UIC GSM FlexJet User manual

FlexJet Head Assembly FlexJet Head Assembly
FlexJet Head Assembly
FlexJet Head Assembly
FlexJet Head Assembly
FlexJet Head
Assembly
T47541109
Rev. J
01-01djh,fg,djh
This document supports
assembly
47541109 Rev.F

i
FlexJet Head Assembly T47541109 Rev. J
TECHNICAL PUBLICATIONS
This Document Supports Assembly 47541109 Rev. F
Table of Contents
Assembly Drawings....................................................................................................................................................... 1
Notes .................................................................................................................................................................... 9
Lubricants and Adhesives:................................................................................................................................... 9
Bill of Materials ................................................................................................................................................. 10
Functional Description ................................................................................................................................................ 12
Maintenance Concept .................................................................................................................................................. 12
Adjustments and Other Procedures for Maintenance Technicians....................................................................12
Preventive Maintenance..................................................................................................................................... 13
Procedures for Universal Instruments Field-Service Engineers ........................................................................ 13
Calibration Table ......................................................................................................................................................... 14
Prerequisite Information.............................................................................................................................................. 15
Acronyms........................................................................................................................................................... 15
Related Information..................................................................................................................................................... 16
Procedures and Adjustments ....................................................................................................................................... 17
Prepare the Machine for Maintenance ............................................................................................................... 17
Prepare the Machine for Production .................................................................................................................. 17
Installing the FlexJet Head ................................................................................................................................ 18
Prerequisites ............................................................................................................................................. 18
Initial Steps............................................................................................................................................... 19
Mount the FlexJet Head ........................................................................................................................... 19
Attach Pneumatics and Electrical Cables................................................................................................. 19
Final Steps ................................................................................................................................................ 21
Removing the FlexJet Head ............................................................................................................................... 22
Initial Steps............................................................................................................................................... 22
Disconnect the Electrical and Pneumatic Cables ..................................................................................... 22
Remove the Head from the Carriage........................................................................................................ 23
Final Steps ................................................................................................................................................ 23
Head/Changer Nozzle Setup .............................................................................................................................. 23
Verifying the Vacuum Level ............................................................................................................................. 24
Prerequisites ............................................................................................................................................. 24
Verify the Main Vacuum Pressure ........................................................................................................... 24
Access the Pneumatic Panel ........................................................................................................... 24
Install the Panel and Covers ........................................................................................................... 25
Lower the Spindles................................................................................................................................... 25
Install the Vacuum Gauge ........................................................................................................................ 26
Measure the Vacuum Level ..................................................................................................................... 26
Raise the Spindles .................................................................................................................................... 28
Final Steps ................................................................................................................................................ 29
Verifying Air Kiss.............................................................................................................................................. 29
Initial Steps............................................................................................................................................... 29
Check the Air Kiss ................................................................................................................................... 30
Final Steps ................................................................................................................................................ 31
Inspecting the Theta- and Z-Motor Belts........................................................................................................... 31
Initial Steps............................................................................................................................................... 31
Check the Belts......................................................................................................................................... 32
Final Steps ................................................................................................................................................ 33
Verifying the Touch-Down Sensors .................................................................................................................. 33
Move the Head ......................................................................................................................................... 33
Lower the Spindles................................................................................................................................... 33
Check the Signal Strength ........................................................................................................................ 34
Cleaning the Pin Mirrors.................................................................................................................................... 35
Prerequisites ............................................................................................................................................. 35

ii
T47541109 Rev. J FlexJet Head Assembly
TECHNICAL PUBLICATIONS
This Document Supports Assembly 47541109 Rev. F
Position the FlexJet Head ......................................................................................................................... 35
Lower the Spindles................................................................................................................................... 36
Clean the Reflective Surfaces of the Mirrors ........................................................................................... 36
Raise the Spindles .................................................................................................................................... 37
Perform Adjustments and Calibration...................................................................................................... 38
Setting the Touch-Down Sensors ...................................................................................................................... 38
Prerequisites ............................................................................................................................................. 38
Machine Preparation ................................................................................................................................ 39
Sensor Setup ............................................................................................................................................. 39
Install the Impact Sensor Setup Tool.............................................................................................. 39
Lower a Spindle.............................................................................................................................. 41
Adjust the Sensor............................................................................................................................ 42
Setup Verification .................................................................................................................................... 44
Comprehensive Head Maintenance ................................................................................................................... 45
Prerequisites ............................................................................................................................................. 45
Initial Steps............................................................................................................................................... 46
Clean the Pin Mirrors ............................................................................................................................... 46
Verify/Adjust the Camera Mirror Cable .................................................................................................. 49
Inspect the Mirror Spring Shaft................................................................................................................ 50
Inspect the Linear Bearings...................................................................................................................... 51
Verify/Adjust Tension of Spindle Drive Belts ......................................................................................... 51
Inspect Theta and Z-Motor Belts ............................................................................................................. 51
General Inspection ................................................................................................................................... 51
Clean the Camera Mirrors ........................................................................................................................ 52
Install the FlexJet Head ............................................................................................................................ 54
Final Steps ................................................................................................................................................ 54
Zeroing the Theta Encoder ................................................................................................................................ 55
Prerequisites ............................................................................................................................................. 55
Install the Theta Alignment Tool ............................................................................................................. 55
Adjust the Encoder Counts Value ............................................................................................................ 56
Verify the Encoder Counts Value ............................................................................................................ 58
Final Steps ................................................................................................................................................ 58
Verifying/Adjusting the Z-Safe Sensor ............................................................................................................. 59
Prerequisite............................................................................................................................................... 59
Initial Steps............................................................................................................................................... 59
Verify the Z Safe Sensor Signal ............................................................................................................... 61
Adjust the Sensor Signal .......................................................................................................................... 62
Final Steps ................................................................................................................................................ 63
Adjusting the Spindle Drive Belt Tension ......................................................................................................... 64
Prerequisites ............................................................................................................................................. 64
Initial Steps............................................................................................................................................... 64
Procedure.................................................................................................................................................. 64
Final Steps ................................................................................................................................................ 66
Adjusting the Stop Brake Belt Tension ............................................................................................................. 66
Adjusting the Stop Bracket Belt Tension .......................................................................................................... 67
Replacing/Aligning a Coupler Body ................................................................................................................. 67
Prerequisites ............................................................................................................................................. 67
Initial Steps............................................................................................................................................... 68
Replace the Coupler Body ....................................................................................................................... 69
Adjust the Coupler Body.......................................................................................................................... 70
Final Steps ................................................................................................................................................ 70
Replacing the PCA Flex Jet Control.................................................................................................................. 71
Prerequisites ............................................................................................................................................. 71
Initial Steps............................................................................................................................................... 71
Remove the Current PCA FlexJet Control............................................................................................... 71

iii
FlexJet Head Assembly T47541109 Rev. J
TECHNICAL PUBLICATIONS
This Document Supports Assembly 47541109 Rev. F
Install the New PCA FlexJet Control ....................................................................................................... 72
Install the Electrical Cabling .................................................................................................................... 73
Final Steps ................................................................................................................................................ 74
Advanced Support Information ................................................................................................................................... 76
Replacing the Stop Brake Belt........................................................................................................................... 76
Prerequisites ............................................................................................................................................. 76
Initial Steps............................................................................................................................................... 76
Remove the Damaged Belt....................................................................................................................... 77
Install the New Belt.................................................................................................................................. 77
Final Steps ................................................................................................................................................ 78
Replacing the Z Stop Brake Assembly .............................................................................................................. 79
Prerequisites ............................................................................................................................................. 79
Initial Steps............................................................................................................................................... 79
Remove the Faulty Stop Brake Assembly ............................................................................................... 79
Install the New Stop Brake Assembly...................................................................................................... 80
Final Steps ................................................................................................................................................ 81
Replacing a Spindle Touch-Down Sensor ......................................................................................................... 81
Prerequisites ............................................................................................................................................. 81
Initial Steps............................................................................................................................................... 81
Procedure.................................................................................................................................................. 82
Final Steps ................................................................................................................................................ 84
Replacing a Clutch............................................................................................................................................. 85
Prerequisites ............................................................................................................................................. 85
Initial Steps............................................................................................................................................... 85
Disassemble the Head .............................................................................................................................. 86
Install the New Clutch.............................................................................................................................. 89
Final Steps ................................................................................................................................................ 91
Replacing a Manifold Tubing ............................................................................................................................ 92
Prerequisite............................................................................................................................................... 92
Initial Steps............................................................................................................................................... 92
Procedure.................................................................................................................................................. 93
Final Steps ................................................................................................................................................ 94
Replacing the Manifold ..................................................................................................................................... 94
Prerequisites ............................................................................................................................................. 94
Initial Steps............................................................................................................................................... 95
Remove the Current Manifold ................................................................................................................. 95
Install the New Manifold.......................................................................................................................... 96
Final Steps ................................................................................................................................................ 98
Replacing a Fiber Optic Cable........................................................................................................................... 98
Prerequisites ............................................................................................................................................. 98
Initial Steps............................................................................................................................................... 98
Disassemble the FlexJet Head .................................................................................................................. 99
Install the New Fiber Optic Cable.......................................................................................................... 100
Install the PCA FlexJet Control ............................................................................................................. 100
Final Steps .............................................................................................................................................. 101
Replacing the Spindle Drive Belt .................................................................................................................... 102
Prerequisites ........................................................................................................................................... 102
Initial Steps............................................................................................................................................. 102
Change the Belt ...................................................................................................................................... 103
Final Steps .............................................................................................................................................. 103
Replacing a FlexJet Spindle Assembly............................................................................................................ 104
Prerequisites ........................................................................................................................................... 104
Initial Steps............................................................................................................................................. 104
Procedure................................................................................................................................................ 104
Disassemble the Head................................................................................................................... 105

iv
T47541109 Rev. J FlexJet Head Assembly
TECHNICAL PUBLICATIONS
This Document Supports Assembly 47541109 Rev. F
Replace the Spindle Assembly ..................................................................................................... 106
Connect the Spindle to the Platform Assembly............................................................................ 106
Perform Final Installations and Adjustments ............................................................................... 108
Final Steps .............................................................................................................................................. 108
Changes To This Revision ........................................................................................................................................ 109

Page 1
FlexJet Head Assembly T47541109 Rev. J
TECHNICAL PUBLICATIONS
This Document Supports Assembly 47541109 Rev. F

Page 2
T47541109 Rev. J FlexJet Head Assembly
TECHNICAL PUBLICATIONS
This Document Supports Assembly 47541109 Rev. F
(Ref) - 80026907 (2)
(Ref) - 80026810 (2)
4
(6) 15
5
(2) 22
9
10
7
47813303 - (Ref)
(Ref) - 47814003
86
80 IN-OZ
.56 NM
(6) 16
86
20 IN-LB
2.26 NM
(Ref) - 80029805 (3)

Page 3
FlexJet Head Assembly T47541109 Rev. J
TECHNICAL PUBLICATIONS
This Document Supports Assembly 47541109 Rev. F
Detail A
(Page 4)
Detail B
(Page 4)
(4)18
8
17
(2)
19
11
(4) 22
24
25
26
(Ref)5
27
28
(4)30
23
29
(4)29
(4) 17
(4) 31
(Ref)
10

Page 4
T47541109 Rev. J FlexJet Head Assembly
TECHNICAL PUBLICATIONS
This Document Supports Assembly 47541109 Rev. F
Detail A
Detail B
(Ref) 47749501 ,Clearflo Tubing
7 x 4in
(Ref) 80031302
(Ref) 80031705
(Ref) 80055601
40659579 (Ref)

Page 5
FlexJet Head Assembly T47541109 Rev. J
TECHNICAL PUBLICATIONS
This Document Supports Assembly 47541109 Rev. F
14
20
(2) 21