Toshiba THL Series User manual

STE 85357-11
THL Series
INSTRUCTION MANUAL
MAINTENANCE MANUAL
Notice
1. Make sure that this instruction manual is delivered to the final
user of this product.
2. Before using this product, read through and completely
understand this manual.
3. After reading through this manual, keep it nearby for future
reference.
July, 2012
TOSHIBA MACHINE CO., LTD.
NUMAZU, JAPAN
Robot controller TSL3000
Robot controller TSL3000E
Robot controller TS3000
Robot controller TS3000E

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This Operation Manual describes the following robots:
THL Series: THL300, THL400, THL500, THL600, THL700, THL800, THL900 and THL1000
Copyright 2012 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 prior notice to effect
improvements.

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WARRANTY
This product 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) Eighteen (18) months from the date of dispatch from our plant.
2) Twelve (12) months from the date of machine installation at customer’s job site.
3) 2,400 running hours from the date of initial machine operation.
2. Contents of warranty
1) Only the product 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 secondary or associated damage caused by malfunction of the 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 product purchased in Japan was shipped overseas.
4. Precautions
1) Unless the product was used pursuant to its specifications, Toshiba Machine will
not guarantee the basic performance of the product.
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.
(*1) The consumable parts signify the replacement parts for maintenance as
listed in Section 8 of this manual.

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INTRODUCTION
This manual describes the maintenance of this product, THL series, and the TSL3000,
TSL300E, TS3000 and TS3000E controllers.
The maintenance and inspection are essential to maintain the product 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 imminently
lead to fatalities or serious injuries.”
!WARNING
This means that “incorrect handling may 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 this product safely.
!DANGER
Prohibited
•DO NOT incinerate, disassemble or charge the batteries.
Otherwise, they may rupture.
Mandatory
•Be sure to remove the power plug of the controller from the
power source before starting inspection or maintenance.
•Batteries should be disposed of according to the user's
in-house regulations.
!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
1. Maintenance......................................................................................................................13
1.1 Maintenance Schedule............................................................................................13
1.2 Items for Maintenance and Inspection.....................................................................14
1.2.1 Inspection at Power OFF (at Non-Operation) ..............................................14
1.2.2 Inspection at Power ON (at Operation)........................................................15
1.2.3 Overhaul .....................................................................................................15
1.3 Cautions on Maintenance and Inspection................................................................16
1.4 Maintenance Tools...................................................................................................16
1.5 Clamping Hexagon Socket Head Cap Screws and Set screws................................17
1.6 Maintenance Contract and Repair ...........................................................................18
1.6.1 Maintenance Contract.................................................................................18
1.6.2 Repair .........................................................................................................18
1.6.3 Modification.................................................................................................19
2. Maintenance of the Main Robot (THL300, THL400) ..........................................................20
2.1 Details of Inspection ................................................................................................20
2.1.1 Check of Each Bolt (or Screw) for Clamping................................................20
2.1.2 Check of Each Cable and Air Tube for Abrasion..........................................22
2.1.3 Check of Cable Clamp Tightening...............................................................23
2.1.4 Check of Each Axis for Operation................................................................24
2.2 Layout of Robot Components and Drive Mechanism...............................................25
2.3 Dismounting and Mounting Each Cover...................................................................26
2.3.1 Arm 2 Cover................................................................................................27
2.3.2 Base Covers................................................................................................28
2.4 Replacing Motor ......................................................................................................31
2.4.1 Type of Motor..............................................................................................31
2.4.2 Motor Locations...........................................................................................32
2.4.3 Dismounting Axis 1 Motor............................................................................33
2.4.4 Mounting Axis 1 Motor.................................................................................34
2.4.5 Dismounting Axis 2 Motor............................................................................37
2.4.6 Mounting Axis 2 Motor.................................................................................39
2.4.7 Dismounting Axis 3 Motor............................................................................42
2.4.8 Mounting Axis 3 Motor.................................................................................43
2.4.9 Dismounting Axis 4 Motor............................................................................45
2.4.10 Mounting Axis 4 Motor.................................................................................47
2.5 Adjusting and Replacing Timing Belt........................................................................48

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2.5.1 Type of Timing Belt......................................................................................48
2.5.2 Timing Belt Locations..................................................................................49
2.5.3 Replacing Axis 3 Timing Belt.......................................................................49
2.5.4 Replacing Axis 4 Timing Belt .......................................................................53
2.5.5 Check Timing Belt Adjustment.....................................................................58
2.6 Filling Grease to Ball Screw Spline Unit and Replacement......................................59
2.6.1 Type of Ball Screw Spline Unit.....................................................................59
2.6.2 Ball Screw Spline Unit Location...................................................................60
2.6.3 Greasing Ball Screw Spline Unit and Applying Anticorrosive........................60
2.6.4 Dismounting Ball Screw Spline Unit.............................................................64
2.6.5 Mounting Ball Screw Spline Unit..................................................................68
2.7 Reduction Gear Replacement..................................................................................71
2.7.1 Type of Reduction Gear ..............................................................................71
2.7.2 Reduction Gear Locations...........................................................................72
2.7.3 Dismounting Axis 1 Reduction Gear............................................................72
2.7.4 Mounting Axis 1 Reduction Gear.................................................................74
2.7.5 Dismounting Axis 2 Reduction Gear............................................................77
2.7.6 Mounting Axis 2 Reduction Gear.................................................................78
2.7.7 Replacing Axis 4 Reduction Gear................................................................80
3. Maintenance of the Main Robot (THL500, THL600, THL700)............................................82
3.1 Details of Inspection ................................................................................................82
3.1.1 Check of Each Bolt (or Screw) for Clamping................................................82
3.1.2 Check of Each Cable and Air Tube for Abrasion..........................................84
3.1.3 Check of Cable Clamp Tightening...............................................................85
3.1.4 Check of Each Axis for Operation................................................................86
3.2 Layout of Robot Components and Drive Mechanism...............................................87
3.3 Dismounting and Mounting Each Cover...................................................................88
3.3.1 Arm 2 Cover................................................................................................89
3.3.2 Base Covers................................................................................................89
3.4 Replacing Motor ......................................................................................................92
3.4.1 Type of Motor..............................................................................................92
3.4.2 Motor Locations...........................................................................................93
3.4.3 Dismounting Axis 1 Motor............................................................................94
3.4.4 Mounting Axis 1 Motor.................................................................................95
3.4.5 Dismounting Axis 2 Motor............................................................................98
3.4.6 Mounting Axis 2 Motor.................................................................................99
3.4.7 Dismounting Axis 3 Motor..........................................................................102

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3.4.8 Mounting Axis 3 Motor...............................................................................103
3.4.9 Dismounting Axis 4 Motor..........................................................................105
3.4.10 Mounting Axis 4 Motor...............................................................................106
3.5 Adjusting and Replacing Timing Belt......................................................................107
3.5.1 Type of Timing Belt....................................................................................107
3.5.2 Timing Belt Locations................................................................................108
3.5.3 Replacing Axis 3 Timing Belt .....................................................................108
3.5.4 Replacing Axis 4 Timing Belt ..................................................................... 111
3.5.5 Check Timing Belt Adjustment...................................................................114
3.6 Filling Grease to Ball Screw Spline Unit and Replacement....................................115
3.6.1 Type of Ball Screw Spline Unit...................................................................115
3.6.2 Ball Screw Spline Unit Location.................................................................116
3.6.3 Greasing Ball Screw Spline Unit and Applying Anticorrosive......................116
3.6.4 Dismounting Ball Screw Spline Unit...........................................................119
3.6.5 Mounting Ball Screw Spline Unit................................................................122
3.7 Reduction Gear Replacement................................................................................126
3.7.1 Type of Reduction Gear ............................................................................126
3.7.2 Reduction Gear Locations.........................................................................127
3.7.3 Dismounting Axis 1 Reduction Gear..........................................................127
3.7.4 Mounting Axis 1 Reduction Gear...............................................................129
3.7.5 Dismounting Axis 2 Reduction Gear..........................................................133
3.7.6 Mounting Axis 2 Reduction Gear...............................................................134
3.7.7 Replacing Axis 4 Reduction Gear..............................................................136
4. Maintenance of the Main Robot (THL800, THL900, THL1000)........................................138
4.1 Details of Inspection ..............................................................................................138
4.1.1 Check of Each Bolt (or Screw) for Clamping..............................................138
4.1.2 Check of Each Cable and Air Tube for Abrasion........................................140
4.1.3 Check of Cable Clamp Tightening.............................................................141
4.1.4 Check of Each Axis for Operation..............................................................142
4.2 Layout of Robot Components and Drive Mechanism.............................................143
4.3 Dismounting and Mounting Each Cover.................................................................144
4.3.1 Arm 2 Cover..............................................................................................145
4.3.2 Base Covers..............................................................................................146
4.4 Replacing Motor ....................................................................................................147
4.4.1 Type of Motor............................................................................................147
4.4.2 Motor Locations.........................................................................................148
4.4.3 Dismounting Axis 1 Motor..........................................................................149

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4.4.4 Mounting Axis 1 Motor...............................................................................151
4.4.5 Dismounting Axis 2 Motor..........................................................................154
4.4.6 Mounting Axis 2 Motor...............................................................................156
4.4.7 Dismounting Axis 3 Motor..........................................................................159
4.4.8 Mounting Axis 3 Motor...............................................................................161
4.4.9 Dismounting Axis 4 Motor..........................................................................162
4.4.10 Mounting Axis 4 Motor...............................................................................163
4.5Adjusting and Replacing Timing Belt......................................................................165
4.5.1 Type of Timing Belt....................................................................................165
4.5.2 Timing Belt Locations................................................................................166
4.5.3 Replacing Axis 3 Timing Belt .....................................................................166
4.5.4 Replacing Axis 4 Timing Belt .....................................................................169
4.5.5 Check Timing Belt Adjustment...................................................................173
4.6 Filling Grease to Ball Screw Spline Unit and Replacement....................................174
4.6.1 Type of Ball Screw Spline Unit...................................................................174
4.6.2 Ball Screw Spline Unit Location.................................................................175
4.6.3 Greasing Ball Screw Spline Unit and Applying Anticorrosive......................175
4.6.4 Dismounting Ball Screw Spline Unit...........................................................178
4.6.5 Mounting Ball Screw Spline Unit................................................................182
4.7 Reduction Gear Replacement................................................................................186
4.7.1 Type of Reduction Gear ............................................................................186
4.7.2 Reduction Gear Locations.........................................................................187
4.7.3 Dismounting Axis 1 Reduction Gear..........................................................187
4.7.4 Mounting Axis 1 Reduction Gear...............................................................188
4.7.5 Dismounting Axis 2 Reduction Gear..........................................................191
4.7.6 Mounting Axis 2 Reduction Gear...............................................................192
4.7.7 Replacing Axis 4 Reduction Gear..............................................................194
5. Maintenance of Controller (TSL3000)..............................................................................196
5.1 Cautions on Maintenance and Inspection..............................................................196
5.2 Layout of Controller Parts......................................................................................197
5.3 Maintenance Procedures.......................................................................................198
5.3.1 Check of Controller Air Vent Holes ............................................................198
5.3.2 Check of Safety Devices for Function........................................................199
5.3.3 Battery Replacement.................................................................................201
5.3.4 Replacement of Switching Power Supply Unit...........................................203
5.3.5 Replacement of Fuse (X8YX Printed Board) .............................................207
5.3.6 Replacement of Output ICs (X8YX Printed Board) ....................................209