Juki Ke-3010 Operating manual

High-Speed Chip Shooter

KE-3010

High-Speed Flexible Mounter

KE-3020V/3020VR

MAINTENANCE GUIDE

JUKI CORPORATION

CUSTOMER SUPPORT DEPARTMENT

ELECTRONIC ASSEMBLY SYSTEMS BUSINESS UNIT

Important

(1) No part of this document may be copied or reproduced without the prior

permission of JUKI Corporation. (Including software and program)

(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

or ﬁnd any error or omission in writing, contact our dealer or JUKI Corporation.

(4) JUKI Corporation shall disclaim all the responsibility for any trouble resulting

from the user's abnormal operation regardless of Item (3).

(5) Windows is a registered trademark of Microsoft Corporation USA.

The company names and product names mentioned in this document are

generally registered trademarks or trademarks of the respective companies.

Rev. 2.0

Maintenance Guide

Table of Contents

[1] X-Y UNIT...............................................................................................................1-1

1-1. Replacing the Servomotor...................................................................................1-1

1-1-1. Replacing the X-Motor .............................................................................1-1

1-1-2. Replacing the YL-Motor ...........................................................................1-3

1-1-3. Replacing the YR-Motor...........................................................................1-5

1-2. Replacing the Magnescale ..................................................................................1-7

1-2-1. X-Axis Magnescale Affixing Position........................................................1-9

1-2-2. Y-Axis Magnescale Affixing Position......................................................1-11

1-2-3. Adjusting the Clearance of the Magnescale...........................................1-13

1-2-4. Clearance between the Sensor Head and Y-Axis LM Guide

(Y-axis_XL Board Specifications Only) ..................................................1-16

1-3. Replacing the Limit Sensor and Origin Near Sensor .........................................1-17

1-3-1. Replacing the X-Axis Limit Sensor and

the X-Axis Home Proximity Sensor........................................................1-17

1-3-2. Replacing the Y-Axis Limit Sensor and

the Y-Axis Home Proximity Sensor........................................................1-21

1-3-3. Checking the Limit Sensor Operation ....................................................1-25

1-3-4. Checking the X- and Y-NEAR SENSOR Operation ...............................1-27

1-4. Replacing the Home Position Sensor................................................................1-29

1-4-1. X-Axis ....................................................................................................1-29

1-4-2. Y-Axis ....................................................................................................1-29

1-5. Replacing the Cableveyor .................................................................................1-30

1-5-1. Replacing the X-Axis Cableveyor ..........................................................1-30

1-5-2. Replacing the Y-Axis Cableveyor ..........................................................1-32

1-6. Replacing the Cables in the X/Y Veyor-Cable...................................................1-34

1-6-1. Removing the X Cable ...........................................................................1-34

1-6-2. Checking the Cable Marking (X) ............................................................1-36

1-6-3. Assembling the Cable ............................................................................1-37

1-6-4. Removing the Y Veyor-Cable ................................................................1-40

1-6-5. Placing Marks on the Y Veyor-Cable .....................................................1-40

1-6-6. Assembling the Cable ............................................................................1-41

1-6-7. Wiring around the Head .........................................................................1-48

1-7. Replacing the Cableveyor Link..........................................................................1-51

1-7-1. X Cableveyor Structure and Part Names ...............................................1-51

1-7-2. Detaching the Arm and Lock Stay .........................................................1-51

1-7-3. Separating the Link................................................................................1-52

Rev. 2.0

Maintenance Guide

1-7-4. Connecting the Cableveyor....................................................................1-52

1-7-5. Mounting the Arm and Lock Stay...........................................................1-53

1-7-6. Y Cableveyor Structure and Part Names...............................................1-54

1-7-7. Detaching the Arm and Lock Stay .........................................................1-54

1-7-8. Separating the Link................................................................................1-55

1-7-9. Connecting the Cableveyor....................................................................1-56

1-7-10. Mounting the Arm and Lock Stay...........................................................1-56

1-8. Replacing the X Ball Screw...............................................................................1-58

1-8-1. Preparations for X Ball Screw Replacement..........................................1-58

1-8-2. Removing the X Ball Screw ...................................................................1-60

1-8-3. Mounting the X Ball Screw.....................................................................1-63

1-8-4. Adjusting the X Ball Screw.....................................................................1-66

1-9. Replacing the Y Ball Screw...............................................................................1-70

1-9-1. Preparations for Y Ball Screw Replacement..........................................1-70

1-9-2. Removing the Y Ball Screw ...................................................................1-78

1-9-3. Mounting the Y Ball Screw.....................................................................1-83

1-9-4. Adjusting the Y Ball Screw.....................................................................1-88

[2] HEAD UNIT ..........................................................................................................2-1

2-1. Replacing and Adjusting the Head......................................................................2-1

2-1-1. LNC60 Head............................................................................................2-1

2-1-2. IC Head (KE-3020V)................................................................................2-4

2-1-3. IC Head (KE-3020VR) .............................................................................2-5

2-2. Replacing the Motor............................................................................................2-6

2-2-1. Replacing the Z-Motor (LNC60 Head) .....................................................2-6

2-2-2. Replacing the θ-Motor..............................................................................2-7

2-2-3. Replacing the Z-Motor (IC Head).............................................................2-8

2-2-4. Replacing the θ-Motor (IC Head).............................................................2-9

2-3. Replacing the T-Sensor.....................................................................................2-10

2-4. Replacing the Laser Sensor..............................................................................2-11

2-4-1. Replacing the Laser Sensor (LNC60)....................................................2-11

2-4-2. Replacing the Point Sensor (KE-3020V)................................................2-12

2-4-3. Replacing the FMLA (KE-3020VR)........................................................2-14

2-5. Replacing the Head Up Cylinder.......................................................................2-16

2-6. Replacing the Belts ...........................................................................................2-17

2-6-1. Replacing the Timing Belt Z...................................................................2-17

2-6-2. Replacing the Timing Belt θ...................................................................2-17

2-6-3. IC Head..................................................................................................2-18

2-7. Replacing the Z-Slide Shaft...............................................................................2-20

Rev. 2.0

Maintenance Guide

2-8. Readjustment After Replacement of Head Unit.................................................2-21

[3] PARTS AROUND THE HEAD ..............................................................................3-1

3-1. Replacing the Solenoid Valve Components ........................................................3-1

3-1-1. Replacing the Solenoid Valves ................................................................3-1

3-1-2. Replacing the Filter..................................................................................3-2

3-1-3. Replacing the Filter for Release to Atmosphere ......................................3-2

3-2. Replacing the Bad Mark Sensor (Optional) .........................................................3-3

3-2-1. Sensor Assembly.....................................................................................3-3

3-2-2. Adjusting the Sensor Height ....................................................................3-4

3-2-3. Amplifier...................................................................................................3-5

3-2-4. Assembling the Fiber Unit to the Amplifier ...............................................3-5

3-2-5. Setting the Switches on the Bad Mark Sensor Assembly ........................3-6

3-3. Replacing the HMS .............................................................................................3-6

3-3-1. Replacing the HMS Head ........................................................................3-6

3-3-2. Adjusting the HMS Height........................................................................3-7

3-4. Replacing the Head Board ..................................................................................3-8

3-4-1. Replacing the Head Main Board ..............................................................3-8

3-4-2. Replacing the Servo Amplifier Board .......................................................3-9

[4] OCC ASSEMBLY..................................................................................................4-1

4-1. Replacing the OCC Assembly.............................................................................4-1

4-2. Replacing the CCD Camera and Lens ................................................................4-2

4-3. Replacing the OCC Coaxial/Angle Light Board Assemblies................................4-3

4-4. Replacing the Lens Filter/Light Diffuser...............................................................4-4

4-5. Adjusting the Focus.............................................................................................4-6

4-6. Adjusting the OCC Light Quantity........................................................................4-7

4-7. Readjustment After Replacement of OCC Unit ...................................................4-7

[5] BOARD TRANSPORT UNIT ................................................................................5-1

5-1. Replacing the Transport Belt...............................................................................5-1

5-2. Replacing the Transport Pulley ...........................................................................5-2

5-2-1. Transport Pulley A Assembly: E21117150A0 ..........................................5-2

5-2-2. Transport Pulley B Assembly: E20897210A0 ..........................................5-2

5-3. Replacing the IN and OUT Motors ......................................................................5-3

5-4. Replacing the CENTER Motor ............................................................................5-4

5-5. Replacing the Timing Belt ...................................................................................5-5

5-5-1. Replacing the Timing Belt for Adjustment of the Transport Width............5-5

5-5-2. Replacing the Timing Belt for the Transport Motor ..................................5-7

5-6. Replacing the LEFT and RIGHT Sensors ...........................................................5-8

Rev. 2.0

Maintenance Guide

5-6-1. Replacing the LEFT and RIGHT Sensors

(M and L Board Specifications)................................................................5-8

5-6-2. Replacing the LEFT and RIGHT Sensors (XL Board Specifications).....5-10

5-7. Replacing the WAIT/STOP/C-OUT Sensors .....................................................5-12

5-7-1. Replacing the WAIT Sensor (M and L Board Specifications).................5-12

5-7-2. Replacing the WAIT Sensor (M and L Board Specifications).................5-13

5-7-3. Replacing the WAIT, STOP and C-OUT Sensors

(XL Board Specifications) ......................................................................5-15

5-8. Replacing the Stopper Cylinder.........................................................................5-20

5-9. Replacing the Support Table Home Position Sensor

(BU Home Position Sensor) ..............................................................................5-21

5-10. Replacing the T-PIN Sensor (Optional) .............................................................5-22

5-11. Replacing the Pusher Y Cylinder (Outer Shape Reference) .............................5-23

5-12. Replacing the Pressure Reducing Valve ...........................................................5-24

5-13. Replacing the Centering Pin (Option)................................................................5-25

5-14. Replacing the Support Table Motor (BU Motor) ................................................5-26

5-14-1. Adjusting the Gap between Torque Supporter and Support Motor ........5-27

5-14-2. Adjusting the Tension of the Support Table Driving Timing Belt ............5-28

5-14-3. Placing the Support Table Surface Horizontally.....................................5-29

5-15. Replacing the Support Table Encoder...............................................................5-30

5-16. Replacing the Backup Stopper (for EN Type Only) ...........................................5-31

5-17. Solenoid Valve ..................................................................................................5-32

[6] CAL BLOCK.........................................................................................................6-1

6-1. Replacing the CAL Block Board Assembly..........................................................6-1

6-2. Replacing the Ejector ..........................................................................................6-2

6-3. Replacing the Load Cell ......................................................................................6-3

[7] ATC.......................................................................................................................7-1

7-1. Replacing the Air Cylinder...................................................................................7-1

7-2. Replacing the ATC OPEN and CLOSE Sensors .................................................7-4

7-3. Adjusting the Speed Controller............................................................................7-4

[8] VCS.......................................................................................................................8-1

8-1. Replacing the CCD Camera Lens

(Replace the CCD Camera and Lens as S-VCS Camera Assembly.).................8-1

8-2. Replacing the Standard S-VCS →Optional S-VCS Switching Cylinder..............8-3

8-3. Replacing the Light Boards .................................................................................8-4

8-3-1. Transmission Light Board, Coaxial Light Board .......................................8-4

8-3-2. Downward Light Board, Side Light Board ................................................8-5

Rev. 2.0

Maintenance Guide

[9] FEEDER BANK AND REPLACEMENT TABLE (OPTIONAL).............................9-1

9-1. Common Parts and Units for Mechanical Feeder and Electric Feeder................9-1

9-1-1. Replacing the Mechanical Valve (Optional Replacement Table) .............9-3

9-1-2. Replacing the Bank-up Cylinder (Optional Replacement Table)..............9-5

9-1-3. Adjusting the Speed Controller of the Bank-Up Cylinder

(Optional Replacement Table) .................................................................9-7

9-1-4. Replacing the Bank-Up Detection Sensor

(Optional Replacement Table) .................................................................9-8

9-1-5. Replacing the Selector Switch (Optional Replacement Table).................9-9

9-1-6. Replacing the Cylinder for Drive Cylinder Unit Up/Down

(Specifications Common to Optional Electric and

Mechanical Replacement Tables)..........................................................9-10

9-1-7. Replacing the Cylinder Sensor for Drive Cylinder Unit Up/Down

(Specifications Common to Optional Electric and

Mechanical Replacement Tables)..........................................................9-11

9-1-8. Replacing the Electric Bank Support Cylinder

(Optional Replacement Table) ...............................................................9-12

9-2. Bank and Replacement Table for Mechanical Feeder.......................................9-14

9-2-1. Replacing the Drive Cylinder

(Mechanical Fixed Bank and Mechanical Replacement Table) .............9-15

9-2-2. Replacing the Drive Cylinder

(Specifications Common to Optional Electric and

Mechanical Replacement Tables)..........................................................9-17

9-2-3. Adjusting the Speed Controller of the Drive Cylinder.............................9-19

9-2-4. Replacing the Feeder Bank Board (Optional) ........................................9-19

9-2-5. Replacing the Bank PCB .......................................................................9-20

9-3. Bank and Replacement Table for Electric Feeder.............................................9-21

9-3-1. Replacing the Bank PCB .......................................................................9-23

9-3-2. Replacing the Connector Cable .............................................................9-24

9-3-3. Replacing the Connector for Off-Line Setup ..........................................9-25

9-4. Trash Box..........................................................................................................9-26

[10] PNEUMATIC UNITS ...........................................................................................10-1

10-1. Replacing the Digital Pressure Switch...............................................................10-1

10-1-1. Adjusting the Digital Pressure Switch (Positive Pressure) .....................10-2

10-1-2. Adjusting the Digital Pressure Switch (Negative Pressure)....................10-4

10-2. Replacing the Filter Element .............................................................................10-6

10-3. Replacement of Vacuum Pump Parts ...............................................................10-7

[11] SWITCH AND COVER RELATED......................................................................11-1

Rev. 2.0

Maintenance Guide

11-1. Replacing the Push-Button Switch ....................................................................11-1

11-1-1. Replacing the Push-Button Switch

(Machine with the Standard Specifications) ...........................................11-1

11-1-2. Replacing the Push-Button Switch

(Machine with the EN Specifications) ....................................................11-3

11-2. Replacing the EMERGENCY STOP Switch ......................................................11-4

11-3. Replacing the Cover Open Switch.....................................................................11-5

11-4. Replacing the Safety Cover Lock Cylinder ........................................................11-6

[12] REPLACING AND ADJUSTING THE FEEDER FLOAT SENSOR ....................12-1

12-1. Replacing the Sensor and Adjusting the Height ................................................12-1

12-2. Checking and Adjusting the Sensor Operation..................................................12-8

[13] OTHER UNITS....................................................................................................13-1

13-1. LCD Monitor ......................................................................................................13-1

13-1-1. Replacing the LCD Monitor....................................................................13-1

13-1-2. Setting Up the Touch Panel ...................................................................13-2

13-2. Replacing the System Disk ...............................................................................13-4

13-2-1. Replacing the SSD ................................................................................13-4

13-2-2. Setting Up the BIOS...............................................................................13-7

13-2-3. Setting Up the Network

(Setup is required when communicating with the IS.) ..........................13-13

13-2-4. KE-3010/3020V/3020VR System Programs ........................................13-24

13-2-5. Upgrading the System Version ............................................................13-33

13-2-6. Installing the Main Unit Software into the SSD for the White List Type

Antivirus Software (Optional) ...............................................................13-39

13-3. Load Cell (Optional) ........................................................................................13-41

13-3-1. Replacing the Load Cell.......................................................................13-41

13-4. Coplanarity Sensor (Optional) .........................................................................13-43

13-4-1. Replacing the Sensor...........................................................................13-43

13-4-2. Changing the IP Address of the Coplanarity CPU ...............................13-45

13-4-3. Changing the Mounter Settings ...........................................................13-49

[14] ELECTRICAL COMPONENTS...........................................................................14-1

14-1. Layout of Electrical Components.......................................................................14-1

14-1-1. Layout of Electrical Components (M and L Board Specifications) .........14-1

14-1-2. Layout of Electrical Components (XL Board Specifications) ..................14-3

14-2. Power Supply Unit.............................................................................................14-5

14-2-1. Structure of Power Supply Unit (M and L Board Specifications) ............14-5

14-2-2. Structure of Power Supply Unit (XL Board Specifications)...................14-12

Rev. 2.0

Maintenance Guide

14-3. Control Unit .....................................................................................................14-19

14-3-1. Structure of Control Unit ......................................................................14-19

14-3-2. CPU Board (40103723) .......................................................................14-20

14-3-3. Position Board (40044540) ..................................................................14-21

14-3-4. IEEE1394 Board (40048003)...............................................................14-22

14-3-5. ETHER-MAIN Board (40048066).........................................................14-23

14-3-6. IP-X7 BASE ASM (40071283), IP-X7 SUB ASM (40071293) ..............14-24

14-3-7. MOUSE/KEYBOARD Selector (40003281) .........................................14-25

14-3-8. SUPERIMPOSE Board (40048082).....................................................14-26

14-3-9. SCM3 Board (40114496) Laser Board for FMLA

(KE-3020VR Only) ...............................................................................14-27

14-3-10. S-Light Control (40108607)..................................................................14-27

14-3-11. Feeder Board (40047560)....................................................................14-27

14-3-12. S-XY Relay Board (40106795) ............................................................14-27

14-3-13. MAGNETIC SCALE Board (40095130) (XL Specifications Only) ........14-27

14-3-14. BASE IO Board (40071680).................................................................14-27

14-4. ATX Power Supply (40048006) .......................................................................14-28

14-4-1. Battery Unit (40048007).......................................................................14-29

14-5. X-Y Unit...........................................................................................................14-31

14-5-1. Structure of X-Y Unit ............................................................................14-31

14-5-2. Display Indication of XY Servo Amplifier..............................................14-32

14-6. Z-θUnit ...........................................................................................................14-33

14-6-1. Structure of Z-θUnit.............................................................................14-33

14-6-2. LED Indications....................................................................................14-34

14-7. Transport Unit..................................................................................................14-35

14-7-1. Structure of Transport Unit...................................................................14-35

14-7-2. Adjusting the BASE I/O Board (40071680) ..........................................14-39

14-7-3. Adjusting the Stepping Driver ..............................................................14-39

14-8. Head Unit ........................................................................................................14-41

14-8-1. S-HEAD MAIN PCB ASM (40106799) .................................................14-41

14-8-2. Adjusting the Point Sensor...................................................................14-43

14-9. Covers.............................................................................................................14-44

14-9-1. Structure of Operation Unit ..................................................................14-44

14-9-2. Jumper Switch Settings on the Operation Board Assembly.................14-44

14-9-3. Mounting Switches onto the Operation Switchboard ...........................14-46

14-10. Replacing the Fuse of the AC Input Unit...................................................14-52

14-11. ETF Power Supply (Option for M and L Board Specifications ) ................14-53

14-11-1. Replacing the ETF Power Supply Unit.................................................14-53

Rev. 2.0

Maintenance Guide

[15] AUTO BOARD WIDTH ADJUSTMENT (OPTIONAL)........................................15-1

15-1. Assembling the AWC Bracket ...........................................................................15-1

15-2. Assembling to the Machine Main Unit ...............................................................15-2

15-2-1. Mounting the AWC Bracket Assembly ...................................................15-2

15-2-2. Mounting the Origin Sensor Dog............................................................15-3

15-3. Support Pin Detection Sensor ...........................................................................15-4

15-3-1. Mounting the Support Pin Detection Sensor ..........................................15-4

15-4. Bundling the Support Pin Detection Sensor ......................................................15-6

15-4-1. Mounting the Support Pin Detection Sensor (Bundling the Cables).......15-6

15-5. Adjusting the Sensor .........................................................................................15-7

15-6. Mounting the Driver Bracket..............................................................................15-7

15-7. Setting the Driver...............................................................................................15-8

15-8. Mounting the Support Pin Sensor Dog ..............................................................15-9

[16] FEEDER POSITION INDICATOR (FPI) (OPTIONAL)........................................16-1

16-1. Detaching the FPI (Front) (M and L Board Specifications) ................................16-1

16-2. Detaching the FPI (Rear) (M and L Board Specifications).................................16-2

16-3. Structure of Parts and Components inside FPI (Front)

(M and L Board Specifications) .........................................................................16-3

16-4. Structure of Parts and Components inside FPI (Rear)

(M and L Board Specifications) .........................................................................16-4

16-5. Detaching the FPI (Front) (XL Board Specifications).........................................16-5

16-6. Detaching the FPI (Rear) (XL Board Specifications) .........................................16-6

16-7. Structure of Parts and Components inside FPI (Front)

(XL Board Specifications)..................................................................................16-7

16-8. Structure of Parts and Components inside FPI (Rear)

(XL Board Specifications)..................................................................................16-8

[17] OFFSET PLACEMENT AFTER SOLDER SCREEN-PRINTING LIGHT

(OPTIONAL).......................................................................................................17-1

17-1. Replacing the Offset Placement after Solder Screen-Printing Light ..................17-1

17-2. Adjusting the Light Quantity of the Offset Placement after

Solder Screen-Printing Light .............................................................................17-2

[18] TAPE CUTTER (OPTIONAL) .............................................................................18-1

18-1. Overall Drawing.................................................................................................18-1

18-2. Replacing the Tape Cutter Main Unit ................................................................18-2

18-3. Replacing the Tape Cutter Blade ......................................................................18-5

[19] CVS (OPTIONAL)...............................................................................................19-1

19-1. Replacing the CONTACT SUB UNIT ................................................................19-1

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