Toshiba THP700 User manual

STE 85321-0
THP700/TS3100
MAINTENANCE MANUAL
Notice
1. Make sure that this instruction manual is delivered to the final
user of this product.
2. Before using this product robot, read through and completely
understand this manual.
3. After reading through this manual, keep it nearby for future
reference.
January, 2011
TOSHIBA MACHINE CO., LTD.

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Copyright 2011 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) 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 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 5 of this manual.

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INTRODUCTION
This manual describes the maintenance of this product, THP700, and the TS3100
controller.
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 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.
!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.............................................................................................................9
1.1 Maintenance Schedule....................................................................................9
1.2 Items for Maintenance and Inspection...........................................................10
1.2.1 Inspection at Power OFF (at Non-Operation)....................................10
1.2.2 Inspection at Power ON (at Operation) .............................................11
1.2.3 Overhaul............................................................................................11
1.3 Maintenance Tools.........................................................................................12
1.4 Maintenance Contract and Repair.................................................................12
1.4.1 Maintenance Contract.......................................................................12
1.4.2 Repair................................................................................................12
1.4.3 Modification.......................................................................................13
2. Maintenance of the Main Robot..............................................................................14
2.1 Cautions on Maintenance and Inspection......................................................14
2.1.1 Clamping Hexagon Socket Head Cap Screws..................................14
2.2 Details of Inspection ......................................................................................16
2.2.1 Check of Each Bolt (or Screw) for Clamping.....................................16
2.2.2 Check of Each Cable and Air Tube for Abrasion ...............................19
2.2.3 Check of Each Axis for Operation .....................................................19
2.3 Layout of Robot Components and Drive Mechanism.....................................20
2.4 Dismounting and Mounting Each Cover ........................................................21
2.4.1 Arm 2 Cover......................................................................................22
2.4.2 Arm 1 Covers....................................................................................23
2.4.3 Base Covers......................................................................................23
2.5 Replacing Motor.............................................................................................25
2.5.1 Type of Motor....................................................................................26
2.5.2 Motor Locations.................................................................................27
2.5.3 Dismounting Axis 1 Motor..................................................................28
2.5.4 Mounting Axis 1 Motor.......................................................................30
2.5.5 Dismounting Axis 2 Motor..................................................................31
2.5.6 Mounting Axis 2 Motor.......................................................................34
2.5.7 Dismounting Axis 3 Motor..................................................................38
2.5.8 Mounting Axis 3 Motor.......................................................................39
2.5.9 Dismounting Axis 4 Motor..................................................................41

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2.5.10 Mounting Axis 4 Motor.......................................................................42
2.6 Adjusting and Replacing Timing Belt .............................................................43
2.6.1 Type of Timing Belt............................................................................43
2.6.2 Timing Belt Locations........................................................................44
2.6.3 Replacing Axis 3 Timing Belt.............................................................44
2.6.4 Replacing Axis 4 Timing Belt.............................................................46
2.6.5 Adjusting Timing Belt.........................................................................49
2.7 Filling Grease to Ball Screw Spline Unit and Replacement............................50
2.7.1 Type of Ball Screw Spline Unit ..........................................................50
2.7.2 Ball Screw Spline Unit Location.........................................................51
2.7.3 Filling Grease to Ball Screw Spline Unit............................................51
2.7.4 Dismounting Ball Screw Spline Unit ..................................................53
2.7.5 Mounting Ball Screw Spline Unit .......................................................56
2.8 Filling Grease to Reduction Gear and Replacement......................................59
2.8.1 Type of Reduction Gear ....................................................................59
2.8.2 Reduction Gear Locations.................................................................60
2.8.3 Filling Grease to Reduction Gear......................................................60
2.8.4 Dismounting Axis 1 Reduction Gear..................................................62
2.8.5 Mounting Axis 1 Reduction Gear.......................................................63
2.8.6 Dismounting Axis 2 Reduction Gear..................................................65
2.8.7 Mounting Axis 2 Reduction Gear.......................................................67
2.8.8 Replacing Axis 4 Reduction Gear......................................................69
2.9 Replacing Position Detector (or Encoder) Batteries.......................................71
2.9.1 Battery Box Location.........................................................................72
2.9.2 Replacing Batteries...........................................................................72
2.9.3 Battery Error Code ............................................................................73
3. Maintenance of Controller.......................................................................................74
3.1 Cautions on Maintenance and Inspection......................................................74
3.2 Layout of Controller Parts..............................................................................75
3.3 Maintenance Procedures...............................................................................76
3.3.1 Check of Controller Air Vent Holes....................................................76
3.3.2 Check of Safety Devices for Function ...............................................77
3.3.3 Battery Replacement.........................................................................80
3.3.4 Replacement of Switching Power Supply Unit ..................................82
3.3.5 Replacement of Fuse (X8GN, X8GI Printed Board)..........................83
3.3.6 Replacement of Output ICs (X8GN, X8GI Printed Board).................84

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4. Robot Home Point and Position Detector Error......................................................86
4.1 Setting Robot Home Point.............................................................................86
4.2 Position Detector Error ..................................................................................87
4.3 Restoring Operation from Position Detector Error .........................................90
4.3.1 Encoder Status Display.....................................................................90
4.3.2 Encoder Error Reset Operation.........................................................92
4.4 Restoring Home Position Data by HOME Function .......................................93
4.4.1 Outline of HOME Function ................................................................93
4.4.2 Setting HOME1 and HOME2.............................................................94
4.4.3 How to Restore Data by HOME1 or HOME2.....................................95
4.4.4 Locations of Robot Home Point Match-Marks...................................96
4.4.5 How to Restore Data by HOME3 or HOME4.....................................96
4.5 Restoring Home Position Data by ZEROP Function......................................98
4.5.1 Preparation before Restoring Operation............................................98
4.5.2 Setting New Home Position Data......................................................99
4.5.3 Confirming Home Position...............................................................101
4.5.4 Saving Data.....................................................................................101
4.6 Restoring Home Position Data by Multi-Turn Data Clear.............................102
5. Replacement Parts for Maintenance.....................................................................103
5.1 List of Replacement Parts – Main Robot .....................................................103
5.2 List of Replacement Parts – Controller........................................................104

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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.
0
1200
2400
3600
4800
6000
7200
8400
9600
24000
(h)
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
3-month check
Running hours (h)
Daily inspection
3-month check
3-month check
3-month check
3-month check
3-month check
3-month check
3-month check
Overhaul (every 5 years)
6-month check
6-month check
6-month check
6-month check
1-year check
1-year check

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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
Tool set bolts  
Robot installation bolts  
Bolts for each joint
reduction gear

Make sure that all bolts
are completely tightened
and secured. Otherwise,
tighten the bolts
completely.
Motor set bolts

Para.
2.2.1
Entire robot  Make sure that no cut or
scratch is found. Clean
the contaminant, if any. Arm 2 interior

Ball screw shaft  Para.
2.7.3
Make sure that enough
volume of grease is filled.
Otherwise, fill the grease. 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.
2.2.2
Make sure that each axis
can be operated properly
by moving the axis by
hand.
Entire robot
Para.
2.2.3

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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 ~ M14
• Nippers
• Pliers
• Torque wrench extension bar
• Plastic hammer
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
• Manufacture number 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 M3 M4 M5 M6 M8 M10 M14
Clamping
torque 2.0 N･m4.7N･m 9.0N･m 15N･m 37N･m 75N･m 110N･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 (option), 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 (option)
Tool flange clamp bol
t
M4 ×4 pcs. Tool
Tool set bolt
M4 ×4 pcs.

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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
M16x4 pcs.; Recommended
clamping torque 170 N·m
Axis 1 joint clamp bolt
M14x6 pcs.
The arm cover must be removed
beforehand.
See Para. 2.4.2 for how to
remove the arm cover.
Axis 2 joint clamp bolt
M10x8 pcs.

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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.
Location of bolt Type Bolts
used Reference Para.
Axis 1 drive motor set bolt M8x20 4 pcs. 2.5.3 Dismounting Axis 1 Motor
Axis 1 motor base set bolt M6x30 11 pcs. 2.5.3 Dismounting Axis 1 Motor
Axis 2 drive motor set bolt M5x16 4 pcs. 2.5.5 Dismounting Axis 2 Motor
Axis 2 motor base set bolt M6x20 10 pcs. 2.5.5 Dismounting Axis 2 Motor
Axis 3 drive motor set bolt M4x16 4 pcs. 2.5.7 Dismounting Axis 3 Motor
Axis 3 motor base set bolt M4x12 4 pcs. 2.5.7 Dismounting Axis 3 Motor
Axis 4 drive motor set bolt M4x16 4 pcs. 2.5.9 Dismounting Axis 4 Motor
Axis 4 reduction gear set bolt M5x16 4 pcs. 2.8.8 Mounting Axis 4 Reductgion
Gear
Axis 4 motor base set bolt M4x12 4 pcs. 2.6.4 Replacing Axis 4 Timing Belt
For the recommended clamping torque, see page 14.

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2.2.2 Check of Each Cable andAir Tube for Abrasion
Disassemble the arm 2 cover and base cover and make sure that each cable and air
tube are not worn out, broken or cracked. Especially, take careful precautions to
inspect the vicinity of the cable outlets of the axis 1 joint and axis 2 joint.
For how to dismounting the covers, see Para. 2.4.
Fig. 2.4 Cable and air tube check points
2.2.3 Check of Each Axis for Operation
Turn on the main power switch of the controller, then keep the EMERGENCY
pushbutton switch in the depressed condition. Move each axis by hand and make
sure that it can move smoothly.
For the axis 3, when the brake OFF pushbutton switch is pressed, the brake is
released. Take careful precautions at this time as the tool shaft may drop according
to the weight of the hand and tool.
Check the cables in the
vicinity of the axis 2 motor.
Check the vicinity of the duct outlet for abrasion.
* The nylon sleeve may appear to be frayed or
abraded, but there is no adverse effect on the
quality.
Check the vicinity of the
duct inlet for abrasion.