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Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-1
Table of ContentsB. Base Utility Coupler ................................................................................................................B-4G2x/G5x Series—Utility Couplers with Integrated Compliance ...............................................B-41. Product Overview ..................................................................................................................B-4
1.1 G2x/G5x Compliant Utility Coupler Master ............................................................................. B-5
1.2 G2x/G5x Utility Coupler Tool .................................................................................................... B-6
1.3 9121-G2B Utility Coupler .......................................................................................................... B-71.3.1 9121-G2B-CUCM Compliant Utility Coupler Master .......................................................B-7
1.3.2 9121-G2B-UCT Utility Coupler Tool .................................................................................B-7
1.4 9121-G2x Utility Coupler ........................................................................................................... B-81.4.1 9121-G2 and 9121-G2A Compliant Utility Coupler Master ..............................................B-8
1.4.2 9121-G2-UCT Utility Coupler Tool ...................................................................................B-9
1.5 9121-G2E Compliant Utility Coupler ...................................................................................... B-101.5.1 9121-G2E-CUCM Compliant Utility Coupler Master .....................................................B-10
1.5.2 9121-G2E-UCT Utility Coupler Tool ...............................................................................B-10
1.6 9121-G5A Compliant Utility Coupler ...................................................................................... B-121.6.1 9121-G5A Compliant Utility Coupler Master ..................................................................B-12
1.6.2 9121-G5-UCT Utility Coupler Tool .................................................................................B-12
1.7 9121-G2-GC Drive Cylinders .................................................................................................. B-13
2. Installation ...........................................................................................................................B-142.1 Utility Coupler Master Installation ......................................................................................... B-14
2.2 Utility Coupler Master Removal ............................................................................................. B-15
2.3 Utility Coupler Tool Assembly Installation ............................................................................ B-15
2.4 Utility Coupler Tool Assembly Removal ................................................................................ B-16
2.5 Electrical Connections ............................................................................................................ B-16
2.6 Pneumatic Connections ......................................................................................................... B-172.6.1 Air Check Ports .............................................................................................................B-17
2.7 Guided Cylinder Sensor Adjustment Procedure .................................................................. B-182.7.1 Adjust the Sensor Height ..............................................................................................B-18
2.7.2 Adjust the Sensor Position ............................................................................................B-18
3. Operation .............................................................................................................................B-193.1 Conditions for Coupling ......................................................................................................... B-19
3.2 Guided Cylinder Dependency ................................................................................................ B-19
3.3 Conditions for Uncoupling ..................................................................................................... B-22
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-2
4. Maintenance .........................................................................................................................B-234.1 Preventive Maintenance ......................................................................................................... B-23
4.2 Clean, Inspect, and Lubricate Thrust Bearings for Utility Couplers .................................. B-24
4.3 Pin Block Inspection and Cleaning ....................................................................................... B-25
4.4 Clear Dust and Debris from Compliance Springs Area ....................................................... B-26
5. Troubleshooting and Service Procedures ........................................................................B-275.1 Troubleshooting Procedures ................................................................................................. B-27
5.2 Service Procedures ................................................................................................................. B-285.2.1 Clean, Inspect, Lubricate, Replace Components for G2B Master side Check Port ......B-29
5.2.2 Clean, Inspect, Lubricate, Replace Components for G2B Tool side Check Port ...........B-31
5.2.3 Clean, Inspect, Lubricate, Replace Components for G2, G2A, G2E, and G5A Master Side Check Port .....................................................................................................................B-33
5.2.4 Replacement of the G2, G2A, G2E, and G5A Tool Side Check Port ............................B-35
5.2.5 Seal Replacement .........................................................................................................B-36
5.2.6 Tool Presence Sensor Replacement for G5A Units .......................................................B-37
5.2.7 Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement for Utility Coupler ................................................................................................................B-38
5.2.8 Compliance Spring Replacement for Utility Coupler (Preferred Method) ........................................................................................................B-39
5.2.9 Compliance Spring Replacement for Utility Coupler (Alternative Method) ......................................................................................................B-40
5.2.10 Center Swivel Replacement for Utility Coupler .............................................................B-41
5.2.11 Alignment Pin Replacement ..........................................................................................B-42
6. Serviceable Parts ................................................................................................................B-436.1 Models 9121-G2B-CUCM ........................................................................................................ B-43
6.2 Models 9121-G2-CUCM, 9121-G2A-CUCM, and 9121-G5A-CUCM ...................................... B-44
6.3 Models 9121-G2E-CUCM ......................................................................................................... B-45
6.4 Models 9121-G2B-UCT ............................................................................................................ B-46
6.5 Models 9121-G2-UCT and 9121-G5-UCT ............................................................................... B-47
6.6 Models 9121-G2E-UCT ............................................................................................................ B-48
6.7 Models 9121-G2-GC-B80S100 Guided Cylinder ................................................................... B-49
6.8 Models 9121-G2-GC-B150S150 Guided Cylinder ................................................................. B-50
7. Specifications ......................................................................................................................B-51
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-3
8. Drawings ..............................................................................................................................B-528.1 G2 Compliant Utility Coupler Drawings ................................................................................ B-52
8.2 G2 Application Utility Coupler General Dimensions ........................................................... B-55
8.3 G2A Compliant Utility Coupler Drawings .............................................................................. B-56
8.4 G2A Application Utility Coupler General Dimensions ........................................................ B-59
8.5 G2B Compliant Utility Coupler Drawings .............................................................................. B-60
8.6 G2B Application Utility Coupler with 10 Port Option .......................................................... B-63
8.7 G2E Compliant Utility Coupler Drawings .............................................................................. B-64
8.8 G2E Application Utility Coupler General Dimensions ........................................................ B-67
8.9 G5A Utility Coupler Drawings ................................................................................................ B-69
8.10 G5A Application Utility Coupler General Dimensions ........................................................ B-72
9. Guided Cylinder Proximity Sensor Information ...............................................................B-739.1 9121-G2-GC-B80S100-SG Guided Cylinder Proximity Sensor ............................................ B-73
9.2 9121-G2-GC-B80S100-SR Guided Cylinder Proximity Sensor ............................................ B-74
9.3 9121-G2-GC-B150S150-SG Guided Cylinder Proximity Sensor (8590-9909999-133) ........ B-75
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-4
B. Base Utility Coupler
G2x/G5x Series—Utility Couplers with Integrated Compliance1. Product Overview
The G2x/G5x Utility Coupler is designed for heavy‑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 ledge mounted modules. Consult ATI for further details. Refer to Table 1.1 for Utility Couplers, the Master and Tool assemblies are grouped into compatible modules.
The Utility Couplers are comprised of a compliant Master side and Tool side (refer to Figure 1.1). The Master side is equipped with a unique compliance mechanism that allows for large tooling misalignments. The Utility Coupler depends on brute force from the guided cylinder assembly to maintain constant coupling pressure. The recommended operating pressure for the guided cylinder is 80 psi. The unit will work with operating pressures between 60–120 psi.
Table 1.1—G2x/G5x Utility CouplersPart Number Description
9121-G2-CUCM-0-0-0-0 Compliant Utility Coupler Master ± 4 mm X-Y, 3 Degrees Angular, (2) 3/4" NPT (National Pipe Thread) Checked Ports
9121-G2A-CUCM-0-0-0-0 Compliant Utility Coupler Master with (2) 3/4" NPT Checked Ports - SHORT PINS
9121-G2-UCT-0-0-0-0 Utility Coupler Tool with (2) 3/4" NPT Ports
9121-G2B-CUCM-0-0-0-0 Compliant Utility Coupler Master, ± 4 mm X-Y, 3 Degrees Angular, with (10) ¼ʺ NPT ports
9121-G2B-UCT-0-0-0-0 Utility Coupler Tool, with (10) 1/4ʺ NPT Ports
9121-G2E-CUCM-0-0-0-0-SG Compliant Utility Coupler Master with (4) 3/4" NPT Checked Ports, (2) PNP Sensors to Detect Tool Presence
9121-G2E-CUCM-0-0-0-0-SG1 Compliant Utility Coupler Master with (4) 3/4” NPT Checked Ports, (2) PNP M12 Quick Disconnect Tool Presence Sensors
9121-G2E-UCT-0-0-0-0 Utility Coupler Tool with (4) 3/4" NPT Checked Ports
9121-G5A-CUCM-0-0-0-0-SG Compliant Utility Coupler Master with (2) 1/2" BSPP Checked Ports-SHORT PINS, (2) PNP Sensors
9121-G5-UCT-0-0-0-0 Utility Coupler Tool with (2) 1/2" BSPP Ports and Tool Presence Sensor Targets
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-5
Figure 1.1—G2x/G5x Compliant Utility Coupler with Guided Cylinder Assembly
Utility Coupler Tool Side(9121-G2-UCT Shown)
Utility Coupler Master Side(9121-G2-CUCM Shown)
Guided Cylinder Assemblywith Position Sensors(9121-G2-GC-B80S100-SG Shown)
1.1 G2x/G5x Compliant Utility Coupler MasterThe Master plate assembly includes an anodized aluminum body and hardened stainless steel alignment pins. The Utility Coupler Master has a center swivel that allows for ± 4 mm compliance in any direction of the coupling plane. Also it allows for ± 3 degrees angular compliance. There are three sets of preloaded springs internal to the plate that force the main body to self‑center on custom chamfered thrust bearings. This system allows for a relatively large misalignment of the Master and Tool plates prior to coupling; (3) hardened‑steel overload pins provide for the compliance limits.The Master plate has built‑in features to pass utilities on to the Tool side, in addition the Master and Tool plates are equipped with up to (4) module ledge mount flats that provide support for additional Utility Coupler utility modules. Consult ATI for further details.
Figure 1.2—G2x/G5x Compliant Utility Coupler Master Assembly (9121-G2B Shown)
Hardened StainlessSteel Alignment Pins
Ledge Mounting Feature for StandardATI Add-on Utility Modules
Built in PassThrough Utilities
(3) Compliance Overload Pins withCustom Self-Centering Thrust Bearings
Center SwivelCompliant InterfaceMounting Plate
AnodizedAluminum Body
(3) Sets of Preloaded SpringsProvide Centering Reliability
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
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1.2 G2x/G5x Utility Coupler ToolThe Tool plate assembly includes an anodized aluminum body and hardened‑steel alignment bushings. The Tool plate also includes a 100 mm BC mounting pattern for direct customer tool mounting.The Tool plate has built in features to receive utilities from the Master side. The Tool plates are equipped with up to (4) module ledge mount flats that provide support for additional Utility Coupler utility modules. Consult ATI for further details.
Figure 1.3—G2x/G5x Utility Coupler Tool assembly (9121-G2B Shown)
Hardened StainlessSteel Alignment Bushings
Built in PassThrough Utilities
Ports for PassThrough Utilities
Circular MountingHole Pattern
AnodizedAluminum Body
Ledge Mounting Feature for StandardATI Add-on Utility Modules
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-7
1.3 9121-G2B Utility CouplerThe Master and Tool bodies are equipped with (2) ledge mount flats that enable the coupler to accept up to (2) additional utility modules. Contact ATI for further details.
1.3.1 9121-G2B-CUCM Compliant Utility Coupler MasterThe G2B model provides (10) 1/4ʺ NPT integrated checked ports or (10) 1/4ʺ BSPP integrated checked ports. Refer to Table 1.1 for specific model numbers and compatible Tool models. The Utility Coupler is equipped with standard hardened stainless steel alignment pins.
Figure 1.4—9121-G2B Compliant Utility Coupler Master
(2) Standard Alignment Pins
Ledge Mounting Feature Flat B
Ledge Mounting Feature Flat A
(10) Integrated AirChecked Ports
(10) 1/4" NPT Ports
9121-G2B-CUCMCompliant Utility Coupler
1.3.2 9121-G2B-UCT Utility Coupler ToolThe G2B model provides (10) 1/4ʺ NPT integrated ports. Refer to Table 1.1 for specific model numbers and compatible Master models.
Figure 1.5—9121-G2B Utility Coupler Tool
(2) Alignment Bushings
Ledge Mounting Feature Flat B
Ledge Mounting Feature Flat A
(10) Integrated AirChecked Ports
(10) 1/4" NPT Ports
9121-G2B-UCTUtility Coupler Tool
100 mm Bolt CircleMounting Pattern
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
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1.4 9121-G2x Utility CouplerThe Master and Tool bodies are equipped with (4) ledge mount flats that enable the coupler to accept up to (4) additional utility modules. Contact ATI for further details.
1.4.1 9121-G2 and 9121-G2A Compliant Utility Coupler MasterThe G2 model provides (2) 3/4ʺ NPT integrated checked ports and (4) ledge mounting flats. Refer to Table 1.1 for specific model numbers and compatible Tool models. The G2 Utility Coupler is equipped with standard hardened stainless steel alignment pins and the G2A is equipped with short hardened stainless‑steel alignment pins.
Figure 1.6—9121-G2 and 9121-G2A Compliant Utility Coupler Master
Ledge Mounting Feature Flat D
Ledge Mounting Feature Flat B
Ledge Mounting Feature Flat B
Ledge Mounting Feature Flat D
Ledge MountingFeature Flat C
Ledge MountingFeature Flat C
Ledge MountingFeature Flat A
Ledge MountingFeature Flat A
(2) Integrated AirChecked Ports
(2) Integrated AirChecked Ports
(2) Standard Alignment Pins
(2) Short Alignment Pins
(2) 3/4" NPT Ports
(2) 3/4" NPT Ports
(2) 3/4" NPT Plugs
(2) 3/4" NPT Plugs
9121-G2-CUCMCompliant Utility Coupler
9121-G2A-CUCMCompliant Utility Coupler
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
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1.4.2 9121-G2-UCT Utility Coupler ToolThe G2‑UCT model provides (2) 3/4ʺ NPT integrated ports and (4) ledge mounting flats. Refer to Table 1.1 for specific model numbers and compatible Master models.
Figure 1.7—9121-G2-UCT Utility Coupler Tool
Ledge Mounting Feature Flat B
Ledge Mounting Feature Flat D
(2) 3/4" NPT Port
9121-G2-UCTUtility Coupler Tool
100 mm Bolt CircleMounting Pattern
(2) 3/4" NPT Plug(Not Shown)
Ledge MountingFeature Flat A
Ledge MountingFeature Flat C
(2) Integrated AirChecked Port
(2) Alignment Bushing
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
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1.5 9121-G2E Compliant Utility CouplerThe Master and Tool bodies are equipped with (4) ledge mount flats that enable the coupler to accept up to (4) additional utility modules. Contact ATI for further details.
1.5.1 9121-G2E-CUCM Compliant Utility Coupler MasterThe G2E model provides (4) 3/4ʺ NPT integrated checked ports and (4) ledge mounting flats. Refer to Table 1.1 for specific model numbers and compatible Tool models. The Utility Coupler is equipped with standard hardened stainless‑steel alignment pins. The 9121‑G2E‑CUCM‑0‑0‑0‑0‑SG model has integrated PNP sensors to detect Tool presence.
Figure 1.8—9121-G2E-CUCM Compliant Utility Coupler Master
(2) Standard Alignment Pins
Ledge Mounting Feature Flat B
Ledge Mounting Feature Flat D
(4) Integrated AirChecked Ports
(4) 3/4" NPT Ports
9121-G2E-CUCMCompliant Utility Coupler
PNP ToolPresence Sensor
Ledge MountingFeature Flat A
Ledge MountingFeature Flat C
PNP ToolPresence Sensor
1.5.2 9121-G2E-UCT Utility Coupler ToolThe G2E‑UCT model provides (4) 3/4ʺ NPT integrated ports and (4) ledge mounting flats. Refer to Table 1.1 for specific model numbers and compatible Master models. The Tool has integrated present sensor targets.
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-11
Figure 1.9—9121-G2E-UCT Utility Coupler Tool
(2) Alignment Bushing
Ledge Mounting Feature Flat B
Ledge Mounting Feature Flat D
(2) 3/4" NPT Ports
9121-G2E-UCT Utility Coupler Tool
100 mm Bolt CircleMounting Pattern
Ledge MountingFeature Flat A
Ledge MountingFeature Flat C
(4) Integrated AirChecked Port
(2) Present Sensor Target
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
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1.6 9121-G5A Compliant Utility CouplerThe Master and Tool bodies are equipped with (2) ledge mount flats that enable the coupler to accept up to (2) additional utility modules. Contact ATI for further details.
1.6.1 9121-G5A Compliant Utility Coupler MasterThe G5A model provides (2) G 1/2ʺ BSPP integrated checked ports and (4) ledge mounting flats. Refer to Table 1.1 for specific model numbers and compatible Tool models. The Utility Coupler is equipped with short hardened stainless‑steel alignment pins and integrated PNP sensors to detect Tool presence.
Figure 1.10—9121-G5A Compliant Utility Coupler Master
(2) Short Alignment Pins
Ledge Mounting Feature Flat D
Ledge Mounting Feature Flat B
(2) Integrated AirChecked Ports
(2) G 1/2" BSPP Ports
9121-G5ACompliant Utility Coupler
PNP ToolPresence Sensor
Ledge MountingFeature Flat C
Ledge MountingFeature Flat A
PNP ToolPresence Sensor
Cable Channel
(Not Visible)(2) G 1/2" BSPP Plugs
1.6.2 9121-G5-UCT Utility Coupler ToolThe G5‑UCT model provides (2) G 1/2ʺ BSPP integrated ports and (4) ledge mounting flats. Refer to Table 1.1 for specific model numbers and compatible Master models. The Tool has integrated present sensor targets.
Figure 1.11—9121-G5-UCT Utility Coupler Tool
(2) Alignment Bushing
Ledge Mounting Feature Flat D
Ledge Mounting Feature Flat B
(2) G 1/2" BSPP Ports
9121-G5-UCTUtility Coupler Tool
100 mm Bolt CircleMounting Pattern
Ledge MountingFeature Flat C
Ledge MountingFeature Flat A
(2) Integrated AirChecked Port
(2) Present Sensor Target
(2) G 1/2" BSPP Plug
(Not Shown)
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
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1.7 9121-G2-GC Drive CylindersCertain drive cylinders may not be compatible with all Utility Couplers refer to Table 1.2 for available drive cylinders and compatible Utility Couplers. The use of additional utility modules, utility supply line flexibility, and other factors will affect the selection of the drive cylinder. Consult ATI for proper drive cylinder selection.
Table 1.2—9121-G2-GC Drive Cylinder Models and Compatibility
Part Number Description
Compatible with Utility
Coupler Models
9121-G2-GC-B150S150-SG Guided Cylinder Assembly 150 mm Bore 150 mm Stroke PNP Prox Sensor to Detect Retract Position G2E
9121-G2-GC-B80S100-S0, SG, & SR
Guided Cylinder Assembly 80 mm Bore 100 mm Stroke PNP Prox Sensors
G2, G2A, G2B, G5A
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
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2. InstallationThe G2x/G5x 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 Master and drive cylinder.
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: 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.
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.
2.1 Utility Coupler Master InstallationThe compliant Utility Coupler Master assembly is normally attached to the guided drive cylinder. The Master plate is designed with a rectangular mounting pattern to accommodate (4) M8 socket head cap screws.Refer to Figure 2.1Tools Required: 6 mm hex key, 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. Secure the Master assembly using the (4) M8 x 35 mm socket head cap screws using a 6 mm hex key. Tighten to 280 in‑lbs (31.64 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.
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
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Figure 2.1—Utility Coupler Master Installation
Pnuematic Connections
Utility Coupler Master Side(9121-G2-CUCM Shown)
Guided Cylinder Assemblywith Position Sensors(9121-G2-GC-B80S100-SG Shown)
Add-on Module(9121-DA2-M Shown)
Sensor Connections
Electrical Connections
(4) M8 x 35 mm SocketHead Cap Screws
(with Pre-applied Thread Locker)
2.2 Utility Coupler Master RemovalThe compliant Utility Coupler Master assembly is normally attached to the guided drive cylinder. The Master plate is designed with a rectangular mounting pattern to accommodate (4) M8 socket head cap screws.Tools Required: 6 mm hex key
1. Uncouple the Utility Coupler to allow clear access to the Master and Tool plates.2. Turn off and de‑energize all energized circuits (for example: electrical, pneumatic, hydraulic).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) M8 x 35 mm socket head cap screws securing the Master assembly to the drive cylinder
using a 6 mm hex key 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 (6) M10 socket head cap screws and (2) dowel holes. These features are used to accurately position and secure the Utility Coupler Tooling. Refer to Figure 2.2Tools Required: 8 mm hex key, torque wrenchSupplies Required: clean rag, Loctite 242
1. 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 400 in‑lbs (45.19 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.
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-16
Figure 2.2—Utility Coupler Tool Installation
Customer SuppliedInterface Plate
Electrical Connections
Add-on Module(9121-DA2-T Shown)
Utility Coupler Tool Assembly(9121-GL2-UCT Shown)
User SuppliedM10 Fasteners
Pneumatic Connections
2.4 Utility Coupler Tool Assembly RemovalTools Required: 8 mm hex key
1. Uncouple the Utility Coupler to allow clear access to the Master and Tool plates.
2. Turn off and de‑energize all energized circuits (for example: electrical, pneumatic, hydraulic).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 (6) M10 socket head cap screws securing the Tool assembly to the customer supplied fixture
using a 8 mm hex key 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
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2.6 Pneumatic ConnectionsThe 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 is acceptable for operation of the guided cylinder and the Utility Coupler, with a setting of 80 psi suggested. The air should be filtered 50 micron or better.
2.6.1 Air Check PortsPrior to pressurization, verify that the checked port pistons on the Master side are seated flush as in Figure 2.5. By design they are self‑centering, and as a result have the ability to swivel inside their housings. If a piston is swiveled like in Figure 2.4, then pressure is supplied to the port and the port will leak until the unit is actually coupled. Once the unit is coupled the first time, the swivel is corrected and no leakage occurs.
Figure 2.4—Check Port Pistons Swiveled
Figure 2.5—Check Port Pistons Flush
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2.7 Guided Cylinder Sensor Adjustment ProcedureThe sensors for the guided cylinder assembly are supplied pre‑adjusted to detect the fully retracted and fully extended states. The sensor is adjusted to be 0.2ʺ to 0.25ʺ away from the top of the fastener. For wiring information refer to Section 9—Guided Cylinder Proximity Sensor Information. To adjust the sensors height or position:
2.7.1 Adjust the Sensor Height Tools Required: 2 mm hex key, torque wrenchSupplies Required: Loctite 222To adjust the sensor distance from the target on the Guided Cylinder assembly, complete the following steps:
1. Loosen the M4 set screws using a 2 mm hex key. 2. Adjust the sensor distance by rotating it. The optimal distance from the sensor to the target is
0.2 to 0.25ʺ (5 to 6.35 mm). 3. Apply Loctite 222 to the M4 set screws and tighten to 10 in‑lbs (1.13 Nm) using
a 2 mm hex key.
Figure 2.6 Guided Cylinder Sensor Adjustment
M5 Set Screw SensorM4 Set Screw
Target
0.2-0.35"(5-6.35 mm)
Rail
SensorMount
2.7.2 Adjust the Sensor PositionTools Required: 2.5 mm hex key, torque wrenchSupplies Required: Loctite 222You can adjust the sensors using a rail on the Guided Cylinder assembly. To adjust the sensor position, complete the following steps:
1. Loosen the (2) M5 set screws on the sensor mounts using a 2.5 mm hex key.2. Adjust the sensor position by sliding the sensor holder along the rail.3. Apply Loctite 222 to the M5 set screws and tighten to 20 in‑lbs (2.26 Nm) using a
2.5 mm hex key.
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3. OperationThe Master coupling plate is pneumatically‑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 Conditions for CouplingPosition the Tool to within the extendable reach of the Master and move the Master into coupling position. The mating surfaces of the Master and Tool should be parallel and not touching. Make sure that the tapered alignment pins from the Master side enter the alignment bushings on the Tool side. The alignment pins should be relatively concentric with the alignment holes such that they do not rub against the edge.For some applications, cylinder stroke proximity sensing is included, providing the ability to sense cylinder retracted and extended states. The target for the cylinder and proximity sensors face on the Master housing must be positioned within approximately 5 mm of each other for the sensor to detect 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: Never couple or uncouple the unit without first disconnecting and discharging 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 DependencyIf the Utility coupler is not equipped with a locking mechanism and the air supply is lost 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.
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.
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Figure 3.1 shows the resistance force on the 3/4ʺ checked valve ports corresponding to line pressure. For example, for the 2‑port Utility Coupler, such as G2 and G2A, the resistance force of the ports, if they are pressurized to 60 psi, is 400 lbs. For the G2E 4‑port coupler, the resistance force at 60 psi is 800 lbs. It is recommended that drive unit be sized with ample factor of safety to handle these resistance forces from the ports. Also, remember to consider what additional utilities are being passed on optional modules, and consider at what pressure the drive cylinder will be operated.
Figure 3.1—ResistanceForceonthe¾ʺCheckedValvePortsCorrespondingtoLinePressure
Figure 3.2 shows the maximum recommended line pressure for the (2) checked air lines when plotted against the cylinder line pressure. This is for applications that use the G2‑port coupler with the 9121‑G2‑GC‑B80 drive cylinder. For example, if the cylinder is pressurized to 80 psi, the max line pressure is approximately 115 psi.
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Figure 3.2—Maximum Line Pressure for Two Checked Air Line Against Cylinder Line Pressure
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Figure 3.3 shows the maximum recommended line pressure for the (4) checked air lines when plotted against the cylinder line pressure. This is for applications that use the G2E 4‑port coupler with the 9121‑G2‑GC‑B150 drive cylinder. For example, if the cylinder is pressurized to 80 psi, the max line pressure is approximately 200 psi. Since the checked port max line pressure is rated for 100 psi, this gives a factor of safety of 2.
Figure 3.3—Maximum Line Pressure for Four Checked Air Line Against Cylinder Line Pressure
If your application requires a redundant fail‑safe feature, please consult ATI and ask about our standard line of Quick Change Tool Changers. ATI’s patented Quick Change 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.
3.3 Conditions for UncouplingThe Utility Coupler should be positioned in the same location as that when coupling took place. After the Utility coupler is in the proper location air must be supplied to the unlock side of the drive cylinder to uncouple the Master and Tool sides.
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4. MaintenanceThe G2x/G5x 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.
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.
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.
PinBlocks,ElectricalContacts,andV‑ringseals,refertoSection 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 5.2.5—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. 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 G2B Master side Check Port, Section 5.2.2—Clean, Inspect, Lubricate, Replace Components for G2B Tool side Check Port, Section 5.2.3—Clean, Inspect, Lubricate, Replace Components for G2, G2A, G2E, and G5A Master Side Check Port, and Section 5.2.4—Replacement of the G2, G2A, G2E, and G5A Tool Side Check Port.
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4.2 Clean, Inspect, and Lubricate Thrust Bearings for Utility CouplersSupplies Required: cotton swabs, clean rag, MobilGrease XHP™222 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 (for example: electrical, pneumatic, hydraulic).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—Compliance Spring Replacement for Utility Coupler (Preferred 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 XHP 222 Special grease to thrust bearings chamfered edge. If thrust bearing or other components are worn, replace worn components. Refer to Section 5.2.7—Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement for Utility Coupler.
6. Inspect the (2) alignment pins in the Master body for wear or damage. If pins are not worn, apply MobilGrease XHP 222 Special grease to alignment pins. If pins are worn or damaged, replace. Refer to Section 5.2.11—Alignment Pin Replacement.
7. Safely resume normal operation.
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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 (for example: electrical, pneumatic, hydraulic).4. Inspect the Master and Tool pin blocks for 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 are present, use a vacuum to remove the debris, 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 there are stuck pins or pin block damage, contact ATI for either a possible pin replacement procedure or module replacement.
8. Safely resume normal operation.
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4.4 Clear Dust and Debris from Compliance Springs AreaSupplies Required: compressed air, clean rag
1. Uncouple the Master and Tool plates.2. Turn off and de‑energize all energized circuits (for example: electrical, pneumatic, hydraulic).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 or the compliance assembly, as shown in Figure 4.5. 4. Wipe off unit with a clean rag. 5. Safely resume 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
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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.
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.
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
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.
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 Connections.
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 Check fixture alignment and make adjustments as necessary.
Reduced air flow to 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 G2B Master side Check Port, Section 5.2.2—Clean, Inspect, Lubricate, Replace Components for G2B Tool side Check Port, Section 5.2.3—Clean, Inspect, Lubricate, Replace Components for G2, G2A, G2E, and G5A Master Side Check Port, and Section 5.2.4—Replacement of the G2, G2A, G2E, and G5A Tool Side Check Port.
Hose or connector leaking or damage
Inspect hoses and connectors, if damaged or leaking, repair or replace.
Unit 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.
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Table 5.1—TroubleshootingSymptom Cause Resolution
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 5.2.5—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.
5.2 Service ProceduresComponent replacement procedures are provided in the following section.Refer to Section 6—Serviceable Parts for seal kit Part Numbers for the specific Utility Coupler model being serviced. Periodically, the condition of the self‑sealing valves should be checked. Replace any damaged or degraded components as necessary. Any contamination in or around the mating surfaces of the modules should be removed using a stiff nylon brush.
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5.2.1 Clean, Inspect, Lubricate, Replace Components for G2B Master side Check PortParts Required: Refer to Section 6—Serviceable PartsTools required: 2.5 mm hex key, 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 (for example: electrical, pneumatic, hydraulic).
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 hex key. 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—MasterSelf‑SealingValve
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)
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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—MasterSelf‑SealingValveInstallation
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. Safely resume normal operation.
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5.2.2 Clean, Inspect, Lubricate, Replace Components for G2B Tool side Check PortParts Required: Refer to Section 6—Serviceable PartsTools required: 10 mm hex key, 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 (for example: electrical, pneumatic, hydraulic).
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 hex key.7. Remove the spring and valve assembly from the housing.
Figure 5.3—ToolSelf‑SealingValve(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.
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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—ToolSelf‑SealingValve(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 hex key 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 hex key to 30 in‑lbs (3.39 Nm).18. Verify the check valve piston is seated properly in the housing.19. Safely resume normal operation.
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5.2.3 Clean, Inspect, Lubricate, Replace Components for G2, G2A, G2E, and G5A Master Side Check PortParts Required: Refer to Section 6—Serviceable Parts
Tools required: Snap ring pliersSupplies required: clean rag, Magnalube G (Teflon/Petroleum based grease)
1. Place the Tool in a secure location.2. Uncouple the Master and Tool plates.3. Turn off and de‑energize all energized circuits (for example: electrical, pneumatic, hydraulic).
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.
5. Remove the retaining ring using snap ring pliers.6. Remove the valve stem, valve piston and spring, inspect for wear or damage. Replace any worn
or damaged components. Refer to Figure 5.5.7. Remove the O‑rings form the valve piston and the valve bore in the housing.8. Clean the valve bore and internal components with a clean dry rag.
Figure 5.5—MasterSelf‑SealingValve
Retaining Ring
Valve Stem
O-ring
Spring
O-ring
Valve Piston
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Figure 5.6—MasterSelf‑SealingValveCrossSectionalView
O-ring
Valve Stem
Spring
Retaining Ring
Valve Piston
O-ring
9. Lubricate the replacement O‑rings and valve piston with Magnalube G (Teflon/Petroleum based grease).
10. Place the larger O‑ring on the seat of the valve bore. Refer to Figure 5.6.11. Place the smaller O‑ring in the groove of the valve piston.12. Place the spring to the bottom boss of the valve piston, and insert into the valve bore.13. Place the valve stem in the bore of the housing so that the stem’s flange rests on the seat of the
housing. The valve piston should be flush with the top rim of the valve stem.14. Using snap ring pliers, secure the self‑sealing valve assembly by installing the retaining ring in
the groove of the housing.15. Safely resume normal operation.
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-35
5.2.4 Replacement of the G2, G2A, G2E, and G5A Tool Side Check PortParts Required: Refer to Section 6—Serviceable PartsTools Required: Spanner wrench (legacy product) or 5 mm hex key (latest product revision) Supplies Required: clean rag, Magnalube G (Teflon/Petroleum based grease), Loctite 242
1. Place the Tool in a secure location.2. Uncouple the Master and Tool plates.3. Turn off and de‑energize all energized circuits, for example, electrical, air, and water.
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.
5. Use a spanner wrench or 5 mm hex key to remove the valve stem assembly, the valve piston assembly, and spring from the housing.
Figure 5.7—RemoveValveStemAssembly,ValvePistonAssembly,andSpring
Valve Piston Assembly
Valve Stem Assembly
Spring
Valve Piston Assembly
Spring
(Legacy Product)
Valve Stem Assembly(Latest ProductRevision)
6. Inspect the valve stem, valve piston, and the spring for wear or damage; replace all worn or damaged components.
7. Remove all O‑ring and Quad‑ring seals from the valve stem and piston assemblies.
Figure 5.8—Replace the O-rings and Quad-rings
Valve Stem
O-ring (Face Seal)
Valve PistonQuad-Ring
O-ring
Valve Stem
Valve PistonQuad-Ring
Quad-Ring
O-ring (Face Seal)(Lubricate after installation) (Lubricate after installation)
NOTICE: Do not lubricate the O-ring face seal for the valve piston prior to installation.
8. Lubricate the replacement valve Piston Quad‑ring and the valve stem Quad‑ring or O‑ring.9. Install the O‑ring face seal into the top groove in the valve piston. Then lubricate the O‑ring.10. Clean the check port with a clean dry rag. Assemble the components in the order shown.11. Apply Loctite 242 on the valve stem’s threads. Push down, compressing the spring, and thread
the valve stem into the housing. Tighten to 110 in‑lbs (12.4 Nm) using a spanner wrench or 5 mm hex key.
12. Safely resume normal operation.
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-36
5.2.5 Seal ReplacementParts Required: Refer to Section 6—Serviceable PartsThe seal protects the electrical connection between the Master and Tool module. If the seal becomes worn or damaged, replace the seal.
1. Place the Tool in a secure location.2. Uncouple the Master and Tool plates.3. Turn off and de‑energize all energized circuits (for example: electrical, pneumatic, hydraulic).4. To remove the existing seal, pinch the edge of the seal, and pull the seal away from the pin
block on the Master module.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.
7. Safely resume normal operation.
Figure 5.9—V‑ringSealReplacement
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
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-37
5.2.6 Tool Presence Sensor Replacement for G5A 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. Uncouple the Master and Tool plates.3. Turn off and de‑energize all energized circuits (for example: electrical, pneumatic, hydraulic).4. Disconnect the sensor cable, loosening the lock nut using a 1/2” socket wrench, and unscrewing
the sensor from the body.5. 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.
6. Apply Loctite 222 to the exposed threaded area of the sensor where the lock nut will seat (only this area).
7. 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).
8. Connect the sensor cable.9. Safely resume normal operation.
Figure 5.10—Tool Presence Sensor Replacement (G5A Shown)
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-38
5.2.7 Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement for Utility CouplerParts Required: Refer to Section 6—Serviceable PartsTools Required: 6 mm hex key, torque wrenchSupplies Required: Loctite 7649 and 242, Mobilgrease XHP 222 Specail grease, clean ragRemove
1. Uncouple the Utility Coupler to allow clear access to the Master and Tool plates.2. Uncouple the Master and Tool plates.3. Turn off and de‑energize all energized circuits (for example: electrical, pneumatic, hydraulic).4. Press on Utility Coupler Master to compress the springs and release the pressure on the thrust
bearing, chamfered washer and shoulder bolt.5. Remove the M12 shoulder bolt using a 6 mm hex key.6. 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.7. Clean the housing with a rag to remove grease and debris.Install
8. Apply Loctite Primer 7649 to the threads in the Master body and the threads of the shoulder bolt.
9. Insert the new thrust bearing with the chamfered side facing outward.10. Apply MobilGrease XHP 222 Special grease the chamfered edges of the thrust bearing and the
new chamfered washer.11. Insert the new chamfered washer with the chamfer facing inward.12. Apply Loctite 242 to the threads of the new shoulder bolt.13. 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 5.11—Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement
14. Insert the new shoulder bolt and tighten the new shoulder bolt using 6 mm hex key to 250 in‑lbs (28.25 Nm).
15. Safely resume normal operation.
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-39
5.2.8 Compliance Spring Replacement for Utility Coupler (Preferred Method)Note: If environment is dirty or gritty an alternative method may be preferable, refer to Section 5.2.9—Compliance Spring Replacement for Utility Coupler (Alternative Method).Parts Required: Refer to Section 6—Serviceable PartsTools Required: 5/16” hex key Supplies Required: Loctite 222, compressed air, clean rag
1. Uncouple the Utility Coupler to allow clear access to the Master and Tool plates.2. Uncouple the Master and Tool plates.3. Turn off and de‑energize all energized circuits (for example: electrical, pneumatic, hydraulic).4. Remove Utility Coupler Master from drive cylinder refer to Section 2.2—Utility Coupler
Master Removal.5. 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—Compliance Springs Replacement
6. Using a 5/16ʺ hex key, remove the compliant preload pusher from the interface plate.7. Remove the (2) compression springs.8. Insert (2) new compression springs.9. Apply Loctite 222 to the threads of the new compliant preload pusher.10. Using a 5/16ʺ hex key, tighten the compliant preload pusher until it is 0.4ʺ to 0.5ʺ below the
face of the interface plate.11. Install the Utility Coupler Master to the drive cylinder refer to Section 2.1—Utility Coupler
Master Installation.12. Safely resume normal operation.
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-40
5.2.9 Compliance Spring Replacement for Utility Coupler (Alternative Method)Parts Required: Refer to Section 6—Serviceable PartsTools Required: 6 mm hex key, torque wrenchSupplies Required: Loctite 7649 and 242, compressed air, clean rag
1. Uncouple the Utility Coupler to allow clear access to the Master and Tool plates.2. Uncouple the Master and Tool plates.3. Turn off and de‑energize all energized circuits (for example: electrical, pneumatic, hydraulic).4. Remove Utility Coupler Master from drive cylinder refer to Section 2.2—Utility Coupler
Master Removal.5. 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.6. Remove the (3) shoulder bolts, thrust washers, and chamfered washers, refer to Section 5.2.7—
Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement for Utility Coupler.7. Lift off the Master body to expose the compression springs.
Figure 5.13—Compliance Springs Replacement (G2A Shown)
(3) ShoulderBolts
(3) ChamferedWashers
(3) ThrustBearings
(6) CompressionSprings
Master Body
8. 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.
9. 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.
10. Replace the (3) shoulder bolts, thrust washers, and chamfered washers, refer to Section 5.2.7—Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement for Utility Coupler (Install).
11. Install the Utility Coupler Master to the drive cylinder refer to Section 2.1—Utility Coupler Master Installation.
12. Safely resume normal operation.
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-41
5.2.10 Center Swivel Replacement for Utility CouplerParts Required: Refer to Section 6—Serviceable PartsTools Required: 6 mm and 8 mm hex key, torque wrenchSupplies Required: Loctite 7649, 242, and 271, compressed air, clean rag
1. Uncouple the Utility Coupler to allow clear access to the Master and Tool plates.2. Uncouple the Master and Tool plates.3. Turn off and de‑energize all energized circuits (for example: electrical, pneumatic, hydraulic).4. Remove Utility Coupler Master from drive cylinder refer to Section 2.2—Utility Coupler
Master Removal.5. 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, refer to Section 4.4—Clear Dust and Debris from Compliance Springs Area.
6. Remove the (3) shoulder bolts, thrust washers, and chamfered washers, refer to Section 5.2.7—Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement for Utility Coupler (Remove).
7. Lift off the Master body to expose the center pivot.8. Using a 8 mm hex key, remove the set screw and ball tip set screw.
Figure 5.14—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)
9. Apply Loctite Primer 7649 and then Loctite 271 to the threads of the new ball tip set screw.10. Using a 8 mm hex key, 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.11. Allow 5 minutes for the Loctite to dry before proceeding to the next step.12. Apply Loctite Primer 7649 and then Loctite 271 to the threads of the set screw.13. Using a 8 mm hex key, install the set screw. Tighten to 150 in‑lbs (16.95 Nm).14. 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.15. Replace the (3) shoulder bolts, thrust washers, and chamfered washers, refer to
Section 5.2.7—Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement for Utility Coupler (Install).
16. Install the Utility Coupler Master to the drive cylinder refer to Section 2.1—Utility Coupler Master Installation.
17. Safely resume normal operation.
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-42
5.2.11 Alignment Pin ReplacementParts Required: Refer to Section 6—Serviceable PartsTools required: 5 mm hex key, torque wrenchSupplies required: Mobilgrease XHP 222 Specail grease
1. Uncouple the Utility Coupler to allow clear access to the Master and Tool plates.2. Uncouple the Master and Tool plates.3. Turn off and de‑energize all energized circuits (for example: electrical, pneumatic, hydraulic).4. Remove the M6 socket head cap screw using a 5 mm hex key.5. Remove the alignment pin from the housing.
NOTICE: If the alignment pin is difficult to remove, it can be pressed out using a 0.1” diameter pin from the back side of the housing.
6. Insert the new alignment pin into the housing, align the tapped hole in the pin with the M6 screw hole in the housing.
Figure 5.15—Alignment Pin Replacement
Alignment Pin
M6 Socket HeadCap Screw
M6 Threaded Hole
7. Secure the alignment pin with the M6 socket head cap screw using a 5 mm hex key, and tighten to 140 in‑lbs (15.82 Nm).
8. Apply MobilGrease XHP 222 Special grease to the alignment pin.9. Safely resume normal operation.
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-43
6. Serviceable Parts6.1 Models 9121-G2B-CUCM
1 19 2 17
18
16
8
1514
12 131110
97
6
5
4
3
Figure 6.1—Master plate Item No. Qty Part Number Description
1 1 9121-G2B-CUCM-0-0 G2B Compliant Utility Coupler Master with (10) 1/4" NPT ports
2 3 3610-1725001-10 Steel Compression Spring 2‑1/2ʺ L, 5/8ʺ OD
3 3 3700-20-4676 Custom SAE 841 Bronze Thrust Bearing
4 3 3700-20-4675 Custom Chamfered Washer
5 3 3500-2070035-11 Socket Head Cap Screw Shoulder M12 x 35 Shoulder M10 Thread
6 1 3690-6600900-10 Rolling Ball Tip Set Screw, Black Oxide Steel
7 1 3700-20-8254 M16-2.0 x 9 mm Set Screw, Hollow Hex
8 1 3700-20-4718 LONG ½ʺ Dia. Alignment Pin 4 mm Taper Diamond
9 1 3700-20-4732 LONG ½ʺ Dia. Alignment Pin 4 mm Taper Round
10 10 3410-0001183-01 O-Ring 6 mm X 2 mm Buna D90
11 10 3700-20-2996 Valve Stem, High Strength
12 10 3410-0001065-01 O-Ring 14 mm X 2 mm Buna
13 10 3700-20-2994 Master Check Valve Piston, FA44
14 10 3410-0001068-01 Mini U-Cup Seal 18 mm ID x 22 mm Buna
15 10 3700-20-1459 SW-150A Master Fluid / Air Spring SS
16 2 3500-1066016-15A M6x16 Socket Head Cap Screw, Class 12.9, Blue dyed Magni-565, ND Microspheres Epoxy
17 3 3610-1925001-20 Steel Spring .845ʺ OD, 2.5ʺ Long 43.4 Rate
18 3 3700-20-4716 Compliant IP Preload Pusher
19 4 3500-1068025-15A M8x25 Socket Head Cap Screw, 12.9, ISO4762/DIN912, ES-ATI-007, YL M-spheres/IFI 525
20 1 9005-20-2230 Utility Coupler Compliance Kit (Includes item #6,7)(Not Shown)
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-44
6.2 Models 9121-G2-CUCM, 9121-G2A-CUCM, and 9121-G5A-CUCM12
34
5
6
7
22
9
1011 12
1315
16
18
171419
19
8
21
Figure 6.2—Master Plate Item No. Qty Part Number Description
1
1 9121-G2-CUCM-0-0-0-0 Compliant Utility Coupler Master with (2) 3/4" NPT Checked Ports
1 9121-G2A-CUCM-0-0-0-0 Compliant Utility Coupler Master with (2) 3/4" NPT Checked Ports - SHORT PINS
1 9121-G5A-CUCM-0-0-0-0-SG Compliant Utility Coupler Master with (2) G 1/2” BSPP Checked Ports - SHORT PINS, and (2) PNP Tool Presence Sensors
1 9121-G5A-CUCM-0-0-0-0-SL Compliant Utility Coupler Master with (2) G 1/2" BSPP Checked Ports - SHORT PINS, and (2) PNP Tool Presence Sensors with LED Cables
22 3490-0001036-01 ¾ʺ NPT Hex Socket Plug, SS (for G2 and G2A models)
2 3490-0001045-01 G 1/2” BSPP Plug, Nickel Plated Brass (for G5A models)
3 3 3700-20-4676 Custom SAE 841 Bronze Thrust Bearing
4 3 3700-20-4675 Custom Chamfered Washer
5 3 3500-2070035-11 Socket Head Cap Screw Shoulder M12 x 35 Shoulder M10 Thread
6 1 3690-6600900-10 Rolling Ball Tip Set Screw, Black Oxide Steel
7 1 3700-20-8254 M16-2.0 x 9 mm Set Screw, Hollow Hex
8 1 3700-20-4718 LONG ½ʺ Dia. Alignment Pin 4 mm Taper Diamond (G2)
9 1 3700-20-4732 LONG ½ʺ Dia. Alignment Pin 4 mm Taper Round (G2)
10 2 3690-8500001-11 Retaining Ring, Internal Inverted (Also See #13)
11 2 3700-20-4924 3/4ʺ Valve Master Stem
12 2 3700-20-6161 3/4ʺ Valve Piston
13 1 9123-GL2CM-SEAL Seal Kit for Master Assembly Check Valve (2 sets of Seals #13 & Rings #10)
14 3 3610-1725001-10 Steel Compression Spring 2‑1/2ʺ L, 5/8ʺ OD
15 2 3610-2015100-20 Spring, 1.1 inch dia, .586 long, 13 lb/in SS
16 2 3500-1066016-15A M6x16 Socket Head Cap Screw, Class 12.9, Blue dyed Magni-565, ND Microspheres Epoxy
17 3 3610-1925001-20 Steel Spring .845ʺ OD, 2.5ʺ Long 43.4 Rate
18 3 3700-20-4716 Compliant IP Preload Pusher
19 4 3500-1068025-15A M8x25 Socket Head Cap Screw, 12.9, ISO4762/DIN912, ES-ATI-007, YL M-spheres/IFI 525
20 1 9005-20-2230 Utility Coupler Compliance Kit (Includes item #6,7)
21 1 3700-20-4875 SHORT ½ʺ Dia. Alignment Pin 4 mm Taper Diamond (G2A, G5A)
22 1 3700-20-4876 SHORT ½ʺ Dia. Alignment Pin 4 mm Taper Round (G2A, G5A)
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-45
6.3 Models 9121-G2E-CUCM1
34
5
6
7
9
1415
13121110
8
16
18
201719
Figure 6.3—Master plate Item No. Qty Part Number Description
1
1 9121-G2E-CUCM-0-0-0-0 Compliant Utility Coupler Master with (4) 3/4” NPT Checked Ports
1 9121-G2E-CUCM-0-0-0-0-SG Compliant Utility Coupler Master with (4) 3/4” NPT Checked Ports, (2) PNP Sensors to Detect Tool Presence
1 9121-G2E-CUCM-0-0-0-0-SG1 Compliant Utility Coupler Master with (4) 3/4” NPT Checked Ports, (2) PNP M12 Quick Disconnect Tool Presence Sensors
2 1 9005-20-2230 Utility Coupler Compliance Kit (Includes item #6,7)(Not Shown)
3 3 3700-20-4676 Custom SAE 841 Bronze Thrust Bearing
4 3 3700-20-4675 Custom Chamfered Washer
5 3 3500-2070035-11 Socket Head Cap Screw Shoulder M12 x 35 Shoulder M10 Thread
6 1 3690-6600900-10 Rolling Ball Tip Set Screw, Black Oxide Steel
7 1 3700-20-8254 M16-2.0 x 9 mm Set Screw, Hollow Hex
8 1 3700-20-4718 LONG ½ʺ Dia. Alignment Pin 4 mm Taper Diamond
9 1 3700-20-4732 LONG ½ʺ Dia. Alignment Pin 4 mm Taper Round
10 4 3690-8500001-11 Retaining Ring, Internal Inverted (Also See #13)
11 4 3700-20-4924 3/4ʺ Valve Master Stem
12 4 3700-20-6161 3/4ʺ Valve Piston
13 2 9123-GL2CM-SEAL Seal Kit for Master Assembly Check Valve (2 sets of seals #13 & Retaining rings #10)
142 8590-9909999-34 True 2 PNP Proximity Sensor (SG model)
2 8590-9909999-127 Prox Sensor M8 Barrel M12 Connection, N.O. 3 Wire DC PNP, 4 mm Sensing Range (SG1 model)
15 4 3610-2015100-20 Spring, 1.1 inch dia, .586 long, 13 lb/in SS
16 2 3500-1066016-15A M6x16 Socket Head Cap Screw, Class 12.9, Blue dyed Magni-565, ND Microspheres Epoxy
17 3 3610-1725001-10 Steel Compression Spring 2‑1/2ʺ L, 5/8ʺ OD
18 3 3700-20-4716 Compliant IP Preload Pusher
19 4 3500-1068025-15A M8x25 Socket Head Cap Screw, 12.9, ISO4762/DIN912, ES-ATI-007, YL M-spheres/IFI 525
20 3 3610-1925001-20 Steel Spring .845ʺ OD, 2.5ʺ Long 43.4 Rate
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-46
6.4 Models 9121-G2B-UCT
1
234
5
6
Figure 6.4—Tool plate Item No. Qty Part Number Description
1 1 9121-G2B-UCT-0-0 G2B Utility Coupler Tool with (10) 1/4” NPT Ports
2 10 3410-0001067-01 O-ring, .669OD x .047 wall, 70D, Buna-N
3 10 3700-20-1457-02 QC-151 Tool Check Valve Piston
4 10 3700-20-1460-02 SW-150A tool Fluid/Air Spring
5 10 3410-0001284-01 O-ring, .669OD x .047 wall, 70D, Buna-N
6 10 3700-20-3288 Plug, F/A Tool (Includes Dowel Pin 1/16” x 3/4” 18-8 Stainless Steel)
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-47
6.5 Models 9121-G2-UCT and 9121-G5-UCT
12
34
5
6
9
7
8
Figure 6.5—Tool plate Item No. Qty Part Number Description
11 9121-G2-UCT-0-0-0-0 G2 Utility Coupler Tool with (2) 3/4” NPT Ports
1 9121-G5-UCT-0-0-0-0 G5 Utility Coupler Tool with (2) G 1/2” BSPP Checked Ports, Tool Presence Targets
22 3490-0001036-01 3/4” NPT Socket Hex Plug, SS (G2 Model)
2 3490-0001057-01 G 1/2 BSPP Plug, Nickel Plated Brass (G5 Model)
3 2 3610-2015001-20 Spring
4 2 3700-20-6807 (Legacy) 3/4ʺ Valve Piston, Tool
5 2 3700-20-6808 (Legacy) 3/4ʺ Valve Stem, Tool
6 1 9123-GL2T-SEAL (Legacy) Seal Kit for Tool Assembly Check Valve (2 sets of seals)
7 2 3700-20-9610 3/4ʺ Valve Piston, Tool, Conical Seal
8 2 3700-20-9609 3/4ʺ Valve Stem, Tool, Conical Seal
9 1 9005-20-8554 3/4” Valve Seal Kit, Tool, Hex Stem
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-48
6.6 Models 9121-G2E-UCT
8
6
7
1
2
3
4
5
Figure 6.6—Tool plate Item No. Qty Part Number Description
1 1 9121-G2E-UCT-0-0-0-0 G2E Utility Coupler Tool with (2) 3/4” NPT Ports
2 4 3610-2015001-20 Spring
3 4 3700-20-6807 (Legacy) 3/4ʺ Valve Piston, Tool
4 4 3700-20-6808 (Legacy) 3/4ʺ Valve Stem, Tool
5 2 9123-GL2T-SEAL (Legacy) Seal Kit for Tool Assembly Check Valve (2 sets of seals)
6 4 3700-20-9610 3/4ʺ Valve Piston, Tool, Conical Seal
7 4 3700-20-9609 3/4ʺ Valve Stem, Tool, Conical Seal
8 2 9005-20-8554 3/4” Valve Seal Kit, Tool, Hex Stem, Blind Thread Housing
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-49
6.7 Models 9121-G2-GC-B80S100 Guided Cylinder
1
2
3
4
Figure 6.7—Guided Cylinder Item No. Qty Part Number Description
1
1 9121-G2-GC-B80S100-S0 Guided Cylinder Assembly, 80 mm Bore, 100 mm Stroke, Sensor Holder for 18 mm Barrel Proximity Sensor
1 9121-G2-GC-B80S100-SG G2 Guided Cylinder Assembly with 80 mm Bore, 100 mm Stroke, and PNP Prox Sensors
1 9121-G2-GC-B80S100-SR G2 Guided Cylinder Assembly, 80 mm Bore, 100 mm Stroke, PNP Turck Prox Sensors
2 1 3710-20-3460 Modified Guided Cylinder 80 mm Bore (Cylinder Only)
3 2 3405-2010004-01 3/8 NPT Flow Control
4 2 8590-9909999-45 Prox Sensor 12 mm Sensing Range, 18 mm Barrel 3-wire DC PNP; 2-wire DC PNP/NPN (SG Models)
4 2 8590-9909999-103 18 mm Barrel, PNP 3 wire DC Prox (SR Models)
5 2 9120-C-4EM-4EF-020 Prox Cable, 2 Meter Long, 4 pin Euro (Not Shown)
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-50
6.8 Models 9121-G2-GC-B150S150 Guided Cylinder1
2
3
Figure 6.8—Guided Cylinder Item No. Qty Part Number Description
1 1 9121-G2-GC-B150S150-SG Guided Cylinder Assembly, 150 mm Bore, 150 mm Stroke, PNP Proximity Sensor to Detect Retracted Position
2 1 3710-20-3384 Triple Rod Cylinder 6ʺ Bore (Cylinder Only)
3 1 8590-9909999-133 Prox Sensor for Guided Cylinder, PNP, NO, Strokemaster M12
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-51
7. SpecificationsTable 6.1—Master and Standard Tool Plates
Recommended Max Payload Not applicable Total end-effector weight should be supported independently of the Utility Coupler
Max. Recommended distance between Master and Tool plate TBD **Recommended distance between Master and Tool
plate is at least 4 mm less than cylinder stroke length.
Operating Pressure 60–100 psi(4.5–6.9 bar)
Locking mechanism supply pressure operating range. Supply should be clean, dry, and filtered to 50 micron or better.
Weight1
G2 Coupler Master TBD lbs, (TBD kg) Tool TBD lbs, (TBD kg) G2A Coupler Master TBD lbs, (TBD kg) Tool TBD lbs, (TBD kg) G2B Coupler Master TBD lbs, (TBD kg) Tool TBD lbs, (TBD kg) G2E Coupler Master TBD lbs, (TBD kg) Tool TBD lbs, (TBD kg) G5A Coupler Master TBD lbs, (TBD kg) Tool TBD lbs, (TBD kg)
*Note: Weights do not include add-on modules or Compliance assembly weight, refer to Compliance Assemblies in this section or specific module manual for weights of add‑on modules.
Pass through Port, (Qty) Size
G2 Coupler (2) 3/4ʺ NPT PortsG2A Coupler (2) 3/4ʺ NPT PortsG2B Coupler (10) 1/4ʺ NPT PortsG2E Coupler (4) 3/4ʺ NPT PortsG5A Coupler (2) G ½ʺ BSPP Ports
Mounting Patterns See Section 8—DrawingsNote:
1. Weights do not include add-on modules or Compliance assembly weight, refer to Compliance Assemblies in this section or specific module manual for weights of add‑on modules.
Table 6.2—G2 Drive Cylinders
Coupling Force @ 80 psi 620 lbs (2314 N) Axial holding force. 9121-G2-GC-B80
Coupling Force @ 80 psi 2190 lbs (9741 N) Axial holding force. 9121-G2-GC-B150
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-52
8. Drawings8.1 G2 Compliant Utility Coupler Drawings
3rd
AN
GLE
PRO
JEC
TION
45.6
Tool
52.6
Mas
ter
98.2
Cou
pled
13
45.
2
3/4"
NPT
Air P
ass
Thru
3/4"
NPT
Air P
ass
Thru
3/4"
NPT
Air P
ass
Thru
3/4"
NPT
Air P
ass
Thru
4X M
8 x
1.25
SHC
S
241
.3
6X
10.
7 TH
RU
ALL
17.
3 10
.4Fr
om O
ther
SId
eEq
ually
Spa
ced
For M
10 S
HC
S
2X
10m
mD
owel
Slip
Fit
12m
m
86.
6
43.
3
25
50
141
B.C
.10
0
Flat
A
Flat
B
Flat
D
Flat
C
Tool
Sid
e Vi
ew
4X M
8 x
1.25
SHC
S
6mm
Slip
Fit
6mm
55.
7
65
130
25 5
0 Fl
at A
Flat
D
Flat
C
Flat
B
Mas
ter S
ide
View
Part
Num
bers
:(A
) Mas
ter:
9121
-G2-
CU
CM
-0-0
-0-0
(B) T
ool:
9
121-
G2-
UC
T-0-
0-0-
0
Not
es:
1) C
ontin
uous
Cou
plin
g Fo
rce
mus
t
be
mai
ntai
ned
in o
rder
to k
eep
Mas
ter
a
nd T
ool e
ngag
ed.
Rev.
Des
crip
tion
Initi
ator
Dat
e
07EC
O 1
7831
: She
et 1
: Upd
ated
4X
M8
x 1.
25 S
HCS
leng
th to
13
was
23.
She
et 2
: Ad
ded
vie
w w
ith n
uts
expl
oded
. Upd
ated
exp
lod
ed p
ositi
on o
f scr
ews.
TBC
3/29
/201
9
B1:
51
3RE
VISI
ON
NO
TES:
UN
LESS
OTH
ERW
ISE
SPEC
IFIE
D.
DO
NO
T SC
ALE
DRA
WIN
G.
ALL
DIM
ENSI
ON
S A
RE IN
M
ILLIM
ETER
S.
DRA
WN
BY:
CHE
CKE
D B
Y:
D.B
rew
er, 2
/11/
11
DAN
, 2/1
0/11
TITLE SC
ALE
SIZE
DRA
WIN
G N
UMBE
R
PRO
JEC
T #
SHEE
T
O
F 96
30-2
0-G
2-
07
PRO
PERT
Y O
F A
TI IN
DUS
TRIA
L A
UTO
MA
TION
, IN
C. N
OT
TO B
E RE
PRO
DUC
ED IN
AN
Y M
AN
NER
EXC
EPT
ON
ORD
ER O
R W
ITH P
RIO
R W
RITT
EN A
UTHO
RIZA
TION
OF
ATI.
1031
Goo
dwor
th Dr
ive, A
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
G2
Com
plia
nt U
tility
Cou
pler
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-53
3rd
AN
GLE
PRO
JEC
TION
17
14
18
19
10
11
1
3
6
16
1312
5
9
8
1522
2
Mag
nalu
be
Mag
nalu
be
21 4
420
Mag
nalu
be
7
G2
Com
plia
nt U
tility
Cou
pler
Mas
ter A
ssem
bly
ITEM
NO
.Q
TYPA
RT
NU
MBE
RD
ESC
RIP
TIO
N1
234
10-0
0010
15-0
1O
-Rin
g M
aste
r AS5
68-0
262
234
10-0
0012
49-0
1O
-RIN
G, D
ash
#119
Nitr
ile 9
0 D
urom
eter
32
3490
-000
1036
-01
3/4"
NPT
Hex
Soc
ket P
lug,
SS
42
3500
-106
6016
-15A
M6-
1 x
16m
m S
HC
S, B
lue,
Pre
-App
lied
54
3500
-106
8025
-15A
M8-
1.25
x 2
5mm
SH
CS,
Blu
e, P
re-A
pplie
d6
335
00-2
0700
35-1
1SH
CS
Shou
lder
M12
x 3
5 Sh
ould
er M
10 T
hrea
d7
335
05-0
8700
01-1
2H
ex N
ut M
10x1
.5, 8
mm
Tal
l 17m
m W
ide
Zinc
Pla
ted
Stee
l8
336
10-1
7250
01-1
0St
eel C
ompr
essi
on S
prin
g 2-
1/2"
L, 5
/8" O
D,.0
80" W
ire9
336
10-1
9250
01-2
0St
eel S
prin
g .8
45" O
D, 2
.5" L
ong
43.4
Rat
e10
236
10-2
0151
00-2
0Sp
ring,
1.1
inch
dia
, 2.5
" lon
g, 1
0.8#
/in S
S11
236
90-8
5000
01-1
1R
etai
ning
Rin
g, In
tern
al In
verte
d Tr
uarc
# 5
008-
187
123
3700
-20-
4675
Cus
tom
Cha
mfe
red
Was
her
133
3700
-20-
4676
Cus
tom
SAE
841
Bro
nze
Thru
st B
earin
g14
137
00-2
0-47
13G
2 C
ompl
iant
Inte
rface
Pla
te B
ody
153
3700
-20-
4716
Com
plia
nt IP
Pre
load
Pus
her
161
3700
-20-
4718
1/2"
Dia
. Alig
nmen
t Pin
4m
m T
aper
171
3700
-20-
4732
1/2"
Dia
. Alig
nmen
t Pin
4m
m T
aper
182
3700
-20-
4924
3/4"
Val
ve M
aste
r Ste
m19
237
00-2
0-61
613/
4" V
alve
Pis
ton
201
3700
-20-
1032
2C
ente
r Com
plia
nce
Pivo
t Pin
211
3700
-20-
1041
4R
est B
utto
n, 1
0mm
Dia
. Ste
m, .
79 D
ia. B
utto
n, S
7 St
eel
221
3700
-20-
1041
5G
Ser
ies
Com
plia
nt In
terfa
ce P
late
, Bas
e M
ount
B1:
22
3RE
VISIO
N
NO
TES:
UN
LESS
OTH
ERW
ISE
SPEC
IFIED
.
DO
NO
T SC
ALE
DRA
WIN
G.
ALL
DIM
ENSI
ON
S A
RE IN
M
ILLIM
ETER
S.
DRA
WN
BY:
CHE
CKE
D B
Y:
D.Br
ewer
, 2/1
1/11
DAN,
2/1
0/11
TITLE SC
ALE
SIZE
DRA
WIN
G N
UMBE
R
PRO
JEC
T #SH
EET
O
F 96
30-2
0-G
2-
07
PRO
PERT
Y O
F A
TI IN
DUS
TRIA
L A
UTO
MA
TION
, IN
C. N
OT T
O B
E RE
PRO
DUC
ED IN
AN
Y M
AN
NER
EXC
EPT O
N O
RDER
OR
WITH
PRI
OR
WRI
TTEN
AUT
HORI
ZATIO
N O
F A
TI.
1031
Goo
dwor
th Dr
ive, A
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
G2
Com
plia
nt U
tility
Cou
pler
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-54
3rd
AN
GLE
PRO
JEC
TION
Mag
nalu
be Mag
nalu
beN
ote
2.
Mag
nalu
be B
ores
6
4
59
1
2
3
8
4
7
7
Not
e 2.
Mag
nalu
beN
ote
2. Mag
nalu
be
Not
es: Se
e M
anua
l for
repl
acem
ent p
arts
, inc
ludi
ng o
lder
val
ve
2.de
sign
s w
hich
requ
ire a
spa
nner
wre
nch
for S
tem
in
stal
latio
n. N
ew S
tem
s in
stal
l with
a h
ex w
renc
h.
G2
Com
plia
nt U
tility
Cou
pler
Too
l Ass
embl
y
ITEM
NO
.Q
TYPA
RT
NU
MBE
RD
ESC
RIP
TIO
N1
234
10-0
0010
99-0
1Q
uad-
Rin
g 1-
5/16
"ID2
234
10-0
0013
41-0
1O
-Rin
g,1-
3/16
IDx3
/32,
AS5
68-1
23 B
una-
N, D
903
234
10-0
0014
50-0
1O
-Rin
g, A
S568
-116
, Bun
a-N
, A90
42
3490
-000
1036
-01
3/4"
NPT
Hex
Soc
ket P
lug,
SS
52
3610
-201
5001
-20
Sprin
g6
137
00-2
0-47
17G
2 U
tility
Cou
pler
Too
l Bod
y7
237
00-2
0-52
74D
rill B
ushi
ng 1
/2" d
ia, 7
/8 O
D, 1
" lon
g8
237
00-2
0-96
093/
4" V
alve
Ste
m, T
ool,
Con
ical
Sea
l9
237
00-2
0-96
103/
4" V
alve
Pis
ton,
Too
l, C
onic
al S
eal
B1:
23
3RE
VISI
ON
NO
TES:
UN
LESS
OTH
ERW
ISE
SPEC
IFIE
D.
DO
NO
T SC
ALE
DRA
WIN
G.
ALL
DIM
ENSI
ON
S A
RE IN
M
ILLIM
ETER
S.
DRA
WN
BY:
CHE
CKE
D B
Y:
D.B
rew
er, 2
/11/
11
DAN
, 2/1
0/11
TITLE SC
ALE
SIZE
DRA
WIN
G N
UMBE
R
PRO
JEC
T #
SHEE
T
O
F 96
30-2
0-G
2-
07
PRO
PERT
Y O
F A
TI IN
DUS
TRIA
L A
UTO
MA
TION
, IN
C. N
OT
TO B
E RE
PRO
DUC
ED IN
AN
Y M
AN
NER
EXC
EPT
ON
ORD
ER O
R W
ITH P
RIO
R W
RITT
EN A
UTHO
RIZA
TION
OF
ATI.
1031
Goo
dwor
th Dr
ive, A
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
G2
Com
plia
nt U
tility
Cou
pler
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-55
8.2 G2 Application Utility Coupler General Dimensions (Shown with Optional DA2 DeviceNet Module)
3rd
AN
GLE
PRO
JEC
TION
96.
2 27
1.5
Not
e 5
63.9
Not
e 4
3/8"
NPT
R
OSS
Bra
ndFl
ow C
ontro
l
9121
-G2-
UC
T-D
A2-0
-0-0
Util
ity C
oupl
er T
ool
With
(2) I
nteg
rate
d 3/
4" N
PT C
heck
edPo
rts
9121
-G2-
CU
CM
-DA2
-0-0
-0 C
ompl
iant
Util
ity C
oupl
er M
aste
rW
ith (2
) Int
egra
ted
3/4"
NPT
Che
cked
Por
ts
Mas
ter S
ide
is C
ompl
iant
to +
/- 4m
m
Plus
3 A
ngul
ar C
ompl
ianc
e
9121
-G2-
GC
-B80
S100
-SG
Line
ar A
ctua
tor U
nit
See
Not
es S
ectio
n
PNP
18m
m P
rox
Not
e 6
45.
6
75R
ecom
men
ded
Dis
tanc
e to
Clo
se
43.
2
52.
6
292
.1
177
.8
196.
5N
ote
567
.7N
ote
4
3/4"
NPT
3/4"
NPT
3/4"
NPT
3/4"
NPT
188.
2
314
.9
19.1
Plat
eTh
ickn
ess
DA2
Mas
ter
Dev
icen
et
Mod
ule
See
9630
-20-
DA2
241
2X10
mm
D
owel
Sl
ip F
it12
mm
141
50 25 4
3.3
86.
6
B.C
.10
0
6X
10.
7 Th
ru 1
7.3
10.4
Fro
m O
ther
Sid
eEq
ually
Spa
ced
For M
10 S
HC
S
DA2
Too
l D
evic
enet
Mod
ule
See
9630
-20-
DA2
ZX
Y
230
4X
10.
7 Th
ru 1
7.3
10.4
From
Oth
er S
ide
For M
20 S
HC
S
140
70
2X
10m
m D
owel
Slip
Fit,
Thr
u Pl
ate
12.
7 8
8.9
TOP
VIEW
RET
RAC
TED
TOO
L SI
DE
VIEW
MAS
TER
SID
E VI
EW
ISO
VIE
W
NO
TES: Line
ar A
ctua
tor U
nit i
s D
riven
by
SMC
Gui
ded
Cyl
inde
r Ser
ies
MG
PM1.
For P
rope
r Ope
ratio
n, C
ylin
der P
ress
ure
MU
ST B
E M
AIN
TAIN
ED in
2.
o
rder
to re
sist
the
sprin
g fo
rces
in th
e in
tegr
ated
3/4
" che
cked
Por
ts.
3.
Util
ity c
oupl
er c
oupl
ing
forc
e is
app
roxi
mat
ely
625l
bs a
t 80
psi.
C
are
is n
eede
d in
des
igni
ng m
atin
g cu
stom
er fi
xtur
e.4.
M
aste
r sid
e co
uple
r bod
y co
mpr
esse
s 2m
m -
4mm
whe
n co
uple
d.5.
M
ax C
ylin
der s
troke
is 1
00m
m.
Rec
omm
ende
d M
aste
r to
Tool
spa
cing
is 7
5mm
.6.
P
ositi
on o
f cyl
inde
r pro
xes
are
adju
stab
le o
nce
inst
alle
d.
TOP
VIEW
EXT
END
ED
CYL
IND
ER M
OU
NTI
NG
PL
ATE
VIEW
Rev.
Des
crip
tion
Initi
ator
Dat
e
09EC
O 1
7187
: Upd
ate
dra
win
g fo
r cha
nges
to
9121
-G2-
CUC
M-0
-0-0
-0 a
ssem
bly.
TBC
1/18
/201
9
B1:
41
1RE
VISI
ON
NO
TES:
UN
LESS
OTH
ERW
ISE
SPEC
IFIE
D.
DO
NO
T SC
ALE
DRA
WIN
G.
ALL
DIM
ENSI
ON
S A
RE IN
M
ILLIM
ETER
S.
DRA
WN
BY:
CHE
CKE
D B
Y:
Dan
Nor
ton
1/9/
05
D. S
wan
son,
6/1
6/05
TITLE SC
ALE
SIZE
DRA
WIN
G N
UMBE
R
PRO
JEC
T #
SHEE
T
O
F 92
30-2
0-23
3505
0920
-109
PRO
PERT
Y O
F A
TI IN
DUS
TRIA
L A
UTO
MA
TION
, IN
C. N
OT
TO B
E RE
PRO
DUC
ED IN
AN
Y M
AN
NER
EXC
EPT
ON
ORD
ER O
R W
ITH P
RIO
R W
RITT
EN A
UTHO
RIZA
TION
OF
ATI.
1031
Goo
dwor
th Dr
ive, A
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
Ope
nrob
ogat
e C
ompl
iant
Util
ity C
oupl
er
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-56
8.3 G2A Compliant Utility Coupler Drawings
3rd
AN
GLE
PRO
JEC
TION
98.3
Cou
pled
45.6
Tool
3/4
NPT
Air P
ass
Thru
3/4
NPT
Air P
ass
Thru
52.6
Mas
ter
3/4
NPT
Air P
ass
Thru
3/4
NPT
Air P
ass
Thru
15.
1
13
18.9
Pin
4X M
8 x
1.25
SHC
S
50 2
5
141
241
.3
86.
6
43.
3
B.C
. 10
0
2X10
mm
Dow
elSl
ip F
it12
mm
6X
10.
7 Th
ru 1
7.3
10.
4Fr
om O
ther
Sid
eEq
ually
Spa
ced
For M
10 S
HC
S
Flat
B
Flat
D
Flat
C
Flat
A
Tool
Sid
e Vi
ew
50
25
65
55.
7
130
2X
6 Sl
ip F
it6
Flat
A4X
M8
x 1.
25SH
CS
Flat
B
Flat
C
Mas
ter S
ide
View
Flat
D
Part
Num
bers
:(A
) Mas
ter:
9121
-G2A
-CU
CM
-0-0
-0-0
(B) T
ool:
9
121-
G2-
UC
T-0-
0-0-
0
Not
es: Con
tinuo
us C
oupl
ing
Forc
e m
ust
1.be
mai
ntai
ned
in o
rder
to k
eep
Mas
ter a
nd T
ool e
ngag
ed.
Rev.
Des
crip
tion
Initi
ator
Dat
e
08EC
O 1
7831
: Upd
ated
4X
M8
x 1.
25 S
HCS
leng
th to
13
was
23.
TBC
3/29
/201
9
B1:
21
3RE
VISI
ON
NO
TES:
UN
LESS
OTH
ERW
ISE
SPEC
IFIE
D.
DO
NO
T SC
ALE
DRA
WIN
G.
ALL
DIM
ENSI
ON
S A
RE IN
M
ILLIM
ETER
S.
DRA
WN
BY:
CHE
CKE
D B
Y:
D B
rew
er, 2
/7/1
1
DAN
, 2/1
0/11
TITLE SC
ALE
SIZE
DRA
WIN
G N
UMBE
R
PRO
JEC
T #
SHEE
T
O
F 96
30-2
0-G
2A-
08
PRO
PERT
Y O
F A
TI IN
DUS
TRIA
L A
UTO
MA
TION
, IN
C. N
OT
TO B
E RE
PRO
DUC
ED IN
AN
Y M
AN
NER
EXC
EPT
ON
ORD
ER O
R W
ITH P
RIO
R W
RITT
EN A
UTHO
RIZA
TION
OF
ATI.
1031
Goo
dwor
th Dr
ive, A
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
G2A
Com
plia
nt U
tility
Cou
pler
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-57
3rd
AN
GLE
PRO
JEC
TION
159 4
4 17
16
14
3
2120
6
12
13
8
5
22
1
219
1118
10
G2A
Com
plia
nt U
tility
Cou
pler
Mas
ter A
ssem
bly
Mag
nalu
be
Mag
nalu
be
7
B1:
52
3RE
VISI
ON
NO
TES:
UN
LESS
OTH
ERW
ISE
SPEC
IFIE
D.
DO
NO
T SC
ALE
DRA
WIN
G.
ALL
DIM
ENSI
ON
S A
RE IN
M
ILLIM
ETER
S.
DRA
WN
BY:
CHE
CKE
D B
Y:
D B
rew
er, 2
/7/1
1
DAN
, 2/1
0/11
TITLE SC
ALE
SIZE
DRA
WIN
G N
UMBE
R
PRO
JEC
T #
SHEE
T
O
F 96
30-2
0-G
2A-
08
PRO
PERT
Y O
F A
TI IN
DUS
TRIA
L A
UTO
MA
TION
, IN
C. N
OT
TO B
E RE
PRO
DUC
ED IN
AN
Y M
AN
NER
EXC
EPT
ON
ORD
ER O
R W
ITH P
RIO
R W
RITT
EN A
UTHO
RIZA
TION
OF
ATI.
1031
Goo
dwor
th Dr
ive, A
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
G2A
Com
plia
nt U
tility
Cou
pler
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-58
3rd
AN
GLE
PRO
JEC
TION
Mag
nalu
be B
ores
Mag
nalu
beN
ote
2.
Not
e 2.
Mag
nalu
beN
ote
2.
Mag
nalu
be
Mag
nalu
be
9
1
2
3
8
6
74 5
74
Not
es: Se
e M
anua
l for
repl
acem
ent p
arts
, inc
ludi
ng o
lder
2.
valv
e de
sign
s w
hich
requ
ire a
spa
nner
wre
nch
for
Stem
inst
alla
tion.
New
Ste
ms
inst
all w
ith a
hex
wre
nch.
ITEM
NO
.Q
TYPA
RT
NU
MBE
RD
ESC
RIP
TIO
N1
234
10-0
0010
99-0
1Q
uad-
Rin
g 1-
5/16
"ID2
234
10-0
0013
41-0
1O
-Rin
g,1-
3/16
IDx3
/32,
AS5
68-1
23 B
una-
N, D
903
234
10-0
0014
50-0
1O
-Rin
g, A
S568
-116
, Bun
a-N
, A90
42
3490
-000
1036
-01
3/4"
NPT
Hex
Soc
ket P
lug,
SS
52
3610
-201
5001
-20
Sprin
g6
137
00-2
0-47
17G
2 U
tility
Cou
pler
Too
l Bod
y7
237
00-2
0-52
74D
rill B
ushi
ng 1
/2" d
ia, 7
/8 O
D, 1
" lon
g8
237
00-2
0-96
093/
4" V
alve
Ste
m, T
ool,
Con
ical
Sea
l9
237
00-2
0-96
103/
4" V
alve
Pis
ton,
Too
l, C
onic
al S
eal
B1:
23
3RE
VISI
ON
NO
TES:
UN
LESS
OTH
ERW
ISE
SPEC
IFIE
D.
DO
NO
T SC
ALE
DRA
WIN
G.
ALL
DIM
ENSI
ON
S A
RE IN
M
ILLIM
ETER
S.
DRA
WN
BY:
CHE
CKE
D B
Y:
D B
rew
er, 2
/7/1
1
DAN
, 2/1
0/11
TITLE SC
ALE
SIZE
DRA
WIN
G N
UMBE
R
PRO
JEC
T #
SHEE
T
O
F 96
30-2
0-G
2A-
08
PRO
PERT
Y O
F A
TI IN
DUS
TRIA
L A
UTO
MA
TION
, IN
C. N
OT
TO B
E RE
PRO
DUC
ED IN
AN
Y M
AN
NER
EXC
EPT
ON
ORD
ER O
R W
ITH P
RIO
R W
RITT
EN A
UTHO
RIZA
TION
OF
ATI.
1031
Goo
dwor
th Dr
ive, A
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
G2A
Com
plia
nt U
tility
Cou
pler
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-59
8.4 G2A Application Utility Coupler General Dimensions (Shown with Optional DA2 DeviceNet Module)
3rd
AN
GLE
PRO
JEC
TION
20M
IN D
ista
nce
toC
lose
45.
6 5
2.6
A
3/4"
NPT
3/4"
NPT
3/4"
NPT
3/4"
NPT
50
25
2X 1
0mm
Dow
elSl
ip F
it12
mm
6X 1
0.7
THR
U A
LL 1
7.3
1
0.4
From
Oth
er S
ide
Equa
lly S
pace
dFo
r M10
SH
CS
86.
6
43.
3 B.C
.10
0
DA2
Too
lD
evic
enet
Mod
ule
See
9630
-20-
DA2
TOO
L SI
DE
VIEW
315
.5 241
.4 1
41
2X
6.06
06.
035m
m S
lip F
it6.
4
130
50
55.
7
4X 8
.7 T
hru
From
Oth
er S
ide
For M
8 SH
CS
Mas
ter S
ide
Mou
ntin
g Pa
ttern
187
.9
4"Y
" Dire
ctio
n C
ompl
ianc
e
4"X
" Dire
ctio
nC
ompl
ianc
eDA2
Mas
ter
Dev
icen
et M
odul
eSe
e 96
30-2
0-D
A2
3°An
gula
rC
ompl
ianc
e
2mm
-4m
m"Z
" Dire
ctio
n C
ompl
ianc
e
9121
-G2-
UC
T-D
2-0-
0-0
Util
ity C
oupl
er T
ool
With
(2) I
nteg
rate
d3/
4 N
PT C
heck
edPo
rts91
21-G
2A-C
UC
M-D
A2-0
-0-0
Com
plia
nt U
tility
Cou
pler
Mas
ter
With
(2) I
nteg
rate
d3/
4" N
PT C
heck
ed P
orts
Mas
ter S
ide
is C
ompl
iant
to +
/- 4m
mPl
us 3
" Ang
ular
Com
plia
nce
18.9
Pin
Leng
th
DET
AIL
A SC
ALE
1 : 2
YZ
XIS
O V
IEW
NO
TES: Util
ity C
oupl
er re
quire
d co
uplin
g fo
rce
is a
ppro
xim
atel
y 62
5lbs
1.
at 8
0psi
air
line
pres
sure
. C
are
is n
eede
d in
acc
omod
atin
g th
is
forc
e in
mat
ing
cust
omer
fixt
ure.
Cur
rent
Des
ign
does
not
hav
e in
tegr
ated
sen
sing
. 2.
Mas
ter S
ide
Com
plia
nce
is a
ccom
plis
hed
via
use
of P
relo
aded
3.
D
ie S
prin
gs, a
nd C
usto
m T
hrus
t Bea
rings
.4.
M
aste
r and
Too
l Bod
ies
have
(2) I
nteg
rate
d C
heck
ed 3
/4" N
PT
P
orts
to P
ass
Air U
tiliti
es, P
LUS
(4) A
dditi
onal
U
tility
Mod
ule
Mou
ntin
g Fl
ats.
5.
UN
IT M
UST
BO
TTO
M O
UT
IN "Z
" DIR
ECTI
ON
IN
OR
DER
TO
CO
UPL
E
MAS
TER
AN
D T
OO
L U
NC
OU
PLED
MAS
TER
AN
D T
OO
L C
OU
PLED
MAS
TER
SID
E VI
EW
Rev.
Des
crip
tion
Initi
ator
Dat
e
07EC
O 1
7187
: Upd
ate
dra
win
g fo
r cha
nges
to
9121
-G2A
-CUC
M-0
-0-0
-0 a
ssem
bly.
187
.9
was
187
.8.
TBC
1/18
/201
9
B1:
41
1RE
VISI
ON
NO
TES:
UN
LESS
OTH
ERW
ISE
SPEC
IFIE
D.
DO
NO
T SC
ALE
DRA
WIN
G.
ALL
DIM
ENSI
ON
S A
RE IN
M
ILLIM
ETER
S.
DRA
WN
BY:
CHE
CKE
D B
Y:
Dan
Nor
ton
3/31
/06
D. S
wan
son,
3/3
1/06
TITLE SC
ALE
SIZE
DRA
WIN
G N
UMBE
R
PRO
JEC
T #
SHEE
T
O
F 92
30-2
0-23
89---
------
---07
PRO
PERT
Y O
F A
TI IN
DUS
TRIA
L A
UTO
MA
TION
, IN
C. N
OT
TO B
E RE
PRO
DUC
ED IN
AN
Y M
AN
NER
EXC
EPT
ON
ORD
ER O
R W
ITH P
RIO
R W
RITT
EN A
UTHO
RIZA
TION
OF
ATI.
1031
Goo
dwor
th Dr
ive, A
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
Com
plia
nt U
tility
Cou
pler
(Lift
er A
pplic
atio
n)
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-60
8.5 G2B Compliant Utility Coupler Drawings
3rd
AN
GLE
PRO
JEC
TION
Scal
e 1:
3
41.6
Tool
94.2
Cou
pled
52.6
Mas
ter
14 1
5.1
45.2
Pin
4X M
8 x
1.25
SHC
S
141
5
0 25
86.
6
43.
3
228
.6 2X
10D
owel
Slip
Fit
8.7
6X
10.
7 Th
ru 1
7.3
10.
4Fr
om O
ther
Sid
eEq
ually
Spa
ced
For M
10 S
HC
S
B.C
.10
0
Flat
A
Flat
B
Tool
Sid
e Vi
ew
50
25
65
130
49.
3
2X6.
060
6.03
5mm
Slip
Fit
6mm
Mas
ter S
ide
View
Flat
B
Flat
A
4X M
8 x
1.25
SHC
S
Part
Num
bers
:(A
) Mas
ter:
9121
-G2B
-CU
CM
-0-0
(B) T
ool:
9
121-
G2B
-UC
T-0-
0
Not
es:
1) C
ontin
uous
Cou
plin
g Fo
rce
mus
t
be
mai
ntai
ned
in o
rder
to k
eep
Mas
ter
a
nd T
ool e
ngag
ed.
Rev.
Des
crip
tion
Initi
ator
Dat
e06
ECO
178
31: U
pdat
ed 4
X M
8 x
1.25
SHC
S le
ngth
to 1
4 w
as 2
4.TB
C3/
29/2
019
B1:
21
3RE
VISI
ON
NO
TES:
UN
LESS
OTH
ERW
ISE
SPEC
IFIE
D.
DO
NO
T SC
ALE
DRA
WIN
G.
ALL
DIM
ENSI
ON
S A
RE IN
M
ILLIM
ETER
S.
DRA
WN
BY:
CHE
CKE
D B
Y:
D. B
rew
er, 2
/14/
11
D. N
orto
n, 2
/14/
11
TITLE SC
ALE
SIZE
DRA
WIN
G N
UMBE
R
PRO
JEC
T #
SHEE
T
O
F 96
30-2
0-G
2B-
06
PRO
PERT
Y O
F A
TI IN
DUS
TRIA
L A
UTO
MA
TION
, IN
C. N
OT
TO B
E RE
PRO
DUC
ED IN
AN
Y M
AN
NER
EXC
EPT
ON
ORD
ER O
R W
ITH P
RIO
R W
RITT
EN A
UTHO
RIZA
TION
OF
ATI.
G2B
Com
plia
nt U
tility
Cou
pler
1031
Goo
dwor
th Dr
ive, A
pex,
NC 27
539,
USA
Tel: +
1.919
.772.0
115
w
ww.at
i-ia.co
mFa
x: +1
.919.7
72.82
59
ISO
9001
Reg
ister
ed C
ompa
ny
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-61
3rd
AN
GLE
PRO
JEC
TION
3
121
11
10
2
18
5
16
20
9
13
14
44
21
7815
19
6
17
Mag
nalu
be
Mag
nalu
be
Mag
nalu
be
G2B
Com
plia
nt U
tility
Cou
pler
Mas
ter A
ssem
bly
ITEM
NO
.Q
TYPA
RT
NU
MBE
RD
ESC
RIP
TIO
N1
1034
10-0
0010
65-0
1O
-Rin
g 14
MM
X 2
MM
Bun
a2
1034
10-0
0010
68-0
1M
ini U
-Cup
Sea
l 18m
m ID
x 2
2mm
Bun
a3
1034
10-0
0011
83-0
1O
-Rin
g 6M
M X
2M
M B
una
D90
42
3500
-106
6016
-15A
M6-
1 x
16m
m S
HC
S, B
lue,
Pre
-App
lied
54
3500
-106
8025
-15A
M8-
1.25
x 2
5mm
SH
CS,
Blu
e, P
re-A
pplie
d6
335
00-2
0700
35-1
1SH
CS
Shou
lder
M12
x 3
5 Sh
ould
er M
10 T
hrea
d7
336
10-1
7250
01-1
0St
eel C
ompr
essi
on S
prin
g 2-
1/2"
L, 5
/8" O
D,.0
80" W
ire8
336
10-1
9250
01-2
0St
eel S
prin
g .8
45" O
D, 2
.5" L
ong
43.4
Rat
e
91
3690
-660
0900
-10
Rol
ling
Ball
Tip
Set S
crew
, M16
-2.0
x 2
3.3m
m lo
ng, B
lack
Oxi
de
Stee
l10
1037
00-2
0-14
59SW
-150
A M
aste
r Flu
id /
Air S
prin
g SS
1110
3700
-20-
2994
Mas
ter C
heck
Val
ve P
isto
n, F
A44
1210
3700
-20-
2996
VALV
E ST
EM, H
IGH
STR
ENG
TH13
337
00-2
0-46
75C
usto
m C
ham
fere
d W
ashe
r14
337
00-2
0-46
76C
usto
m S
AE 8
41 B
ronz
e Th
rust
Bea
ring
153
3700
-20-
4716
Com
plia
nt IP
Pre
load
Pus
her
161
3700
-20-
4718
1/2"
Dia
. Alig
nmen
t Pin
4m
m T
aper
171
3700
-20-
4732
1/2"
Dia
. Alig
nmen
t Pin
4m
m T
aper
181
3700
-20-
5162
G2B
Com
plia
nt M
aste
r Bod
y, (1
0) In
tegr
ated
Por
ts19
137
00-2
0-76
89G
Ser
ies
Com
plia
nt In
terfa
ce P
late
, Bas
e M
ount
201
3700
-20-
8254
M16
-2.0
x 9
mm
Set
Scr
ew, H
ollo
w H
ex21
137
00-2
0-94
67R
est B
utto
n, H
arde
ned
S7
Stee
l
B1:
102
3RE
VISI
ON
NO
TES:
UN
LESS
OTH
ERW
ISE
SPEC
IFIE
D.
DO
NO
T SC
ALE
DRA
WIN
G.
ALL
DIM
ENSI
ON
S A
RE IN
M
ILLIM
ETER
S.
DRA
WN
BY:
CHE
CKE
D B
Y:
D. B
rew
er, 2
/14/
11
D. N
orto
n, 2
/14/
11
TITLE SC
ALE
SIZE
DRA
WIN
G N
UMBE
R
PRO
JEC
T #
SHEE
T
O
F 96
30-2
0-G
2B-
06
PRO
PERT
Y O
F A
TI IN
DUS
TRIA
L A
UTO
MA
TION
, IN
C. N
OT
TO B
E RE
PRO
DUC
ED IN
AN
Y M
AN
NER
EXC
EPT
ON
ORD
ER O
R W
ITH P
RIO
R W
RITT
EN A
UTHO
RIZA
TION
OF
ATI.
G2B
Com
plia
nt U
tility
Cou
pler
1031
Goo
dwor
th Dr
ive, A
pex,
NC 27
539,
USA
Tel: +
1.919
.772.0
115
w
ww.at
i-ia.co
mFa
x: +1
.919.7
72.82
59
ISO
9001
Reg
ister
ed C
ompa
ny
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-62
3rd
AN
GLE
PRO
JEC
TION
1
26
7
8
8
4
35
Mag
nalu
be
Mag
nalu
beG
2B C
ompl
iant
Util
ity C
oupl
er T
ool A
ssem
bly
ITEM
NO
.Q
TY.
PAR
T N
UM
BER
DES
CR
IPTI
ON
110
3410
-000
1067
-01
O-ri
ng, 1
0mm
x 2
mm
, Bun
a N
, Dur
. 90
210
3410
-000
1284
-01
O-ri
ng, .
669O
D x
.047
wal
l, 70
D,
Buna
-N3
1035
40-0
1017
50-2
11/
16 D
ia X
.75
Dow
el P
in4
1037
00-2
0-14
57SW
-150
A To
ol C
heck
Val
ve P
isto
n5
1037
00-2
0-14
60SP
RIN
G, F
/A T
OO
L6
1037
00-2
0-32
88Pl
ug, F
/A T
ool
71
3700
-20-
5163
G2B
Util
ity C
oupl
er T
ool B
ody
82
3700
-20-
5274
Dril
l Bus
hing
1/2
" dia
, 7/8
OD
, 1" l
ong
B1:
53
3RE
VISI
ON
NO
TES:
UN
LESS
OTH
ERW
ISE
SPEC
IFIE
D.
DO
NO
T SC
ALE
DRA
WIN
G.
ALL
DIM
ENSI
ON
S A
RE IN
M
ILLIM
ETER
S.
DRA
WN
BY:
CHE
CKE
D B
Y:
D. B
rew
er, 2
/14/
11
D. N
orto
n, 2
/14/
11
TITLE SC
ALE
SIZE
DRA
WIN
G N
UMBE
R
PRO
JEC
T #
SHEE
T
O
F 96
30-2
0-G
2B-
06
PRO
PERT
Y O
F A
TI IN
DUS
TRIA
L A
UTO
MA
TION
, IN
C. N
OT
TO B
E RE
PRO
DUC
ED IN
AN
Y M
AN
NER
EXC
EPT
ON
ORD
ER O
R W
ITH P
RIO
R W
RITT
EN A
UTHO
RIZA
TION
OF
ATI.
G2B
Com
plia
nt U
tility
Cou
pler
1031
Goo
dwor
th Dr
ive, A
pex,
NC 27
539,
USA
Tel: +
1.919
.772.0
115
w
ww.at
i-ia.co
mFa
x: +1
.919.7
72.82
59
ISO
9001
Reg
ister
ed C
ompa
ny
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-63
8.6 G2B Application Utility Coupler with 10 Port Option (Shown with Optional DA2 DeviceNet Module)
3rd
AN
GLE
PRO
JEC
TION
94.
3
93.
2 67
.7N
ote
4
271.
5N
ote
5
3/8"
NP
T R
OS
S B
rand
Flow
Con
trol
9121
-G2B
-UC
T-D
A2-
0 U
tility
Cou
pler
Too
lW
ith D
A2,
and
(10)
1/4
" NP
T In
tegr
ated
Che
cked
Air
Por
ts
9121
-G2B
-CU
CM
-DA
2-0
G2B
Com
plia
nt U
tility
Cou
pler
Mas
ter
DA
2, (1
0) In
tegr
ated
Che
cked
1/4
" NP
T A
ir P
orts
,M
aste
r Sid
e is
Com
plia
nt to
+/-
4mm
P
lus
3 A
ngul
ar C
ompl
ianc
e
9121
-G2-
GC
-B80
S10
0-S
GLi
near
Act
uato
r Uni
tS
ee N
otes
Sec
tion
PN
P
18m
m P
rox
Not
e 6
45.6
75m
mR
ecom
men
ded
Dis
tanc
e to
Clo
se
52.
6
43.
1
292
.1 4X
1
0.7
Thru
17.
3 10
.4Fo
r M10
SH
CS
177
.8
196.
5N
ote
5
67.7
Not
e 4
86.
6 2
28.6
50
25
(2)
10m
m
Slip
Fit
12
(6)
10.
7 TH
RU
ALL
17.
3 10
.4
From
Oth
er S
ide
Equ
ally
Spa
ced
For M
10 S
HC
S
43.
3
141
2
15.1
DA
2 To
ol
Dev
icen
et M
odul
eS
ee 9
630-
20-D
A2
Z
X
Y
DA
2 M
aste
r D
evic
enet
Mod
ule
See
963
0-20
-DA
2
(5) 1
/4" N
PT
Con
nect
ions
(5) 1
/4" N
PT
Con
nect
ions
(5) 1
/4" N
PT
Con
nect
ions
(5) 1
/4" N
PT
Con
nect
ions
19.
1 230
70
140
4X
1
0.7
Thru
17.
3 10
.4Fr
om O
ther
Sid
eFo
r M10
SH
CS
88.
9 1
2.7
2X
10m
m D
owel
Slip
Fit
Thru
Pla
te
TOP
VIE
W R
ETR
AC
TED
TOP
VIE
W E
XTE
ND
ED
TOO
L S
IDE
VIE
W
ISO
VIE
W
NO
TES
:D
rive
Cyl
inde
r Ass
embl
y fe
atur
es S
MC
Gui
ded
Cyl
inde
r Ser
ies
MG
PM
1.Fo
r Pro
per O
pera
tion,
Cyl
inde
r Pre
ssur
e M
US
T B
E M
AIN
TAIN
ED
in
2.
ord
er to
resi
st th
e sp
ring
forc
es in
the
inte
grat
ed c
heck
ed P
orts
. 3.
U
tility
Cou
pler
cou
plin
g fo
rce
is a
ppro
xim
atel
y 62
5lbs
at 8
0 ps
i. C
are
is n
eede
d in
acco
mod
atin
g th
is fo
rce
in th
e m
atin
g cu
stom
er fi
xtur
e.
4.
Mas
ter s
ide
coup
ler b
ody
com
pres
ses
2mm
- 4m
m w
hen
coup
led.
5.
Max
cyl
inde
r stro
ke is
100
mm
. R
ecom
men
ded
Mas
ter t
o To
ol s
paci
ng is
75m
m.
6.
Pos
ition
of c
ylin
der p
roxe
s ar
e ad
just
able
onc
e in
stal
led.
Rev.
Des
crip
tion
Initi
ator
Dat
e
05EC
O 1
4986
; Upd
ated
due
to n
ew B
OM
stru
ctur
eSZ
J11
/7/2
016
B1:
41
1RE
VISI
ON
NO
TES:
UN
LESS
OTH
ERW
ISE
SPEC
IFIE
D.
DO
NO
T SC
ALE
DRA
WIN
G.
ALL
DIM
ENSI
ON
S A
RE IN
M
ILLIM
ETER
S.
DRA
WN
BY:
CHE
CKE
D B
Y:
Dan
Nor
ton
3/20
/07
D. S
wan
son,
3/2
0/07
TITLE SC
ALE
SIZE
DRA
WIN
G N
UMBE
R
PRO
JEC
T #
SHEE
T
O
F 92
30-2
0-25
72---
------
--05
PRO
PERT
Y O
F A
TI IN
DUS
TRIA
L A
UTO
MA
TION
, IN
C. N
OT
TO B
E RE
PRO
DUC
ED IN
AN
Y M
AN
NER
EXC
EPT
ON
ORD
ER O
R W
ITH P
RIO
R W
RITT
EN A
UTHO
RIZA
TION
OF
ATI.
1031
Goo
dwor
th Dr
ive, A
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
G2B
Com
plia
nt U
tility
Cou
pler
With
10
Port
Opt
ion
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-64
8.7 G2E Compliant Utility Coupler Drawings
3rd
AN
GLE
PRO
JEC
TION
45.6
Tool
52.6
Mas
ter
98.2
Cou
pled
12.8
45.2
3/4"
NPT
Air P
ass
Thru
3/4"
NPT
Air P
ass
Thru
3/4"
NPT
Air P
ass
Thru
3/4"
NPT
Air P
ass
Thru
4X M
8 x
1.25
S
HC
S
141
254
8
6.6
43.
3
25
50
10.
7 TH
RU
ALL
17.
3 1
0.4
From
Oth
er S
ide
Equa
lly S
pace
dFo
r M10
SH
CS
2X
10m
mD
owel
Slip
Fit
12m
m
B.C
. 10
0
Flat
A Flat
D
Flat
B
Flat
C
62
130
92.
7
27.
5 55
65
46.
4
Flat
A
Flat
C
Flat
B
Flat
D
4X M
8 x
1.25
SH
CS
2X 6
mm
Slip
Fit
6m
m
Scal
e 1:
3
Tool
Sid
e Vi
ewM
aste
r Sid
e Vi
ew
Part
Num
bers
:(A
) Mas
ter:
9121
-G2E
-CU
CM
-0-0
-0-0
-SG
(B) T
ool:
9
121-
G2E
-UC
T-0-
0-0-
0
Not
es: Con
tinuo
us C
oupl
ing
Forc
e m
ust b
e 1.
mai
ntai
ned
in o
rder
to k
eep
Mas
ter
and
Tool
eng
aged
.
Rev.
Des
crip
tion
Initi
ator
Dat
e
07EC
O 1
7176
: She
et 2
: Upd
ated
Cus
tom
er D
raw
ing
for c
hang
es to
91
21-G
2E-C
UCM
-0-0
-0-0
-SG
Mas
ter a
ssem
bly.
TBC
9/17
/201
8
B1:
51
3RE
VISI
ON
NO
TES:
UN
LESS
OTH
ERW
ISE
SPEC
IFIE
D.
DO
NO
T SC
ALE
DRA
WIN
G.
ALL
DIM
ENSI
ON
S A
RE IN
M
ILLIM
ETER
S.
DRA
WN
BY:
CHE
CKE
D B
Y:
D.B
rew
er, 2
/11/
11
DAN
, 2/1
0/11
TITLE SC
ALE
SIZE
DRA
WIN
G N
UMBE
R
PRO
JEC
T #
SHEE
T
O
F 96
30-2
0-G
2E-
07
PRO
PERT
Y O
F A
TI IN
DUS
TRIA
L A
UTO
MA
TION
, IN
C. N
OT
TO B
E RE
PRO
DUC
ED IN
AN
Y M
AN
NER
EXC
EPT
ON
ORD
ER O
R W
ITH P
RIO
R W
RITT
EN A
UTHO
RIZA
TION
OF
ATI.
1031
Goo
dwor
th Dr
ive, A
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
G2E
Com
plia
nt U
tility
Cou
pler
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-65
3rd
AN
GLE
PRO
JEC
TION
5
16
3
21
1422
9
8
19
4
3
1513
12
20
11
172
181
10
23
G2E
Com
plia
nt U
tility
Cou
pler
Mas
ter A
ssem
bly
Mag
nalu
be
Mag
nalu
be
7
6
B1:
22
3RE
VISI
ON
NO
TES:
UN
LESS
OTH
ERW
ISE
SPEC
IFIE
D.
DO
NO
T SC
ALE
DRA
WIN
G.
ALL
DIM
ENSI
ON
S A
RE IN
M
ILLIM
ETER
S.
DRA
WN
BY:
CHE
CKE
D B
Y:
D.B
rew
er, 2
/11/
11
DAN
, 2/1
0/11
TITLE SC
ALE
SIZE
DRA
WIN
G N
UMBE
R
PRO
JEC
T #
SHEE
T
O
F 96
30-2
0-G
2E-
07
PRO
PERT
Y O
F A
TI IN
DUS
TRIA
L A
UTO
MA
TION
, IN
C. N
OT
TO B
E RE
PRO
DUC
ED IN
AN
Y M
AN
NER
EXC
EPT
ON
ORD
ER O
R W
ITH P
RIO
R W
RITT
EN A
UTHO
RIZA
TION
OF
ATI.
1031
Goo
dwor
th Dr
ive, A
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
G2E
Com
plia
nt U
tility
Cou
pler
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-66
3rd
AN
GLE
PRO
JEC
TION
75
6
4
8
2
3
9
1N
ote
2.
Not
e 2.
Not
e 2.
Mag
nalu
be
Mag
nalu
beM
agna
lube
Mag
nalu
be B
ores
Mag
nalu
be
G2E
Com
plia
nt U
tility
Cou
pler
Too
l Ass
embl
y
Not
e:Se
e M
anua
l for
repl
acem
ent p
arts
, inc
ludi
ng o
lder
2.
valv
e de
sign
s w
hich
requ
ire a
spa
nner
wre
nch
for
Stem
inst
alla
tion.
New
Ste
ms
inst
all w
ith a
hex
wre
nch.
B1:
23
3RE
VISI
ON
NO
TES:
UN
LESS
OTH
ERW
ISE
SPEC
IFIE
D.
DO
NO
T SC
ALE
DRA
WIN
G.
ALL
DIM
ENSI
ON
S A
RE IN
M
ILLIM
ETER
S.
DRA
WN
BY:
CHE
CKE
D B
Y:
D.B
rew
er, 2
/11/
11
DAN
, 2/1
0/11
TITLE SC
ALE
SIZE
DRA
WIN
G N
UMBE
R
PRO
JEC
T #
SHEE
T
O
F 96
30-2
0-G
2E-
07
PRO
PERT
Y O
F A
TI IN
DUS
TRIA
L A
UTO
MA
TION
, IN
C. N
OT
TO B
E RE
PRO
DUC
ED IN
AN
Y M
AN
NER
EXC
EPT
ON
ORD
ER O
R W
ITH P
RIO
R W
RITT
EN A
UTHO
RIZA
TION
OF
ATI.
1031
Goo
dwor
th Dr
ive, A
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
G2E
Com
plia
nt U
tility
Cou
pler
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-67
8.8 G2E Application Utility Coupler General Dimensions (Shown with Optional DR2 DeviceNet Module)
3rd
AN
GLE
PRO
JEC
TION
3/4"
NPT
Por
t 2
Ports
on
Each
Sid
e,
4 Po
rts T
otal
Ports
are
Che
cked
on
Mas
ter a
nd T
ool H
alve
s
ZX
Y52
.640
.666
.7 N
ote
4
203
.2
17.
2
298
.5
165
.1
125m
mM
ax D
ista
nce
To C
lose
45.
3
(A)
(C)
(B)
3/4"
NPT
3/4"
NPT
3/4"
NPT
3/4"
NPT
9121
-DR
2-M
See
9630
-20-
DR
291
21-D
R2-
TSe
e 96
30-2
0-D
R2
254
141
43.
3 8
6.6
25
50
30°
6X C
'Bor
ed fo
r M10
SH
CS
10.4
from
oth
er s
ide
Equa
lly S
pace
d
2X
10.0
6110
.036
mm
Dow
elSl
ip F
it,
12
BC
100
244
.5
4X
20.6
TH
RU
200
2
35
94.
5
Prox
Sen
sor D
etec
ts F
ully
Ret
ract
edPN
P 3
Wire
DC
TOO
L SI
DE
MO
UN
TIN
G V
IEW
TOP
VIEW
RET
RA
CTE
D
BO
TTO
M V
IEW
RET
RA
CTE
D
ISO
VIE
W
Part
Num
bers
:(A
) Mas
ter:
9121
-G2E
-CU
CM
-DR
2-0-
0-0-
SG(B
) Too
l: 91
21-G
2E-U
CT-
DR
2-0-
0-0
(C) A
ctua
tor:
9121
-G2-
GC
-B15
0S15
0-SG
NO
TES:
1. L
inea
r Act
uato
r Uni
t is
Trip
le R
od C
ylin
der 6
" Max
Stro
ke, a
nd fe
atur
es a
Pro
x Se
nsor
to d
etec
t ful
ly re
tract
ed p
ositi
on.
Prox
is P
NP
3 W
ire D
C.
2. D
rive
Cyl
inde
r ext
erts
app
roxi
mat
ely
2,20
0lbs
of c
oupl
ing
forc
e at
80
psi.
Car
e is
nee
ded
to a
ccom
odat
e th
ese
coup
ling
forc
es in
the
desi
gn o
f the
mat
ing
cust
omer
fixt
ure.
3. F
or P
rope
r Ope
ratio
n, C
ylin
der P
ress
ure
Mus
t be
Mai
ntai
ned
in o
rder
to re
sist
th
e sp
ring
forc
es in
the
inte
grat
ed 3
/4" C
heck
ed P
orts
.4.
Mas
ter s
ide
coup
ler b
ody
com
pres
ses
2mm
-4m
m w
hen
coup
led.
5. M
ax c
ylin
der s
troke
is 1
50m
m.
Rec
omm
ende
d M
AX M
aste
r to
Tool
Spa
cing
is
125m
m.
Rev.
Des
crip
tion
Initi
ator
Dat
e
05EC
O 1
7187
: Upd
ate
dra
win
g fo
r cha
nges
to
9121
-G2E
-CUC
M-0
-0-0
-0-S
G a
ssem
bly.
TBC
1/18
/201
9
B1:
41
2RE
VISI
ON
NO
TES:
UN
LESS
OTH
ERW
ISE
SPEC
IFIE
D.
DO
NO
T SC
ALE
DRA
WIN
G.
ALL
DIM
ENSI
ON
S A
RE IN
M
ILLIM
ETER
S.
DRA
WN
BY:
CHE
CKE
D B
Y:
Dan
Nor
ton
3/3/
10
KRZ
5/24
/10
TITLE SC
ALE
SIZE
DRA
WIN
G N
UMBE
R
PRO
JEC
T #
SHEE
T
O
F 92
30-2
0-31
3010
0204
-105
PRO
PERT
Y O
F A
TI IN
DUS
TRIA
L A
UTO
MA
TION
, IN
C. N
OT
TO B
E RE
PRO
DUC
ED IN
AN
Y M
AN
NER
EXC
EPT
ON
ORD
ER O
R W
ITH P
RIO
R W
RITT
EN A
UTHO
RIZA
TION
OF
ATI.
1031
Goo
dwor
th Dr
ive, A
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
G2E
Arra
ngem
ent
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-68
3rd
AN
GLE
PRO
JEC
TION
Prox
Sen
sor
Det
ects
Cyl
inde
r Ful
l Ret
ract
1/2"
NPT
Air S
uppl
yR
etra
ct
1/2"
NPT
Ai
r Sup
ply
Exte
nd
Prox
Sen
sor
Det
ects
Too
l Sid
e Pr
esen
ce
Prox
Sen
sor
Det
ects
Too
l Sid
e Pr
esen
ceIS
O V
IEW
CYL
IND
ER R
ETR
AC
TED
3.9
9
8.2
493.
3Se
e N
otes
Sec
tion
Shee
t 1
SID
E VI
EW W
ITH
CYL
IND
ER E
XTEN
DED
B1:
42
2RE
VISI
ON
NO
TES:
UN
LESS
OTH
ERW
ISE
SPEC
IFIE
D.
DO
NO
T SC
ALE
DRA
WIN
G.
ALL
DIM
ENSI
ON
S A
RE IN
M
ILLIM
ETER
S.
DRA
WN
BY:
CHE
CKE
D B
Y:
Dan
Nor
ton
3/3/
10
KRZ
5/24
/10
TITLE SC
ALE
SIZE
DRA
WIN
G N
UMBE
R
PRO
JEC
T #
SHEE
T
O
F 92
30-2
0-31
3010
0204
-105
PRO
PERT
Y O
F A
TI IN
DUS
TRIA
L A
UTO
MA
TION
, IN
C. N
OT
TO B
E RE
PRO
DUC
ED IN
AN
Y M
AN
NER
EXC
EPT
ON
ORD
ER O
R W
ITH P
RIO
R W
RITT
EN A
UTHO
RIZA
TION
OF
ATI.
1031
Goo
dwor
th Dr
ive, A
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
G2E
Arra
ngem
ent
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-69
8.9 G5A Utility Coupler Drawings
3rd
AN
GLE
PRO
JEC
TION
45.6
Tool
52.6
Mas
ter
98.2
Cou
pled
3.87
15.1
13
18.9
Pin
3/4"
NPT
Air P
ass
Thru
3/4"
NPT
Air P
ass
Thru
3/4"
NPT
Air P
ass
Thru
3/4"
NPT
Air P
ass
Thru
4X M
8 x
1.25
S
HC
S
50
86.6
25
43.3
12m
m
2X10
mm
Dow
elSl
ip F
it
For M
10 S
HC
SEq
ually
Spa
ced
From
Oth
er S
ide
17.
3 1
0.4
6X
10.
7 T
HR
U A
LL
241
.3
141
B.C
. 10
0
Flat
A
Flat
D
Flat
B
Flat
C
130
50
55.7
25
65
Flat
A
Flat
C
Flat
B
Flat
D
4X M
8 x
1.25
SH
CS
2X 6
mm
Slip
Fit
6m
m
Scal
e 1:
3
Tool
Sid
e Vi
ewM
aste
r Sid
e Vi
ew
Part
Num
bers
:(A
) Mas
ter:
9121
-G5A
-CU
CM
-0-0
-0-0
-SG
(B) T
ool:
9
121-
G5-
UC
T-0-
0-0-
0
Not
es:
1) C
ontin
uous
Cou
plin
g Fo
rce
mus
t
be
mai
ntai
ned
in o
rder
to k
eep
Mas
ter
a
nd T
ool e
ngag
ed.
Rev.
Des
crip
tion
Initi
ator
Dat
e05
ECO
178
31: U
pdat
ed 4
X M
8 x
1.25
SHC
S le
ngth
to 1
3 w
as 2
3.
TBC
4/16
/201
9
B1:
51
3RE
VISI
ON
NO
TES:
UN
LESS
OTH
ERW
ISE
SPEC
IFIE
D.
DO
NO
T SC
ALE
DRA
WIN
G.
ALL
DIM
ENSI
ON
S A
RE IN
M
ILLIM
ETER
S.
DRA
WN
BY:
CHE
CKE
D B
Y:
D.B
rew
er, 2
/10/
11
DAN
, 2/1
0/11
TITLE SC
ALE
SIZE
DRA
WIN
G N
UMBE
R
PRO
JEC
T #
SHEE
T
O
F 96
30-2
0-G
5A-
05
PRO
PERT
Y O
F A
TI IN
DUS
TRIA
L A
UTO
MA
TION
, IN
C. N
OT
TO B
E RE
PRO
DUC
ED IN
AN
Y M
AN
NER
EXC
EPT
ON
ORD
ER O
R W
ITH P
RIO
R W
RITT
EN A
UTHO
RIZA
TION
OF
ATI.
1031
Goo
dwor
th Dr
ive, A
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
Com
plia
nt G
5A U
tility
Cou
pler
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-70
3rd
AN
GLE
PRO
JEC
TION
G5A
Com
plia
nt U
tility
Cou
pler
Mas
ter A
ssem
bly
20
78
23
23
3
4 18
5
13
4
12
6
1610
2115
91
219
17
11
14
22
Mag
nalu
beM
agna
lube
ITEM
NO
.Q
TYPA
RT
NU
MBE
RD
ESC
RIP
TIO
N1
234
10-0
0010
15-0
1O
-Rin
g M
aste
r AS5
68-0
262
234
10-0
0012
49-0
1O
-RIN
G, D
ash
#119
Nitr
ile 9
0 D
urom
eter
32
3490
-000
1045
-01
1/2
BSPP
Plu
g, N
icke
l Pla
ted
Bras
s4
235
00-1
0660
16-1
5AM
6-1
x 16
mm
SH
CS,
Blu
e, P
re-A
pplie
d5
435
00-1
0680
25-1
5AM
8-1.
25 x
25m
m S
HC
S, B
lue,
Pre
-App
lied
63
3500
-207
0035
-11
SHC
S Sh
ould
er M
12 x
35
Shou
lder
M10
Thr
ead
73
3610
-172
5001
-10
Stee
l Com
pres
sion
Spr
ing
2-1/
2" L
, 5/8
" OD
,.080
" Wire
83
3610
-192
5001
-20
Stee
l Spr
ing
.845
" OD
, 2.5
" Lon
g 43
.4 R
ate
92
3610
-201
5100
-20
Sprin
g, 1
.1 in
ch d
ia, 2
.5" l
ong,
10.
8#/in
SS
101
3690
-660
0900
-10
Rol
ling
Ball
Tip
Set S
crew
, M16
-2.0
x 2
3.3m
m lo
ng, B
lack
Oxi
de
Stee
l11
236
90-8
5000
01-1
1R
etai
ning
Rin
g, In
tern
al In
verte
d Tr
uarc
# 5
008-
187
123
3700
-20-
4675
Cus
tom
Cha
mfe
red
Was
her
133
3700
-20-
4676
Cus
tom
SAE
841
Bro
nze
Thru
st B
earin
g14
337
00-2
0-47
16C
ompl
iant
IP P
relo
ad P
ushe
r
151
3700
-20-
4875
1/2"
Dia
. Util
ity C
oupl
er A
lignm
ent P
in 4
mm
Tap
er, S
hort
Dia
mon
d
161
3700
-20-
4876
1/2"
Dia
. Util
ity C
oupl
er A
lignm
ent P
in 4
mm
Tap
er, S
hort,
R
ound
172
3700
-20-
4924
3/4"
Val
ve M
aste
r Ste
m18
137
00-2
0-60
16G
5 C
ompl
iant
Inte
rface
Pla
te B
ody
192
3700
-20-
6161
3/4"
Val
ve P
isto
n20
137
00-2
0-76
89G
Ser
ies
Com
plia
nt In
terfa
ce P
late
, Bas
e M
ount
211
3700
-20-
8254
M16
-2.0
x 9
mm
Set
Scr
ew, H
ollo
w H
ex22
137
00-2
0-94
67R
est B
utto
n, H
arde
ned
S7
Stee
l23
285
90-9
9099
99-0
8PN
P (T
rue
2mm
)Pro
xim
ity S
enso
rB
1:5
23
REVI
SIO
N
NO
TES:
UN
LESS
OTH
ERW
ISE
SPEC
IFIE
D.
DO
NO
T SC
ALE
DRA
WIN
G.
ALL
DIM
ENSI
ON
S A
RE IN
M
ILLIM
ETER
S.
DRA
WN
BY:
CHE
CKE
D B
Y:
D.B
rew
er, 2
/10/
11
DAN
, 2/1
0/11
TITLE SC
ALE
SIZE
DRA
WIN
G N
UMBE
R
PRO
JEC
T #
SHEE
T
O
F 96
30-2
0-G
5A-
05
PRO
PERT
Y O
F A
TI IN
DUS
TRIA
L A
UTO
MA
TION
, IN
C. N
OT
TO B
E RE
PRO
DUC
ED IN
AN
Y M
AN
NER
EXC
EPT
ON
ORD
ER O
R W
ITH P
RIO
R W
RITT
EN A
UTHO
RIZA
TION
OF
ATI.
Com
plia
nt G
5A U
tility
Cou
pler
1031
Goo
dwor
th Dr
ive, A
pex,
NC 27
539,
USA
Tel: +
1.919
.772.0
115
w
ww.at
i-ia.co
mFa
x: +1
.919.7
72.82
59
ISO
9001
Reg
ister
ed C
ompa
ny
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-71
3rd
AN
GLE
PRO
JEC
TION
4
8
6
79
3
21
105
G5A
Com
plia
nt U
tility
Cou
pler
Too
l Ass
embl
y
Not
e 2.
Not
e 2.
Not
e 2.
Mag
nalu
be B
ores M
agna
lube
Mag
nalu
be
Not
es: Se
e M
anua
l for
repl
acem
ent p
arts
, inc
ludi
ng o
lder
val
ve
2.de
sign
s w
hich
requ
ire a
spa
nner
wre
nch
for S
tem
in
stal
latio
n. N
ew S
tem
s in
stal
l with
a h
ex w
renc
h.
Mag
nalu
be
Mag
nalu
be
ITEM
NO
.Q
TYPA
RT
NU
MBE
RD
ESC
RIP
TIO
N1
234
10-0
0010
99-0
1Q
uad-
Rin
g 1-
5/16
"ID2
234
10-0
0013
41-0
1O
-Rin
g,1-
3/16
IDx3
/32,
AS5
68-1
23 B
una-
N, D
903
234
10-0
0014
50-0
1O
-Rin
g, A
S568
-116
, Bun
a-N
, A90
42
3490
-000
1045
-01
1/2
BSPP
Plu
g, N
icke
l Pla
ted
Bras
s5
236
10-2
0150
01-2
0Sp
ring
62
3690
-560
3100
-10
Res
t But
ton,
Ste
el, 6
mm
Ste
m D
ia, .
39" B
utto
n D
ia7
237
00-2
0-52
74D
rill B
ushi
ng 1
/2" d
ia, 7
/8 O
D, 1
" lon
g8
137
00-2
0-60
17G
5 To
ol B
ody
92
3700
-20-
9609
3/4"
Val
ve S
tem
, Too
l, C
onic
al S
eal
102
3700
-20-
9610
3/4"
Val
ve P
isto
n, T
ool,
Con
ical
Sea
l
B1:
53
3RE
VISI
ON
NO
TES:
UN
LESS
OTH
ERW
ISE
SPEC
IFIE
D.
DO
NO
T SC
ALE
DRA
WIN
G.
ALL
DIM
ENSI
ON
S A
RE IN
M
ILLIM
ETER
S.
DRA
WN
BY:
CHE
CKE
D B
Y:
D.B
rew
er, 2
/10/
11
DAN
, 2/1
0/11
TITLE SC
ALE
SIZE
DRA
WIN
G N
UMBE
R
PRO
JEC
T #
SHEE
T
O
F 96
30-2
0-G
5A-
05
PRO
PERT
Y O
F A
TI IN
DUS
TRIA
L A
UTO
MA
TION
, IN
C. N
OT
TO B
E RE
PRO
DUC
ED IN
AN
Y M
AN
NER
EXC
EPT
ON
ORD
ER O
R W
ITH P
RIO
R W
RITT
EN A
UTHO
RIZA
TION
OF
ATI.
Com
plia
nt G
5A U
tility
Cou
pler
1031
Goo
dwor
th Dr
ive, A
pex,
NC 27
539,
USA
Tel: +
1.919
.772.0
115
w
ww.at
i-ia.co
mFa
x: +1
.919.7
72.82
59
ISO
9001
Reg
ister
ed C
ompa
ny
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-72
8.10 G5A Application Utility Coupler General Dimensions (Shown with Optional DA2 DeviceNet Module)
3rd
AN
GLE
PRO
JEC
TION
98.2
271.
5N
ote
5
64.5
Not
e 4
(2) 3
/8" N
PT
RO
SS
Bra
ndFl
ow C
ontro
l
9121
-G5-
UC
T-D
A2-
0-0-
0U
tility
Cou
pler
Too
lW
ith (2
) Int
egra
ted
1/2"
BS
PP
Che
cked
Por
ts
9121
-G5A
-CU
CM
-DA
2-0-
0-0-
SG
Com
plia
nt U
tility
Cou
pler
Mas
ter
With
(2) I
nteg
rate
d 1/
2" B
SP
P C
heck
ed P
orts
M
aste
r Sid
e is
Com
plia
nt to
+/-
4mm
P
lus
3 A
ngul
ar C
ompl
ianc
e(2
) PN
P T
ool P
rese
nce
Sen
sors
9121
-G2-
GC
-B80
S10
0-S
GLi
near
Act
uato
r Uni
tS
ee N
otes
Sec
tion
PN
P 1
8mm
Pro
xN
ote
6
(2) 3
/8" N
PT
to 3
/8" B
SP
P A
dapt
er
Clo
se
75R
ecom
men
ded
Dis
tanc
e to
45.6
14.5
52.6 67
.7N
ote
4
196.
5N
ote
5 1
77.8
292
.1
1/2"
BS
PP
1/2"
BS
PP
1/2"
BS
PP
1/2"
BS
PP
187.
9
318
19.1
Pla
te
Thic
knes
s
DA
2 M
aste
r D
evic
enet
Mod
ule
See
963
0-20
-DA
2
(2)
10m
m
Dow
el
Slip
Fit
12m
m
25
43.3
86.6
50
241
141
B.C
.10
0
6X
10.
7 Th
ru 1
7.3
10.4
Fr
om O
ther
Sid
eE
qual
ly S
pace
dFo
r M10
SH
CS
DA
2 To
ol
Dev
icen
et M
odul
eS
ee 9
630-
20-D
A2
ZX
Y
Loca
tion
of
Tool
Pre
senc
e S
enso
r
Loca
tion
of
Tool
Pre
senc
e S
enso
r
2X
10m
m D
owel
Slip
Fit,
Thr
u P
late
4X
10.
7 Th
ru 1
7.3
10.4
From
Oth
er S
ide
For M
10 S
HC
S
88.
9
70
140
230
12.
7
TOP
VIEW
RET
RA
CTE
D
TOP
VIEW
EXT
END
ED
TOO
L SI
DE
VIEW
MA
STER
SID
E VI
EW
ISO
VIE
W
NO
TES
:Li
near
Act
uato
r Uni
t is
Driv
en b
y S
MC
Gui
ded
Cyl
inde
r Ser
ies
MG
PM
1.Fo
r Pro
per O
pera
tion,
Cyl
inde
r Pre
ssur
e M
US
T B
E M
AIN
TAIN
ED
in
2.
ord
er to
resi
st th
e sp
ring
forc
es in
the
inte
grat
ed c
heck
ed P
orts
. 3.
U
tility
Cou
pler
cou
plin
g fo
rce
is a
ppro
xim
atel
y 62
5lbs
at 8
0 ps
i. C
are
is n
eede
d to
acc
omod
ate
thes
e fo
rces
in th
e de
sign
of t
he m
atin
g cu
stom
er fi
xtur
e.
4.
M
aste
r sid
e co
uple
r bod
y co
mpr
esse
s 2m
m-4
mm
whe
n co
uple
d.5.
M
ax c
ylin
der s
troke
is 1
00m
m. R
ecom
men
ded
mas
ter t
o to
ol s
paci
ng is
75m
m.
6.
Pos
ition
of c
ylin
der p
roxe
s ar
e ad
just
able
onc
e in
stal
led.
7.
Too
l Pre
senc
e S
enso
rs a
re T
urck
PN
P 8
mm
.
Rev.
Des
crip
tion
Initi
ator
Dat
e
07EC
O 1
4986
; Upd
ated
due
to n
ew B
OM
stru
ctur
eSZ
J11
/7/2
016
B1:
41
1RE
VISI
ON
NO
TES:
UN
LESS
OTH
ERW
ISE
SPEC
IFIE
D.
DO
NO
T SC
ALE
DRA
WIN
G.
ALL
DIM
ENSI
ON
S A
RE IN
M
ILLIM
ETER
S.
DRA
WN
BY:
CHE
CKE
D B
Y:
Dan
Nor
ton,
6/1
6/09
D. S
wan
son,
6/1
6/09
TITLE SC
ALE
SIZE
DRA
WIN
G N
UMBE
R
PRO
JEC
T #
SHEE
T
O
F 92
30-2
0-29
7909
0616
-207
PRO
PERT
Y O
F A
TI IN
DUS
TRIA
L A
UTO
MA
TION
, IN
C. N
OT
TO B
E RE
PRO
DUC
ED IN
AN
Y M
AN
NER
EXC
EPT
ON
ORD
ER O
R W
ITH P
RIO
R W
RITT
EN A
UTHO
RIZA
TION
OF
ATI.
1031
Goo
dwor
th Dr
ive, A
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
G5
Com
plia
nt U
tility
Cou
pler
, (2)
1/2
" BSP
P C
heck
ed P
orts
, (2
) PN
P To
ol P
rese
nce
Sens
ors
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-73
9. Guided Cylinder Proximity Sensor Information9.1 9121-G2-GC-B80S100-SG Guided Cylinder Proximity Sensor
IGS209IGKC012-ASKG/M/US
Inductive sensorMetal thread M18 x 1
ConnectorOperation as 3-wire or 2-wire
possibleIncreased sensing range
Optical setting aid (2 LED)gold-plated contacts
Sensing range 12 mm [nf]non-flush mountable
Made in Germany
Electrical design 3-wire DC PNP; 2-wire DC PNP/NPN
Output normally open
Operating voltage [V] 10...30 DCCurrent rating [mA] 100Minimum load current [mA] 2 *)Short-circuit protection pulsedReverse polarity protection yesOverload protection yesOverload protection yesVoltage drop [V] < 2.8Leakage current [mA] < 0.5 *)Current consumption [mA] < 12 (24 V)
Real sensing range [mm] 12 ± 10 %Operating distance [mm] 0...9.7Switch-point drift [% of Sr] -10...10Hysteresis [% of Sr] 3...15Switching frequency [Hz] 300Correction factors mild steel = 1 / stainless steel approx. 0.7 / brass approx. 0.5 / Al approx. 0.4 / Cu
approx. 0.3
Ambient temperature [°C] -25...70Protection IP 67, IIEMC EN 61000-4-2 ESD: 4 kV CD / 8 kV AD
EN 61000-4-3 HF radiated: 10 V/m (80...1000 MHz)EN 61000-4-4 Burst: 2 kVEN 61000-4-6 HF conducted: 10 V (0.15...80 MHz)EN 55011: class B
Housing materials brass white bronze coated; active face: PBT (Pocan)Function displaySwitching status LED yellow (4 x 90°)Setting aid LED red
Connection M12 connector; gold-plated contacts
Weight [kg] 0.054Remarks suitable for PLC type 1 according to IEC 61131-2
*) only in 2-wire operationAccessories (included) 2 lock nuts
Wiring
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-74
9.2 9121-G2-GC-B80S100-SR Guided Cylinder Proximity Sensor
Manual, Utility Coupler, G2x and G5xDocument #9620-20-B-G2x,G5x-15
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com B-75
9.3 9121-G2-GC-B150S150-SG Guided Cylinder Proximity Sensor (8590-9909999-133)
Recommended