Toshiba TH650A User manual

STE 85306–3
TH650A/TS3100
MAINTENANCE MANUAL
Notice
1. Make sure that this instruction manual is delivered to the final
user of Toshiba Machine's industrial robot.
2. Before operating the industrial robot, read through and
completely understand this manual.
3. After reading through this manual, keep it nearby for future
reference.
October, 2010
TOSHIBA MACHINE CO., LTD.
NUMAZU, JAPAN

MAINTENANCE MANUAL
Copyright 2007 by Toshiba Machine Co., Ltd.
All rights reserved.
No part of this document may be reproduced in any form without obtaining prior written
permission from Toshiba Machine Co., Ltd.
The information contained in this manual is subject to change without notice to effect
improvements.
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WARRANTY
This machine is delivered to each customer only after it is inspected very carefully to
make sure that it satisfies the Toshiba Machine’s standard. Should it cause an
inconvenience, we will guarantee as described below.
1. Warranty period
Toshiba Machine agrees to repair or replace as necessary all defective material or
workmanship up to the period shown below, whichever comes first.
1) Twenty-four (24) months from the date of dispatch from our plant.
2) Eighteen (18) months from the date of machine installation at customer’s job site.
3) 4,000 running hours from the date of initial machine operation.
2. Contents of warranty
1) Only the product delivered to the customer is subject to Toshiba Machine’s
Guarantee. Such Guarantee covers the specifications and functions as defined
in the product specifications manual, catalog, instruction manual, etc. In no
event does the Guarantee cover any damage caused by malfunction of the
delivered product.
2) Toshiba Machine repairs the product free of charge only when it malfunctioned
after handling or use according to the instruction manual attached to the product
within the specified warranty period.
3. Exemption from responsibility
Toshiba Machine’s Guarantee shall not cover the following cases.
1) Incorrect use not described in the instruction manual, and trouble or damage
caused by negligent use.
2) Inconvenience caused by aged deterioration or long-term usage (natural fading
of coating or painting, deterioration of consumable parts (*1), etc.).
3) Inconvenience caused by sensuous phenomena (noise generation, etc. which
will not affect the function).
4) Remodeling or disassembly which Toshiba Machine will not permit.
5) Trouble and damage caused by insufficient maintenance/inspection or improper
repair.
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6) Trouble and damage caused by disaster, fire or other external factor.
7) Internal data such as program and point which were created by the customer.
8) When the robot purchased in Japan was shipped overseas.
(*1) The consumable parts signify the replacement parts for maintenance as
listed in Section 5 of this manual.
4. Precautions
1) Unless the robot was used pursuant to its specifications, Toshiba Machine will
not guarantee the basic performance of the robot.
2) If the customer did not observe the warnings and cautions described in this
manual, Toshiba Machine will not assume the responsibility for any
consequential accident resulting in injury or death, damage or trouble.
3) Please note that the warnings, cautions and other descriptions stipulated in this
manual are only those which can be assumed by Toshiba Machine as of now.
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INTRODUCTION
This manual describes the TH650A industrial robot and TS3100 controller.
The maintenance and inspection are essential to maintain the robot performance for long
years to prevent a trouble and improve the safe work.
Before starting an actual operation, it is strongly recommended to read through this
manual and draw up a maintenance schedule.
CAUTIONS ON SAFETY
This manual contains the important information on the robot and controller to prevent
injury to the operators and persons nearby, to prevent damage to assets and to assure
correct use.
Make sure that the following details (indications and symbols) are well understood before
reading this manual. Always observe the information that is noted.
[Explanation of indications]
Indication Meaning of indication
! DANGER
This means that "incorrect handling will lead to fatalities or
serious injuries."
! WARNING
This means that "incorrect handling will lead to fatalities or
serious injuries."
! CAUTION
This means that "incorrect handling may lead to personal
injuries *1) or physical damage *2)."
*1) Injuries refer to injuries, burns and electric shocks, etc., which do not require
hospitalization or long-term medical treatment.
*2) Physical damage refers to damages due to destruction of assets or resources.
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[Explanation of symbols]
Symbol Meaning of symbol
This means that the action is prohibited (must not be done).
Details of the actions actually prohibited are indicated with
pictures or words in or near the symbol.
This means that the action is mandatory (must be done).
Details of the actions that must be done are indicated with
pictures or words in or near the symbol.
This means danger and caution.
The details of the actual caution are indicated with pictures or
words in or near the symbol.
[Maintenance and inspection]
Be sure to observe the following items to use the robot safely.
! DANGER
Prohibited
• DO NOT incinerate, disassemble or charge the batteries.
Otherwise, they may rupture.
Mandatory
• Be sure to turn off the main power switch of the controller
before starting inspection or maintenance.
• Batteries should be disposed of according to the user's
in-house regulations.
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!CAUTION
Disassembly
prohibited
• The user must NEVER replace or modify parts other than
those described in the instruction manual. Otherwise, the
performance may deteriorate or faults or accidents will be
caused.
Mandatory
• Always use the Toshiba Machine's designated spare parts
when replacing the parts.
• Maintenance and inspection should be performed regularly.
Otherwise, the system may malfunction or accidents will be
caused.
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Table of Contents
Page
1. Maintenance...........................................................................................................11
1.1 Maintenance Schedule..................................................................................11
1.2 Items for Maintenance and Inspection...........................................................12
1.2.1 Inspection at Power OFF (at Non-Operation)....................................12
1.2.2 Inspection at Power ON (at Operation).............................................13
1.2.3 Overhaul............................................................................................13
1.3 Maintenance Tools........................................................................................14
1.4 Maintenance Contract and Repair.................................................................14
1.4.1 Maintenance Contract.......................................................................14
1.4.2 Repair................................................................................................14
1.4.3 Modification.......................................................................................15
2. Maintenance of the Main Robot..............................................................................16
2.1 Cautions on Maintenance and Inspection......................................................16
2.1.1 Clamping Hexagon Socket Head Cap Screws..................................16
2.2 Details of Inspection......................................................................................18
2.2.1 Check of Each Bolt (or Screw) for Clamping.....................................18
2.2.2 Check of Each Connector for Clamping............................................21
2.2.3 Check of Each Cable and Air Tube for Abrasion ..............................21
2.2.4 Check of Each Axis for Operation.....................................................22
2.3 Layout of Robot Components and Drive Mechanism....................................23
2.4 Dismounting and Mounting Each Cover........................................................25
2.4.1 Arm 2 Cover......................................................................................26
2.4.2 Arm 1 Covers....................................................................................27
2.4.3 Base Covers......................................................................................27
2.5 Replacing Motor.............................................................................................29
2.5.1 Type of Motor....................................................................................30
2.5.2 Motor Locations.................................................................................31
2.5.3 Dismounting Axis 1 Motor .................................................................32
2.5.4 Mounting Axis 1 Motor ......................................................................33
2.5.5 Dismounting Axis 2 Motor .................................................................35
2.5.6 Mounting Axis 2 Motor ......................................................................38
2.5.7 Dismounting Axis 3 Motor .................................................................41
2.5.8 Mounting Axis 3 Motor ......................................................................42
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2.5.9 Dismounting Axis 4 Motor .................................................................44
2.5.10 Mounting Axis 4 Motor ......................................................................45
2.6 Adjusting and Replacing Timing Belt.............................................................46
2.6.1 Type of Timing Belt...........................................................................46
2.6.2 Timing Belt Locations........................................................................47
2.6.3 Replacing Axis 3 Timing Belt.............................................................47
2.6.4 Replacing Axis 4 Timing Belt.............................................................49
2.6.5 Adjusting Timing Belt ........................................................................52
2.7 Filling Grease to Ball Screw Spline Unit and Replacement...........................54
2.7.1 Type of Ball Screw Spline Unit..........................................................54
2.7.2 Ball Screw Spline Unit Location ........................................................55
2.7.3 Filling Grease to Ball Screw Spline Unit............................................55
2.7.4 Dismounting Ball Screw Spline Unit..................................................57
2.7.5 Mounting Ball Screw Spline Unit.......................................................60
2.8 Filling Grease to Reduction Gear and Replacement.....................................63
2.8.1 Type of Reduction Gear....................................................................63
2.8.2 Reduction Gear Locations.................................................................64
2.8.3 Filling Grease to Reduction Gear......................................................64
2.8.4 Dismounting Axis 1 Reduction Gear ................................................69
2.8.5 Mounting Axis 1 Reduction Gear.......................................................71
2.8.6 Dismounting Axis 2 Reduction Gear.................................................73
2.8.7 Mounting Axis 2 Reduction Gear.......................................................74
2.8.8 Replacing Axis 4 Reduction Gear .....................................................77
2.9 Replacing Position Detector (or Encoder) Batteries ......................................79
2.9.1 Battery Box Location.........................................................................80
2.9.2 Replacing Batteries...........................................................................80
2.9.3 Battery Error Code............................................................................81
3. Maintenance of Controller ......................................................................................82
3.1 Cautions on Maintenance and Inspection......................................................82
3.2 Layout of Controller Parts..............................................................................83
3.3 Maintenance Procedures...............................................................................84
3.3.1 Check of Controller Air Vent Holes ...................................................84
3.3.2 Check of Safety Devices for Function...............................................85
3.3.3 Battery Replacement.........................................................................88
3.3.4 Replacement of Switching Power Supply Unit..................................90
3.3.5 Replacement of Fuse (X8GN, X8GI Printed Board)..........................91
3.3.6 Replacement of Output ICs (X8GN, X8GI Printed Board).................92
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4. Robot Home Point and Position Detector Error......................................................94
4.1 Setting Robot Home Point.............................................................................94
4.2 Position Detector Error ..................................................................................95
4.3 Restoring Operation from Position Detector Error.........................................98
4.3.1 Encoder Status Display.....................................................................98
4.3.2 Encoder Error Reset Operation.......................................................100
4.4 Restoring Home Position Data by HOME Function.....................................101
4.4.1 Outline of HOME Function..............................................................101
4.4.2 Setting HOME1 and HOME2 ..........................................................102
4.4.3 How to Restore Data by HOME1 or HOME2 ..................................103
4.4.4 Locations of Robot Home Point Match-Marks.................................104
4.4.5 How to Restore Data by HOME3 or HOME4 ..................................104
4.5 Restoring Home Position Data by ZEROP Function....................................106
4.5.1 Preparation before Restoring Operation.........................................106
4.5.2 Setting New Home Position Data....................................................107
4.5.3 Confirming Home Position ..............................................................109
4.5.4 Saving Data.....................................................................................109
4.6 Restoring Home Position Data by Multi-Turn Data Clear ............................110
5. Replacement Parts for Maintenance....................................................................111
5.1 List of Replacement Parts – Main Robot.....................................................111
5.2 List of Replacement Parts – Controller........................................................112
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1. Maintenance
1.1 Maintenance Schedule
Maintenance comes in the two (2) types; daily inspection, and regular inspection and
maintenance. For the regular inspection and maintenance, inspection items are
added every 1,200 running hours.
3-month
check
3-month
check
3-month
check
3-month
check
1-year
check
3-month
check
3-month
check
3-month
check
6-month
check
6-month
check
6-month
check
6-month
check
1-year
check
Overhaul
(every 5 years)
Daily inspection
Running hours
(h)
0
1200
2400
4800
3600
6000
7200
8400
9600
24000
(h)
3-month
check
Inspection schedule
• When the system is operated for 16 hours per day:
16 hours ×25 days ×3 months = 1,200 hours
• When the system is operated for 24 hours per day:
24 hours ×25 days ×3 months = 1,800 hours
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1.2 Items for Maintenance and Inspection
This section describes the items for maintenance and inspection.
For the executing procedures, see the relevant paragraph listed in the table below.
1.2.1 Inspection at Power OFF (at Non-Operation)
D: Daily inspection Q: Quarterly inspection
S: Semi-annual inspection A: Annual inspection
Description Check position D Q S A Refer to
Make sure that all bolts
are completely tightened
and secured. Otherwise,
tighten the bolts
completely.
Tool set bolts   Para.
2.2.1
Robot installation bolts   
Bolts for each joint
reduction gear 
Motor set bolts 
Make sure that all
connectors are tightened
completely.
Base connector   Para.
2.2.2
External wiring for axis 5   
Make sure that no cut or
scratch is found. Clean
the contaminant, if any.
Entire robot   
Arm 2 interior  
Make sure that enough
volume of grease is filled.
Otherwise, fill the grease.
Ball screw shaft   Para.
2.7.3
Reduction gear interior  Para.
2.8.3
Make sure that each
timing belt is not worn off
or cracked. Check each
timing belt for tension.
Arm 2 interior  Para.
2.6.5
Make sure that the cables
and air tubing are not
worn out.
Cables and air tubing of
each unit   Para. 2.2.3
Make sure that each axis
can be operated properly
by moving the axis by
hand.
Entire robot  Para.
2.2.4
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1.2.2 Inspection at Power ON (at Operation)
D: Daily inspection Q: Quarterly inspection
S: Semi-annual inspection A: Annual inspection
Description Check position D Q S A Refer to
Push each arm by hand in
the servo ON condition to
make sure that the arm is
secured.
Each joint 
Make sure that no
abnormal vibration or
noise is caused.
Entire robot 
Check for the
repeatability. Entire robot   
Replace the batteries for
position detection with
new ones.
Battery box  Para.
2.9.2
1.2.3 Overhaul
Description Maintenance parts Every 5
years Refer to
Check for the consumable
parts and replace as
necessary.
Reduction gears, ball screws,
motors, belts Para. 2.4 ~ 2.7
Replace the battery with a
new one. Backup battery in the controller  Para. 3.3.3
Replace the switching
power supply unit with a
new one.
In the controller  Para. 3.3.4
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1.3 Maintenance Tools
We recommend to use the following tools for maintaining the robot and controller.
• Phillips screwdrivers
• Hexagonal wrench set: M3 ~ M16
• Torque wrench set: M4 ~ M10
• Nippers
Recommended provisions other than the tools:
• Grease gun
• Waste cloth
• Vice (clamp)
• Liquid gasket (recommendation: 1211 made by ThreeBond)
• Seal tape
• Loctite adhesives (242; mid adhesive force)
• Belt tension meter
• TSPC program creation/teaching support software (option)
1.4 Maintenance Contract and Repair
1.4.1 Maintenance Contract
For the inspection items for maintenance and inspection to be done semi-annually
and after, it is rather difficult for the user to execute, except for greasing and
lubrication. We recommend that the user contact Toshiba Machine Service
Department and conclude an after-sale service contract with us.
1.4.2 Repair
If a fault has occurred or if repair is necessary, turn off the controller power and
contact the Toshiba Machine Service Department. At this time, advise us of the
details of the fault and the following information stated on the robot and controller.
• Robot model
• Manufacture number
• Date of manufacture of controller
• Date of manufacture of robot
• Running hours
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For the manufacture number and date of manufacture, see the following labels
attached to main base of the robot.
1.4.3 Modification
The robot and controller MUST NOT be modified or disassembled without a prior
consent from Toshiba Machine.
! CAUTION
• The user must NEVER replace or modify parts other than those described in
the instruction manual. Otherwise, the performance may deteriorate or faults
or accidents will be caused.
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2. Maintenance of the Main Robot
2.1 Cautions on Maintenance and Inspection
When performing inspection or maintenance of the robot, strictly observe the following
precautions to protect yourself and coworkers.
!DANGER
• Be sure to turn off the main power switch of the controller before approaching
the robot for maintenance and inspection.
• When moving the robot by hand while the power is turned on, be sure to assure
the safe work and effect an emergency stop beforehand.
• In the above situation, if the work is to be done while the axis 3 motor brake
OFF switch is pressed, be sure to perform the work by two (2) persons.
One person should carry out the work while the other is monitoring the work
outside the hazardous zone. The latter person should watch the work and be
ready to turn off the controller switch if any abnormality occurs. Once the
controller power is turned off, the motor brake actuates even if the axis 3 motor
brake OFF switch is kept pressed.
• If the axis 3 motor brake OFF switch is pressed while the robot is carrying a
heavy workpiece, the axis 3 may drop suddenly. To avoid this, the customer
should take all necessary measures by themselves.
2.1.1 Clamping Hexagon Socket Head Cap Screws
This robot uses hexagon socket head cap screws at places requiring mechanical
strength. At the time of factory-assembly, lock adhesives are applied and each
screw is tightened with the following clamping torque.
When these screws are tightened again according to the inspection and
maintenance as stipulated in this manual, use a torque wrench, etc. to assure the
appropriate clamping torque.
The places which do not fall under the table below are detailed in the paragraph of
the replacement procedures.
Screw M4 M5 M6 M8 M10
Clamping torque 4.7 N·m 8.8 N·m 17 N·m 27 N·m 54 N·m
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For the screws arranged on a circle for mounting the reduction gear, etc., tighten
them in the diagonal order, as shown below.
DO NOT tighten one (1) screw at a time. Tighten each screw in multiple steps,
using a hexagonal wrench key, and secure with appropriate clamping torque by
means of a torque wrench.
1
8
7
6
5
4
3
2
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2.2 Details of Inspection
2.2.1 Check of Each Bolt (or Screw) for Clamping
(1) Tool Set Bolts
Make sure, using the hexagonal wrench key, that the hexagon socket head cap
screws of the tool set flange, which are clamped to the tool shaft are tightened
completely. If loosened, tighten them completely.
Make sure, using the hexagonal wrench key, that the hexagon socket head cap
screws securing the tool flange and tool are tightened completely. Otherwise,
tighten them completely.
Fig. 2.1 Tool set bolts
(2) Robot Installation Bolts
Make sure, using the hexagonal wrench key, that the installation bolts of the
main robot base are tightened completely. If loosened, tighten them
completely.
Tool flange
Tool flange clamp bolt
M5 x 4 pcs.; Recommended
clamping torque 8.8 N·m
Tool
Tool set bolt
M5 x 4 pcs.; Recommended
clamping torque 8.8 N·m
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Fig. 2.2 Robot base set bolts
(3) Bolts for each joint
Make sure, using the hexagonal wrench key, that the bolts for the axis 1 and 2
joints (i.e., bolts for clamping each reduction gear and arm) are tightened
completely. If loosened, tighten them completely.
Fig. 2.3 Axes 1 and 2 set bolts
Main robot installation bolt
M16 x 4 pcs.; Recommended
clamping torque 170 N
·m
For how to remove the arm cover 1
attached to the arm 1, see Para. 2.4.2.
Axis 1 joint clamp bolt
M8
x 8 pcs.; Recommended clamping
torque 27 N
·m
Axis 2 joint clamp bolt
M10 x 4 pcs.; Recommended clamping
torque 54 N
·m
* DO NOT tighten with clamping torque
exceeding 54
N·m.
For how to remove the axis 2 gear case
and center gear, see Para. 2.5.5.
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(4) Motor Set Bolts
Make sure, using the hexagonal wrench key, that the bolts for securing each axis
drive motor are tightened completely. If loosened, tighten them completely.
Also make sure that the motor base set bolts are tightened completely.
For the places where the following bolts are used, see Para. 2.5.
Axis 1 drive motor set bolt: M5 ×20, 4 pcs. Recommended clamping
torque: 8.8 N·m
Axis 1 motor base set bolt: M5 ×25, 4 pcs. Recommended clamping
torque: 8.8 N·m
Axis 2 drive motor set bolt: M4 ×16, 4 pcs. Recommended clamping
torque: 4.7 N·m
Axis 2 gear case set bolt: M6 ×35, 6 pcs. Recommended clamping
torque: 17 N·m
Axis 3 drive motor set bolt: M4 ×16, 4 pcs. Recommended clamping
torque: 4.7 N·m
Axis 3 motor base set bolt: M5 ×16, 4 pcs. Recommended clamping
torque: 8.8 N·m
Axis 4 drive motor set bolt: M4 ×16, 4 pcs. Recommended clamping
torque: 4.7 N·m
Axis 4 reduction gear set bolt: M5 ×16, 4 pcs. Recommended clamping
torque: 8.8 N·m
Axis 4 motor base set bolt: M5 ×16, 4 pcs. Recommended clamping
torque: 8.8 N·m
For the axis 4 reduction gear set bolts and axis 4 motor base set bolts, see Para.
2.8.8 and Para. 2.6.4, respectively.
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