JUKI KE-1070 Maintenance Manual
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JUKI KE-1070 Maintenance Manual

High-speed chip scooter
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High-Speed Chip Shooter
KE-1070/1070C/2070C/2070
High-Speed Flexible Mounter
KE-1080/2080/2080R
MAINTENANCE GUIDE
PART I
Contact info@goldlandsmt.com for PART II
CUSTOMER SUPPORT DEPARTMENT

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Summary of Contents for JUKI KE-1070

  • Page 1 High-Speed Chip Shooter KE-1070/1070C/2070C/2070 High-Speed Flexible Mounter KE-1080/2080/2080R MAINTENANCE GUIDE PART I Contact info@goldlandsmt.com for PART II CUSTOMER SUPPORT DEPARTMENT...
  • Page 2 (2) The contents of this document are subject to change without notice. (3) This manual is prepared with extreme care. However, if you have any question (4) JUKI Corporation shall disclaim all the responsibility for any trouble resulting from the user's abnormal operation regardless of Item (3).

  • Page 3: Table Of Contents

    Maintenance Guide Table of Contents X-Y UNIT ................... 1-1 1-1. Replacing the Timing Belt and Adjusting the Belt Tension ......... 1-1 1-1-1. Timing Belt XM ........................1-1 1-1-2. Timing Belt XB ........................1-3 1-1-3. Timing Belt YM ........................1-6 1-1-4. Timing Belt YB ........................
  • Page 4 Maintenance Guide 1-8-7. Assembling the Cables ....................1-30 1-8-8. Wiring around the Head ....................1-35 1-9. Replacing the Cables in the X/Y Veyor-Cable (KE-2080R) ......1-36 1-9-1. Removing the X Cable ....................1-36 1-9-2. Checking the Cable Marking (X) ..................1-39 1-9-3.
  • Page 5 Maintenance Guide PARTS AROUND THE HEAD ............3-1 3-1. Replacing the Ejector Unit .................. 3-1 3-2. Replacing the Bad Mark Sensor ................. 3-2 3-2-1. Sensor Assembly ......................3-1 3-2-2. Adjusting the Sensor Height..................... 3-2 3-2-3. Amplifier ........................... 3-3 3-2-4. Assembling the Fiber Unit to the Amplifier (F10R Amplifier) ..........3-3 3-2-5.
  • Page 6 Maintenance Guide 5-6. Replacing the WAIT Sensor ................5-6 5-6-1. Replacing the Fiber ......................5-6 5-6-2. Replacing the Amplifier Unit ....................5-7 5-7. Replacing the STOP and C. OUT Sensors ............5-8 5-8. Replacing the Stopper Cylinder ................5-9 5-9. Replacing the Support Table Home Position Sensor (BU Home Position Sensor) ................
  • Page 7 Maintenance Guide FEEDER BANK AND REPLACEMENT TABLE (OPTIONAL) ..9-1 9-1. Overall Drawing ....................9-1 9-2. Replacing the Drive Cylinder ................9-2 9-3. Adjusting the Speed Controller of the Drive Cylinder .......... 9-4 9-4. Replacing the Feeder Bank Board and Feeder I/F Board ........9-5 9-5.
  • Page 8 13-5. Replacing the Load Cell Amplifier (Optional Unit) ........... 13-47 [14] ELECTRICAL COMPONENTS ............14-1 14-1. Layout of Electrical Components ..............14-1 14-1-1. Part Names (KE-1070/1070C/1080) ................14-1 14-1-2. Part Names (KE-2070/2070C/2080/2080R) ..............14-2 14-2. Layout of Top of Base Frame ................14-3 14-2-1.
  • Page 9 Maintenance Guide 14-5. X-Y Unit ......................14-34 14-5-1. Structure of X-Y Unit ...................... 14-34 14-5-2. Display Indication of XY Servo Amplifier ............... 14-35 14-6. Z- ......................14-36 14-6-1. Structure of Z- ...................... 14-36 14-6-2. LED Indications ......................14-37 14-7. Transport Unit ....................14-38 14-7-1.
  • Page 10 20-1. Replacing the RS-232C Port Expansion Board ..........20-1 20-2. To replace the barcode reader: ................ 20-2 [21] JIG LISTS ..................21-1 21-1. KE-1070/1070C Jig Lists .................. 21-1 21-2. KE-1080/2070/2080/2080R Jig Lists ..............21-3 Appendix 1. Checking the Board Function Rev., Board Pattern Rev., and DIP SW ..... A-1 2.

  • Page 11: X-Y Unit

    Maintenance Guide To prevent any trouble caused by accidental machine start, always shut-down the power before starting the maintenance and DANGER adjustment work. X-Y UNIT 1-1. Replacing the Timing Belt and Adjusting the Belt Tension If a tension of any belt drops below the criteria value, you must adjust it. For details about the criteria value, see “Readjustment on market”...
  • Page 12 Maintenance Guide (2) Loosen the NM6050001SC, and then SM8053002TP that applies the tension to the timing belt XM. (3) Remove the timing belt XB. (See section 1-1-2.) (4) Remove the SL6064092TN fixing the XA-pulley bracket assembly, and SL6062092TN fixing the XA-pulley base to detach the XA-pulley bracket assembly. (5) Remove the SL6062092TN fixing the motor assembly to detach the X-motor assembly.

  • Page 13: Timing Belt Xb

    Maintenance Guide 1-1-2. Timing Belt XB (1) Remove the SL6053592TN (2 pcs.) X-belt support assembly and SL6052592TN (2 pcs.), then detach the head plate and the X-belt support assembly. (2) Loosen the X-belt tension adjustment screw (SM6057552TP). Head plate (3) Remove the SM6042092TN sandwiching the timing belt to Figure 1-1-2-1 replace the belt.
  • Page 14 Maintenance Guide <Adjustment Procedure> Make measurements with a Yunitta's tension meter placed at the positions indicated by the arrows in the figure below and check to make sure that the values are within the specification value range. When adjusting the X-motor belt, measure the tension at several positions (at least five positions) while rotating the pulley and check that the averaged value is within the specification value range.
  • Page 15 Maintenance Guide Adjusting method Timing belt XM Loosen the SL6051692TN fixing the X-motor. Loosen the NM605001YN adjust tension using the SM8053002TN. X-axis frame Tighten the SL6051692TN assembly firmly. (Tightening torque: 15 N m) Lock the NM6050001TN. Timing belt XB Loosen the SL6052592TN fixing the X-belt support L and X-belt support R.

  • Page 16: Timing Belt Ym

    Maintenance Guide 1-1-3. Timing Belt YM (1) Detach the pulley cover. (2) Remove the timing belt YB. (See section 1-1-4.) (3) Loosen the SL6061492TN fixing the Y-motor assembly. (4) Loosen the SM6041202TN to loosen the tension of the timing belt YM. (5) Loosen the SL6064092TN to detach the YM-bracket assembly.

  • Page 17: Timing Belt Yb

    Maintenance Guide 1-1-4. Timing Belt YB To carry out the work efficiently, detach the side covers. Remove the cover fixing screws and slide the cover toward the rear to detach the side cover. (1) Remove the SL6062092TN fixing the Y-belt support (1) to the X-frame end. If it is not easy to remove it, use a heat gun or other tool to heat the connection part before removing it.
  • Page 18 Maintenance Guide <Adjustment Procedure> Make measurements with a Yunitta's tension meter placed at the positions indicated by the arrows in the figure below and check to make sure that the values are within the specification value range. When adjusting the Y-motor belt, measure the tension at several positions (at least five positions) while rotating the pulley and check that the averaged value is within the specification value range.
  • Page 19 Maintenance Guide Adjusting method Timing belt YM Loosen the SL6061492TN fixing Y-axis frame the Y-motor. Adjust the tension using the SM6041602TN. Tighten the SL6061492TN firmly. (Tightening torque: 10 N m) Timing belt YB Loosen the SL6062592TN fixing YB-bracket Timing belt YB the YB-pulley bracket.

  • Page 20: Replacing The Pulleys

    Maintenance Guide 1-2. Replacing the Pulleys 1-2-1. Replacing the Pulley XA Carry out the replacement work in the same manner as for the timing belt XM in 1-1-1. 1-2-2. Replacing the Pulley XM (X-Motor Assembly) Carry out the replacement work in the same manner as for the timing belt XM in 1-1-1. 1-2-3.

  • Page 21: Replacing The Servomotors

    Maintenance Guide 1-3. Replacing the Servomotors 1-3-1. Replacing the X-Motor Carry out the replacement work in the same manner as for the timing belt XM in 1-1-1. 1-3-2. Replacing the Y-Motor Carry out the replacement work in the same manner as for the timing belt YM in 1-1-3. 1-11...

  • Page 22: Replacing The Magnescale

    Maintenance Guide 1-4. Replacing the Magnescale Before replacing the magnescale, leave a new magnescale near the machine for 1 hr. or longer so that its temperature becomes the same as that of the machine. (1) Detach the magnescale head from the bracket. (2) Peel off the old magnescale.
  • Page 23 Maintenance Guide Y-axis magnescale affixing procedure (1) With the Y-axis affixing jig (part No. 40008105) made in contact with the side of the Linear way Y and the top of the Y-axis, make the magnescale in contact with the Y-axis affixing jig to affix the magnescale.

  • Page 24: Clearance Of The Magnescale

    Maintenance Guide 1-4-2. Clearance of the Magnescale (1) Put the MSC clearance jig (part No. 40008106) with a thickness of 0.25 mm in the clearance between the magnescale and sensor head, and then tighten the screw again. (2) Check that the MSC clearance jig with a thickness of 0.35 mm is not put in the clearance between the magnescale and sensor head in the XY-axes full-stroke.
  • Page 25 Maintenance Guide (6) If the P-P value is not 2.0V±0.5V, loosen the screw securing the sensor (screw for the X-axis and screw for the Y-axis shown in the figure below). X-axis Y-axis Clearance between the magnescale and sensor head: 0.25 ± 0.1 mm 1-15...

  • Page 26: Clearance Between The Sensor Head And The Y-Axis Linear Way (For Y-Axis Only)

    Maintenance Guide 1-4-3. Clearance between the Sensor Head and the Y-Axis Linear Way (for Y-Axis Only) (1) Put a 0.65-mm clearance gauge in the clearance between the Y-axis linear way and sensor head, and check that no play exists and that the clearance gauge is inserted smoothly.

  • Page 27: Replacing The Limit Sensor And The X-Axis Home Proximity Sensor

    Maintenance Guide 1-5. Replacing the Limit Sensor and the X-Axis Home Proximity Sensor 1-5-1. Replacing the X-Axis Limit Sensor and the X-Axis Home Proximity Sensor If only the sensor is replaced, it is not necessary to adjust the position. If the sensor is replaced together with the bracket, it is necessary to adjust the position. (1) Loosen the screw fixing the X-limit sensor bracket and make the adjustment so that the distances from the X-frame L and R are those shown in the figure below.

  • Page 28: Replacing The Y-Axis Limit Sensor And The Y-Axis Home Proximity Sensor

    Maintenance Guide 1-5-2. Replacing the Y-Axis Limit Sensor and the Y-Axis Home Proximity Sensor If only the sensor is replaced, it is not necessary to adjust the position. If the sensor is replaced together with the bracket, it is necessary to adjust the position. (1) Loosen the screw fixing the Y-limit sensor bracket and make the adjustment so that the distance from the end face of the linear way is that shown in the figure below.
  • Page 29 Maintenance Guide 1-5-3. Replacing the Y-Axis Limit Sensor and the Y-Axis Home Proximity Sensor KE-1070C/2070C If only the sensor is replaced, it is not necessary to adjust the position. If the sensor is replaced together with the bracket, it is necessary to adjust the position. (1) Loosen the screw fixing the Y-limit sensor bracket and make the adjustment so that the distance from the end face of the linear way is that shown in the figure below.

  • Page 30: Replacing The Home Position Sensor

    Maintenance Guide 1-6. Replacing the Home Position Sensor 1-6-1. X-Axis The X-axis home position sensor is not provided on the KE-2070/80. It is built in the magnescale. 1-6-2. Y-Axis The Y-axis home position sensor is an important device that determines the squareness between the X-axis and Y-axis.

  • Page 31: Replacing The Plastic Rail

    Maintenance Guide 1-7. Replacing the Plastic Rail 1-7-1. Replacing the X-Axis Plastic Rail X-Axis Plastic Rail (Part No. 40046023) (1) Loosen the SL3051292TN and NM6060001SC, and then detach the X-axis plastic rail from the nut plate and X-axis frame assembly. (2) Loosen the SL6040892TN and detach the cable clamp X.
  • Page 32 Maintenance Guide 1-7-2. Replacing the Y-Axis Plastic Rail Y-Axis Plastic Rail (Part No. 40046022) (1) Loosen the NM3061232TN and remove the X-axis plastic rail from the nut plate. Loosen the SL3061232TN and remove the Y-axis plastic rail from the X-frame end assembly. (2) Loosen the SL6061092TN and detach the cable clamp YB.

  • Page 33: Replacing The Cables In The X/Y Veyor-Cable

    Maintenance Guide 1-8. Replacing the Cables in the X/Y Veyor-Cable 1-8-1. Removing the X Cable (1) Detach the head top cover and disconnect the connectors connected to XY veyor-cable, 1394 robot cable, and OPTICAL FIBER CABLE 7M. Figure 1-8-1-1 OPTICAL FIBER CABLE 7M 1394 robot cable XY veyor-cable Figure 1-8-1-2...
  • Page 34 Maintenance Guide (2) Detach the FC support. Then cut and remove the tie-up band. FC support Figure 1-8-1-3 (3) Detach the cable clamp X from the X-axis plastic rail CB support, and then cut and remove the tie-up bands. Cable clamp X Figure 1-8-1-4 (4) Detach the cover of the plastic rail and remove the cable to be replaced.

  • Page 35: Checking The Cable Marking (X)

    Maintenance Guide 1-8-2. Checking the Cable Marking (X) (1) Check the marking position of the XY veyor-cable (40058385). (Place the marks at a position 350mm from the CN805 connector end.) For the machine with the extra specifications, the following cables are used. XY veyor-cable (E) 40059779 Y veyor-cable (E) 40059789 This instruction also applies to the following pages.

  • Page 36: Assembling The Cable

    Maintenance Guide 1-8-3. Assembling the Cable (1) Apply the grease to portions where the 40058385, 40044517, and 40048070 cables are put in the plastic rail, and place the cables and air tubes in the X-axis plastic rail as shown in the figure below (figure viewed from A).
  • Page 37 Maintenance Guide (3) For the head side of the cable, align the marking positions of the cables with the upper end of the FC support and secure them. (4) For the opposite side, place a mark at the top end of the mounting fixture with the cable pulled in the direction shown in the figure below.

  • Page 38: Separating The Fusion-Bonded Parts Of The Cables

    Maintenance Guide 1-8-4. Separating the Fusion-bonded Parts of the Cables (1) Separate the fusion-bonded parts of the cables with a cutter so that the 40058384 and 40058385 cables can be bent to the Y-axis veyor-cables at an angle of 90 degrees. Incise with a cutter.

  • Page 39: Removing The Y Veyor-Cable

    Maintenance Guide 1-8-5. Removing the Y Veyor-Cable (1) Disconnect the binding of the swing part (connector bracket) at the entrance of the Y-axis plastic rail and the relay connector. Figure 1-8-5-1 (2) Detach the cover of the Y plastic rail and remove the cable to be replaced. Figure 1-8-5-2 1-8-6.

  • Page 40: Assembling The Cables

    Maintenance Guide 1-8-7. Assembling the Cables (1) Apply the grease to the portions of the 40058384 and 40058385 cables, which are to be stored into the plastic rail. (2) Place the 40058384 cables on the cables routed from the X-axis so that its CN166 side is located inside (Figure 1-8-7-1).
  • Page 41 Maintenance Guide (4) Align the marking of the 40058384 cables with the end surface of the cable clamp YB (of the plastic rail side) and fix the cables. Place marks on the sides of 40058385 cables aligning with the marking of 40058384 cables. 40058384 (410mm) Fix at the marking position.
  • Page 42 Maintenance Guide (6) Bind the lower portion of the plastic rail support as shown in the figure below. Figure 1-8-7-5 Figure 1-8-7-6 (7) Wiring of the XL motor Figure 1-8-7-7 1-32...
  • Page 43 Maintenance Guide (8) Wiring of the XL motor relay line, limit sensor relay line, and YL magnescale relay line Figure 1-8-7-8 (9) Wiring of the XR motor relay line, limit sensor relay line, and YR magnescale relay line Figure 1-8-7-9 1-33...
  • Page 44 Maintenance Guide (10) Place a mark at the top end of the mounting fixture with the Y-veyor-cable pulled in the direction shown in the figure below. Next, place a mark with the cable pushed in the direction in the same manner as described above. (For details, see the figure below.) (11) Hold the cables with the cable clamp YB at a position where the center position between two mark positions meets the top end of the mounting fixture and secure them.
  • Page 45 Maintenance Guide 1-8-8. Wiring around the Head Connect the cables coming from the XY-veyor-cable (40058385) to the following locations. It is common throughout KE2070/2070C/2080, KE1070/1070C/1080 (1) Pass the cables CN801, CN802, and CN808 through the hole shown in the following figure and insert them until the far side of the head main board.

  • Page 46: Replacing The Cables In The X/Y Veyor-Cable (Ke-2080R)

    Maintenance Guide 1-9. Replacing the Cables in the X/Y Veyor-Cable (KE-2080R) 1-9-1. Removing the X Cable (1) Detach the head top cover and disconnect the connectors connected to XY veyor-cable, 1394 robot cable, and OPTICAL FIBER CABLE 7M LA sensor veyor-cable. Figure 1-9-1-1 OPTICAL FIBER CABLE 7M 1394 robot cable...
  • Page 47 Maintenance Guide LA sensor veyor-cable Figure 1-9-1-3 1-37...
  • Page 48 Maintenance Guide (2) Detach the FC support. Then cut and remove the tie-up band. FC support Figure 1-9-1-4 (3) Detach the cable clamp X from the X-axis plastic rail CB support, and then cut and remove the tie-up bands. Cable clamp X Figure 1-9-1-5 (4) Detach the cover of the plastic rail and remove the cable to be replaced.

  • Page 49: Checking The Cable Marking (X)

    Maintenance Guide 1-9-2. Checking the Cable Marking (X) (1) Check the marking position of the XY veyor-cable (40058385). (Place the marks at a position 350mm from the CN805 connector end.) For the machine with the extra specifications, the following cables are used. XY veyor-cable (E) 40059779 Y veyor-cable (E) 40059789 This instruction also applies to the following pages.
  • Page 50 Maintenance Guide (3) Check the marking position of the LA sensor veyor-cable (40080206). (Place the marks at a position 700mm from the ZTD-CN5 connector end.) For the machine with the extra specifications, the following cable is used. LA sensor veyor-cable (E) 40080214 This instruction also applies to the following pages.

  • Page 51: Assembling The Cable

    Maintenance Guide 1-9-3. Assembling the Cable (1) Apply the grease to portions where the 40058385, 40044517, 40044543, and 40080206 cables are put in the plastic rail, and place the cables and air tubes in the X-axis plastic rail as shown in the figure below (figure viewed from A). Check the connector orientation and take care so that the air tubes do not become warped.
  • Page 52 Maintenance Guide (3) For the head side of the cable, align the marking positions of the cables with the upper end of the FC support and secure them. (4) For the opposite side, place a mark at the top end of the mounting fixture with the cable pulled in the direction shown in the figure below.

  • Page 53: Separating The Fusion-Bonded Parts Of The Cables

    Maintenance Guide 1-9-4. Separating the Fusion-bonded Parts of the Cables (1) Separate the fusion-bonded parts of the cables with a cutter so that the 40058384 and 40058385 cables can be bent to the Y-axis veyor-cables at an angle of 90 degrees. Incise with a cutter.

  • Page 54: Removing The Y Veyor-Cable

    Maintenance Guide 1-9-5. Removing the Y Veyor-Cable (1) Disconnect the binding of the swing part (connector bracket) at the entrance of the Y-axis plastic rail and the relay connector. Figure 1-9-5-1 (2) Detach the cover of the Y plastic rail and remove the cable to be replaced. Figure 1-9-5-2 1-9-6.

  • Page 55: Assembling The Cables

    Maintenance Guide 1-9-7. Assembling the Cables (1) Apply the grease to the portions of the 40058384 and 40058385 cables, which are to be stored into the plastic rail. (2) Place the 40058384 cables on the cables routed from the X-axis so that its CN166 side is located inside (Figure 1-9-7-1).
  • Page 56 Maintenance Guide (4) Align the marking of the 40058384 cables with the end surface of the cable clamp YB (of the plastic rail side) and fix the cables. Place marks on the sides of 40058385 cables aligning with the marking of 40058384 cables. 40058384 (410mm) Fix at the marking position.
  • Page 57 Maintenance Guide (6) Bind the lower portion of the plastic rail support as shown in the figure below. Figure 1-9-7-5 Figure 1-9-7-6 (7) Wiring of the XL motor Figure 1-9-7-7 1-47...
  • Page 58 Maintenance Guide (8) Wiring of the XL motor relay line, limit sensor relay line, and YL magnescale relay line Figure 1-9-7-8 (9) Wiring of the XR motor relay line, limit sensor relay line, and YR magnescale relay line Figure 1-9-7-9 1-48...
  • Page 59 Maintenance Guide (10) Place a mark at the top end of the mounting fixture with the Y-veyor-cable pulled in the direction shown in the figure below. Next, place a mark with the cable pushed in the direction in the same manner as described above. (For details, see the figure below.) (11) Hold the cables with the cable clamp YB at a position where the center position between two mark positions meets the top end of the mounting fixture and secure them.

  • Page 60: Wiring Around The Head

    Maintenance Guide 1-9-8. Wiring around the Head Connect the cables coming from the XY-veyor-cable (40058385) to the following locations. (Common for KE2070/2080) (1) Pass the cables CN801, CN802, and CN808 through the hole shown in the following figure and insert them until the far side of the head main board. (2) Insert the camera cable (CN805) into the left side of the triple-connector on the head main board.

  • Page 61: Head Unit

    Maintenance Guide To prevent any trouble caused by accidental machine start, always shut-down the power before starting the maintenance and DANGER adjustment work. HEAD UNIT 2-1. Replacing and Adjusting the Head 2-1-1. LNC Head Head main board Ejector bracket Figure 2-1-1 Figure 2-1-2 (1) Turn OFF the compressed air to the machine main unit.
  • Page 62 Maintenance Guide (12) While keeping the head by hand so that it does not fall down, remove the M5 16 SEMS cap bolts (6 pcs.). (13) Pull out two parallel pins. Raise the head so that it is not in contact with other components, and then detach it.

  • Page 63: Ic Head (Ke-1080/2080)

    Maintenance Guide 2-1-2. IC Head (KE-1080/2080) 6 air tube Point sensor amplifier 4 air tube Figure 2-1-5 (1) Disconnect the Z -motor cables from the servo amplifier board. (2) Disconnect the Z-sensor cables from the head main board. (3) Disconnect the fibers (2 pcs.) from the point sensor amplifier and detach the amplifier main unit from the bracket.

  • Page 64: Ic Head (Ke-2080R)

    Maintenance Guide 2-1-3. IC Head (KE-2080R) (1) Disconnect the Z -motor cables from the servo amplifier board. (2) Disconnect the Z-sensor cables and T-sensor cables from the head main board. (3) Disconnect the connector of the LA connection cable from the FMLA sensor. (4) Disconnect the 4 and 6 air tubes.

  • Page 65: Replacing The Motor

    Maintenance Guide 2-2. Replacing the Motor 2-2-1. Z-Motor (LNC Head) After the Z motor has been replaced, it is absolutely necessary to re-input the MS parameters related to the Z-axis home position adjustment, Z-axis height, and laser. (For details of input items, see section 2-9.) (1) Disconnect the motor cables from the servo amplifier board.
  • Page 66 Maintenance Guide <Procedure> Put the screw in the tap of the Z-motor and lock the mounting screw with the screw pulled in the direction indicated by an arrow with a force of 21.6 N (2.2 kgf) using a tension gauge. Tension meter set value (For check) Timing belt Z Weight: 0.9g/m...

  • Page 67: Motor (Lnc Head)

    Maintenance Guide 2-2-2. -Motor (LNC Head) After the -motor has been replaced, it is absolutely necessary to re-input the MS parameters related to the axis home. (For details of input items, see section 2-9.) (1) Disconnect the motor cables from the servo amplifier board.

  • Page 68: Z-Motor (Ic Head)

    Maintenance Guide 2-2-3. Z-Motor (IC Head) After the Z-motor has been replaced, it is absolutely necessary to re-input the MS parameters related to the Z-axis home position adjustment, Z-axis height, and laser. (For details of input items, see section 2-9.) (1) Disconnect the motor cables from the servo amplifier board.
  • Page 69 Maintenance Guide <Procedure> With the flange part of the Z-motor kept pushed with a force of 21.6N (2.2kgf) using the bar tension in the direction indicated by an arrow, secure the flange part using the mounting screws. Tension meter set value (For check) Push Weight: 0.9g/m Width: 8.0mm Span: 32mm...

  • Page 70: Motor (Ic Head: Ke-1080/2080)

    Maintenance Guide 2-2-4. -Motor (IC Head: KE-1080/2080) After the -motor has been replaced, it is absolutely necessary to re-input the MS parameters related to the axis home. (For details of input items, see section 2-9.) (1) Disconnect the motor cables from the servo amplifier board. (2) Remove the mounting screws (3 pcs.) of the IC T-motor bracket.

  • Page 71: Motor (Ic Head: Ke-2080R)

    Maintenance Guide 2-2-5. -Motor (IC Head: KE-2080R) After the -motor has been replaced, it is absolutely necessary to re-input the MS parameters related to the axis home. (For details of input items, see section 2-9.) (1) Disconnect the motor cables from the servo amplifier board.

  • Page 72: Replacing The Z-Sensor

    Maintenance Guide 2-3. Replacing the Z-Sensor After the Z-sensor has been replaced, perform the home position return to check that it functions correctly. After the home position return has been completed, it is necessary to input the MS parameters related to the Z-axis again. (For details about input items, see section 2-9.) 2-3-1.

  • Page 73: Ic Head

    Maintenance Guide 2-3-2. IC Head (1) Remove the mounting screws (2 pcs.) of the IC Z-sensor bracket and detach the bracket. (2) Cut the tie-up bands binding the Z-sensor cable and replace the Z-sensor. (3) Reassemble the components in the reverse order of assembly. Figure 2-3-2 (4) Check following the procedure below and make adjustments if necessary.

  • Page 74: Replacing The T-Sensor (Ke-2080R)

    Maintenance Guide 2-4. Replacing the T-Sensor (KE-2080R) After the T-sensor has been replaced, perform the home position return to check that it functions correctly. (For details about input items, see section 2-9.) (1) Detach the T-sensor bracket from the head. (2) Remove the mounting screws (2 pcs.) of the T-sensor bracket and detach the bracket.

  • Page 75: Replacing The Laser Sensor

    Maintenance Guide 2-5. Replacing the Laser Sensor 2-5-1. Replacing the LNC After the LNC has been replaced, it is absolutely necessary to re-input the MS parameters related to the laser. (See section 2-9.) (1) Disconnect the connectors (encoder and IEEE1394) and remove the mounting screws (3 pcs.) to detach the LNC.

  • Page 76: Replacing The Point Sensor (Ke-1080/2080)

    Maintenance Guide 2-5-2. Replacing the Point Sensor (KE-1080/2080) After the point sensor has been replaced, it is absolutely necessary to re-input the MS parameters related to the laser. (See section 2-9.) (1) Disconnect the fiber from the point sensor amplifier. (2) Remove the mounting screws (4 pcs.) from the diffuser base and detach the point sensor assembly.
  • Page 77 Maintenance Guide <Adjusting the offset and sensitivity of the point sensor> (1) Before starting the adjustment, set the sensitivity change-over switch to “NORM” and the response time change-over switch to “FAST”. (2) Connect “+” and “-“ of the voltmeter to the check terminals TP23 and TP21 on the HEAD MAIN PCB ASM, respectively.

  • Page 78: Replacing The Fmla (Ke-2080R)

    Maintenance Guide 2-5-3. Replacing the FMLA (KE-2080R) After the LA sensor has been replaced, it is absolutely necessary to re-input the MS parameters related to the laser. (See section 2-9.) After the replacement work has been completed, clean the laser window of the LA sensor with a clean cloth rag.
  • Page 79 Maintenance Guide After cutting the tie-up band(s) to remove the FMLA, bundle cables as shown below. Connector on far side of EA9500B0100 left sensor Tie-up band (small) 40080206 LA SENSOR BEAR CABLE ASM Insert the cable assembly firmly. Connector on front side of left sensor E93457210A0 LA SENSOR CONNECT...

  • Page 80: Replacing The Head Up Cylinder

    Maintenance Guide 2-6. Replacing the Head Up Cylinder (1) Turn OFF the compressed air to the main unit and disconnect the air tubes. Air cylinder (2) Remove the head up springs from both ends, and then remove the nut from the top end of the air cylinder to detach the release bar.

  • Page 81: Replacing The Belts

    Maintenance Guide 2-7. Replacing the Belts 2-7-1. LNC Head <Replacing the timing belt Z> After the timing belt Z has been replaced, it is absolutely necessary to re-input the MS parameters related to the Z-axis home position adjustment, Z-axis height, and laser. (For details of input items, see section 2-9.) (1) Loosen the screws (3 pcs.) shown in the...

  • Page 82: Ic Head

    Maintenance Guide 2-7-2. IC Head <Replacing the timing belt Z IC> After the timing belt Z IC has been replaced, it is absolutely necessary to re-input the MS parameters related to the Z-axis home position adjustment, Z-axis height, and laser. (For details of input items, see section 2-9.) (1) Loosen the screws (3 pcs.) shown in...
  • Page 83 Maintenance Guide <Replacing the timing belt : KE-2080R> After the timing belt has been replaced, it is absolutely necessary to re-input the MS parameters related to the Z-axis home. (For details of input items, see section 2-9.) (1) Detach the T-sensor dog (2) Loosen the stop screws (2 pcs.) of the Timing belt spline pulley...

  • Page 84: Replacing The Z-Slide Shaft

    Maintenance Guide 2-8. Replacing the Z-Slide Shaft When the Z-slide shaft has been replaced, it is necessary to input the MS parameters related to -axis and Z-axis home position adjustment, Z-axis height, and laser again. (For details about input items, see section 2-9.) (1) Remove the set screws from the lower portion of the coupling.

  • Page 85: List Of Readjustment Items After Replacement

    Maintenance Guide 2-9. List of Readjustment Items after Replacement Laser Laser Head Mounting VCS camera VCS general offset scaling offset general offset offset offset Head unit assembly (Note 2) (Note 1) (Note 1) Z-motor (Note 2) (Note 1) (Note 1) -motor Z-sensor T-sensor...

  • Page 86: Parts Around The Head

    Maintenance Guide To prevent any trouble caused by accidental machine start, always shut-down the power before starting the maintenance and DANGER adjustment work. PARTS AROUND THE HEAD 3-1. Replacing the Ejector Unit Before replacing the ejector unit, always shut-down the main compressed air. Since both the solenoid valve and pressure sensor are a type of connector connection, carefully connect them to avoid improper connections.

  • Page 87: Replacing The Bad Mark Sensor

    Maintenance Guide 3-2. Replacing the Bad Mark Sensor 3-2-1. Sensor Assembly KE-1070/2070 mounting HMS bracket position BM holder KE-2080 mounting position M3 6 SEMS cap ( 2) Washer Fiber lens Figure 3-2-1 Replacing the Bad Mark Sensor Secure the fiber with the nut and washer supplied with the fiber. After the fiber is secured as illustrated in the figure above, mount the zoom lens.

  • Page 88: Amplifier

    Maintenance Guide 3-2-3. Amplifier Left OCC camera Left OCC camera Left OCC camera assembly assembly assembly Camera bracket Camera bracket Camera bracket Amplifier bracket Bad mark sensor Bad mark sensor amplifier Bad mark sensor amplifier F10R amplifier F70R F70R Washer assembled Hexagon socket hexagon socket head cap screw with...

  • Page 89: Setting The Switches On The Bad Mark Sensor Assembly (F10R Amplifier)

    Maintenance Guide 3-2-5. Setting the Switches on the Bad Mark Sensor Assembly (F10R Amplifier) Use the bad mark sensor assembly with the settings made before shipment from the factory (default settings). SET button Mode switch AUTO Output timer Operation mode selector switch selector switch NORMAL...
  • Page 90 Maintenance Guide LNC60 motor cover Bad mark sensor amplifier (F70R) 4006356: AMP BRACKET Accessories: DIN rail Hexagon socket head bolt (x 2) Amplifier mounting (before M/C Rev. L) LNC60 motor cover 40063956 AMP BRACKET Accessories: DIN rail...
  • Page 91 Maintenance Guide Mounting onto the amplifier of the fiber unit Set down the lock lever of the main unit, and insert the projecting side of the fiber unit up to the innermost while turning this side toward the bottom of the amplifier. After inserting the projecting side up to the innermost, set the lock lever at the original status and make sure that the fiber unit cannot come out.

  • Page 92: Manual Setting Method For The F70R Fiber Sensor Amplifier

    Maintenance Guide 3-2-7. Manual Setting Method for the F70R Fiber Sensor Amplifier The amplifier setting method is different from the factory-set status. Set this amplifier manually. Setting the operation mode Operation mode Sensor function Mode switch Selecting the sensor function (teaching mode setting method) Switch the sensor mode switch from [RUN] to [SELECT].

  • Page 93: Replacing The Hms

    3-3-1. Replacing the HMS Head When viewed from the Hexagon socket mounting hole positions: head cap bolt ( 2) For a KE-1070/1070C For a KE-2070/2070C For a KE-2080/1080 Figure 3-3-1 Replacing the HMS Head 3-3-2. Replacing the Amplifier After the amplifier has been mounted, try to move it to check that it does not come off.

  • Page 94: Sticking The Label

    Maintenance Guide 3-3-3. Sticking the Label After the label sticking surface has been degreased, stick the label. Figure 3-3-3 Replacing the Amplifier (Left: label/right: label stuck) 3-3-4. Adjusting the HMS Height Move the HMS sensor to a point above the calibration block. Loosen the SEMS cap bolts at two places so that the distance between the bottom surface of the height sensor and the top surface of the calibration block becomes 40 0.2 mm.

  • Page 95: Replacing The Head Board

    Maintenance Guide 3-4. Replacing the Head Board 3-4-1. Replacing the Head Main Board Round screw ( 4) Head top cover Round head screw ( 6) Head main board assembly Figure 3-4-1 Replacing the Head Main Board Since the head main board is delivered after it has been adjusted correctly, no adjustment work is required.
  • Page 96 Maintenance Guide To replace the head main board and the servo amplifier board with other ones respectively, cut the tie-up band shown in Figure 3-4-2, and then remove them only after confirming that any load will not be applied to each wire. In addition, be careful so that any bending load exceeding 60 degrees cannot be applied to the root of the connector.

  • Page 97: Occ Assembly

    Maintenance Guide To prevent any trouble caused by accidental machine start, always shut-down the power before starting the maintenance and DANGER adjustment work. OCC ASSEMBLY 4-1. Replacing the OCC Assembly (1) Remove the SEMS cap bolts , the head screws and detach the camera.

  • Page 98: Replacing The Ccd Camera And Lens

    Maintenance Guide 4-2. Replacing the CCD Camera and Lens (1) Detach the camera assembly from the head plate using the procedure described in section 4-1, Replacing the OCC Assembly. (2) Remove the fixing screws securing the CCD camera and lens, and replace the CCD camera and lens.

  • Page 99: Replacing The Occ Front/Angle Light Board Assembly

    Maintenance Guide 4-3. Replacing the OCC Front/Angle Light Board Assembly (1) Detach the light assembly from the head plate using the procedure described in 4-1. "Replacing the OCC Assembly". (2) Remove the pan head machine screw to detach the OCC front light board assembly. (3) Remove the washer assembled hexagon socket head cap bolt to detach the OCC angle light board assembly.

  • Page 100: Replacing The Lens Filter

    Maintenance Guide 4-4. Replacing the Lens Filter (1) Detach the light assembly from the head plate using the procedure described in "Replacing the OCC Assembly". (2) Remove the washer assembled hexagon socket head cap bolt, collar and shoulder screws to detach the light filter U support, lens filter and guide plate. (3) Remove the countersunk-head screws to detach the lens filter (4) Reassemble the components in the reverse order of disassembly.

This manual is also suitable for:

Ke-1070cKe-2070cKe-2070Ke-1080Ke-2080Ke-2080r

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