JUKI RS-1 Operating manual

Fast Smart Modular Mounter
RS-1/RS-1XL/RS-1R
MAINTENANCE GUIDE

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) Microsoft, Windows are registered trademarks or trademarks of Microsoft
Corporation in the United States and /or other countries.
The company names and product names mentioned in this document are
generally registered trademarks or trademarks of the respective companies.

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........................................................................................... 1-2
1-1-3. Replacing the YR-Motor .......................................................................................... 1-5
1-2. Replacing the Limit Sensor and Origin Near Sensor ........................................................ 1-8
1-2-1. Replacing the X-Axis Limit Sensor and the X-Axis Home Proximity Sensor............. 1-8
1-2-2. Replacing the Y-Axis Limit Sensor and the Y-Axis Home Proximity Sensor........... 1-10
1-2-3. Checking the Sensor Operation............................................................................. 1-12
1-3. Replacing the Cableveyor .............................................................................................. 1-13
1-3-1. Replacing the X-Axis Cableveyor .......................................................................... 1-13
1-3-2. Replacing the Y-Axis Cableveyor .......................................................................... 1-14
1-4. Replacing the Cables in the X/Y Veyor-Cable ................................................................ 1-16
1-4-1. Removing the X Cable .......................................................................................... 1-16
1-4-2. Checking the Cable Marking (X)............................................................................ 1-19
1-4-3. Assembling the Cable ........................................................................................... 1-20
1-4-4. Removing the Y Veyor-Cable ................................................................................ 1-23
1-4-5. Assembling the Cable ........................................................................................... 1-24
1-4-6. Wiring around the Head......................................................................................... 1-27
1-5. Replacing the Cableveyor Link....................................................................................... 1-28
1-5-1. X Cableveyor Structure and Part Names............................................................... 1-28
1-5-2. Detaching the Arm and Lock Stay ......................................................................... 1-28
1-5-3. Separating the Link ............................................................................................... 1-29
1-5-4. Connecting the Cableveyor ................................................................................... 1-29
1-5-5. Mounting the Arm and Lock Stay........................................................................... 1-30
1-6. Replacing the X Ball Screw ............................................................................................ 1-31
1-6-1. Preparations for X Ball Screw Replacement.......................................................... 1-31
1-6-2. Removing the X Ball Screw ................................................................................... 1-34
1-6-3. Mounting the X Ball Screw .................................................................................... 1-37
1-6-4. Adjusting the X Ball Screw .................................................................................... 1-40
1-7. Replacing the Y Ball Screw ............................................................................................ 1-44
1-7-1. Preparations for Y Ball Screw Replacement.......................................................... 1-44
1-7-2. Removing the Y Ball Screw ................................................................................... 1-47
1-7-3. Mounting the Y Ball Screw .................................................................................... 1-54
1-7-4. Adjusting the Y Ball Screw .................................................................................... 1-59
1-8. Readjustment after XY part exchange............................................................................ 1-66

Maintenance Guide
2 Head.............................................................................................................................2-1
2-1 8-Nozzle Head .................................................................................................................. 2-1
2-1-1 Replacing the Head Unit........................................................................................... 2-1
2-1-2 Replacing the Z-Motor.............................................................................................. 2-9
2-1-3 Replacing the θ-Motor ............................................................................................ 2-14
2-1-4 Replacing the Timing Belts Z.................................................................................. 2-18
2-1-5 Replacing the Timing Belt θ.................................................................................... 2-18
2-1-6 Replacing the Ball Screw........................................................................................ 2-20
2-1-7 Replacing the LNC120-8 ........................................................................................ 2-24
2-1-8 Replacing the Z-Slide Shaft.................................................................................... 2-25
2-1-9 Replacing the Head Up Cylinder ............................................................................ 2-26
2-1-10 Replacing the θ-Origin Sensor.............................................................................. 2-28
2-1-11 Replacing the ZA-Motor........................................................................................ 2-31
2-1-12 Replacing the Head Unit (When the Head Revision Number Is A or Later)........... 2-32
2-1-13 Replacing the Z-Motor (When the Head Revision Number Is A or Later).............. 2-39
2-1-14 Replacing the θ-Motor (When the Head Revision Number Is A or Later) .............. 2-49
2-1-15 Replacing the Timing Belt Z (When the Head Revision Number Is A or Later) ..... 2-52
2-1-16 Replacing the Timing Belt θ (When the Head Revision Number Is A or Later)...... 2-52
2-1-17 Replacing the Ball Screw (When the Head Revision Number Is A or Later).......... 2-53
2-1-18 Replacing the LNC120 (When the Head Revision Number Is A or Later) ............. 2-56
2-1-19 Replacing the Z-Slide Shaft (When the Head Revision Number Is A or Later)...... 2-56
2-1-20 Replacing the Head-up Cylinder (When the Head Revision Number Is A or Later)2-57
2-1-21 Replacing the θ-Origin Sensor (When the Head Revision Number Is A or Later) . 2-59
2-2 Readjustment after Replacement of Head Unit ............................................................... 2-62
3. PARTS AROUND THE HEAD .....................................................................................3-1
3-1 Solenoid valve unit............................................................................................................ 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
3-1-4 Replacing the HMS .................................................................................................. 3-3
3-1-5 Replacing the Electromagnetic Valve
(When the Head Revision Number Is A or Later)................................................... 3-4
3-2 Replacing the Head Board ................................................................................................ 3-5
3-2-1 Replacing the Head Main Board............................................................................... 3-5
3-2-2 Replacing the Servo Amplifier Board........................................................................ 3-6
4 OCC Unit......................................................................................................................4-1
4-1 Replacing the OCC Unit.................................................................................................... 4-1
4-2 Replacing the CCD Camera and Lens .............................................................................. 4-2

Maintenance Guide
4-3 Replacing the OCC Coaxial/Angle Light Board ................................................................. 4-3
4-4 Replacing the Lens Filter .................................................................................................. 4-4
4-5 Adjusting the Focus and the OCC Light Quantity .............................................................. 4-5
4-6 Readjustment Items After Replacing OCC Unit................................................................. 4-5
5 Board Transport..........................................................................................................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 Conveyor (Board Transport) Motor ............................................................. 5-3
5-4 Replacing the AWC (Board Width Adjustment) Motor ....................................................... 5-6
5-5 Replacing the Timing Belt ................................................................................................. 5-7
5-5-1 Replacing the Timing Belt for Adjustment of the Transport Width ............................. 5-7
5-5-2 Replacing the Conveyor Motor Timing Belt .............................................................. 5-8
5-5-3 Replacing the Transport Width Adjustment Connection Timing Belt ......................... 5-9
5-6 Replacing the LEFT/RIGHT Sensors .............................................................................. 5-11
5-6-1 Replacing the LEFT/RIGHT Sensors...................................................................... 5-11
5-6-2 Adjusting the Sensor Sensitivity ............................................................................. 5-12
5-7 Replacing the STOP Sensor ........................................................................................... 5-13
5-7-1 Replacing the Front STOP Sensor Fiber ................................................................ 5-13
5-7-2 Replacing the Rear STOP Sensor Fiber................................................................. 5-15
5-7-3 Replacing the Fiber Amplifier ................................................................................. 5-17
5-8 Replacing the BU Pin Detection Sensor.......................................................................... 5-20
5-9 Replacing the Support Table Origin Sensor (BU Origin Sensor) ..................................... 5-21
5-10 Replacing the AWC Origin Sensor ................................................................................ 5-22
5-11 Replacing the Support Table Motor (BU Table Motor)................................................... 5-23
5-11-1 Removing the support table.................................................................................. 5-23
5-11-2 Adjusting the Gap between Torque Supporter Assembly and
Support Table Motor ........................................................................................... 5-26
5-11-3 Adjusting the Tension of the Support Table Driving Timing Belt ........................... 5-27
5-11-4 Placing the Support Table Surface Horizontally.................................................... 5-28
5-11-5 Reacquiring the Support Table Offset................................................................... 5-29
5-12 Replacing the Backup Stopper...................................................................................... 5-29
5-13 Replacing the Support Guide Cylinder .......................................................................... 5-30
5-14 Switching the Conveyor Direction.................................................................................. 5-31
5-14-1 Switching the Conveyor Direction......................................................................... 5-31
5-15 Replacing the Mechanical Stopper................................................................................ 5-35
5-15-1 Replacing the Stopper Sensor.............................................................................. 5-35

Maintenance Guide
5-15-2 Replacing the Stopper Cylinder ............................................................................ 5-36
6. CAL BLOCK................................................................................................................6-1
6-1. Replacing the CAL Block Board Assembly....................................................................... 6-1
6-2. Replacing the Ejector....................................................................................................... 6-2
7. ATC ..............................................................................................................................7-1
7-1. Replacing the Air Cylinder................................................................................................ 7-1
7-2. Replacing the ATC OPEN and CLOSE Sensors .............................................................. 7-3
7-3. Adjusting the Speed Controller......................................................................................... 7-3
8 Feeder Bank ................................................................................................................8-1
8-1 Feeder Bank ..................................................................................................................... 8-1
8-1-1 Replacing the Bank PCB.......................................................................................... 8-2
8-1-2 Replacing the FDC................................................................................................... 8-4
8-1-3 Replacing the Slide Rail ........................................................................................... 8-5
8-1-4 Replacing the Bank Connector A (Exchange Trolley Only)....................................... 8-6
8-1-5 Replacing the Inline Filter (Exchange Trolley Only) .................................................. 8-7
8-2 Bank Lifter......................................................................................................................... 8-8
8-2-1 Replacing the Mechanical Valve............................................................................... 8-8
8-2-2 Replacing the Bank Up Cylinder............................................................................... 8-9
8-2-3 Replacing the Selector ........................................................................................... 8-10
8-2-4 Replacing the Bank Connector B............................................................................ 8-11
8-2-5 Replacing the Actuator Valve ................................................................................. 8-12
8-2-6 Replacing the O-Ring ............................................................................................. 8-12
8-2-7 Replacing the Bank Limit Switch (EN Only) ............................................................ 8-13
9 Tape Cutter ..................................................................................................................9-1
9-1 Overall Drawing ................................................................................................................ 9-1
9-2 Replacing the Tape Cutter Blade ...................................................................................... 9-2
10 Feeder Float Sensor ...............................................................................................10-1
10-1 Layout........................................................................................................................... 10-1
10-1-1 Replacing the light receiving side sensor.............................................................. 10-2
10-1-2 Replacing the light emitting side sensor ............................................................... 10-2
11 Switch Related ........................................................................................................ 11-1
11-1 Replacing the Push-Button Switch ................................................................................ 11-1
11-2 Replacing the EMERGENCY STOP Switch .................................................................. 11-3
11-3 Replacing the Cover Open Switch................................................................................. 11-5
11-4 Replacing the Safety Cover Lock Cylinder .................................................................... 11-6
11-5 Replacing the Assist hinge............................................................................................ 11-9

Maintenance Guide
12. Electrical Components..........................................................................................12-1
12-1 Layout of Electrical Components ................................................................................. 12-1
12-2 Electrical Component Unit ........................................................................................... 12-3
12-2-1 Electrical Component Unit A................................................................................ 12-3
12-2-2 Electrical Component Unit B................................................................................ 12-6
12-3 Control Unit ............................................................................................................... 12-13
12-3-1 CPU BOARD (40123242).................................................................................. 12-14
12-3-2 IO CONTROL PCB ASM (40128871)................................................................ 12-22
12-3-3 POSITION BOARD (40129648) ........................................................................ 12-24
12-3-4 IP-X11 SET GEN ASM (49133294)................................................................... 12-25
12-3-5 SUPERIMPOSE BOARD (40129641) ............................................................... 12-26
12-4 ATX Power Supply .................................................................................................... 12-27
12-5 Battery Unit ............................................................................................................... 12-28
12-6 XY-Driver Unit ........................................................................................................... 12-29
12-6-1 Structure of XY Unit .......................................................................................... 12-29
12-6-2 Adjustment Items after Replacement of XY Driver............................................. 12-30
12-6-3 Display Indication of XY Servo Amplifier ........................................................... 12-30
12-7 Z,T Unit ..................................................................................................................... 12-31
12-7-1 Configuration of 8-Nozzle Head ........................................................................ 12-32
12-8 Transport Unit............................................................................................................ 12-35
12-8-1 Structure of Transport Unit ................................................................................ 12-35
12-8-2 Connecting the CONVEYOR Board and Sensors.............................................. 12-36
12-8-3 Connecting the Transport Motor........................................................................ 12-38
12-8-4 List of Other Sensors, Solenoid Valves, and Cable Assemblies ........................ 12-39
12-8-5 CONVEYOR PCB ASM (40128875).................................................................. 12-40
12-8-6 Adjusting the Stepping Motor Driver .................................................................. 12-41
12-9 SAFETY PCB ASM (40128872) ................................................................................ 12-44
12-10 Head Unit .................................................................................................................. 12-46
12-10-1HEAD MAIN PCB ASM (40128873) .................................................................. 12-46
12-10-2HEAD RELAY PCB ASM (40128874) ............................................................... 12-47
12-11 E BANK RELAY PCB ASM (40128876)..................................................................... 12-48
12-11-1Outside View of Board....................................................................................... 12-48
12-11-2Setting the Switches.......................................................................................... 12-48
12-11-3Adjusting the Volumes....................................................................................... 12-48
12-12 Others ....................................................................................................................... 12-49
12-12-1LIGHT CONTROL PCB ASM (40132991) ......................................................... 12-49
12-12-2Replacing the Filter Element ............................................................................. 12-50
12-12-3Replacement of Vacuum Pump Parts................................................................ 12-51

Maintenance Guide
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.......................................................................................... 13-5
13-2-1 Replacing the SSD.............................................................................................. 13-5
13-2-2 Setting Up the Network
(Setup is required when communicating with the JaNets.)................................. 13-7
13-2-3 RS-1 System Programs..................................................................................... 13-18
13-2-4 Upgrading the RS-1 System Version................................................................. 13-26
13-2-5 McAfee Embedded Control ............................................................................... 13-31
13-3 JaNets (ISM/MES Cooperation) Option ..................................................................... 13-32
13-3-1 Replacing the Bar-code Reader ........................................................................ 13-32
13-3-2 Operation check after Replacement .................................................................. 13-33
13-3-3 Initial setting after replacement (pick mode) ...................................................... 13-34
13-4 Tape setting unit........................................................................................................ 13-35
13-4-1 Replacement of the connector cable ................................................................. 13-35
13-4-2 Replacement of the slide rail ............................................................................. 13-35
14 VCS ..........................................................................................................................14-1
14-1 Replacing the VCS Cylinder (Up-Down cylinder)........................................................... 14-1
14-2 Replacing the VCS Sensor (Up-Down sensor).............................................................. 14-6
14-3 Replacing the VCS camera switching cylinder .............................................................. 14-7
14-4 Replacing the VCS Light Unit Assembly (Detach as shown in Figure 14-4-1.)............ 14-8
14-5 Replacing and Adjusting the Camera ............................................................................ 14-9
15 Solder Recognition and Placement Position Correction.....................................15-1
15-1 Replacing the Solder Recognition Light Board .............................................................. 15-1
15-2 Light Quantity of the Solder Recognition Light............................................................... 15-2
16 Load Cell..................................................................................................................16-1
16-1 Replacing the Load Cell ................................................................................................ 16-1
17 Coplanarity Sensor.................................................................................................17-1
17-1 Replacing the Sensor.................................................................................................... 17-2
17-2 Changing the IP Address of the Coplanarity CPU ......................................................... 17-4
17-2-1 Required Parts ..................................................................................................... 17-4
17-2-2 Setting Preparations............................................................................................. 17-4
17-2-3 Changing the Coplanarity CPU Setting................................................................. 17-5
17-2-4 Changing the Mounter Setting.............................................................................. 17-9

Maintenance Guide
18 CVS ..........................................................................................................................18-1
18-1 Changing the CONTACT SUB UNIT ............................................................................. 18-1
18-2 Changing the CVS Board.............................................................................................. 18-4
19 Nozzle RFID READER .............................................................................................19-1
19-1 Changing the RFID READER/WRITER......................................................................... 19-1
RS-1 Appendix Jig Lists............................................................................................. A-1
RS-1 Appendix List of Measuring Instruments........................................................ B-1

Maintenance Guide
1-1
1. X-Y UNIT
1-1. Replacing the Servomotor
1-1-1. Replacing the X-Motor
1) Remove the B_COVER_SCREW to detach the MOTOR_COVER_R.
2) Loosen the COUPLING_X_screw (do not remove the screw at this time) and disconnect the
connector of the SERVO MOTOR 750W cable.
3) Remove the SL6062042TN and replace the SERVO MOTOR 750W.
4) Reassemble the components in the reverse order of disassembly.
∗The clearance between the COUPLING and motor is 8 mm. The tightening torque of the
COUPLING_X_screw is 3.7 N⋅m. (Figure 1-1-1-4)
Carefully check the motor orientation.
Figure 1-1-1-1
Figure 1-1-1-2
Figure 1-1-1-3
SERVO MOTOR 750W
SL6062042TN (×4)
Figure 1-1-1-4
COUPLING_X_screw
COUPLING_X
8
FRONT
B_COVER_SCREW
（
×4
）
MOTOR COVER R