the slave arm as shown in Figure 2-4, Minimum Distance to Bulkhead Hose Fittings on page 4.
2. Minimum bend radius for slave arm hoses is 2 in (51 mm).
3. If control hose lengths exceed 20 feet, consult Schilling
Robotics 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
Drawings & Part Lists chapter.
Table 2-1 lists the control and drain hose connections at the slave arm, and identifies actuator
functions, hose codes, and actuator movements. The slave arm hydraulic hoses are fitted with
female -4 JIC fittings for connecting all user-supplied hydraulics.
Table 2-1 Slave Arm Hose Connections
Slave Arm
Actuator/Function
Joint
Travel
Hose
Code
Actuator
Movement
Right
1A
Extend
Left
1B
Retract
Up
2A
Extend
Down
2B
Retract
Out
3A
Extend
In
3B
Retract
N/A
4A
Rotate CCW
N/A
4B
Rotate CW
Open
5A
Extend
Close
5B
Retract
N/A
N/A
Azimuth yaw
Shoulder pitch
Boom
Wrist rotate*
Jaw
Wrist Drain**
*Forearm and wrist roll CW/CCW movements are referenced from behind the slave arm.
**The maximum wrist drain/return pressure is 350 psi or less. 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.
Page 6 of 10
Installation
05841

Install Pressure Relief Valves on
Rigmaster Slave Arms
Compliance:
Recommended*
ISSUE DATE
March 17, 2008
AFFECTED PRODUCTS
Rigmaster Slave Arms
AFFECTED COMPONENTS
Pressure relief valves and cross-port check valves
SERVICE INFORMATION
Earlier revisions of the Rigmaster hydraulic schematic showed pressure relief valves
on azimuth, boom, and shoulder functions only. This can result in failure of the wrist
slip-ring manifold due to the actuator over-pressurizing the jaw circuit. All Rigmaster
functions should have pressure relief valves as per the updated hydraulic schematic
(Figure 1).
FIELD ACTION
Install pressure relief valves on wrist and jaw functions in addition to the existing azimuth, shoulder,
and boom function valves. It is also recommended to add cross-port check valves to the azimuth,
shoulder, and boom functions only. 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).

Tel: +1 530 753 6718 (USA) or +44 (0) 1224 560 900 (UK)
Fax: +1 530-753-1534 (USA) or +44 (0) 1224 560 901 (UK)
Page 1
Figure 1 Rigmaster Hydraulic Schematic
Page 2 Service Bulletin 0117203

Relief valves prevent damage to
wrist motor slip ring housing
Compliance:
Mandatory*
ISSUE DATE
April 23, 2008
AFFECTED PRODUCTS
Rate-controlled Slave Arms (RigMaster, Conan 7R, Orion 4R and 7R models) and
Hydraulic Pan & Tilt Units
AFFECTED COMPONENT
All Wrist Motor Assemblies
SERVICE ISSUE
Over pressurization of the Jaw Close 5B circuit/tilt circuit inside the wrist motor may
cause the slip ring housing to fracture and allow hydraulic fluid to flow directly into
the wrist case drain (hydraulic return). Properly installed over-pressure relief valves
will prevent this from occurring.
Without relief valves, housing fractures may occur when the pressure in the cylinder exceeds 5000 psi. This typically occurs when
the jaw or tilt assembly is involved in a collision and the piston is
forced open. An typical fracture is shown at right (arrow).
Slip-ring housings manufactured after March 10, 2008 have been
strengthened in the critical area, but relief valves are still recommended.
FIELD ACTION
To prevent an over-pressure event, a relief valve must be installed on each hydraulic circuit including the jaw/tilt function (see sample RigMaster and Pan & Tilt schematics on following page). Verify
that all rate slave arms and pan & tilt units have properly positioned and adjusted over-pressure
relief valves installed for all functions.
If a circuit has an adjustable flow control valve (throttle valve), as shown in the RigMaster jaw and
Pan & Tilt tilt schematics, the relief valve must be located between the actuator and the flow control
valve.

Field action is MANDATORY to ensure personnel safety, equipment functionality, and/or
MANDATORY
RECOMMENDED
OPTIONAL
Field action may be useful under certain circumstances. Compliance is OPTIONAL and left
ADVISORY
Tel: +1 530 753 6718 (USA) or +44 (0) 1224 560 900 (UK)
Fax: +1 530-753-1534 (USA) or +44 (0) 1224 560 901 (UK)
Page 1
RigMaster
Pan & Tilt

Figure 1
Placement and adjustment of over-pressure relief valves
Page 2

Removing the Titan 4 Wrist Camera
Compliance:
Advisory*
ISSUE DATE
September 2, 2008
AFFECTED PRODUCT(S)
Titan 4 Manipulator Systems
AFFECTED COMPONENT
PAL Wrist Camera, 101-6040 and NTSC Wrist Camera, 101-6039
SERVICE INFORMATION
Titan 4 Manipulators Systems with wrist cameras are equipped with a pitch/yaw wire
cover and four additional screws (002-0038P). It is important to keep these items in a
safe place; they will be required if the camera is removed due to damage or for service.
In addition to the pitch/yaw wire cover, four shorter manifold screws (002-0052P) are
required to install the wrist manifold when the camera is removed.
To remove a Titan 4 wrist camera, 101-6039 or 101-6040, follow the instructions below.

Tel: +1 530 753 6718 (USA) or +44 (0) 1224 560 900 (UK)
Fax: +1 530-753-1534 (USA) or +44 (0) 1224 560 901 (UK)
Page 1

Wire cover screws,
002-0038P (qty 4)
Manifold plate screws,

002-0333P (qty 4)
A - Camera Installed
101-6040 (PAL camera)

or
101-6039 (NTSC camera)
Pitch/Yaw wire cover,

001-2676
B - Camera Removed
Wire cover screws,
002-0038P (qty 4)
Manifold plate screws,

002-0052P (qty 4)
Figure 1
1.
Remove the four wire cover screws (Figure 1, A) and save for step 6.
2.
Remove the four manifold plate screws (Figure 1, A). These screw will not be reused.
3.
Cut off the shrink tubing from the coax cable connector and disconnect from the PCB camera
board. See Figure 2.
4.
Disconnect the white harness cable connector from the PCB camera mount. See Figure 2.
NOTE:
The coax cable and white harness cable can be tucked into the yaw actuator housing
for future camera installation. If doing so, install a piece of heat shrink (005-1706) onto the coax cable connector to insulate it against a ground fault.
Sockethead cap
screws, 002-0679P
Yaw actuator housing
Coax cable connector, 005-4948
White harness connector, 101-5158

PCB camera board, 101-6005
Figure 2
0117224
Page 2

5.
Before installing the pitch/yaw wire cover (Figure 1, B):

Inspect the O-ring (004-0139) and replace if necessary.
Check the two sockethead cap screws (Figure 2) and confirm that they are torqued to 7.3
Nm (65 lbf/in).
6.
Secure the pitch/yaw wire cover with the four wire cover screws removed in step 1. Lubricated
the bolts with AquaShield and torque to 28.5 Nm (21 lbf/ft). See Figure 1, B.
7.
Re-install four new manifold plate screws (002-0052P) to the yaw actuator (Figure 1, B).
Lubricated the bolts with AquaShield and torque to 28.5 Nm (21 lbf/ft).
The Titan 4 wrist camera has been successfully removed and the slave arm is ready for normal operation. Refer to the Titan 4 Technical Manual specific to your system for further information.
0117224
Page 3

New Customer Service Bulletins
Compliance:
Advisory*
ISSUE DATE
December 19, 2008
AFFECTED PRODUCT(S)
All systems
SERVICE INFORMATION
You are receiving this bulletin because you are a customer, partner, or associate of Schilling Robotics. If you would like to add additional recipients or unsubscribe from this bulletin,
please reply to this e-mail.
Schilling Robotics Customer Service Departments goal is to provide reliable information, technical
support and solutions to all Schilling Robotics Customers. To further assist our customers, Schilling
has developed this Service Bulletin Information System to broadcast service updates to customers
and partners. All recipients of the Bulletin will be able to reply with questions, concerns, and
changes relating to Schilling Robotics products. The Bulletin Information System is in its final
stages of completion, and should be ready for use in the next few weeks.
FIELD ACTION
If there is a need for a recipient to be added or removed from this distribution list, please notify us by
replying to this e-mail at any time.

Tel: +1 530 753 6718 (USA) or +44 (0) 1224 560 900 (UK)
Fax: +1 530-753-1534 (USA) or +44 (0) 1224 560 901 (UK)
Page 1

New Torque Specification for Jaw
Bolt 001-7520
Compliance:
Advisory*
ISSUE DATE
March 31, 2009
AFFECTED PRODUCTS
Conan, Orion, and Rigmaster systems; Titan systems with 7.8-in. intermeshing jaw
AFFECTED COMPONENT
Non-fused jaw bolt 001-7520
SERVICE ISSUES
The torque specification for jaw bolt 001-7520 has been changed from 300 ft-lb
(407 Nm) to160 ft-lb (217 Nm). When jaw service is performed, jaw bolt 0017520 must be used and torqued to 160 ft-lb. Replace older fuse type jaw bolts
(001-5382 and 001-5397) with bolt 011-7520.
FIELD ACTIONS
No action is needed for currently installed bolts. The next time a bolt is removed or
replaced, follow the steps below to avoid damage to the manipulator while un-installing and
re-installing the jaw bolts at the new torque setting. You should have the following tools
before beginning:
A bench vice
11/16 12 pt. socket (1/2-in. drive) and breaker bar
Conan Jaw Bolt tool 010-0991 or CLP Jaw Tool 010-0173
To Un-install Jaw Bolts Torqued to 300 ft-lb:

Refer to the drawing and part list Nose Block Kit, Conan/Rigmaster, 101-3853 on page 3 while performing the following steps:
! Caution
Shut off and isolate all hydraulics before beginning this procedure.
NOTE: It is recommended that you have a bucket available to capture oil from the jaw.
MANDATORY
RECOMMENDED
OPTIONAL
Field action may be useful under certain circumstances. Compliance is OPTIONAL and left
ADVISORY
Tel: +1 530 753 6718 (USA) or +44 (0) 1224 560 900 (UK)
Fax: +1 530-753-1534 (USA) or +44 (0) 1224 560 901 (UK)
Page 1
1.
Remove the four HHCS 002-1135 (item 14) and remove the 101-3853 nose block assembly from
the manipulator wrist.
2.
Install the nose block assembly 101-3853 into tool 010-0991 or 010-0173 and clamp the tool in
a bench vise.
3.
Use an 11/16 twelve-point socket (1/2-in. drive) with breaker bar and remove the jaw bolt (0017520 HHCS, item 13). If an older fused bolt 001-5382 or 001-5397 is removed, replace it with a
non-fused bolt 001-7520.
4.
Inspect piston 001-5395 (item 2) and T-bar plate 001-5396 (item 12) for damage, and replace if
necessary.
5.
Check for worn seals and replace as needed (spares are in Kit, Soft Goods, Nose Block w/
Adapter, 008-0232 on page 7).
To Install Jaw Bolts:

Refer to the drawing and part list Kit, Jaw Piston, Conan, 101-4205 on page 5 while performing the
following steps:
1.
Apply anti-seize (item 6) under the jaw bolt head and on the threads.
2.
Install the bolt 001-7520 (item 3) and torque to 160 ft-lb (217 Nm).
3.
Remove tool 010-0991 or 010-0173 from the bench vise and remove the nose block assembly
101-3853 from the tool.
4.
Apply Aqua lube 002-0805 to the threads of the four HHCS 002-1135 (item 14) and re-attach
nose block 101-3853 to the manipulator wrist with HHCS 002-1135. Torque the HHCS to 73 ftlb (99 Nm).
Page 2
Nose Block Kit, Conan/Rigmaster, 101-3853

Rev.U
Item
P/N
Description
Qty
001-5395
PISTON,1 PIECE,2.25 DIA,JAW
001-5399
BRG,PSTN,2.25DIA,ORKOT
004-0616
SEAL,PSTN,SHAMBAN,34G02250-A46
101-4108
BLK,NOSE,W/BRG,CON
004-0542
004-0541
RING,BACKUP,8-034 BUNA 90
001-5398
BRG,ROD,1.0DIA,ORKOT
004-0650
SEAL,ROD,LIN ACTR,GAMMA
12
001-5396
PLATE,T-BAR,LOCKING
13
001-7520
BOLT,12 POINT,NAS 1277-36,MOD
14
002-1135
NAS 6406U4
15
011-5011
SVCE INSTR,ITMSHG JAW NOSE BLK
16
002-1439
WSHR,3/8ID,5/8OD
17
101-3853-WI
WORK INSTRUCTIONS
18
010-0991
TOOL,CONAN JAW BOLT
23
002-1925
ANTI-SIEZE,1 OZ TUBE
Nose Block Kit, Conan/Rigmaster, 101-3853
Kit, Jaw Piston, Conan, 101-4205

Rev.D
Item
P/N
Description
Qty
001-5395
PISTON,1 PIECE,2.25 DIA,JAW
001-5396
PLATE,T-BAR,LOCKING
001-7520
BOLT,12 POINT,NAS 1277-36,MOD
004-0616
SEAL,PSTN,SHAMBAN,34G02250-A46
001-5399
BRG,PSTN,2.25DIA,ORKOT
002-1925
ANTI-SIEZE,1 OZ TUBE
010-0991
TOOL,CONAN JAW BOLT
12
011-9534
DOC,JAW PSTN KIT S4205,CONAN
Jaw, Piston, Conan, 101-4205
Kit, Soft Goods, Nose Block w/Adapter, 008-0232

Rev. A
Item
P/N
Description
Qty
001-0900
BRG,PSTN
004-0588
001-0903
BRG,ROD
004-0039
SEAL,ROD STEP RSW100750-Z48NA,
12
004-0646
SEAL,JAW PSTN,GAMMA
13
004-0046
102
004-0541
RING,BACKUP,8-034 BUNA 90
103
004-0840
O-RING,2-034,N90

Preventing Titan 4 Azimuth Movement When Hydraulics Are Disabled
Compliance:
Optional*
ISSUE DATE:
February 20, 2009
AFFECTED PRODUCT(S)
Titan 4 Manipulator Systems
AFFECTED COMPONENT
Azimuth actuator
SERVICE INFORMATION
The azimuth actuator of the Titan 4 slave arm can be moved when hydraulic power is
disabled and an external force is applied (including movement by the vehicle against
the slave arm mass). This movement may cause unintended contact between the slave
arm and the vehicle (or other equipment).
This is a normal condition of the azimuth actuator and does not indicate that the seals or other components require replacement. The movement is caused by hydraulic fluid that is allowed to pass
through the azimuth servo valve spool. The flow rate varies, depending on the location of the spool
when hydraulic power was turned off (with some azimuth movement possible even when the spool is
centered). Action options to prevent azimuth movement are described below.
FIELD ACTION
There are two corrective options if azimuth movement (while hydraulics are disabled)
is a problem.
Option 1
To prevent movement of the azimuth when the arm is stowed (or in any other position), leave
hydraulics to the slave arm enabled. To prevent accidental movement of the slave arm, EXIT from
any one of seven screens (OPERATE, OPTIONS, SLAVE DIAGNOSE, SET LIMITS, SET STOW, SET
OFFSET AND SHUT DOWN) to enter a menu where the slave arm is in the LOCK mode (LOCK
text in upper right-hand corner of screen). A typical screen (MAIN menu) in LOCK mode is shown in
Figure 1.
Tel: +1 530 753 6718 (USA) or +44 (0) 1224 560 900 (UK)
Fax: +1 530-753-1534 (USA) or +44 (0) 1224 560 901 (UK)
Page 1
! Caution
Failure to enter a LOCK mode after stowing or immobilizing the slave arm
while hydraulics enabled can result in unintended slave arm movements and
damage to equipment.
MAIN MENU
LOCK
-------------------------------1> ROBOTICS
SET UP
<5
2> OPTIONS
DIAGNOSE <6
3> OPERATE
SHUT DOWN <7
-------------------------------UP key turns hydraulics OFF
Figure 1 MAIN menu
Option2
Install Lock/Relief Valve Kit 101-6460 under the Azimuth servo valve in the forearm (see part list,
below). After installation, the azimuth joint locks when hydraulics are disabled, and cannot be
rotated accidentally or by hand for service purposes. To order this kit, contact the Customer Service Department at: [email protected].
NOTE:
This kit can be used to lock any joint on the slave arm with unwanted movement except the wrist (due to an internal bypass) and the jaw, where a hydraulic failure could
cause it to remain clamped to anything in its grasp.
Kit, Lock Valve, Relief Valve, T4, 101-6460

Rev. 1
Item
P/N
Description
Qty
101-6190
LOCK VALVE ASSY,3000 PSI,T4
101-3965
RLF V,UNIV
004-0222
004-0114
002-0341P
011-9663
MNL,KIT,T4,AZ LOCK/REL VALVE
Page 2

Con/Rig Tool Kit 010-0689
Status:
Advisory*
ISSUE DATE
June 9, 2009
AFFECTED PRODUCTS
Conan & Rigmaster Tool Kit 010-0689, Revision D or older
AFFECTED COMPONENT
Wrist Clamp Tool 010-1117
SERVICE INFORMATION
The Conan/Rigmaster Tool Kit 010-0689, revision D or older, contains only one
Wrist Clamp Tool 010-1117 (see figure 1). The correct quantity is 2. The additional
part will be supplied at no cost.
Figure 1 010-1117 Wrist Clamp Tool, 1 of 2
FIELD ACTION
Part A Inspect 010-0689 Tool Kit for revision.
Part B Contact Schilling Robotics.
Part C Update affected part list.

MANDATORY
Field action is MANDATORY to ensure personnel safety, equipment functionality, and/or continuation of warranty coverage.
RECOMMENDED
Field action is not required but is highly RECOMMENDED and will result in significantly increased levels of personnel safety and/or equipment functionality.
ADVISORY
Bulletin contains advisory information to assist the owner/operator in more

effective operation or service of the product. Compliance is not rated.
If you have any questions about this service bulletin, contact the Schilling Customer Service
Department at:
Tel: +1 530 753 6718 (USA) or +44 (0) 1224 560 900 (UK)
Fax: +1 530-753-1534 (USA) or +44 (0) 1224 560 901 (UK)
e-mail: [email protected] Web site: http://www.schilling.com
SERVICE BULLETIN 7253.docx
Page 1
Part A Determine Revision of Con/Rig Tool Kit 010-0689

Inspect each Tool Kit 010-0689 and determine its revision. If the Tool Kit is Revision D or older, one additional Wrist Clamp Tool 010-1117 will be needed. Continue to Part B.
NOTE: Revision E or newer kits are supplied with both clamp halves, and no upgrade is necessary.
Part B Contact Schilling Robotics

Please contact Schilling Robotics at [email protected] to request an additional 010-1117 Wrist Clamp Tool. Continue to Part C.
Part C Update affected part

Replace 010-0689 Part List as needed.
Service Bulletin 011-7253
Page 2
Page 3
SERVICE BULLETIN 011 7261

Titan 4 Camera Video Quality
Status:
*Advisory*
ISSUE DATE
August 26, 2009
AFFECTED PRODUCTS
Titan 4 Manipulator Systems 199-0308-3 (NTSC), 199-0308-4 (PAL)
AFFECTED COMPONENT
NTSC Camera 101-5074, PAL Camera, 101-5074-1
SERVICE ISSUE
We have received customer complaints of unacceptable video quality on Titan 4 systems using customer specified connectors in place of the standard Seanet.
FIELD ACTION
We have identified modifications to the Titan 4 system that will improve video quality
when using customer-specified connectors. The initial testing has been completed and
production parts are expected to arrive the week of August 24. Approximately one
week will be required for implementation and testing to qualify the final design. In
early September, we will be contacting customers that are experiencing this problem
and will define individual corrective action plans.

MANDATORY
RECOMMENDED
ADVISORY

Field action is not required but is highly RECOMMENDED and will result in significantly increased levels of personnel safety and/or equipment functionality.
Bulletin contains advisory information to assist the owner/operator in more effective operation or service of the product. Compliance status is not rated.
Tel: +1 530 753 6718 (USA) or +44 (0) 1224 560 900 (UK)
Fax: +1 530-753-1534 (USA) or +44 (0) 1224 560 901 (UK)
Page 1

Customer Service 24 hr Support Line
Status:
Advisory*
ISSUE DATE:
August 31, 2009
SERVICE ANNOUNCEMENT
Our 24hr Technical Support Line has been upgraded to provide a new level of technical assistance to our customers.
z
Within the U.S.A. +1 800 770-1275
Outside the U.S.A +44(0) 1224 560 909
Please refer to the information sheet on page 2 for details on using the new hot line.
PAGE BREAK

MANDATORY
RECOMMENDED
ADVISORY

Tel: +1 530 753 6718 (USA) or +44 (0) 1224 560 900 (UK)
Fax: +1 530-753-1534 (USA) or +44 (0) 1224 560 901 (UK)
Page 1
24-hr Technical Support

M A N I P U L ATO R S Y S T E M S
Availability and Support When You Need It.

Within the U.S.A.:
+1 800 770 1275
Outside of the U.S.A.: +44 (0) 1224 560 909
Schilling is proud to launch an upgraded Technical Support System to ensure that we provide
prompt attention to all of our customers worldwide.
Technical Support 24-hours per Day, 7 Days per Week
Prompt, Accurate, Personal Support
One Centralized Point of Contact
Comprehensive Engineering and Technical Support
In line with Schillings expanding global business, we

understand that customer access to the best technical
support is essential. Schillings 24-hour call center operators
will log your request, give you a reference number, and
directly transfer you to a Schilling technical support
representative.
Information that Will be Requested When Calling:

Your Name and Company
Telephone Number that You are Calling From
Your Email Address
Brief Description of the Problem
So Deep, No One Comes Remotely Close
WWW.SCHILLING.COM
SAFETY BULLETIN 012 0016

Fused Jaw Bolt May Shear at
High Velocity
Status:
SAFETY CRITICAL*
ISSUE DATE
August 26, 2009
AFFECTED PRODUCTS
All Rigmaster, Conan, and Orion slave arms and manipulator systems, Titan Manipulator Systems
AFFECTED COMPONENTS
Fuse-type jaw bolts 001-5382 and 001-5397 (based on jaw type). They have a machined
hole in the bolt head and are located as shown in Figure 1 on the following page.
BACKGROUND
A fuse-type jaw bolt was designed to shear when overloaded in order to prevent damage
to other jaw components. As noted in Service Bulletin 011-7155, the use of fuse-type bolts
was discontinued beginning in November of 2005 because field users found the shear
rate unacceptable. Because fuse-type jaw bolts are in many older spares kits and could
have been used as replacements, they may be on slave arms of any age, old or new.
SERVICE ISSUE
We have been informed that a fused jaw bolt sheared as the jaw function was being tested
on-deck. Part of the bolt was ejected from the jaw at a high velocity, narrowly missing a
crew member. This incident highlights the importance of always using PPE and staying
clear of the slave arms range of motion at all times to avoid risk of injury.
FIELD ACTION
Inspect each slave arm jaw to determine if a fuse-type bolt is used in the jaw. Fused jaw bolts have a
machined hole in the bolt head as shown in Figure 1 on the following page.
1. Slave arms that use fused jaw bolts can continued to be operated under the following conditions:
! WARNING
Use extreme caution when testing a slave arm on deck:
Move all personnel outside the slave arms 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.
Do not stand in front of the jaw assembly while testing jaw functions.
SAFETY CRITICAL
Field action is CRITICAL to ensure the SAFETY of personnel and must be performed IMMEDIATELY
Tel: +1 530 753 6718 (USA) or +44 (0) 1224 560 900 (UK)
Fax: +1 530-753-1534 (USA) or +44 (0) 1224 560 901 (UK)
Page 1
2. If you decide to replace a fuse bolt, use the slave arm or manipulator system technical manual to
determine the part number for the existing fused jaw bolt. Then determine if a non-fused, replacement jaw bolt is available in spares:
Fused jaw bolt 001-5397 (shaft length 3.123-in.): Replace with jaw bolt 001-7520.
Fused jaw bolt 001-5382 (shaft length 2.116-in.): Replace with jaw bolt 001-7519.
Jaw bolts 001-7519 and 001-7520 can be found in many slave arm, manipulator system, and Schilling
ROV system spares kits issued since 2005.
Figure 1 Fuse-type jaw bolt: location (left), machined hole in head (center, right)
Page 2

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Service Bulletins,

Bulletins 011-7151 (September 2005)

DOCUMENT NO. 0117233

TECHNICAL MANUAL REVISION LOG

Service Bulletin 0117233

Service Bulletin 0117151

Install master controller EPROM 014-0695, Rev D if not present.

NOTE: No EPROM change is necessary for Titan 4 in-arm slave controllers.

Service Bulletin 0117151

Service Bulletin 0117151

Other Features of Master Controller EPROM 014-0695, Rev D

If you want to implement operation,

SCHILLING ROBOTICS, LLC

Recommended option: Do not use the

Use the 4> Yes option only if

SCHILLING ROBOTICS, LLC

Service Bulletin 0117151

Service Bulletin 0117153

Figure 1 Display adjustment potentiometer on the display transition PCB

Service Bulletin 0117153

Service Bulletin 0117153

Figure 2 Blue/gray display with bars

Remove the existing adjustable potentiometer.

Install the new adjustable potentiometer (005-0705).

Service Bulletin 0117153

Service Bulletin 0117155

Std. Titan 3 and 4 Manipulator Systems

Orion and custom Titan 3 models using

Orion, Conan, and Rigmaster models

*BULLETIN COMPLIANCE LEVELS

Service Bulletin 0117155

Service Bulletin 0117165

Service Bulletin 0117165

Service Bulletin 0117171

Changes to the Titan 4 Upper Arm

*BULLETIN STATUS LEVELS

Service Bulletin 0117171

Service Bulletin 0117171

Figure 2 Part number of upper arm (arrow)

New Titan 4 Spares Kits

Service Bulletin 0117172

Changes to the Titan 4 Forearm

Figure 1 Titan 4 Forearm Assembly

Service Bulletin 0117172

Service Bulletin 0117172

Relief Valve Kit, 101-5555

Service Bulletin 0117188

Changes to the Titan 4 Forearm

Figure 1 New Titan 4 Forearm Assembly

Service Bulletin 0117188

Service Bulletin 0117188

Figure 2 Previous Titan 4 Forearm Assembly

Titan 4 Lock Valve

SHCS,6-32 X 1/4 ALLOY, ST

ADH,#271 RED LOCTITE 50ML