Manual, Utility Coupler, GKx Document #9620-20-B … · Manual, Utility Coupler, GKx. Document...

Manual, Utility Coupler, GKxDocument #9620-20-B-GKx Utility Coupler-06

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com • Email: [email protected] B-1

Table of ContentsB. Base Utility Coupler ................................................................................................................B-3GKx Series—Compliant Utility Coupler ......................................................................................B-31. Product Overview ..................................................................................................................B-3

1.1 9123-GKx Compliant Utility Coupler Master ........................................................................... B-5

1.2 9123-GKx Compliant Utility Coupler Tool ............................................................................... B-6

1.3 9123-GK1 Master Plate Assembly ............................................................................................ B-7

1.4 9123-GK1 Tool Plate Assembly ................................................................................................ B-7

1.5 9123-GK2 Master Plate Assembly ............................................................................................ B-8

1.6 9123-GK2 Tool Plate Assembly ................................................................................................ B-9

2. Installation ...........................................................................................................................B-102.1 Utility Coupler Master Installation ......................................................................................... B-10

2.2 Utility Coupler Master Removal ..............................................................................................B-11

2.3 Utility Coupler Tool Assembly Installation .............................................................................B-11

2.4 Utility Coupler Tool Assembly Removal ................................................................................ B-12

2.5 Electrical Connections ............................................................................................................ B-12

2.6 Pneumatic Guided Cylinder Assemblies............................................................................... B-13

2.7 Electric Drive Actuator Sensor Setting Procedure............................................................... B-132.7.1 Electric Drive Actuator Sensor Adjustment ....................................................................B-13

3. Operation .............................................................................................................................B-143.1 Coupling ................................................................................................................................... B-14

3.2 Guided Cylinder or Drive Unit Dependency .......................................................................... B-14

3.3 Uncoupling ............................................................................................................................... B-14

4. Maintenance .........................................................................................................................B-154.1 Preventive Maintenance ......................................................................................................... B-15

4.2 Clean, Inspect, and Lubricate Thrust Bearings for Utility Couplers .................................. B-16

4.3 Pin Block Inspection and Cleaning ....................................................................................... B-17

4.4 Clear Dust and Debris from Compliance Springs Area ....................................................... B-18

5. Troubleshooting and Service Procedures ........................................................................B-195.1 Troubleshooting Procedures ................................................................................................. B-19

5.2 Service Procedures ................................................................................................................. B-215.2.1 Clean, Inspect, Lubricate, Replace Components for Master Check Port ......................B-21

5.2.2 Clean, Inspect, Lubricate, Replace Components for Tool Check Port ..........................B-23

5.2.3 V-ring Seal Replacement ...............................................................................................B-25

5.2.4 Tool Presence Sensor Replacement for GK Units ........................................................B-26

5.2.5 GK1CM Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement ...........B-27

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5.2.6 GK2CM Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement ...........B-28

5.2.7 GK1CM Compliance Spring Replacement for Utility Coupler (Preferred Method) ........B-30

5.2.8 GK1CM Compliance Spring Replacement for Utility Coupler (Alternate Method) .........B-31

5.2.9 GK2CM Compliance Spring Replacement for Utility Coupler (Preferred Method) ........B-32

5.2.10 GK2CM Compliance Spring Replacement for Utility Coupler (Alternate Method) .........B-33

5.2.11 Center Swivel Replacement for Utility Coupler .............................................................B-34

5.2.12 GK1CM Alignment Pin Replacement ...........................................................................B-35

5.2.13 GK2CM Alignment Pin Replacement ............................................................................B-36

5.2.14 GK-GC-B63S50Z1 Return Spring Replacement ...........................................................B-38

5.2.15 GK-GC-B63S50Z1ExhaustMufflerReplacement ........................................................B-39

6. Serviceable Parts ................................................................................................................B-406.1 GK1 Compliant Utility Coupler Master (9123-GK1CM-0-0-0-0) ............................................ B-40

6.2 GK2 Compliant Utility Coupler Master (9123-GK2CM-0-00-0-00-N/E/R) ............................. B-41

6.3 GK1 Compliant Utility Coupler Tool 9123-GK1T-0-0-0-0 ...................................................... B-43

6.4 GK2 Compliant Utility Coupler Tool 9123-GK2T-0-00-0-00-N/E/R ....................................... B-43

6.5 Models 9123-GK-GC-B63S50Z1-SG-N ................................................................................... B-44

6.6 Models 9123-GK-GC-B50S75-SG-N, 9123-GK-GC-B63S75-SG-N ........................................ B-45

6.7 Models 9123-GK-GCE-PM24400-B-SG, 9123-GK-GCE2-PM24600-B-SG ............................ B-45

7. Specifications ......................................................................................................................B-468. Drawings ..............................................................................................................................B-48

8.1 GK1 Compliant Utility Coupler Drawings .............................................................................. B-48

8.2 GK2-N Compliant Utility Coupler Drawings .......................................................................... B-51

8.3 GK2-E Compliant Utility Coupler Drawings .......................................................................... B-54

8.4 GK2-R Compliant Utility Coupler Drawings .......................................................................... B-57

8.5 GK-GC-B50S75-SG-N .............................................................................................................. B-60

8.6 GK-GC-B63S50Z1-SG-N .......................................................................................................... B-61

8.7 GK-GC-B63S75-SG-N .............................................................................................................. B-63

8.8 GK-GCE2-PM24600-B-SG ....................................................................................................... B-64

8.9 GK-GCE-PM24400-B-SG ......................................................................................................... B-66

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B. Base Utility Coupler

GKx Series—Compliant Utility Coupler1. Product Overview

The GKx Compliant Utility Coupler is designed for medium-duty industrial applications. The Utility Coupler provides pass through utilities such as air, fluids, and electrical signals from both integrated ports within the body and standard ATI add-on standard rectangular mounted modules. Consult ATI for further details.

This document provides information on the GKx series Utility Couplers listed in Table 1.1.

The Utility Couplers are comprised of a compliant Master side and Tool side. The Master side is equipped with a compliance mechanism that allows for large tooling misalignments. The Utility Coupler depends on force from the guided cylinder assembly to maintain constant coupling pressure. The recommended operating pressure for the guided cylinder is 80 psi (5.52 bar). The unit will work in operating pressures between 60 – 120 psi (4.14 – 8.27 bar).

Figure 1.1—GKx Compliant Utility Coupler with Guided Cylinder Assembly

Guided Drive Cylinder (9123-GK-GC-B50S75-SG-N Shown)

Compliant Utility Coupler Master Side(9123-GK2CM Shown)

Compliant Utility Coupler Tool Side(9123-GK2T Shown)





Some Utility Coupler Master models feature integrated check ports that pass utilities on to the Tool side. Master and Tool bodies are equipped with a standard rectangular mounting feature that enables the coupler to accept up to (4) additional 9120 series Tool Changer utility modules for pass-through air, fluids, and electrical signals. Consult ATI for further details.

Table 1.1—GKx Series Utility Coupler Models

Base AssemblyPart Number Description Configuration

Part Number

Sensors for Tool

PresenceAir Ports

9123-GK1CM-0-0-0-0

GK1 Compliant Utility Coupler Master Base Assembly

9123-GK1CM-0-0-0-0-SE (2) NPN N/A

9123-GK1CM-0-0-0-0-SG (2) PNP N/A

9123-GK1T-0-0-0-0GK1 Utility Coupler Tool Base Assembly

N/A N/A N/A

9123-GK2CM-0-00-0-00-N

GK2 Compliant Utility Coupler Master Base Assembly

9123-GK2CM-0-00-0-00-SE-N (2) NPN (2) 3/8 NPT Checked Ports

9123-GK2CM-0-00-0-00-SG-N (2) PNP (2) 3/8 NPT Checked Ports

9123-GK2CM-0-00-0-00-E

9123-GK2CM-0-00-0-00-SE-E (2) NPN (2) 3/8” BSPP Checked Ports

9123-GK2CM-0-00-0-00-SG-E (2) PNP (2) 3/8” BSPP Checked Ports

9123-GK2CM-0-00-0-00-R9123-GK2CM-0-00-0-00-SE-R (2) NPN (2) 3/8” BSPT

Checked Ports

9123-GK2CM-0-00-0-00-SG-R (2) PNP (2) 3/8” BSPT Checked Ports

9123-GK2T-0-00-0-00-NGK2 Utility Coupler Tool Base Assembly

N/A N/A

(2) 3/8 NPT Checked Ports

9123-GK2T-0-00-0-00-E (2) G 3/8 BSPP Checked Ports

9123-GK2T-0-00-0-00-R (2) Rc 3/8 BSPT Checked Ports





1.1 9123-GKx Compliant Utility Coupler MasterThe Master housing assembly includes an anodized aluminum body, (2) hardened stainless-steel alignment pins, proximity sensors, and hardened steel overload pins to limit compliance. There are preloaded springs internal to the housing that forces the main body to self-center on custom chamfered thrust bearings, which allows for 4 mm compliance in any direction in the coupling plane and for ± 3 degrees angular compliance. This system allows for a relatively large misalignment of the Master and Tool prior to coupling.

Figure 1.2—GK1 Compliant Utility Coupler Master Assembly

(3) Compliance Overload Pins with Custom Self-Centering Thrust Bearings

(2) Hardened StainlessSteel Alignment Pins

Compliant Interface Mounting Plate

(3) Preloaded SpringsProvide Centering Reliability

Center Swivel Bearing

(2) Tool Presence Sensors

AnodizedAluminum Body

Standard Rectangular Mounting Featurefor ATI Add-on Utility Modules

Figure 1.3—GK2 Compliant Utility Coupler Master Assembly

(2) Compliance Overload Pins with Custom Self-Centering Thrust Bearings (2) Hardened Stainless

Steel Alignment Pins

Compliant Interface Mounting Plate(2) Pairs of Preloaded Springs

Provide Centering Reliability Center Swivel Bearing

Built in PassThrough Utilities

AnodizedAluminum Body

Standard Rectangular Mounting Feature for ATI Add-on Utility Modules






1.2 9123-GKx Compliant Utility Coupler ToolThe Tool housing assembly includes an anodized aluminum body and hardened steel alignment bushings. The Tool body is equipped with steel targets that the proximity sensors in the Master body can use to sense Tool presence.Some Utility Coupler models have integrated check ports with NPT, BSPP, or BSPT air pneumatic connections. The Tool body has flats with rectangular mounting features that enable the coupler to accept additional 9120 series Tool Changer utility modules for pass through utilities such as air, fluids, and electrical signals. Consult ATI for further details.

Figure 1.4—GK1 Compliant Utility Coupler Tool Assembly

(2) Proximinty Sensor Targets

(2) Alignment Bushings

Rectangular Mounting Feature Flat

Anodized Aluminum Body

Figure 1.5—GK2 Compliant Utility Coupler Tool Assembly

(2) 3/8 NPT Ports (9123-GK2-N)(2) G 3/8 BSPP Ports (9123-GK2-E) (2) Integrated Pass

Through Checked Ports

(2) Alignment BushingsRectangular Mounting Feature Flat

(2) Proximity sensor Targets

(2) Rc 3/8 BSPT Ports (9123-GK2-R)





1.3 9123-GK1 Master Plate AssemblyThe GK1 Master plate assembly is equipped with (2) short hardened steel alignment pins. The Master body has no integrated check port but provides (4) flats with rectangular mounting features for pass-through utilities such as air, fluids, and electrical signals. There are (3) preloaded springs internal to the housing that force the main body to self-center on custom chamfered thrust bearings. The access to the preloaded springs is from the back of the interface mounting plate. The compliance is limited by (3) overload pins. The interface mounting plate is equipped with a rectangular mounting pattern to accommodate (4) M6 socket head cap screws and has 4 mm dowel pins which can be used for alignment with the drive cylinder. The Master body has (2) proximity sensors to detect Tool presence.

Figure 1.6—GK1 Master Plate Assembly

(2) Short Alignment Pins

Rectangular Mounting Feature Flat A

Rectangular Mounting Feature Flat B

Rectangular Mounting Feature Flat C

Rectangular Mounting Feature Flat D

9123-GK1CM Compliant Utility Coupler



(3) Compliance Overload Pins withCustom Self-Centering Thrust Bearings

Rectangular Mounting Pattern

1.4 9123-GK1 Tool Plate AssemblyThe GK1 Tool plate assembly is equipped with (2) hardened steel alignment bushings. The Tool body has no integrated check port but provides (4) flats with rectangular mounting features for pass-through utilities such as air, fluids, and electrical signals. The Tool body is equipped with a square mounting pattern to accommodate (4) M6 socket head cap screws and (2) dowel holes which can be used for alignment with the Tool. The Tool body is equipped with (2) steel targets that the proximity sensors in the Master body can use to sense Tool presence.

Figure 1.7—GK1 Tool Plate Assembly

(2) Alignment Bushings


Rectangular Mounting Feature Flat D

Rectangular Mounting Feature Flat B


(2) Proximinty Sensor Targets

9123-GK1T Utility Coupler Tool

Square Mounting Pattern





1.5 9123-GK2 Master Plate AssemblyThe GK2 Master plate assembly is equipped with (2) standard hardened steel alignment pins. The Master body has (2) integrated check port and provides (4) flats with rectangular mounting features for pass through utilities such as air, fluids, and electrical signals. The 9123-GK2-N model has 3/8 NPT air ports, the 9123-GK2-E model has G 3/8 BSPP air ports, and the 9123-GK-2-R model has Rc 3/8 BSPT air ports that provide the pneumatic connection for the check ports. There are (2) pairs of preloaded springs internal to the housing that force the main body to self-center on custom chamfered thrust bearings. The access to the preloaded springs is from the front of the Master plate assembly. The compliance is limited by (2) overload pins. The interface mounting plate is equipped with a rectangular mounting pattern to accommodate (4) M6 socket head cap screws and has 4 mm dowel pins which can be used for alignment with the drive cylinder. The Master body has (2) proximity sensors to detect Tool presence.

Figure 1.8—GK2 Master Plate Assembly



(2) Integrated Pass-ThroughCheck Ports

(2) 3/8 NPT Ports (9123-GK2-N) (2) G 3/8 BSPP Ports (9123-GK2-E)

(2) Standard Alignment Pins

Rectangular Mounting Feature Flat B (2) Positions B1 and B2

Rectangular Mounting Feature Flat D(2) position D1 and D2



Rectangular Mounting Pattern

(2) Pairs of Preloaded Springs

(2) Compliance Overload Pins withCustom Self-Centering Thrust Bearings






1.6 9123-GK2 Tool Plate AssemblyThe GK2 Tool plate assembly is equipped with (2) hardened steel alignment bushings. The Tool body has (2) integrated check ports and provides (4) flats with rectangular mounting features for pass-through utilities such as air, fluids, and electrical signals. The Tool body is equipped with a square mounting pattern to accommodate (4) M6 socket head cap screws and (2) dowel holes which can be used for alignment with the Tool. The Tool body is equipped with (2) steel targets that the proximity sensors in the Master body can use to sense Tool presence.

Figure 1.9—GK2 Tool Plate Assembly

(2) 3/8 NPT Ports (9123-GK2-N)(2) G 3/8 BSPP Ports (9123-GK2-E)

Rectangular Mounting Feature Flat ARectangular Mounting Feature Flat C

Rectangular Mounting Feature Flat D(2) Positions D1 and D2

Rectangular Mounting Feature Flat B(2) Positions B1 and B2

(2) Alignment Bushings(2) Proximity Sensor Targets

Square Mounting Pattern

9123-GK2TUtility Coupler Tool

(2) Integrated Pass-Through Check Ports






2. InstallationThe Master unit is designed to attach to any compatible drive unit assembly or can be directly mounted to customer geometry. The GKx Utility Coupler and add-on modules are typically installed by ATI prior to shipment. The following steps outline the field installation or removal of the system components. The Compliant Utility Coupler Master assembly is attached to the Guided Drive Cylinder. The Master housing has a rectangular mounting pattern to accommodate (4) M6 socket head cap screws. The Master assembly also comes with 4 mm dowel pins which are used as needed. Unlike most robot arm applications, the 9123-GKx Master Housing is designed specifically for mounting directly to a Guided Cylinder assembly. No adapter plates should be used.

WARNING: Do not perform maintenance or repairs on Utility Coupler or modules unless all energized circuits (e.g. electrical, air, water, etc.) are turned off, pressurized connections purged, and power discharged from circuits in accordance with the customer’s safety practices and policies. Injury or equipment damage can occur with energized circuits on. Turn off and discharge all energized circuits, purge all pressurized connections, and verify all energized circuits are de-energized before performing maintenance or repair on Utility Coupler or modules.

CAUTION: Thread locker applied to fasteners must not be used more than once. Fasteners might become loose and cause equipment damage. Always apply new thread locker when reusing fasteners.

CAUTION: Do not use fasteners that exceed the thread depth in the Utility Coupler. Refer to Section 8—Drawings for details on mounting hole thread depth. Secure the Utility Coupler with the proper length fasteners. This is true for both robot and tool interfaces.

2.1 Utility Coupler Master InstallationTools Required: 5 mm Allen® wrench, Torque wrenchSupplies Required: Clean rag, Loctite® 242

1. Attach the Utility Coupler Master assembly to the drive cylinder. Align the Master assembly using the dowels in the drive cylinder mounting plate.

2. Using a 5 mm Allen wrench, secure the Master assembly using the (4) M6 x 16 mm socket head cap screws (with pre-applied adhesive) provided. Tighten to 89 in-lbs (10.0 Nm). Note: If fasteners do not have pre-applied thread locker, apply Loctite 242.

3. If add-on modules have not been installed, refer to the module manual for installation instructions.4. Attach the hoses to the Master body and drive cylinder as required.5. Power, signal, and sensor cables can be connected to the module and drive cylinder after attaching

the module to the Utility Coupler. Ensure that the connectors are cleaned prior to being secured as appropriate.

6. After installation is complete, Master assembly may be put into normal operation.





Figure 2.1—Utility Coupler Master Installation

Drive Cylinder(9123-GK-GC-B50S75-SG-N)

Pneumatic Connections

Pneumatic Connection

(4) M6 Socket Head Cap Screws(with Pre-applied Adhesive)

Sensor Connection

Electrical Connection

Add-on Module(9120-SF19-M Shown)

Compliant Utility Coupler(9123-GK2CM-N Shown)

2.2 Utility Coupler Master RemovalTools Required: 5 mm Allen wrench

1. Uncouple the Utility Coupler to allow clear access to the Master and Tool plates.2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.).3. Depending upon the service or repair being done, the customer connections may or may not need to be

disconnected. Remove customer connections as required.4. Remove the (4) M6 x 16 mm socket head cap screws securing the Master assembly to the drive cylinder

using a 5 mm Allen wrench and remove the Master assembly.

2.3 Utility Coupler Tool Assembly InstallationThe Tool plate is attached to a customer supplied fixture. The Tool plate is designed with a 100 mm mounting pattern for (4) M6 socket head cap screws and (2) dowel holes. These features are used to accurately position and secure the Utility Coupler Tooling. Tools Required: 5 mm Allen wrench, Torque wrenchSupplies Required: Clean rag, Loctite 242

1. Using a 5 mm Allen wrench, attach the Utility Coupler Tool assembly to the customer supplied fixture using customer supplied fasteners. Note: Fasteners must be grade 12.9 with pre-applied adhesive, if not using pre-applied adhesive, apply Loctite 242 to fasteners. Tighten fasteners to 89 in-lbs (10.0 Nm).

2. If add-on modules have not been installed, refer to the module manual for installation instructions.3. Attach the hoses to the Tool plate as required.4. Power and signal cables can be connected to the modules after attaching the module to the Utility

Coupler Tool. Ensure that the connectors are cleaned prior to being secured as appropriate.5. After installation is complete, Tool assembly may be put into normal operation.





Figure 2.2—Utility Coupler Tool Installation

Compliant Utility Coupler(9123-GK2CT-N Shown)

User Supplied M6 Fasteners(with Pre-applied Adhesive)

PneumaticConnection

ElectricalConnection

Add-on Module(9120-SF19-T Shown)

User Supplied Fixture

User Supplied 4 mm Alignment Pins

2.4 Utility Coupler Tool Assembly RemovalTools Required: 5 mm Allen wrench

1. Uncouple the Utility Coupler to allow clear access to the Master and Tool plates.

2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.).3. Depending upon the service or repair being done, the customer connections may or may not need to be

disconnected. Remove customer connection as required.4. Remove the (4) M6 socket head cap screws securing the Tool assembly to the customer supplied fixture

using a 5 mm Allen wrench and remove Tool assembly.

2.5 Electrical ConnectionsThe Utility Coupler Master utilizes proximity sensors to detect the position of the piston inside the Master body. The type of sensor is specified by the customer at the time of order. Sensors should be selected to work with the controls used on the customer’s equipment. Available sensors include DC PNP sourcing and NPN sinking. The DC sensors operate at a nominal 24 volts (check the labels attached to the installed sensors prior to connecting to any control circuit). Regardless of sensor type specified, ALL sensors must be installed in series with a resistive load to limit current flow. The figures below show the connections for the DC sensors.

Figure 2.3—PNP and NPN Sensors





2.6 Pneumatic Guided Cylinder AssembliesThe GK Utility Couplers are designed to be driven together by an actuator. They are compatible with a number of pneumatic guided cylinder assemblies. The required size and driving force of the actuator depends on what utilities are being coupled. Since ATI has a very large array of add-on utility modules, there is an infinite number of possible combinations of modules. As a result, it is recommended that each application be reviewed carefully and the correct drive cylinder be determined based on the required coupling force of the fully configured Utility Coupler for that specific application. ATI offers several pneumatic guided cylinder assemblies that are appropriate for many GK Utility Coupler applications. Contact ATI for assistance.The air supply used for coupling and uncoupling the device should be clean, dry, and non-lubricated. A supply pressure in the range of 60 –100 psi (4.14 – 6.89 bar) is acceptable for operation of the guided cylinder, with a setting of 80 psi (5.52 bar) suggested. The air should be filtered 40 micron or better.

2.7 Electric Drive Actuator Sensor Setting ProcedureThe sensors for the drive cylinder assembly are supplied pre-adjusted to detect the fully retracted state. For wiring information refer to Section 2.7.1—Electric Drive Actuator Sensor Adjustment. To adjust the sensors height or position, refer to the following procedure.

Figure 2.4—Electric Drive Actuator Sensor Setting

Sensor for Detecting Full Retracted State

2.7.1 Electric Drive Actuator Sensor AdjustmentTools Required: 1/2” wrench, torque wrenchSupplies Required: Loctite 222

1. Loosen the sensor nut that clamps against the proximity sensor holder. 2. Rotate the sensors as needed. Note: The standard distance that the sensor face protrudes from its

mounting bracket is about 0.30 to 0.35”. 3. Re-tighten the nut to 20 in-lbs (2.3 Nm). Apply Loctite 222 to the exposed threaded area of the

sensor where the lock nut will seat (only this area).





3. OperationThe Master coupling plate is driven to couple and uncouple with the Tool side plate. The Master plate is driven by a guided cylinder assembly.

WARNING: During operation, the area between the Master and Tool must be kept clear. Failure to keep area clear will result in damage to Utility Coupler, add-on modules, or end-of-arm tooling and could cause injury to personnel.

WARNING: During operation, the area between the driver cylinder mounting plate and body must be kept clear. Failure to keep area clear will result in damage to drive cylinder or could cause injury to personnel.

3.1 CouplingPosition the Master to within a pre-determined distance of the Tool and move the Master into locking position. The mating surfaces of the Master and Tool should be parallel and not touching. Make sure that the tapered alignment pins from the Tool block enter the alignment holes on the Master. The alignment pins should be relatively concentric with the alignment holes such that they do not rub against the edge.For some applications, Cylinder Position Proximity sensing is included, providing the ability to sense Cylinder Retracted and Extended States. The target for the Cylinder and Prox sensors face on the Master housing must be positioned within approximately 5 mm of each other for the sensor to detect the target. A signal is not required to couple the Master and Tool but is recommended as further confirmation of coupling.

CAUTION: The guided cylinder must be in the retracted position when attempting to couple the device. Failure to adhere to this condition may result in damage to the unit and/or the machine.

CAUTION:Nevercoupleoruncoupletheunitwithoutfirstdisconnectinganddischarging the power that passes through the contacts. This is especially true if high voltage circuits are involved. Arcing and contact damage will occur if this is not observed. Always disconnect and discharge electrical power from both upstream and downstream modules.

CAUTION: Since the system may not have a secondary locking mechanism, it is critical to the operation of the coupler that cylinder pressure is maintained at all times during operation.

3.2 Guided Cylinder or Drive Unit DependencyFor pneumatically-driven units, in the event of air supply loss to the Guided Cylinder, the Utility Coupler will uncouple. A separation between the Master and Tool plates occurs just after air loss and the utilities will disconnect because the integrated air ports have check valve features that react against the force of the guided cylinder in a manner that will pry the Master and Tool apart.The electrically actuated guided cylinder assembly does have an integrated brake that is energized when power is switched off. If your application requires a redundant fail-safe feature, please contact ATI and ask about our standard line of Tool Changers. ATI’s patented fail-safe design prevents the Tool plate from being released in the event of air-pressure loss to the Lock port, thereby increasing safety and reliability. Positional accuracy may not be maintained during air loss but will be regained once air pressure is re-established to the Lock port.

CAUTION: Drive cylinders can exert thousands of pounds of coupling force. Care is needed to accommodate these coupling forces in the design of the mating customer fixture.

3.3 UncouplingThe Utility Coupler should be positioned in the same location as that when coupling took place.





4. MaintenanceThe GKx Compliant Utility Coupler is designed to provide a long life with little maintenance required. A visual inspection and maintenance schedule is provided in Section 4.1—Preventive Maintenance. Assembly details are provided in Section 8—Drawings of this manual.


4.1 Preventive MaintenanceThe preventive maintenance schedule is based on a general use application with a tool change frequency of less than one per minute. More frequent tool changes or dirty environments will require an increased frequency of the inspection schedule.

Table 4.1—MaintenanceSchedule Checklist

Weekly

Thrust Bearings, Compression Springs, Alignment Pins and bushings, refer to: Section 4.2—Clean, Inspect, and Lubricate Thrust Bearings for Utility Couplers.

г Clean and lubricate bronze thrust bearing in Master body. г Inspect /test compliance springs in Master body. г Inspect alignment pins for wear or damage and proper lubrication in Master body. г Inspect alignment bushing in Tool body.

Pin Blocks, Electrical Contacts, and V-ring seals, refer to Section 4.3—Pin Block Inspection and Cleaning.

г Clean, and inspect pin block and electrical contacts for wear or damage in Master and Tool bodies.

г Inspect V-ring seals on the Master add-on modules, if worn or damaged replace, refer to Section 5.2.3—V-ring Seal Replacement.

Monthly

Mounting Fasteners and Interface Connections in the Master and Tool Modules г Inspect mounting fasteners to verify they are tight and if loose, then tighten to the

proper torque. Refer to Section 2—Installation. г Cable connections should be inspected during maintenance periods to ensure they are

secure. Loose connections should be cleaned and tightened as appropriate. г Inspect cable sheathing for damage, repair or replace damaged cabling. Loose

connections or damaged cabling are not expected and may indicate improper routing and/or strain relieving.

Clean Compliance Springs in the Master г Clean compliance spring area, refer to Section 4.4—Clear Dust and Debris from

Compliance Springs Area.

6 Months

Check Ports and Pass Through ports г Clean, Inspect and Lubricate Check Port seals and components in the Master and

Tool bodies. Refer to Section 5.2.1—Clean, Inspect, Lubricate, Replace Components for Master Check Port and Section 5.2.2—Clean, Inspect, Lubricate, Replace Components for Tool Check Port.





4.2 Clean, Inspect, and Lubricate Thrust Bearings for Utility CouplersSupplies Required: Cotton swabs, clean rag, MobilGrease XHP222 Special Grease

1. Uncouple the Utility Coupler to allow clear access to the Master and Tool plates.2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.). 3. Press on Utility Coupler Master to compress the springs and expose the bronze thrust bearing. Note:

This also tests the compliance springs, if springs do not return the Master to the neutral position replace springs. Refer to Section 5.2.8—GK1CM Compliance Spring Replacement for Utility Coupler (Alternate Method).

Figure 4.1—Press on Utility Coupler Master

Cotton SwabPress on UtilityCouper Master

Press on UtilityCouper Master

Thrust Bearing

4. With the thrust bearing exposed from pressing on the Master plate, remove all the grease from the (3) thrust bearings with a cotton swab or clean rag.

5. Inspect the thrust bearings. If thrust bearing is not worn, apply MobilGrease XHP222 Special grease to thrust bearings chamfered edge. If thrust bearing or other components are worn, replace worn components. Refer to Section 5.2.5—GK1CM Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement or Section 5.2.6—GK2CM Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement.

6. Inspect the (2) alignment pins in the Master body for wear or damage. If pins are not worn, apply MobilGrease XHP222 Special grease to alignment pins. If pins are worn or damaged, replace. Refer to Section 5.2.12—GK1CM Alignment Pin Replacement or Section 5.2.13—GK2CM Alignment Pin Replacement.

NOTICE: Excessive alignment pin/bushing wear may be an indication of poor tool-side position during coupling / uncoupling. Adjust position as needed.

7. If repairs are complete, return circuits to normal operation.





4.3 Pin Block Inspection and CleaningTools required: Nylon Brush (ATI Part Number 3690-0000064-60)

1. Place the Tool in a secure location.2. Uncouple the Master and Tool plates.3. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.).4. Inspect the Master and Tool pin blocks for any debris or darkened pins.

Figure 4.2—Inspect Master and Tool Pin Blocks

Tool Module Pin Block Master Module Pin Block

Note: Pin blocks shown are for illustration purposes only.

Weld Debris

Blackened Pins

5. If debris or darkened pins exist, remove debris using a vacuum and clean using a nylon brush (ATI Part Number 3690-0000064-60).

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

Figure 4.3—Clean Pin Blocks with a Nylon Brush

6. Inspect the Master and Tool pin blocks for stuck pins or pin block damage.

Figure 4.4—Stuck Pin and Pin Block Damage

Stuck Pins Pin Block Damage

Note: Pin blocks shown are for illustration purposes only.

7. If stuck pins or pin block damage exists, contact ATI for possible pin replacement procedures or module replacement.

8. After the procedure is complete, resume normal operation.





4.4 Clear Dust and Debris from Compliance Springs AreaSupplies Required: Compressed air, Clean rag

1. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.). 2. Clear dust and debris out of spring compliance area by blowing with compressed air in the gap between

the interface plate and the Utility Coupler body or the compliance assembly. 3. Wipe off unit with a clean rag. 4. If repairs are complete, return circuits to normal operation.

Figure 4.5—Clear Dust and Debris from Compliance Springs

Blow Compressed Airin Gap Between

Interface Plate andUtility Coupler Body

Interface Plate

Utility Coupler Body





5. Troubleshooting and Service ProceduresThe following section provides troubleshooting and service information to help diagnose conditions and repair the Utility Coupler or control/signal module.


CAUTION: Thread locker applied to fasteners must not be used more than once. Fasteners might become loose and cause equipment damage. Always apply new thread locker when reusing fasteners.

5.1 Troubleshooting ProceduresThe troubleshooting table is provided to assist in diagnosing issues that may cause the Utility Coupler not to function properly.

Table 5.1—TroubleshootingSymptom Cause Resolution

Unit will not Couple.

Electric Drive Cylinder not functioning properly

Check to ensure proper voltage is supplied and that all wires and cables are in good condition. Check power supply and power to motor brake. Verify that cylinder guide rods are moving freely. Clean and lubricate as needed to restore smooth operation.

Object trapped between Master, Tool, add-on modules, or drive cylinder body and mounting plate.

Clear object from between Master, Tool, add-on modules, or drive cylinder Body and mounting plate.

Pneumatic Drive cylinder has improper air supply.

Verify the air is supplied at a minimum of 60 psi (4.1 bar). Refer to Section 2.6—Pneumatic Guided Cylinder Assemblies.

Pneumatic Drive cylinder not functioning properly.

Ensure that the drive cylinder pneumatic connections are properly secured and not leaking, if leaking repair connection.Verify that cylinder guide rods are moving freely. Clean and lubricate as needed to restore smooth operation.Verify the drive cylinder is not leaking air from rod seals, if leaking repair or replace drive cylinder.

Utility Coupler is misaligned beyond the intended specification.

Checkfixturealignmentandmakeadjustmentsasnecessary.

Reducedairflowto Tool function.

Object trapped between Master and Tool or between modules.

Clear object from between Master and Tool or modules.

Master or Tool side Check port O-ring seals worn or damaged.

Inspect O-rings seals, if worn or damaged replace. Refer to Section 5.2.1—Clean, Inspect, Lubricate, Replace Components for Master Check Port and Section 5.2.2—Clean, Inspect, Lubricate, Replace Components for Tool Check Port.

Hose or connector leaking or damage.

Inspect hoses and connectors, if damaged or leaking, repair or replace.





Table 5.1—TroubleshootingSymptom Cause ResolutionUnit is unlocked but Unlock signal does not read “on”.

Unlock sensor/cable is damaged.

Inspect hoses and connectors, if damaged or leaking, repair or replace.

Communications to Tool intermittent or non existent.

Object trapped between Master and Tool or between modules.

Clear object from between Master and Tool or modules. Inspect V-ring seal for damage, replace damaged seal. Refer to Section 5.2.3—V-ring Seal Replacement.

Debris between contacts, worn or damaged contact pins.

Inspect pin blocks, refer to Section 4.3—Pin Block Inspection and Cleaning

Cables or connector loose or damage

Inspect cables and connectors, if connectors are loose, tighten. If cables are damaged, repair or replace.

Pneumatic Cylinder is malfunctioning.

Exhaustmufflerisclogged.Check/Replaceexhaustmuffler;ensurecleanairsupply. Refer to Section 5.2.15—GK-GC-B63S50Z1 Exhaust Muffler Replacement.

No or not enough air pressure on the pneumatic connection.

Make sure Pneumatic connection has minimum pressure, refer to Section 2.6—Pneumatic Guided Cylinder Assemblies.





5.2 Service ProceduresThe following service procedures provide instructions for component replacement.

5.2.1 Clean, Inspect, Lubricate, Replace Components for Master Check PortParts Required: Refer to Section 6—Serviceable PartsTools required: 2.5 mm Allen Wrench, torque wrenchSupplies required: Clean rag, Magnalube G lubricant

1. Place the Tool in a secure location.2. Uncouple the Master and Tool plates.3. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.).

NOTICE: Debris can be expelled at high velocity during the purge, take all required safety precautions.

4. Purge and disconnect all customer plumbing connections to the module. a. Turn the supply lines off.

b. Cover the valves with a rag for safety.

c. Manually actuate the module’s self-sealing valves to purge the line pressure. Note: Debris can be expelled at high velocity during the purge, take all required safety precautions.

5. Depending on the type of service or repair, connections to the module might also need to be disconnected.

6. Remove the valve stem using a 2.5 mm Allen wrench. Do not strip the hex on the valve stem during removal.

7. Remove the check valve piston and spring. Clean any lubrication from the check valve piston, valve stem, spring, and bore in the module housing using a clean rag.

8. Inspect the valve stem for straightness, and replace, if bent.9. Inspect the o-rings and u-cup seal on the valve stem and check valve piston for wear and

damage. Replace components that are damaged or worn.10. Inspect the spring in the assembly and replace if damaged or worn.

Figure 5.1—Master Self-Sealing Valve

Bore in Module Housing(Clean)

2.5 mm Allen Wrench

Valve Stem (Inspect)

Check Valve

Spring (Inspect)

O-Ring(Inspect)

O-Ring(Inspect)

U-Cup Seal(Inspect)

Valve Stem

Check Valve

U-Cup Seal

O-Ring

O-Ring (Face Seal)





11. Lubricate the bore in the module housing with Magnalube G (Teflon/Petroleum based grease).

NOTICE: Do not lubricate the O-ring face seal until after installation. Lubricating the O-ring before installation can cause the O-ring to blow out during coupling and uncoupling.

12. If replacing seals, lubricate the valve stem O-ring and the check valve piston U-cup seal with Magnalube G (Teflon/Petroleum based grease).

13. Install the O-ring on the valve stem. 14. Install the U-cup seal on the check valve. Do not get lubrication in the face seal groove in the

check valve.15. Install the non-lubricated O-ring (face seal) into the check valve.16. Install the spring into the bore in the module housing, seat the check valve on the spring.17. If the threaded end of the valve stem does not have pre-applied adhesive, apply Loctite 7649

primer and then Loctite 222 or similar thread locker to the threaded end of the valve stem. If the module housing is stainless steel, also add Loctite 7649 primer to the housing threads.

Figure 5.2—Master Self-Sealing Valve Installation

Bore in Module Housing (Lubricate)

Valve Stem

Check Valve

Spring

O-Ring (Face Seal)(Lubrication after Installation)

U-Cup Seal (Lubricate)

O-Ring (Lubricate)

Install U-Cup Seal as Shown

18. Install the valve stem. The check valve piston must be pushed down flush with the mating surface of the Master housing in order to install the threaded end of the valve stem. Do not damage the U-cup seal around the check valve piston. A small, flat-head screwdriver can be used to ensure that the U-cup seal is fully located in the recess and not folded over itself prior to screwing in the valve stem. Tighten the stem to 10 in-lbs (1.1 Nm).

19. Lubricate the installed O-ring (face seal) with Magnalube G (Teflon/Petroleum based grease).20. After the procedure is complete, resume normal operation.





5.2.2 Clean, Inspect, Lubricate, Replace Components for Tool Check PortParts Required: Refer to Section 6—Serviceable PartsTools required: 10 mm Allen wrench, Torque wrenchSupplies required: Clean rag, Magnalube G lubricant

1. Place the Tool in a secure location.2. Uncouple the Master and Tool plates.3. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.).

NOTICE: Debris can be expelled at high velocity during the purge, take all required safety precautions.

4. All customer plumbing connections to the module must be purged.a. Verify that the supply lines are turned off.

b. Cover the valves with a rag for safety.

c. Manually actuate the self-sealing valves to purge the line pressure.

5. If required disconnect connections to the module.

NOTICE: You might need to remove the Tool side module to access the plug.

6. Remove the plug assembly from the bottom of the air module using a 10 mm Allen wrench.7. Remove the spring and valve assembly from the housing.

Figure 5.3—Tool Self-Sealing Valve (Disassembly)

10 mm Allen Wrench

Plug Assembly

Spring (Inspect)

Valve Assembly

Dowel Pin(Inspect)

O-Ring(Inspect)

O-Ring(Inspect)

Bore in Module Housing(Clean and Lubricate)

O-Ring(Lubricate)

Plug Assembly

O-Ring(Lubricate)

Valve Assembly

8. Clean all lubrication from the plug assembly, valve assembly, spring, and bore in the housing using a clean rag.

9. Inspect the dowel pin that is contained in the plug assembly for straightness. Replace the plug assembly if the dowel pin is bent.

10. Inspect the O-rings on the plug and valve assemblies, replace if worn or damaged.11. Inspect the spring in the assembly and replace if worn or damaged.





12. If replacing the O-rings, lubricate both new O-rings with Magnalube G (Teflon/Petroleum based grease).

13. Install the O-rings on the plug assembly and the valve assembly.

Figure 5.4—Tool Self-Sealing Valve (Assembly)

Plug Assembly O-RingSpring

Valve AssemblyO-Ring

Torque Wrench

10 mm Allen Wrench

14. Install the check valve piston, make sure it is seated properly in the housing.15. Install the spring into the housing, make sure it is installed over the step on the check valve.

CAUTION: Do not use excess force when installing the plug assembly into the housing. Using excessive force can damage the O-ring and strip the threads on the plug assembly. Thread the plug assembly into the Tool housing by hand, until several threads are engaged into the housing. Then use a 10 mm Allen wrench to complete the installation. Torque the plug to 30 in-lbs (3.39 Nm).

16. Carefully install the plug assembly aligning the dowel pin into the check valve piston. Thread the plug assembly into the housing by hand until several threads are engaged in the housing.

17. Tighten the plug assembly using a 10 mm Allen wrench to 30 in-lbs. (3.39 Nm).18. Verify the check valve piston is seated properly in the housing.19. After the procedure is complete, resume normal operation.





5.2.3 V-ring Seal ReplacementThe seal protects the electrical connection between the Master and Tool module. If the seal becomes worn or damaged, it must be replaced.

1. Place the Tool in a secure location.2. Uncouple the Master and Tool plates.3. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.).4. To remove the existing seal, pinch the edge of the seal with your fingers and pull the seal away

from the pin block on the Master.5. To install a new seal, stretch the new seal over the shoulder of the pin block.6. Push the seal hub down against the pin block using your finger tip.

7. After the procedure is complete, resume normal operation.

Figure 5.5—V-ring Seal Replacement

V-ring Seal

Stretch seal over shoulder of pin block and push seal hub down against

the pin block with finger tipV-ring Seal

Pinch edge of seal with fingers and gently pull away from pin block





5.2.4 Tool Presence Sensor Replacement for GK UnitsParts Required: Refer to Section 6—Serviceable PartsTools Required: 1/2” socket wrench, Torque wrenchSupplies Required: Loctite 222

1. Uncouple the Utility Coupler to allow clear access to the Master and Tool plates.2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.). 3. Disconnect the sensor cable, loosening the lock nut using a 1/2” socket wrench, and unscrewing

the sensor from the body.4. Check to be sure the female threads on the housing are free and clear of debris, then thread a

new sensor into the Tool presence mounting holes until the face of the sensor is flush or 0.010ʺ below flush with the coupling face of the Master assembly.

5. Apply Loctite 222 to the exposed threaded area of the sensor where the lock nut will seat (only this area).

6. Screw the lock nut onto the sensor until it is snug to the Master body using a 1/2” socket wrench. Tighten to 20 in-lbs (2.26 Nm).

7. Connect the sensor cable.8. If repairs are complete, return circuits to normal operation.

Figure 5.6—Tool Presence Sensor Replacement (GL5CM Shown)





5.2.5 GK1CM Thrust Bearing, Chamfered Washer, and Shoulder Bolt ReplacementParts Required: Refer to Section 6—Serviceable PartsTools Required: 6 mm Allen wrench, Torque wrenchSupplies Required: Loctite 7649 and 242, Magnalube G lubricant, Clean ragRemove

1. Uncouple the Utility Coupler to allow clear access to the Master and Tool plates.2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.). 3. Press on Utility Coupler Master to compress the springs and release the pressure on the thrust

bearing, chamfered washer and shoulder bolt.4. Remove the M12 shoulder bolt using a 6 mm Allen wrench.5. Remove the chamfered washer and thrust bearing. Note: To remove the thrust bearing may

require the use of a flat head screw driver (or similar) to push bearing out from the back side.6. Clean the housing with a rag to remove grease and debris.Install

7. Apply Loctite Primer 7649 to the threads of the shoulder bolt.8. Insert the new thrust bearing with the chamfered side facing outward.9. Apply MobilGrease XHP222 Special grease the chamfered edges of the thrust bearing and the

new chamfered washer.10. Insert the new chamfered washer with the chamfer facing inward.11. Apply Loctite 242 to the threads of the new shoulder bolt.12. Press on Utility Coupler Master to compress the springs so that the shoulder bolt will bottom

out in the housing and leave the thrust bearing and chamfered washer loose.

Figure 5.7—GK1CM Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement

Clean the Housing prior toInstalling new Thrust Bearing

Thrust Bearing

Chamfered Washer

Shoulder Bolt

Apply Loctite Primer 7649 and Loctite 242 to Threads on Shoulder Bolt

Orient Thrust Bearing with Chamfered side facing outward

Orient Chamfered Washer Chamfered side facing inward

Press on Utility Coupler Master to Compress Springs and shoulder Bolt will Bottom out in Housing

13. Insert the new shoulder bolt and tighten the new shoulder bolt using 6 mm Allen wrench to 250 in-lbs (28.25 Nm).






5.2.6 GK2CM Thrust Bearing, Chamfered Washer, and Shoulder Bolt ReplacementParts Required: Refer to Section 6—Serviceable PartsTools Required: 6 mm Allen wrench, Torque wrenchSupplies Required: Loctite 7649 and 242, Magnalube G lubricant, Clean ragRemove

1. Uncouple the Utility Coupler to allow clear access to the Master and Tool plates.2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.). 3. Press on Utility Coupler Master to compress the springs and release the pressure on the thrust

bearing, chamfered washer and shoulder bolt.4. Remove the M12 shoulder bolt and M10 hex nut using a 6 mm Allen wrench.5. Remove the chamfered washer and thrust bearing. Note: To remove the thrust bearing may

require the use of a flat head screw driver (or similar) to push bearing out from the back side.6. Clean the housing with a rag to remove grease and debris.Install

7. Apply Loctite Primer 7649 to the threads on the new shoulder bolt.8. Insert the new thrust bearing with the chamfered side facing outward.9. Apply MobilGrease XHP222 Special grease the chamfered edges of the thrust bearing and the

new chamfered washer.10. Insert the new chamfered washer with the chamfer facing inward.11. Apply Loctite 242 to the threads of new shoulder bolt.12. Press on Utility Coupler Master to compress the springs so that the shoulder bolt will bottom

out in the housing and leave the thrust bearing and chamfered washer loose.





Figure 5.8—GK2CM Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement

Clean the Housing prior to Installing new Thrust Bearing

Thrust BearingChamfered

WasherShoulder

Bolt

M10 Hex Nut

Orient Chamfered Washer Chamfered side facing inward

Orient Thrust Bearing with Chamfered side facing outward

Press on Utility Coupler Master to Compress Springs and shoulder Bolt will Bottom out in Housing

Apply Loctite Primer 7649 to threads in NutApply Loctite 242 to Threads on Shoulder Bolt

13. Insert the new shoulder bolt and tighten the new shoulder bolt and hex nut, using 6 mm Allen wrench to 250 in-lbs (28.25 Nm).






5.2.7 GK1CM Compliance Spring Replacement for Utility Coupler (Preferred Method)This method is preferred for a dirty or gritty environment. The fine threads of the compliant preload pusher can get filled with dirt and grit and be damaged when removing or installing the compliance springs. If the environment is free from debris or grit, use the alternative method. Refer to Section 5.2.8—GK1CM Compliance Spring Replacement for Utility Coupler (Alternate Method).Parts Required: Refer to Section 6—Serviceable PartsTools Required: 6 mm Allen wrench, Torque wrenchSupplies Required: Loctite 7649 and 242, Magnalube G lubricant, Compressed air, Clean rag

1. Uncouple the Utility Coupler to allow clear access to the Master and Tool plates.2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.). 3. Remove Utility Coupler Master from drive cylinder refer to Section 2.2—Utility Coupler

Master Removal.4. Clear dust and debris out of spring compliance area by blowing with compressed air in the gap

between the interface plate and the Utility Coupler body.5. Remove the (3) shoulder bolts, thrust washers, and chamfered washers, refer to Section 5.2.5—

GK1CM Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement (Remove).6. Lift off the Master body to expose the compression springs.

Figure 5.9—GK1CM Compliance Springs Replacement (Preferred Method)

(3) Compliance Springs

Back Plate

Master Body

(3) Shoulder Bolts

(3) Chamfered Washers

(3) Thrust Bearings

7. Replace compression springs as necessary. Note: If an individual compression spring is worn out or broken it is recommended that all compression spring be replaced.

8. Place the Master body on the compliance interface plate, making sure the compression springs are in the proper recesses in the back of the Master body.

9. Replace the (3) shoulder bolts, thrust washers, and chamfered washers, refer to Section 5.2.5—GK1CM Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement (Install).

10. Install the Utility Coupler Master to the drive cylinder refer to Section 2.1—Utility Coupler Master Installation.






5.2.8 GK1CM Compliance Spring Replacement for Utility Coupler (Alternate Method)The alternative method can be used for environments that are free of dirt and grit. The fine threads of the compliant preload pusher can get filled with dirt and grit and be damaged when removing or installing the compliance springs. If environment is dirty or gritty use the preferred method, refer to Section 5.2.7—GK1CM Compliance Spring Replacement for Utility Coupler (Preferred Method).Parts Required: Refer to Section 6—Serviceable PartsTools Required: 5/16” Allen wrench Supplies Required: Loctite 222, Compressed air, Clean rag



between the interface plate and the Utility Coupler body.

Figure 5.10—GK1CM Compliance Springs Replacement (Alternative Method)

Compliance Spring

Compliant Preload PusherApply Lotite 222 to Threads

0.08" to 0.125" Depth for Compliant Preload Pusher

5. Using a 5/16ʺ Allen wrench, remove the compliant preload pusher from the interface plate.6. Remove the (2) compression springs.7. Insert (2) new compression springs.8. Apply Loctite 222 to the threads of the new compliant preload pusher.9. Using a 5/16ʺ Allen wrench, tighten the compliant preload pusher until it is 0.08ʺ to 0.125ʺ

below the face of the interface plate.10. Install the Utility Coupler Master to the drive cylinder refer to Section 2.1—Utility Coupler

Master Installation.11. If repairs are complete, return circuits to normal operation.





5.2.9 GK2CM Compliance Spring Replacement for Utility Coupler (Preferred Method)This method is preferred for a dirty or gritty environment. The fine threads of the compliant preload pusher can get filled with dirt and grit and be damaged when removing or installing the compliance springs. If the environment is free from debris or grit, use the alternative method. Refer to Section 5.2.10—GK2CM Compliance Spring Replacement for Utility Coupler (Alternate Method).Parts Required: Refer to Section 6—Serviceable PartsTools Required: 6 mm Allen wrench, Torque wrenchSupplies Required: Loctite 7649 and 242, Magnalube G lubricant, Compressed air, Clean rag



between the interface plate and the Utility Coupler body.5. Remove the (3) shoulder bolts, thrust washers, and chamfered washers, refer to Section 5.2.5—

GK1CM Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement (Remove).6. Lift off the Master body to expose the compression springs.

Figure 5.11—GK2CM Compliance Springs Replacement (Preferred Method)

(2) Outer Compression Springs

(2) Inner Compression SpringsMaster Body

(2) Shoulder Bolt

(2) Chamfered Washer

(2) Thrust Bearing

Back Plate

(2) M10 Hex Nut

7. Replace compression springs as necessary. Note: If an individual compression spring is worn out or broken it is recommended that all compression spring be replaced.

8. Place the Master body on the compliance interface plate, making sure the compression springs are in the proper recesses in the back of the Master body.

9. Replace the (3) shoulder bolts, thrust washers, and chamfered washers, refer to Section 5.2.5—GK1CM Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement (Install).

10. Install the Utility Coupler Master to the drive cylinder refer to Section 2.1—Utility Coupler Master Installation.






5.2.10 GK2CM Compliance Spring Replacement for Utility Coupler (Alternate Method)The alternative method can be used for environments that are free of dirt and grit. The fine threads of the compliant preload pusher can get filled with dirt and grit and be damaged when removing or installing the compliance springs. If environment is dirty or gritty use the preferred method, refer to Section 5.2.9—GK2CM Compliance Spring Replacement for Utility Coupler (Preferred Method).Parts Required: Refer to Section 6—Serviceable PartsTools Required: 5/16” Allen wrench Supplies Required: Loctite 222, Compressed air, Clean rag

1. Uncouple the Utility Coupler to allow clear access to the Master and Tool plates.2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.). 3. Clear dust and debris out of spring compliance area by blowing with compressed air in the gap

between the interface plate and the Utility Coupler body.

Figure 5.12—GK2CM Compliance Springs Replacement (Alternative Method)

Compression Springs

Compression Springs

Compliant Preload Pusher Apply Loctite 222 to Threads

0.36" to 0.38" Depth forCompliant Preload Pusher

4. Using a 5/16ʺ Allen wrench, remove the compliant preload pusher from the interface plate.5. Remove the (2) compression springs.6. Insert (2) new compression springs.7. Apply Loctite 222 to the threads of the new compliant preload pusher.8. Using a 5/16ʺ Allen wrench, tighten the compliant preload pusher until it is 0.36ʺ to 0.38ʺ below

the face of the interface plate.9. If repairs are complete, return circuits to normal operation.





5.2.11 Center Swivel Replacement for Utility CouplerParts Required: Refer to Section 6—Serviceable PartsTools Required: 6 mm Allen wrench, 8 mm Allen wrench, Torque wrenchSupplies Required: Loctite 7649, 242, and 271, Magnalube G lubricant, Compressed air, Clean rag



between the interface plate and the Utility Coupler body, refer to Section 4.4—Clear Dust and Debris from Compliance Springs Area.

5. Remove the (3) shoulder bolts, thrust washers, and chamfered washers, refer to Section 5.2.5—GK1CM Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement (Remove).

6. Lift off the Master body to expose the center pivot.7. Using a 8 mm Allen wrench, remove the set screw and ball tip set screw.

Figure 5.13—Position the Center Swivel

.120

.110 Ball Protrusion Seated Position

(Installed set screw should be below flush)

Set Screw Apply Loctite Primer 7649 and then Loctite 271) (Torque to 150 in-lbs)

Ball Tip Set Screw (Apply Loctite Primer 7649and then Loctite 271)

Utility Coupler Master(Side Toward the Compliance Plate)

8. Apply Loctite Primer 7649 and then Loctite 271 to the threads of the new ball tip set screw.9. Using a 8 mm Allen wrench, install the new ball tip set screw. Position the ball tip set screw so

that the ball tip protrudes between .110” and .120” from the surface of the Utility Coupler body.10. Allow 5 minutes for the Loctite to dry before proceeding to the next step.11. Apply Loctite Primer 7649 and then Loctite 271 to the threads of the set screw.12. Using a 8 mm Allen wrench, install the set screw. Tighten to 150 in-lbs (16.95 Nm).13. Place the Master body on the compliance interface plate, making sure the compression springs

are in the proper recesses in the back of the Master body.14. Replace the (3) shoulder bolts, thrust washers, and chamfered washers, refer to Section 5.2.5—

GK1CM Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement (Install).15. Install the Utility Coupler Master to the drive cylinder refer to Section 2.1—Utility Coupler

Master Installation.16. If repairs are complete, return circuits to normal operation.





5.2.12 GK1CM Alignment Pin ReplacementParts Required: Refer to Section 6—Serviceable PartsTools required: 5 mm Allen wrench, Torque wrenchSupplies required: Magnalube G lubricant

1. Uncouple the Utility Coupler and space to allow clear access to the Master and Tool.2. Turn off all energized circuits (e.g., electrical, air, water, etc.)3. Remove the M6 socket head cap screw using a 5 mm Allen wrench.4. Remove the alignment pin from the housing.

NOTICE:Ifthealignmentpinisdifficulttoremove,itcanbeknockedoutusinga0.1”diameter pin from the back side of the housing.

5. Insert the new alignment pin into the housing, align the tapped hole in the pin with the M6 screw hole in the housing.

Figure 5.14—GK1CM Alignment Pin Replacement

Alignment Pin

M6 Socket HeadCap Screw

M6 Threaded Hole

6. Secure the alignment pin with the M6 socket head cap screw using a 5 mm Allen wrench, and tighten to 140 in-lbs (15.82 Nm).

7. Apply MobilGrease XHP222 Special grease to the alignment pin.8. If repairs are complete, return circuits to normal operation.





5.2.13 GK2CM Alignment Pin ReplacementRefer to Figure 5.15 and Figure 5.16Parts required: Refer to Section 2.1—Utility Coupler Master InstallationTools required: 3 mm, 4 mm, and 5 mm Allen wrench (hex key), torque wrenchSupplies required: Clean rag, MobilGrease XHP222, Loctite 242

1. Place the Tool safely in the tool stand. Uncouple the Tool Changer to allow clear access to the Master and Tool plates.

2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.). 3. Unscrew the alignment pin assembly from the Master plate using a 4 mm Allen wrench. If

alignment was remove, verify that the assembly (pin and set screw) are intact. If the set screw portion of the assembly did not come out, it will be necessary to remove it separately using the access hole in the back plate of the Master plate go to step 4. If the alignment pin and set screw were removed, go to step 6. If alignment pin cannot be removed using the Allen wrench in the tip, go to step 4.

NOTICE: If for any reason the pin cannot be removed using the Allen wrench in the tip, it may be necessary to remove it by other means, such as locking pliers.

Figure 5.15—GK2CM Alignment Pin Replacement

4 mm Allen Wrench

RatchetHex Socket

Alignment Pin

Set Screw with Hex

Socket





4. Another approach would be to use the access hole in the back side of the Master plate. If not already removed, remove the Master plate refer to Section 2.2—Utility Coupler Master Removal. Use a 3 mm Allen wrench to remove the alignment pin from the back side of the Master plate. Refer to Figure 5.16).

Figure 5.16—GK2CM Alignment Pin Replacement Alternate Method

Alignment Pin

3 mm Allen Wrench

Set Screw with Hex Socket

5. Once the alignment pin has been removed, install the Master plate, refer to Section 2.1—Utility Coupler Master Installation.

6. Apply Loctite 242 and install the alignment pin assembly into the bushing on the Tool Changer. Tighten to 60 in-lbs (6.8 Nm).

7. Apply MobilGrease XHP222 Special grease to the alignment pin (see Section 4.2—Clean, Inspect, and Lubricate Thrust Bearings for Utility Couplers).






5.2.14 GK-GC-B63S50Z1 Return Spring Replacement

NOTICE: It is recommended that both return springs be replaced at the same time.

Refer to Figure 5.17Parts required: Refer to Section 6—Serviceable Parts

Tools required: 1/8” Allen® wrench (hex key), torque wrench

1. Ensure that the cylinder is in the full retracted state.2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.). 3. Using a 1/8” Allen wrench, loosen the 1/4” set screw in the shaft collar toward the rear of the

cylinder.4. Slide the shaft collar off the shaft.5. Remove the return spring.6. Install the new return spring onto the shaft.7. Install the shaft collar onto the shaft and using a 1/8” Allen wrench, tighten the set screw.

Ensure the cone point of the set screw is seated in the V-groove on the shaft. Tighten set screw to 25 in-lbs (2.82 Nm).


Figure 5.17—Return Spring Replacement

9123-GK-GC-B63S50Z1-SG-N

Shaft

Return Spring

Shaft Collar

1/4" Set Screw

V-groove





5.2.15 GK-GC-B63S50Z1ExhaustMufflerReplacementThe exhaust muffler allows air from the Tool Changer or Utility Coupler locking mechanism to be exhausted to the atmosphere, if the muffler is clogged it may affect the ability to Latch and Unlatch the customer tooling. Remove and check to make sure the exhaust muffler is not clogged.Parts required: Refer to Section 6—Serviceable PartsTools required: 9/16” wrenchSupplies required: Loctite 569

1. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.).2. Remove the exhaust muffler using a 9/16” wrench, blow through the muffler. If it is difficult

to blow or you can not blow through it at all replace the exhaust muffler. Discard the exhaust muffler.

3. Apply Loctite 569 to the threads of the new exhaust muffler.4. Thread the new exhaust muffler into the fitting. Tighten to contact plus a half turn using a 9/16”

wrench.

Figure 5.18—ExhaustMufflerReplacement

Apply Loctite 569to Threads

Exhaust Muffler

9123-GK-GC-B63S50Z1-SG-N

5. After repair is complete, return all circuits to normal operation (e.g. electrical, air, water, etc.).





6. Serviceable Parts6.1 GK1 Compliant Utility Coupler Master (9123-GK1CM-0-0-0-0)

10

14

611

12

3

78

1

4

4

12

2

2

15

13

9

Figure 6.1—Master Plate Item No. Qty Part Number Description

1 1 9123-GK1CM-0-0-0-0 GK1 Compliance Utility Coupler Base Assembly

2 4 3500-1066016-15A M6 x 16 mm socket head cap screws Blue Dyed Magni ND Microspheres

3 3 3500-2070035-11 SHCS Shoulder M12 x 35 Shoulder M10 Thread

5 3 3610-2520001-11 Steel Spring 15/16" OD, 2" Long 15.54Rate

6 1 3690-6600900-10 Rolling Ball Tip Set Screw, M16-2.0 x 23.3 mm long, Black Oxide Steel

7 3 3700-20-4675 Custom Chamfered Washer

8 3 3700-20-4676 Custom SAE 841 Bronze Thrust Bearing

9 3 3700-20-4716 Compliant IP Preload Pusher

10 1 3700-20-4875 1/2" Dia. Utility Coupler Alignment Pin 4 mm Taper, Short Diamond

11 1 3700-20-4876 1/2" Dia. Utility Coupler Alignment Pin 4 mm Taper, Short, Round


13 1 3700-20-6070 G4 Master Back Plate

14 1 3700-20-8254 M16-2.0 x 9 mm Set Screw, Hollow Hex

9123-GK1CM-0-0-0-0-SE4 2 8590-9909999-120 NPN Proximity Sensor

9123-GK1CM-0-0-0-0-SG4 2 8590-9909999-34 PNP Proximity Sensor





6.2 GK2 Compliant Utility Coupler Master (9123-GK2CM-0-00-0-00-N/E/R)

20

11

514

15

17

213

312

189

16

7

1

7

4

8

10

196


1

1 9123-GK2CM-0-00-0-00-N GK2 Compliant Utility Coupler Base Assembly, (2) 3/8 NPT Checked Air Ports

1 9123-GK2CM-0-00-0-00-E GK2 Compliant Utility Coupler Base Assembly, (2) G 3/8 BSPP Checked Air Ports

1 9123-GK2CM-0-00-0-00-R GK2 Compliant Utility Coupler Base Assembly, (2) Rc 3/8 BSPT Checked Air Ports

2 2 3410-0001065-01 O-Ring 14 mm X 2 mm Buna

3 2 3410-0001183-01 O-Ring 6 mm X 2 mm Buna D90


5 2 3500-2070035-11 SHCS Shoulder M12 x 35 Shoulder M10 Thread

6 2 3505-0870001-12 Hex Nut M10x1.5, 8 mm Tall 17 mm Wide Zinc Plated Steel

8 2 3610-1725001-10 Steel Compression Spring 2-1/2" L, 5/8" OD,.080" Wire

9 2 3610-1907501-21 SS SPRING 7/8 OD

10 2 3610-2520001-11 Steel Spring 15/16" OD, 2" Long 15.54Rate

11 1 3690-6600900-10 Rolling Ball Tip Set Screw, M16-2.0 x 23.3 mm long, Black Oxide Steel

12 2 3700-20-2994 Master Check Valve Piston, FA44

13 2 3700-20-3488 Valve Stem

14 2 3700-20-4675 Custom Chamfered Washer

15 2 3700-20-4676 Custom SAE 841 Bronze Thrust Bearing






16 2 3700-20-4716 Compliant IP Preload Pusher

17 2 9005-20-2241 1/2" Two Piece Pin Assembly

18 2 3410-0001068-01 Mini U-Cup Seal 18 mm ID x 22 mm Buna

19 1 3700-20-7206 G4D Master Mount Plate

20 1 3700-20-8254 M16-2.0 x 9 mm Set Screw, Hollow Hex

9123-GK2CM-0-00-0-00-SG7 2 8590-9909999-120 NPN Proximity Sensors

9123-GK2CM-0-00-0-00-SE7 2 8590-9909999-120 PNP Proximity Sensors





6.3 GK1 Compliant Utility Coupler Tool 9123-GK1T-0-0-0-0

1

Figure 6.3—Tool Plate Item No. Qty Part Number Description

1 1 9123-GK1T-0-0-0-0 GK1 Utility Coupler Tool Base Assembly

6.4 GK2 Compliant Utility Coupler Tool 9123-GK2T-0-00-0-00-N/E/R

1

23

4

5

6

Figure 6.4—Tool Plate Item No. Qty Part Number Description

1

1 9123-GK2T-0-00-0-00-N GK2 Utility Coupler Tool with (2) Integrated checked 3/8 NPT Air Ports

1 9123-GK2T-0-00-0-00-E GK2 Utility Coupler Tool with (2) Integrated checked G 3/8 BSPP Air Ports

1 9123-GK2T-0-00-0-00-R GK2 Utility Coupler Tool with (2) Integrated checked Rc 3/8 BSPP Air Ports

2 2 3410-0001067-01 O-Ring 10 x 2.0 mm Buna-N D90

3 2 3700-20-2303 Check Valve

4 2 3610-6401501-21 SS Spring 14 mm O.D, 13.5#/in

5 2 3410-0001284-01 O-Ring .669 ID x .047, 70 Durometer Buna-N

6 2 3700-20-3288 Plug, Tool, Plastic (Threaded Modules)





6.5 Models 9123-GK-GC-B63S50Z1-SG-N

1

2

3

4

5

6

7

8

9

3

4

10

Figure 6.5—Guided Cylinder Item No. Qty Part Number Description

1 1 9123-GK-GC-B63S50Z1-SG-N GK Guided Cylinder Assembly, 63 mm Bore, 50 mm Stroke, PNP Sensor to Detect Retract, Custom Spring-Return

2 4 3500-1070020-15 M10 x 20 mm socket head cap screws, Blue Dyed Magni-565

3 4 3690-1604401-10 Shaft Collar, 1” OD x 1/2” ID x 7/16” W, 1/4”-20 Set Screw, Steel, Zinc Plated

4 4 3500-1924031-13 Set Screw 1/4”-20 x 5/16” Alloy Steel, Cone Point

5 2 3700-20-9679 Straight Bracket, Spring-Return GK2 Drive Cylinder

6 2 3690-1666001-10 1/2” Shaft, 6.6” Length, Steel, Hard Chrome, Case Hardened, V-Groove Both Ends

7 2 3700-20-9680 Angle Bracket, Spring-Return GK2 Drive Cylinder

8 4 3500-1068025-15A M8 x 25 mm socket head cap screws, Blue Dyed Magni-565 w/ ND Microspheres Epoxy

9 2 3610-1956301-10 Compression Spring, .875” OD, 5.63” Free Length, 16 lb/in, Steel, Zn

10 1 3490-1010004-00 MUFFLER, 1/4NPT, H-FLOW





6.6 Models 9123-GK-GC-B50S75-SG-N, 9123-GK-GC-B63S75-SG-N

1


1 19123-GK-GC-B50S75-SG-N GK Guided Cylinder Assembly, 50 mm Bore, 75 mm Stroke, PNP Sensor

to Detect Retract

9123-GK-GC-B63S75-SG-N GK Guided Cylinder, Pneumatic, NPT, 63 mm Bore, 75 mm Stroke, PNP 3 Wire Position Sensor

6.7 Models 9123-GK-GCE-PM24400-B-SG, 9123-GK-GCE2-PM24600-B-SG

1

2


1 19123-GK-GCE-PM24400-B-SG Utility Coupler Drive Unit, Electric, Perm Magnet Motor, 24VDC, 4.00"

Stroke, Brake Opt, (1) DC PNP

9123-GK-GCE2-PM24600-B-SG GK Utility Coupler Drive Unit, Electric, Perm Magnet Motor, 24VDC, 6.00” Stroke, Brake Opt, (1) DC P

2 1 8590-9909999-34 True 2 PNP Proximity Sensor





7. SpecificationsTable 7.1—Utility Couplers

9123-GK1 - Master and Tool Plates

Suggested Payload Limit Not applicableFixture weight should be supported independently of the Utility Coupler

Weight (coupled) 6.57 lb (2.9 kg) Master 3.61 lb, Tool 2.96 lbMin Recommended distance between Master and Tool plate 1.97 in (50 mm)

Min Required Force to Couple 40 lbs (18.14 kg) Base Model only, no modules attached

Mounting Interface Master and ToolRectangular Pattern ,See Section 8.1—GK1 Compliant Utility Coupler Drawings

9123-GK2-N/E/R - Master and Tool Plates

Suggested Payload Limit Not applicableFixture weight should be supported independently of the Utility Coupler

Weight (coupled) 5.44 lb (2.47 kg) Master 3.34 lb, Tool 2.10 lbMin Recommended distance between Master and Tool plate 1.97 in (50 mm)

Min Required Force to Couple 220 lbs (99.8 kg)

Base Model only, no modules attached. Assuming both integrated checked ports are pressurized to 80 psi.

Integrated Ports (2) 3/8 NPT Checked Ports Master and Tool, Air Only

Mounting Interface Master and Tool

Rectangular Pattern Section 8.2—GK2-N Compliant Utility Coupler DrawingsSection 8.3—GK2-E Compliant Utility Coupler DrawingsSection 8.4—GK2-R Compliant Utility Coupler Drawings





Table 7.2—Guilded Cyclinders9123-GK-GC-B50S75-SG-NBore Size 50 mmMax Stroke Length 75 mmRecommended Stroke Length 50 mmMax Coupling Force @ 80 psi 240 lbs (109 kg)Mounting Interface See Section 8.5—GK-GC-B50S75-SG-N9123-GK-GC-B63S75-SG-NBore Size 63 mmMax Stroke Length 75 mmRecommended Stroke Length 50 mmMax Coupling Force @ 80 psi 383 lbs (174 kg)Mounting Interface See Section 8.7—GK-GC-B63S75-SG-N9123-GK-GC-B63S50Z1-SG-NBore Size 63 mmMax Stroke Length 50 mmRecommended Stroke Length 40 mmMax Coupling Force @ 80 psi 303 lbs (137 kg)Mounting Interface See Section 8.6—GK-GC-B63S50Z1-SG-N9123-GK-GCE-PM24400-B-SG

Max Coupling Force @ 24 VDC, 6 Amps 75 lbs Estimated Axial holding force of brake on electrical drive unit.

Max Stroke Length 4 inchesMounting Interface See Section 8.9—GK-GCE-PM24400-B-SG9123-GK-GCE2-PM24600-B-SG

Max Coupling Force @ 24 VDC, 6 Amps 144 lbs Estimated Axial holding force of brake on electrical drive unit.

Max Stroke Length 6 inchesMounting Interface See Section 8.8—GK-GCE2-PM24600-B-SG





8. Drawings8.1 GK1 Compliant Utility Coupler Drawings

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dwor

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pex,

NC 27

539,

USA

Tel: +

1.919

.772.0

115

Em

ail: in

fo@ati

-ia.co

mFa

x: +1

.919.7

72.82

59

www

.ati-ia

.com

ISO

9001

Reg

ister

ed C

ompa

ny

GK-

GC

E D

rive

Uni

t



Manual, Utility Coupler, GKx Document #9620-20-B … · Manual, Utility Coupler, GKx. Document...

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Transcript of Manual, Utility Coupler, GKx Document #9620-20-B … · Manual, Utility Coupler, GKx. Document...