NXT2 Mechanial Reference

Manual Update Notice
The following manual has been revised and released:
Manual title: NXT II Mechanical Reference

Manual number (updated edition): QD144-17
Manual number (previous edition): QD144-16
Date of issue: March 30, 2012
The main changes that have been made are detailed in the table below.
Chapter, Section Summary of changes

2.13 Related Parts for the Panel Newly added.
Height Detection Function
3.9.1 Panel height detection function Newly added.
4.14 Panel height detection function Newly added.
sensor
Minor changes and corrections have also been made at various locations throughout
the manual.
Note:
For a copy of the entire manual, contact your nearest Fuji sales representative or send
an e-mail request to the address below.
E-mail: intnetqst@fuji.co.jp
Fuji Scalable Placement Platform
NXT II
Mechanical Reference
Original Instructions
QD144-17
CAUTION !
Contact Fuji or a Fuji representative before
transporting this product to a foreign location within
your company or selling it to a third party within
your country or a different country.
If this product is sold or transported to a different
country without contacting Fuji, it may not be
possible for us to supply spare parts or provide
maintenance.
Fuji Scalable Placement Platform
NXT II
Mechanical Reference
The manuals listed below are shipped with the NXT ll machine.
NXT II Setup Manual
NXT II System Reference
NXT II Mechanical Reference
FUJI Intelligent Feeder Manual
NXT II Programming Manual
In order to operate this machine in the safest and most efficient
manner, please read the provided manuals thoroughly and
observe all instructions and warnings.
Keep these manuals in an accessible location near the machine.
QD144-17
FUJI MACHINE MFG. CO., LTD.

Copyrights
All rights regarding this manual are reserved by Fuji Machine Mfg. Co., Ltd. This manual may not, in whole
or in part, be reproduced by any means (electronic, mechanical or otherwise), or reused in any way,
without the prior written permission of Fuji Machine Mfg. Co., Ltd.
Warranty and Liability

Fuji Machine Mfg. Co., Ltd. accepts no responsibility for situations that may arise due to any of the
following:
• The use of third party parts.
• The use of non-genuine Fuji parts.
• Incorrect settings made by the customer.
• Improper use of Fuji equipment.
Notice
Fuji Machine Mfg. Co., Ltd. reserves the right to change the content of this manual without notice.
Every effort has been made to ensure that this manual is correct in every detail. However, please contact
Fuji in the unlikely event that errors or omissions are detected.
Fuji Machine Mfg, Co., Ltd. accepts no liability whatsoever for damages that may arise as a result of this
manual, with the exception of problems that originate in our products.
QD144-17 Contents
Contents
Introduction ................................................................. xix
1. Safety Guidelines.................................................. 1
1.1 About Symbols .................................................. 1
1.1.1 Degree of Hazards...................................................1
1.1.2 Examples of the Symbols ........................................1
1.2 Safety Rules for All Machine Types .................. 2
1.3 Safety Rules for NXT-2 ..................................... 6
1.3.1 Main Unit..................................................................6
1.3.2 Tray Unit-L .............................................................11
1.3.3 Tray Unit-LT/LTC ...................................................12
1.3.4 Tray Unit-M ............................................................13
1.3.5 Disposal of linear motor magnets ..........................13
1.4 Safety Labels .................................................. 14
1.4.1 NXT-2 Safety Label Explanations..........................17
1.5 The EMERGENCY STOP Button.................... 18
1.6 Locking System............................................... 19
1.6.1 Lockout Procedure.................................................19
1.6.2 Unlocking Procedure .............................................21
2. NXT-2 Components ............................................ 23
2.1 Body Components........................................... 23
2.2 Placing Head Components ............................. 24
2.3 Parts Camera Components............................. 28
2.4 Mark Camera & Lighting Components ............ 29
2.5 Feeder Pallet Components ............................. 30
2.6 Tray Unit-L Components ................................. 31
2.7 Tray Unit-LT Components............................... 32
2.8 Tray Unit-LTC Components ............................ 33
2.9 Tray Unit-M Components ................................ 34
2.10 Reject Parts Conveyor Components............. 35
2.11 Nozzle Changer Components ....................... 36
NXT II Mechanical Reference i

Contents QD144-17
2.12 Waste Tape Processing Unit Components ... 37

2.13 Related Parts for the Panel Height Detection
Function............................................................. 38
2.14 PCU (Pallet Change Unit) Components........ 39
2.15 PCU-2 (Pallet Change Unit) Components .... 40
2.16 MCU (Module Change Unit) Components .... 41
2.17 Machine Configuration .................................. 42
2.17.1 Standard machine configuration, M3-2 ............... 42
2.17.2 Standard machine configuration, M6-2/M6-2SP . 43
2.17.3 Standard machine configuration, base................ 45
3. Functions of Each Component ............................ 47
3.1 Base................................................................ 47
3.1.1 2M-2 Base............................................................. 47
3.1.2 4M-2 Base............................................................. 47
3.2 Modules .......................................................... 48
3.2.1 M3-2 Module ......................................................... 48
3.2.2 M6-2 Module ......................................................... 48
3.2.3 M6-2SP Module .................................................... 48
3.3 Placing Head................................................... 49
3.3.1 H01 head............................................................... 50
3.3.2 H02 head............................................................... 50
3.3.3 H04(S) head.......................................................... 50
3.3.4 H08 head............................................................... 50
3.3.5 H12(S) head.......................................................... 50
3.3.6 H12HS head.......................................................... 50
3.3.7 V12 head............................................................... 50
3.3.8 H08M head............................................................ 50
3.4 Nozzle Changer .............................................. 51
3.5 Parts Supply System....................................... 52
3.5.1 Feeder pallet ......................................................... 52
3.5.2 Tray unit-L ............................................................. 52
3.5.3 Tray unit-LT........................................................... 52
3.5.4 Tray unit-LTC ........................................................ 52
ii NXT II Mechanical Reference

QD144-17 Contents
3.5.5 Tray unit-M.............................................................52

3.6 Vision System ................................................. 52
3.6.1 Parts camera .........................................................52
3.6.2 Mark camera..........................................................52
3.7 Panel Conveyance .......................................... 53
3.7.1 Single conveyor .....................................................53
3.7.2 Double conveyor....................................................53
3.7.3 Triple conveyor ......................................................53
3.7.4 M6-2 extended conveyor .......................................53
3.8 Control System................................................ 53
3.8.1 Operation panel .....................................................53
3.8.2 Module CPU box....................................................53
3.8.3 Module servo box ..................................................53
3.8.4 Base CPU box .......................................................53
3.9 Other ............................................................... 54
3.9.1 Panel height detection function..............................54
4. Sensor Positions................................................. 55
4.1 How to check I/Os ........................................... 55
4.2 Base Sensors.................................................. 56
4.2.1 2M-2 base..............................................................56
4.2.2 4M-2 base..............................................................57
4.2.3 Base module related inputs ...................................58
4.2.4 Base inputs ............................................................58
4.2.5 Base module related outputs .................................58
4.3 Placing Head Sensors..................................... 59
4.3.1 H01 head ...............................................................59
4.3.2 H02 head ...............................................................60
4.3.3 H04(S) head ..........................................................62
4.3.4 H08 head ...............................................................63
4.3.5 H12(S) head ..........................................................64
4.3.6 H12HS head ..........................................................65
4.3.7 V12 head ...............................................................66
4.3.8 H08M head ............................................................67
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Contents QD144-17
4.4 Module Base Sensors..................................... 69

4.5 XY-Robot Sensors .......................................... 70
4.5.1 M3-2 module ......................................................... 70
4.5.2 M6-2/M6-2SP module ........................................... 71
4.6 Nozzle Changer Sensors ................................ 72
4.7 Feeder Pallet Sensors .................................... 73
4.8 Waste Tape Processing Sensors.................... 74
4.9 Single Conveyor Sensors ............................... 75
4.9.1 M3-2 module ......................................................... 75
4.9.2 M6-2/M6-2SP module ........................................... 76
4.10 Double Conveyor Sensors ............................ 77
4.10.1 M3-2 module ....................................................... 77
4.10.2 M6-2/M6-2SP module ......................................... 78
4.11 Triple Conveyor Sensors .............................. 79
4.11.1 M3-2 module ....................................................... 79
4.12 M6-2 extended conveyor Sensors ................ 80
4.13 Hybrid Calibration Unit Sensors .................... 81
4.14 Panel height detection function sensor ......... 82
4.15 Tray Unit-L .................................................... 83
4.15.1 Safety components ............................................. 83
4.15.2 Tray tower components....................................... 84
4.15.3 Shuttle components ............................................ 85
4.15.4 Reject parts conveyor ......................................... 86
4.15.5 Remover components ......................................... 87
4.16 Tray Unit-LT .................................................. 88
4.16.4 Reject parts conveyor ......................................... 91
4.17 Tray Unit-LTC ............................................... 92
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QD144-17 Contents
4.17.4 Reject parts conveyor ..........................................95

4.18 Tray Unit-M ................................................... 96
5. Basic Operation .................................................. 99
5.1 Pulling Out/Returning a Module ...................... 99
5.1.1 Pulling out a module ..............................................99
5.1.2 Returning a module .............................................102
5.2 Removing/Inserting a Module ....................... 103
5.2.1 Preparing to remove a module ............................103
5.2.2 Removing a Module from the Machine ................105
5.2.3 Inserting a module into the machine....................113
5.2.4 Loading M3(S) and M6(S) modules onto an NXT-2
base ......................................................................117
5.3 Removing/Loading a Feeder Pallet (PCU).... 118
5.3.1 Removing a feeder pallet.....................................118
5.3.2 Loading a feeder pallet ........................................122
5.4 Removing/Loading a Feeder Pallet (PCU-2). 125
5.4.1 Cautions when using the PCU-2..........................125
5.4.2 Attaching the PCU guide .....................................126
5.4.3 Checking the PCU-2 height .................................136
5.4.4 Removing feeder pallets ......................................138
5.4.5 Attaching feeder pallets .......................................141
5.5 Inserting/Removing a Tray Unit-L ................. 144
5.5.1 Preparation ..........................................................144
5.5.2 Inserting a tray unit-L into the module .................147
5.5.3 Removing a tray unit-L from the module..............148
5.5.4 Preparation for loading a feeder pallet.................149
5.6 Inserting/Removing a Tray Unit-LT ............... 150
5.6.1 Preparing the base ..............................................150
5.6.2 Preparing the module ..........................................152
5.6.3 Inserting a tray unit-LT into the module ...............162
5.6.4 Removing a tray unit-LT from the module ...........163
5.6.5 Preparation for loading a feeder pallet.................163
5.7 Inserting/Removing a Tray Unit-LTC............. 164
5.7.1 Preparation ..........................................................164
NXT II Mechanical Reference v

Contents QD144-17
5.7.2 Inserting a tray unit-LTC into the module ............ 173

5.7.3 Removing a tray unit-LTC from the module ........ 174
5.7.4 Preparation for loading a feeder pallet ................ 174
5.8 Removing/Attaching a Placing Head ............ 175
5.8.1 Important points when removing and attaching
heads.................................................................... 175
5.8.2 Removing a placing head.................................... 176
5.8.3 Attaching a placing head..................................... 179
5.8.4 Important points when using V12 heads and heads
with the part side recognition function .................. 183
5.8.5 Setting nozzle jigs ............................................... 185
5.9 Removing/Attaching a Nozzle Station........... 187
5.9.1 Removing ............................................................ 187
5.9.2 Attaching ............................................................. 190
5.10 Exchanging Backup Plates (When Performing
Dual Lane Production with Lane 2 Brought
Forward) .......................................................... 191
5.10.1 Procedure.......................................................... 192
5.11 Attaching/Removing a Tray Unit-M ............. 197
5.11.1 Preparation........................................................ 198
5.11.2 Attaching procedure .......................................... 199
5.11.3 Attaching procedure (with an optional change unit)
.............................................................................. 200
5.11.4 Removal procedure........................................... 204
5.11.5 Removing procedure
(with an optional change unit)............................... 205
5.11.6 Setting a tray unit-M tape duct or cover ............ 207
5.11.7 Exchanging the separated reject parts box....... 209
6. Preventive Maintenance.................................... 211
6.1 About Preventative Maintenance .................. 211
6.1.1 Maintenance frequency....................................... 211
6.1.2 Points of caution.................................................. 212
6.1.3 Required equipment............................................ 213
6.1.4 Applying grease .................................................. 217
6.2 Maintenance Checklist.................................. 218
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QD144-17 Contents
6.2.1 Maintenance performed by operators when the

machine is waiting to produce...............................218
6.2.2 Maintenance performed by maintenance personnel
..............................................................................219
6.3 Daily Maintenance (Within 24 hrs) ................ 227
6.3.1 Cleaning the waste tape box (Every 8 hrs)..........227
6.3.2 Cleaning the reject parts box (Every 24 hrs) .......228
6.3.3 Cleaning the reject parts box on the tray unit-LT
(Every 24 hrs)........................................................228
6.4 Weekly Maintenance (Every 160 Hrs)........... 229
6.4.1 Cleaning the nozzle station..................................229
6.4.2 Cleaning the feeder pallet....................................230
6.4.3 Cleaning the glass cover on the parts camera ....231
6.4.4 Cleaning the glass cover inside parts camera lighting
unit ........................................................................232
6.4.5 Cleaning inside the module .................................233
6.4.6 Cleaning the tray unit-LT feeder slots and connectors
..............................................................................235
6.4.7 Cleaning the tray unit-LTC feeder slots and
connectors.............................................................235
6.4.8 Cleaning the mirrors on the V12 head .................236
6.4.9 Cleaning the prism glass on the V12 head ..........238
6.5 2 Weekly Maintenance (Every 320 Hrs)........ 239
6.5.1 Lubricating the syringe, Q-axis gear (lower syringe
side) and O-rings on the V12 head .......................239
6.5.2 Lubricating the syringe edge on the H08M head .242
6.6 Monthly Maintenance (Every 700 Hrs).......... 243
6.6.1 Cleaning the reject parts conveyor unit ...............243
6.6.2 Cleaning the tray unit-L shuttle belts (reject parts, tray
drawer) ..................................................................243
6.6.3 Cleaning the tray unit-LT shuttle belts (reject parts,
tray drawer) ...........................................................244
6.6.4 Cleaning the tray unit-LTC shuttle belts (reject parts,
tray drawer) ...........................................................244
6.6.5 Cleaning the placing head vacuum filters ............245
6.6.6 Placing head nozzle clamp pin replacement and
nozzle pick-up surface cleaning ............................249
6.6.7 Cleaning the placing head flange filter.................251
NXT II Mechanical Reference vii

Contents QD144-17
6.6.8 Cleaning the placing head syringes .................... 252

6.6.9 Lubricating the placing head circumference of
syringes, Q-axis gear (lower, syringe side), and
syringe O-rings ..................................................... 256
6.6.10 Checking the placing head mechanical valve
O-rings.................................................................. 265
6.7 3 Monthly Maintenance (Every 2000 Hrs)..... 266
6.7.1 Machine lubrication
(base, module support surfaces) .......................... 266
6.7.2 Cleaning the linear motor cooling fan filter.......... 267
6.7.3 Lubricating the X-axis gears................................ 269
6.7.4 Lubricating the Y-axis flat cable and rollers ........ 274
6.8 6 Monthly Maintenance (Every 4000 Hrs)..... 278
6.8.1 Cleaning the H01 head sleeve assembly
<for heads without flange filter> ........................... 278
6.8.2 Cleaning the tray unit-M ...................................... 282
6.8.3 Lubricating H04(S)/H08/H12(S)/H12HS/V12/H08M
head arm rotation axis for moving mechanical valves
.............................................................................. 283
6.8.4 Lubricating the Q-axis gear and R-axis gear on the
H12HS head ......................................................... 284
V12 head .............................................................. 285
H08M head ........................................................... 286
6.8.7 XY-robot lubrication............................................. 287
6.8.8 Lubricating the XY-robot flat cables .................... 294
6.8.9 Cleaning the filter on the brush unit station type . 298
6.9 Yearly Maintenance (Every 8000 Hrs) .......... 299
6.9.1 Cleaning the air regulator.................................... 299
6.9.2 Cleaning the half mirror of the mark camera light
source................................................................... 300
6.9.3 Cleaning the parts camera lens .......................... 301
6.9.4 Lubricating the nozzle changer up/down shafts .. 304
6.9.5 Replacing the placing head vacuum filters <H04(S),
H08, H12(S), H12HS, V12 and H08M heads> ..... 307
6.9.6 Replacing the linear motor cooling fan filter ........ 307
6.9.7 Replacing the brush on the station type brush unit
.............................................................................. 307
viii NXT II Mechanical Reference

QD144-17 Contents
6.10 12000 Hr Maintenance................................ 308

6.10.1 Cleaning the mist separator filter .......................308
6.10.2 Cleaning the vacuum pump filter .......................309
6.10.3 Cleaning the tray unit-L fan filter........................311
6.10.4 Lubricating the H01 head...................................312
6.10.7 Lubricating the H04S head ................................317
6.10.8 Lubricating the H08/H12(S) head ......................319
6.10.9 Lubricating the H12HS head..............................321
6.10.10 Lubricating the V12 head.................................323
6.10.11 Lubricating the H08M head..............................325
6.10.12 Replacing and lubricating the placing head
mechanical valve O-rings......................................327
6.10.13 Replacing and lubricating the V12 head
6.10.14 Replacing and lubricating the H08M head
6.10.15 Lubricating the conveyor..................................335
6.10.16 Checking the conveyor belt tension.................339
6.10.17 Lubricating the waste tape processing unit......341
6.10.18 Lubricating the tray unit-L ................................342
6.10.19 Checking and adjusting the tray unit-L belt tension
..............................................................................344
6.10.20 Checking and replacing the tray unit-L tray drawer
bottom surface sheet.............................................347
6.10.21 Lubricating the tray unit-LT moving parts ........348
6.10.22 Checking and adjusting the tray unit-LT belt
tension...................................................................350
6.10.23 Checking and replacing the tray unit-LT tray drawer
bottom surface sheet.............................................354
6.10.24 Lubricating the tray unit-LTC moving parts......355
6.10.25 Checking and adjusting the tray unit-LTC belt
tension...................................................................357
6.10.26 Checking and replacing the tray unit-LTC tray
drawer bottom surface sheet.................................361
6.10.27 Lubricating the tray unit-M (TY-axis clutches) .362
6.10.28 Lubricating the tray unit-M (tray stoppers) .......364
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Contents QD144-17
6.10.29 Checking and adjusting the tray unit-M belt tension

.............................................................................. 366
6.11 Irregular Maintenance ................................. 370
6.11.1 Removing rejected parts (reject parts conveyor, tray
unit-L/LT/LTC) ...................................................... 370
6.11.2 Removing empty trays (tray unit-L) ................... 371
6.11.3 Cleaning the Module Top Cover ....................... 372
6.11.4 Cleaning hybrid calibration marks and jig parts 373
6.11.5 Cleaning the nozzles......................................... 374
6.11.6 Cleaning H04(S) nozzles with filters and replacing
nozzle filters.......................................................... 378
6.11.7 Cleaning H08M nozzles with filters and replacing
nozzle filters.......................................................... 385
6.11.8 Cleaning the feeder pallet and part supply base
connector.............................................................. 388
6.11.9 Checking and replacing the placing head vacuum
filters <H01/H02 heads> ....................................... 388
6.11.10 Checking the conveyor belt tension ................ 388
6.11.11 Cleaning the conveyor belt and belt cleaner ... 389
6.11.12 Cleaning the soft backup pins ......................... 390
6.11.13 Checking the CZ-axis belt tension .................. 391
6.11.14 Checking the conveyor motor belt tension ...... 394
6.11.15 Cleaning the waste tape cutter........................ 398
6.11.16 Cleaning the waste tape processing unit duct. 398
6.11.17 Replacing the Brush on Waste Tape Processing
Units ..................................................................... 399
6.11.18 Lubricating the PCU (Pallet Change Unit)....... 401
6.11.19 Lubricating the PCU-2 (Pallet Change Unit) ... 405
7. Replacing Consumable Parts............................ 409
7.1 About Consumable Parts .............................. 409
7.2 Replacing Conveyor Belts............................. 409
7.2.1 Recommended frequency ................................... 409
7.2.2 Procedure............................................................ 409
7.3 Replacing the Conveyor Belt Cleaner ........... 414
7.3.1 Recommended frequency ................................... 414
7.3.2 Procedure............................................................ 414
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QD144-17 Contents
7.4 Replacing Panel Clamper Stopper Bolts....... 415

7.4.1 Recommended frequency....................................415
7.4.2 Procedure ............................................................415
7.5 Replacing the Module Servo Amplifier Battery
........................................................................ 417
7.5.1 Battery type..........................................................417
7.5.3 Procedure ............................................................417
7.6 Replacing the Placing Head Battery ............. 419
7.6.1 Battery type..........................................................419
7.6.3 Procedure ............................................................419
7.7 Replacing the Module CPU Battery .............. 425
7.7.1 Battery type..........................................................425
7.7.3 Preparation procedures .......................................426
7.7.4 Procedure for replacing the battery .....................427
7.7.5 Making all settings after changing the battery .....430
7.8 Replacing the Base CPU battery .................. 434
7.8.1 Battery type..........................................................434
7.8.3 Preparation procedures .......................................434
7.8.4 Procedure for replacing the battery .....................435
7.8.5 Making all settings after changing the battery .....437
7.9 Replacing the Nozzle Station Fluorescent Stickers
........................................................................ 438
7.9.1 Replacement frequency.......................................438
7.9.2 Procedure ............................................................438
7.10 Replacing the Stickers on the V12 Head .... 440
7.10.1 Recommended frequency..................................440
7.10.2 Type...................................................................440
7.10.3 Replacement procedures...................................440
7.11 Replacing a Fuse on a Board inside a Module
........................................................................ 441
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Contents QD144-17
7.11.1 Module remote I/O boards ................................ 441

7.11.2 Module interface board and module connector
board (inside the module control box) .................. 443
7.12 Replacing a Fuse on the Base Remote I/O
Boards ............................................................. 444
7.12.1 Remote I/O board 1 <4M-2 base> .................... 445
7.13 Replacing a Fuse on a Base Control Interface
Board............................................................... 448
7.13.1 Base control Interface board 1 <4M-2 Base> ... 449
7.13.2 Base control Interface board 2 <4M-2 Base> ... 450
7.13.3 Base control Interface board 1 <2M-2 base>.... 451
7.14 Replacing the Thermofuse on the Vacuum Pump
........................................................................ 452
7.14.1 Procedure.......................................................... 452
7.15 Replacing the Tray Unit-L Servo Controller
Battery ............................................................. 453
7.15.1 Battery type ....................................................... 453
7.15.2 Procedure.......................................................... 453
7.16 Replacing the Tray Unit-L Servo Axis Amplifier
Battery ............................................................. 455
7.16.1 Recommended frequency ................................. 455
7.16.2 Procedure.......................................................... 455
7.17 Replacing the Tray Unit-L Interface Board Fuse
........................................................................ 456
7.17.1 Procedure.......................................................... 456
7.18 Replacing the Sponge Pad on the Tray Unit-L
Remover.......................................................... 457
7.18.1 Recommended frequency ................................. 457
7.18.2 Replacing procedure ......................................... 457
7.19 Replacing the Tray Unit-LT Servo Controller
Battery ............................................................. 458
7.19.1 Battery type ....................................................... 458
7.19.2 Procedure.......................................................... 458
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QD144-17 Contents
7.20 Replacing the Tray Unit-LT Servo Axis Amplifier

Battery ............................................................. 460
7.20.2 Procedure ..........................................................460
7.21 Replacing the Tray Unit-LT Interface Board Fuse
........................................................................ 461
7.21.1 Procedure ..........................................................461
7.22 Replacing the Tray Unit-LTC Servo Controller
Battery ............................................................. 462
7.22.1 Battery type........................................................462
7.22.2 Procedure ..........................................................462
7.23 Replacing the Tray Unit-LTC Servo Axis
Amplifier Battery .............................................. 464
7.23.2 Procedure ..........................................................464
7.24 Replacing the Tray Unit-LTC Interface Board
Fuse ................................................................ 466
7.24.1 Procedure ..........................................................466
7.25 Replacing the Tray Unit-M Interface Board Fuses
} ....................................................................... 467
7.25.1 Procedure ..........................................................467
7.26 Replacing the Vacuum Pump's Inlet Valves/
Outlet Valves & Gaskets (for a 2M-2 base vacuum
pump) .............................................................. 468
7.26.2 Required equipment ..........................................468
7.26.3 Replacement procedure ....................................469
7.27 Replacing the Vacuum Pump Valves and
Packings (for the 4M-2 pump (DOP-420SA)) .. 480
7.27.3 Replacement procedure ....................................482
7.28 Replacing the Movable Blades on Waste Tape
Processing Units.............................................. 490
NXT II Mechanical Reference xiii

Contents QD144-17
7.28.3 Procedure for A type ......................................... 492

7.28.4 Procedure for B type ......................................... 498
8. Replacing Parts ................................................. 503
8.1 Replacing the Parts Camera ......................... 503
8.1.1 Required tools ..................................................... 503
8.1.2 Required time...................................................... 503
8.1.3 Procedure............................................................ 503
8.2 Replacing the Mark Camera ......................... 508
8.2.1 Required tools ..................................................... 508
8.2.2 Required time...................................................... 508
8.2.3 Process ............................................................... 508
8.3 Replacing the Reject Parts Unit .................... 511
8.3.1 Required time...................................................... 511
8.3.2 Procedure............................................................ 511
8.4 Replacing the Waste Tape Processing Unit . 513
8.4.1 Required tools ..................................................... 513
8.4.2 Required time...................................................... 513
8.4.3 Procedure............................................................ 513
8.5 Replacing the Module Control Box ............... 516
8.5.1 Required tools ..................................................... 516
8.5.2 Procedure............................................................ 517
8.6 Replacing the Module CPU Box ................... 519
8.6.1 Required tools ..................................................... 519
8.6.2 Preparation procedures....................................... 519
8.6.3 Procedure............................................................ 520
8.6.4 Making all settings after replacing the CPU box . 521
8.7 Replacing Boards in the Module CPU Box ... 522
8.7.1 Required tools ..................................................... 522
8.7.2 Preparation procedures....................................... 522
8.7.3 Replacing the CPU board ................................... 523
8.7.4 Replacing the vision board.................................. 524
8.7.5 Replacing the servo board .................................. 525
8.7.6 After replacing boards ......................................... 525
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QD144-17 Contents
8.8 Replacing the Base Control Box 1 ................ 526

8.8.1 Required tools......................................................526
8.8.2 Procedure ............................................................527
8.9 Replacing the Base Control Box 2 ................ 529
8.9.1 Required tools......................................................529
8.9.2 Procedure ............................................................530
8.10 Replacing the Base CPU Box ..................... 532
8.10.1 Required tools....................................................532
8.10.2 Preparation procedures .....................................532
8.10.3 Procedure ..........................................................533
8.10.4 Settings after replacement.................................535
8.11 Replacing Boards in the Base CPU Box ..... 536
8.11.1 Required tools....................................................536
8.11.2 Preparation procedures .....................................536
8.11.3 Replacing the CPU board ..................................537
8.11.4 Replacing the memory card board.....................538
8.11.5 Procedure after replacement .............................539
8.12 Replacing the Vacuum Pump Control Box.. 540
8.12.1 Required tools....................................................540
8.12.2 Procedure ..........................................................540
8.13 Replacing the DC Power Supply Unit on the
Feeder Pallet ................................................... 542
8.13.1 Required tools....................................................542
8.13.2 M3-2 module......................................................542
8.13.3 M6-2/M6-2SP module........................................543
8.14 Replacing a Conveyer Controller ................ 545
8.14.1 Required tools....................................................545
8.14.2 Replacing single and double conveyor controllers
..............................................................................545
8.14.3 Replacing triple conveyor controllers.................548
8.14.4 Adjusting the controller after replacement .........551
8.15 Removing the Module Top Cover ............... 554
8.15.1 Required tools....................................................554
8.15.2 Procedure ..........................................................554
NXT II Mechanical Reference xv

Contents QD144-17
8.16 Attaching/Removing the Module Side Covers

........................................................................ 555
8.16.1 Required tools ................................................... 555
8.16.2 Attaching ........................................................... 555
8.16.3 Removing .......................................................... 555
8.17 Replacing the Cooling Fan.......................... 556
8.17.1 Module fan (upper side) .................................... 556
8.17.2 Module fan (lower side)..................................... 559
8.17.3 Base fan ............................................................ 560
8.17.4 Fan for the DC power supply unit on the feeder pallet
.............................................................................. 561
8.18 Replacing the Connector between the Feeder
Pallet and the Parts Supply Base.................... 563
8.18.1 Required tools ................................................... 563
8.18.2 M3-2 module ..................................................... 563
8.18.3 M6-2/M6-2SP module ....................................... 564
8.19 Replacing the Connector for the Tray Unit-L and
Parts Supply Base........................................... 565
8.19.1 Required tools ................................................... 565
8.19.2 Procedure.......................................................... 565
8.20 Detaching and Attaching the Tray Unit-L Cover
........................................................................ 566
8.20.1 Required tools ................................................... 566
8.20.2 Tray unit-L cover nomenclature ........................ 566
8.20.3 Detachment....................................................... 567
8.20.4 Attachment ........................................................ 572
8.21 Replacing the Connector for the Tray Unit-LT
and Parts Supply Base.................................... 573
8.21.1 Required tools ................................................... 573
8.21.2 Procedure.......................................................... 573
8.22 Removing Tray Unit-LT Covers .................. 574
8.22.1 Required tools ................................................... 574
8.22.2 Tray unit-LT cover configuration ....................... 574
8.22.3 Removing covers .............................................. 575
8.23 Replacing the Connector for the Tray Unit-LTC
and Parts Supply Base.................................... 582
xvi NXT II Mechanical Reference

QD144-17 Contents
8.23.1 Required tools....................................................582

8.23.2 Procedure ..........................................................582
8.24 Removing Tray Unit-LTC Covers ................ 583
8.24.1 Required tools....................................................583
8.24.2 Tray unit-LTC cover configuration .....................583
8.24.3 Removing covers ...............................................584
8.25 Removing the Conveyor Cover on M6-2
extended Conveyor Modules........................... 591
9. Measurement and Adjustment.......................... 593
9.1 On machine PAM (Placement Accuracy
Measurement) ................................................. 593
9.1.1 Required parts .....................................................593
9.1.2 About the sample job ...........................................596
9.1.3 Notes on performing on machine PAM................597
9.1.4 Positioning backup plates on machines with a double
conveyor................................................................598
9.1.5 Preparing ( Use for version V5.11 or later ) .........599
9.1.6 Preparing ( Use for versions prior to V5.11 ) .......603
9.1.7 Placing accuracy measurement (PAM) flow chart
..............................................................................606
9.1.8 Setting PAM measurement mode........................607
9.1.9 PAM measurements ............................................608
9.1.10 Creating a final offset file ...................................611
9.1.11 Combining multiple offset files into one .............614
9.1.12 Correcting the placement accuracy (final offset file)
..............................................................................616
9.1.13 Changing the type of PAM mode.......................622
9.2 Sensitivity Adjustment for the Conveyor Panel
Pass Sensor .................................................... 623
9.2.1 Remote adjustment procedure ............................623
9.2.2 On-machine adjustment procedure .....................624
9.3 Module Vacuum Sensor................................ 626
9.3.1 Procedure ............................................................626
9.4 Module Pressure Sensor............................... 627
9.4.1 Procedure ............................................................627
NXT II Mechanical Reference xvii

Contents QD144-17
9.5 Base Vacuum Sensor ................................... 628

9.6 Base Pressure Sensor .................................. 629
10. Supplementary Information ............................. 631
10.1 Noise Levels ............................................... 631
10.1.1 Measured noise levels ...................................... 631
Index.......................................................................... 633
xviii NXT II Mechanical Reference

QD144-17 Introduction
Introduction
Provided Manuals
The manuals listed below are shipped with the machine. In order to operate this machine
in the safest and most efficient manner, please read the provided manuals thoroughly and
observe all instructions and warnings.
• NXT II Setup Manual
• NXT II System Reference
• NXT II Mechanical Reference
• NXT II Programming Manual
NXT II Setup Manual

This manual is used for setting up new machines or for moving machines in your factory.
This manual provides instructions from setting up the machine and units to making software
settings.
NXT II System Reference

This manual provides instructions and settings for using the machine in the most efficient
manner for production and changeover. This manual mostly covers software and systems
items.

This manual provides instructions for mechanical aspects of the machine such as adjusting
sensors, preventive maintenance and replacing parts. Refer to this manual when
performing maintenance on the machine such as cleaning, lubrication and adjustments.
NXT II Programming Manual

This manual provides the instructions for programming the machine that are unique for the
NXT II. Refer to this manual when creating jobs or part data in Fuji Flexa, transmitting jobs,
or editing jobs on the machine.
Others
Some of the machine names used in this manual are not the formal machine names.
Formal name Names used in this manual
NXT II NXT-2
M3 II module M3-2 module
M6 II module M6-2 module
M6 IISP module M6-2SP module
2M II base 2M-2 base
4M II base 4M-2 base
PCU II PCU-2
NXT II Mechanical Reference xix

Introduction QD144-17
MEMO:
xx NXT II Mechanical Reference

QD144-17 1. Safety Guidelines
1. Safety Guidelines
Fuji machines are designed and produced with safety as one of our main considerations.
However, even a perfectly designed machine can be damaged, or someone can still be
injured, if the user does not follow the safety rules. It is the responsibility of the user to make
sure that all safety rules are followed at all times.
Be sure to read the safety rules before operating the machine and always use the machine
in accordance with these safety rules.
1.1 About Symbols

This section provides an explanation of the relevant safety precautions to be adhered to by
all people who use or work on this machine. An explanation of the warning labels attached
to the machine is also provided.
This manual employs the use of descriptive symbols and provides details of the level of
danger involved in certain operations to accompany the explanations of machine warning
labels and safety related items. Be sure you understand the meanings of these symbols
before reading the manual.
1.1.1 Degree of Hazards
Symbol Definition
Failure to observe this hazard warning will lead to severe
DANGER injury or death.
Failure to observe this hazard warning may lead to severe

WARNING injury or death.
Failure to observe this hazard warning may lead to

CAUTION personal injury or damage to the machine.
1.1.2 Examples of the Symbols
Symbol Explanation
Hazard
A triangle is used to draw your attention to a hazard. The symbol
inside the triangle indicates the nature of the hazard (in this case,
electrical shock).
Prohibition
A circle with a diagonal line is used to draw your attention to an
operation that is prohibited. The symbol inside the circle indicates
the nature of the operation (in this case, “Do not touch”).
A circle with an exclamation mark is used to draw your attention to a

mandatory action. In other words, you are required to carefully
perform the given instructions.
NXT II Mechanical Reference 1

1. Safety Guidelines QD144-17
1.2 Safety Rules for All Machine Types
DANGER
Do not go near movable parts during automatic or manual
operation.
• Body parts or clothing may get caught in the machine, resulting

in serious injury or death.
WARNING
Do not insert hands or other body parts into the conveyor
inlets.
• Body parts may get caught in the machine, resulting in injury.

• If using a single machine independently, install safety covers or
interlock sensors at the conveyor openings, in accordance with
your local safety regulations, to prevent injuries.
Do not operate the machine with the safety covers or doors

open.
• When safety covers or doors are removed, body parts or

clothing may get caught in the machine, resulting in personal
injury.
• When maintenance work is completed, return the safety covers
and doors to their original (closed) position.
Always verify the position of the EMERGENCY STOP

buttons before operating the machine.
• Always be aware of the positions of the EMERGENCY STOP

buttons so that they can be pushed quickly in case of an
emergency.
Check the safety functions before starting operation.
• Before starting the machine, check the operation of the

EMERGENCY STOP buttons, the safety switches on the
covers and doors, and all other machine safety features.
• Contact a Fuji serviceman immediately if any of the safety
functions fail and do not use the machine.
Do not remove safety switches or disable safety functions.
• Do not short or remove the machine’s safety switches or disable

any safety functions. Persons working on the machine may be
seriously injured if operation commands are issued by mistake.
2 NXT II Mechanical Reference

WARNING
Ensure that there is nobody inside the machine when
working on the machine with two people or more.
• Verify that nobody is in or near the machine before operating

the machine. Operating the machine may result in injury to
people who are in or near the machine.
Do not go near a machine that has stopped moving.
• There are times during automatic operation when the machine

may appear to have stopped, such as while it is waiting for a
panel, waiting for the next machine, reading marks, or
transmitting data. In such cases, once certain conditions are
fulfilled, the machine will begin moving again automatically, so
care should be taken. Only go near the machine after the
EMERGENCY STOP button has been pushed.
• When the “production screen” is displayed on the operation
panel, the machine will begin to move once certain conditions
are satisfied. Be aware that the machine will begin to move
regardless of whether these conditions are satisfied
intentionally or inadvertently.
Do not place hands near the main conveyor.
• Hands or other body parts may get caught in the machine.
Always turn off power to the machine before performing

maintenance.
• Failure to observe this is extremely dangerous and may result

in sudden machine movements or electric shock.
Do not insert or remove connectors while power is being

supplied to the machine.
• Removing or inserting connectors while power is being supplied

to the machine may not only cause damage to the machine, but
may also cause electric shock.
Stay clear from the machine when it is being lifted.
• Never put hands or feet under the machine when the machine
is being raised by means of a jack or other device for leveling or
transport.

WARNING
Do not wear gloves made of cloth when operating the
machine.
• Rubber gloves will tear when caught by the machine and

prevent hands from being drawn into the machine. Gloves
made of cotton or similarly strong material may cause hands to
be drawn into the machine.
Long hair should be tied back.
• Long hair may get caught in machines that are operating.

Hair should be kept short or tied back so that it does not get
caught in the machine.
Turn off the air supply when removing items such as

cylinders, valves, or filters.
• Removing cylinders, valves, or filters without turning the air

supply off may cause parts or particles to be propelled into the
eyes.
• Be sure to turn off the air supply when removing cylinders,
valves, or filters.
Wear protective glasses when removing parts from the

machine.
• Be sure to wear protective glasses when removing or

exchanging parts.
Check the machine operation panel and the target axes while
manually operating the machine.
• When operating the machine, carefully follow the instructions

that are displayed on the operation panel.
• Operating the machine without looking at the operation panel
may lead to operating errors or result in damage to the machine
or products.
Do not touch the servo amp power terminal for at least five
minutes after turning off the power.
• The servo amp retains a high voltage even after the power has
been turned off.
• Always wait at least five minutes, and ensure that the CHARGE
lamp is off, before performing any work that may result in
contact with the servo amp terminal.

CAUTION
Do not operate the machine with sensors removed or
disabled.
• Removing or disabling sensors will disarm the interlock,

resulting in collisions and damage to the machine.
Confirm the operational status from the messages on the

operation panel for machines that support automatic
changeover.
• On machines equipped with an automatic changeover system,

it is difficult to determine the changeover status from the front of
the machine during production. Follow the instructions on the
operation panel.
Use the handle when opening or closing the safety doors,

fences, or covers.
• Opening or closing the safety doors, fences, or covers without

using the handle may result in injury.
• Opening or closing the safety doors, fences, or covers with too
much force may result in damage to the machine.
Always wear an antistatic wrist strap when working with

circuit boards.
• Failure to do so may result in board damage.

• Ensure that the wrist strap is connected to the earth bonding
point.
Always wear headgear when working in or under machines.
• Failure to do so could result in head injuries.

1.3 Safety Rules for NXT-2

1.3.1 Main Unit
WARNING
Do not insert hands or other body parts into the machine in the
spaces between feeders, especially when there are only a few
feeders present on the feeder pallet.
• Failure to do so could result in injury due to contact with the head.
When changing the conveyor width with the module pulled

forward, do not insert hands into the area near the conveyor.
• Body parts may get pinched or caught in the movable conveyor rail,
resulting in serious injury.
When mounting an MCU, ensure that no one is between the MCU

and machine base.
• A person could be seriously injured or even crushed to death if

caught between the MCU and base.
When pushing a module onto the base, check that no one is

behind the module.
• A person could be seriously injured or even crushed to death if

caught between the base and module.
When pushing in a module, do not insert hands between the

module cover support and module.
• Body parts may get pinched or caught, resulting in serious injury.
When pushing in a module, do not insert hands between the

module lower front cover and base.
When pulling out or pushing in a module, do not insert hands or

other body parts in between modules.
• If caught between modules, fingers or other body parts could be cut

or severed.

WARNING
When working on a module in an opening with the cover off,
ensure that no one pushes in or pulls out the module.
When working on a base in the opening above the waste tape

box, ensure that no one pulls out a module.
When working on a base in an opening with the cover off, ensure

that no one pushes in or pulls out the module.
Do not rotate the module lock knob to [UNLOCK] when a module

is loaded on the MCU.
• If the module moves on the MCU, it could pinch and sever body
parts, and if it falls from the MCU it could result in serious injury or
death.
There is a limit to the number of modules that can be pulled out

safely at the same time. (Maximum: Two M3-2 modules on a 4M-
2 base.)
• If the maximum is exceeded, the entire machine may fall over to the
front, possibly resulting in serious injury. This is especially true
when the front leveling bolts have not been adjusted.
Do not release the module stopper mechanism on the base or

remove the module without mounting an MCU first.
• The module could fall from the base, resulting in serious injury or
death.
Do not look directly into the vision processing laser or the panel
conveyance check sensor laser. Wear tinted protective glasses.
• Eye damage may be caused by the looking directly into the sensor
laser.
Stay off of the base.
• Failure to do so could result in injury.

WARNING
When handling the MCU, watch out for corners and protrusions.
Always be ready to apply the caster brake when handling the

MCU.
• Always use the caster brake when stopping an MCU loaded with a
module.
When lifting a backup plate, be careful not to put your hands in

the areas between the plate, width-changing ball screw, and
hexagonal shaft. Also, be careful not to cut your hands on the
corners of the conveyor rails.
Do not lift a backup plate if you are not strong enough, and
maintain correct lifting posture if you do lift a backup plate.
• Because the backup plates are very heavy, lifting them incorrectly
could result in back or other injuries.
Do not insert hands or other body parts into the duct of the
waste tape processing unit.
• There is a very sharp cutter blade inside the unit. Exercise extreme
caution, especially when carrying the unit.
Use two or more people to carry the waste tape processing unit.
• Maintenance of the waste tape processing unit is usually

accompanied by removing the unit from the machine. Use two or
more people to carry the unit because it is very heavy.
Ensure that the work bench where the waste tape processing
unit is placed is flat.
• The unit may fall to the ground if the work bench is tilted, resulting
in personal injury and/or machine damage.
Do not touch linear motors immediately after production is

stopped.
• Contact with the shaft or coil section could cause burns. The shaft
and coil section of linear motors remain very hot even after
production is stopped.

WARNING
People with a heart pacemaker should stay clear of the Y-axis
linear motor in modules (do not come within 400 mm).
• A strong magnetic field is generated by the Y-axis linear motor in

modules. Exercise extreme caution, because pacemakers may
malfunction due to the magnetic field.
Do not disassemble linear motors.
• Never disassemble the linear motor coil and shaft parts. Injury and/
or machine damage may occur by magnetic parts shooting out due
to the strong force of the magnets.
CAUTION
Be careful not to pinch your hands when opening and closing
the front or side covers.
Do not insert fingers or other body parts into the gap between
the machine side cover and base.
When working in front of the base, ensure that clothing or arms

are not caught on the guide pins on the top of the base.
When there is no module on the base, do not block the module

position confirmation sensor or module seating confirmation
sensor that activate the air cylinder.
• The air cylinder may activate and move the lever or clamper,
resulting in injury.
Do not push or pull on the mark camera unit when moving the
placing head.
• The position of the mark camera may be shifted, which negatively

affects the placing accuracy of the machine.

CAUTION
Do not put your hands underneath the nozzle station when
loading it in the machine.
Place the waste tape processing unit upside down on the work
bench.
• The duct may deform under the weight of the unit if it is not placed
upside down.
When working close to a linear motor (within 55 mm) do not use

ordinary metal tools. Use only non-magentic tools.
• The magnetic force can pull metal objects and result in injury (by
trapping fingers or other body parts).
Keep magnetic cards, wristwatches, and other precision

machines away from linear motors (do not bring within 55 mm).
• Damage to items may occur due to the magnetic field generated by

a linear motor.
When pulling forward or returning a module, move the module

slowly and gently so it does not strike the stopper.
• It is possible that the machine position may move if the module

strikes the stopper.
Connect a 200 to 230 V AC +/-10%, 50/60 Hz power supply to the

machine primary power supply side.
• The machine may not function properly or be damaged if a power

supply other than that above is used.

1.3.2 Tray Unit-L
WARNING
When pushing a tray unit-L into the machine, ensure that no one
is between the tray unit-L and machine base.
• A person could be seriously injured or crushed to death if caught

between the tray unit-L and machine.
Lock the caster brake whenever the tray unit-L is removed from
the machine.
• Depending on the slope and condition of the floor, the tray unit-L
could roll unexpectedly, possibly resulting in injury.
CAUTION
Be careful not to pinch body parts when opening or closing the
tray unit-L doors, drawers, or covers. Do not leave the doors,
drawers, or covers open while the tray unit-L is unattended.
• Body parts may get pinched or caught, resulting in injury.
When using the handle that adjusts the height of the tray unit-L,
make sure that body parts are not caught between the handle
and cover.
When removing or replacing the empty tray box, be careful not

to pinch body parts between the tray unit-L and empty tray box.
Do not insert body parts through the bottom of the tray unit-L
into the inner section where mechanical parts are located.

1.3.3 Tray Unit-LT/LTC
WARNING
When pushing a tray unit-LT/LTC into the machine, ensure that
no one is between the tray unit-LT/LTC and machine base.
• A person could be seriously injured or crushed to death if caught

between the tray unit-LT/LTC and machine.
Lock the caster brake whenever the tray unit-LT/LTC is removed

from the machine.
• Depending on the slope and condition of the floor, the tray unit-LT/
LTC could roll unexpectedly, possibly resulting in injury.
Securely grip the magazine rack when lifting, carrying, or

positioning it.
• The magazine rack is heavy and injury could result if dropped.
CAUTION
Be careful not to pinch body parts when opening or closing the
tray unit-LT doors or covers. Do not leave the doors or covers
open while the tray unit-LT/LTC is unattended.
When using the handle that adjusts the height of the tray unit-
LT/LTC, make sure that body parts are not caught between the
handle and cover.
When removing or replacing the empty tray box, be careful not

to pinch body parts between the tray unit-LT/LTC and empty
tray box.
Do not insert body parts through the bottom of the tray unit-LT/
LTC into the inner section where mechanical parts are located.

1.3.4 Tray Unit-M
WARNING
Do not insert hands or other body parts in the space between
the tray unit-M and the feeder pallet when attaching or removing
the tray unit-M.
Use two or more people to lift, carry, or position the tray unit-M.
• The tray unit-M is extremely heavy and injury could result if

dropped.
Do not insert hands or other body parts in the side spaces

between the machine and the tray unit-M during automatic
operation.
CAUTION
Be careful not to pinch body parts in the tray unit-M door when
opening and closing it. Do not leave the door open while the
tray unit-M is unattended.
• Body parts may be pinched or caught, resulting in injury.
1.3.5 Disposal of linear motor magnets

Extremely powerful magnets are used on the stator of the linear motor. It is extremely
important to follow the caution points below when disposing of the linear motor. If disposal
is done by a third party, be sure to instruct them that demagnetization is necessary before
disposal.
• Before removing the stator, be sure to turn off the machine.
• Before removing the stator, prepare a space with no magnetic materials in which
to put it.
• After removing the stator, cover it with non-magnetic material such as paper or
wood to a thickness of at least 55 mm.
• Do not disassemble the stator under any circumstances.
• Heat the stator to at least 330 degrees Celsius for at least 1 hour
(demagnetization processing). Upon cooling, the stator can be disposed of
along with normal industrial waste.

1.4 Safety Labels

To warn the operator of hazards, safety labels are attached to the machine at the positions
indicated in the figure below.
Familiarize yourself with each label and its message before operating the machine.
M3-2 Module
*1
*1
M6-2 Module
M6-2SP Module
*1
*1
NXTSAF010Ef

4M-2 base *1
*2
2M-2 base
*1
*2
NXTSAF011Ea

MSU Engineering panel stand

WARNING
Head Cleaner
Tray unit-LT
Tray unit-L
*1
Tray unit-LTC
*1
*1
*1 Tray unit-M
Side cover
NXTSAF012Ed

1.4.1 NXT-2 Safety Label Explanations
Symbol Explanation
Warning: Pinching danger
Do not insert hands or other body parts in the space between
adjacent modules.
Mandatory action, Direction: Eye protection

Direct exposure to the lighting unit may result in damage to the
eyes. Ensure to use light protection eyewear when necessary.
Caution, Warning: Shock danger

*1: High voltage! Contact may cause electric shock. Turn off
the power prior to servicing.
*2: Connect a 200 - 230V AC +/-10% 50/60Hz primary power
supply to the machine.
Caution, Warning: Cutting danger

An automatic tape cutter is positioned behind this frame.
Exercise extreme caution when performing maintenance.
Warning: Do not step

Do not step or stand on this area.
Caution, Warning: Moving parts

Do not insert hands or other body parts.
Moving parts may cause injury. Turn off the power before
inserting any body parts.
Warning: High Temperature

Contacting with the main body and shaft of the linear motor
could result in burns. They are high temperature.
Warning: Magnetic Field

Heart pacemakers and other precision equipment could be
affected by the magnetic field. Always keep a distance of 400
mm or more.
Warning: Disassembly prohibited

Do not disassemble the linear motor shaft. Injury may occur
by parts shooting out due to the strong force of the magnets.
Mandatory action, Direction: Eye protection

Wear eye protection such as protective glasses while
performing this procedure. There is a danger of foreign
objects such as dust getting in your eyes.

1.5 The EMERGENCY STOP Button

In the event of an emergency, press any of the red EMERGENCY STOP buttons located
on the machine at the positions indicated in the figure below.
EMERGENCY STOP button
EMERGENCY
STOP button
Tray unit-L
EMERGENCY STOP button EMERGENCY STOP button
Tray unit-LT Tray unit-LTC

NXTSAF001Ee

1.6 Locking System

When performing maintenance or service on the machine, all personnel who service the
machine should use locks to prevent others from turning on the machine power or air. This
procedure is referred to as a lockout.
To prevent accidents, especially those caused by mistakes when multiple operators are
present, all related personnel should have thorough knowledge of lockout procedures.
1.6.1 Lockout Procedure

Prepare 2 commercially available padlocks, and require all service personnel to carry
lockout nametags.
1. Switch off the machine power.
2. Rotate the main switch on the base to the OFF position.
NXTSAF004
3. Lock the main switch with a padlock.

All personnel working on the machine should attach their lockout nametags to the
padlock.
Note: Note:The presence of a nametag on the padlock signals that the machine is being serviced
and that the lock is not to be removed.
NXTSAF006

4. In the same manner, rotate the air valve handle to the OFF position and lock with the
second padlock.
All personnel working on the machine should attach their nametags to the padlock.
NXTSAF005
5. The lockout is complete.

1.6.2 Unlocking Procedure

When finished servicing the machine, all personnel should remove their lockout nametags
from the padlocks.
1. Confirm that all personnel are clear of the machine.
2. Confirm that the machine is in a safe condition. Remove the padlock from the air valve
and rotate the handle to the ON position.
NXTSAF007
3. Remove the padlock from the main switch and rotate it to the ON position.
NXTSAF008
4. This concludes the unlocking procedure.

MEMO:

QD144-17 2. NXT-2 Components
2. NXT-2 Components
The primary machine compoments are identified here.
2.1 Body Components

Operation panel
XY-robot
Module
Base
Conveyor
Main switch
Reject parts box
Waste tape box 01MEC-0483E
• Operation Panel:
Used to perform machine operation.
• XY-Robot:
The placing head is attached to the XY-robot.
• Base:
Modules are mounted on the base.
• Module:
Modules can be easily rearranged.
• Conveyor:
The conveyor is responsible for transporting the panels to and from the
production area.
• Reject Parts Box:
Parts that are deemed not to be fit for placement are dumped in a reject parts
box. There are two kinds of reject box: the standard box with one section and
the separated reject box divided into 4 sections (the separated reject box is an
option). The separated reject box can only be installed on M6-2(SP) modules.
• Waste Tape Box:
Used to collect used tape after parts have been picked up.
• Main Switch:
Used to turn the power to the machine ON/OFF.

2. NXT-2 Components QD144-17
2.2 Placing Head Components

The placing head picks up parts from supply devices and places them on the panel.
Battery
<H01 Head>
Z-axis ball screw

Vacuum filters
Z-axis LM rail
Z1-axis ball screw

<H02 Head>
Z2-axis ball screw
Vacuum filters Q1-axis gear

Q2-axis gear
Vacuum filters
Battery 01MEC-0484E

Battery
<H04(S) Head>
Z-axis ball screw
Z-axis guide shaft
Stepping motor
Mechanical valve
Vacuum filter
Battery
<H08 Head>
Z-axis ball screw
Z-axis guide shaft
Stepping motor Mechanical valve
Vacuum filter
01MEC-0485Eb

Battery
<H12(S) Head>
Z-axis guide shaft
Z-axis ball screw
Mechanical valve
Stepping motor Vacuum filter
<H12HS Head>
Battery
Z-axis guide shaft
Z-axis ball screw
Mechanical valve
Vacuum filter
Stepping motor 01MEC-0486E

<V12 Head>
Battery
R-axis gear
Z-axis guide shaft
Q-axis gear
Parts camera
Z-axis ball screw
Mechanical valve
Stepping motor
Vacuum filter
LCD display
Parts side recognition camera

01INS-0932Ea
<H08M Head>
Q-axis gear
Z-axis guide shaft
R-axis gear
Z-axis ball screw
Stepping motor Mechanical valve
Vacuum filter
Battery
01MEC1271E
Note: For details on the OF head, refer to the "NXT/AIM OF Head Instruction Manual". For the
G04 head, refer to the "G04/G04Q Head Instruction Manual". For the H08M/H08MQ
heads, refer to the "H08M Head Instruction Manual". For the H08Q, H12SQ, and H12HSQ
heads, refer to the "Heads with Part Side Recognition Instruction Manual".

2.3 Parts Camera Components

The parts camera captures part images.
For standard, high-resolution, P03, and P05 parts cameras
Cover
Parts camera light
Parts camera
For sidelight type part cameras
Sidelight Frontlight
01MEC-0487Ea

2.4 Mark Camera & Lighting Components

The mark camera is used to read fiducial marks on the panel.
Mark camera
Mark camera light
01MEC-0488Ea

2.5 Feeder Pallet Components

Tape feeders are loaded on the feeder pallet, which enables batch changeover.
Connectors
Clamper
Air cylinder
Connectors
Part supply base
Feeder pallet
<With bucket type tape holder>
01MEC-0489E

2.6 Tray Unit-L Components

The tray unit is used to supply parts to the M6-2(SP) module.
Connector Remover (Option)
Parts removal area

Shuttle
Door
Reject parts conveyor
Parts supply drawer
Control box
Empty tray box

(for remover
equipped units)
Handle
Empty tray stopper

(for remover NXTMTU001Ee
Adjusting knob equipped units)

2.7 Tray Unit-LT Components

Remover (Option)
Upper door
Shuttle
Reject parts
conveyor
Emergency stop button
Lower door
Control box
Empty tray stopper

(for remover
equipped units)
Adjusting bolt
Empty tray stopper

(for remover
Handle
equipped units) 01MEC-0221Ec

2.8 Tray Unit-LTC Components

Upper door Shuttle
Reject parts
conveyor
Emergency stop
button
Feeder pallet
Lower door
Control box
Waste tape box

Handle
Adjusting bolt 01MEC-0500Ea

2.9 Tray Unit-M Components

Communication connector
Clamp lever
Door
Shuttle conveyor
Rack
NXTMTU066E

2.10 Reject Parts Conveyor Components

Parts that are rejected based on vision processing results are rejected here.
Reject parts conveyor-M
Conveyor belt
Reject parts conveyor-L
Clamp lever
Conveyor belt
Clamp lever
01MEC-0490E

2.11 Nozzle Changer Components

The nozzle changer is used to store nozzles. The machine automatically changes to the
optimum nozzles during production. The brush unit station type is an option unit for cleaning
the tips of nozzles.
Note: Examples of some of the available nozzle stations are shown in the illustration below.
Nozzle station
<H01/H02, M3-2 type>
Nozzle station
<H08/H12(S)/H12HS/V12 type>
Nozzle station
<H01/H02, M6-2(SP) type> Station type
brush unit
Nozzle station (Option)
<H01/H02 type for tray unit-L/LT/LTC>
Nozzle changer
Nozzle station
<H04(S) type>
Nozzle station
<H01/H02 type for tray unit-LT/LTC>
Nozzle station
<H04(S) type for tray unit-LT/LTC>
Nozzle station
<H08M type>
Nozzle station
<H04(S) type for tray unit-L/LT/LTC> 01MEC-1030Eb

2.12 Waste Tape Processing Unit Components

This unit cuts waste tape after parts have been picked up.
Cutter
LM guide
Air cylinder
Duct
LM guide
01MEC-0492E

2.13 Related Parts for the Panel Height Detection

Function
This function measures the height of panels. Modules equipped with a PH2 sensor have a
label showing "PH2" attached below the module handle.
PH2 sensor
Block for calibration
Conveyor reference rail
01MEC-1235E

2.14 PCU (Pallet Change Unit) Components

This cart is used for removing and setting feeders pallets in modules.
<PCU for standard feeder pallets>
For M3-2 modules
Guides
Height adjusting handle
<PCU for bucket type feeder pallets>
For M3-2 modules
Guides

01MEC-0493Ea

2.15 PCU-2 (Pallet Change Unit) Components

This cart is used for removing and setting feeders pallets in modules. Feeder pallet
exchange is easier compared to the PCU. When using the PCU-2, install a PCU guide onto
the module base. The PCU-2 and the PCU guide has two panel conveyance heights of 900
mm and 950 mm.
<PCU-2 for standard feeder pallets>

Brake lever
(option) Lever For M3-2 modules
Guides
Height adjustment
lever
Foot pedal
<PCU guide>
Height adjustment bolt
<PCU-2 for bucket type feeder pallets>

Brake lever
(option) Lever
For M3-2 modules
Guides
Height adjustment
lever
Foot pedal
01MEC-1039E

2.16 MCU (Module Change Unit) Components

This cart is used for removing and setting modules on bases.
Two M3-2 modules or one M6-2(SP) module can be loaded on the MCU.
Guides
Level adjusting handle

Lifters NXTBAS262E

2.17 Machine Configuration

2.17.1 Standard machine configuration, M3-2
Module XY-Robot
Placing Head Nozzle
H01 Head
H02 Head
H04 Head H04S Head
H08 Head H08Q Head
H12 Head H12S Head H12HS Head H12SQ Head H12HSQ Head V12 Head
G04 Head
GL Head
Mark Camera Panel height detection function
Parts Camera
Conveyor Backup Pin
Single Conveyor Vacuum Backup Pin Unit

Double Conveyor Soft Backup Pin
Triple Conveyor
Auto PCB Support
Parts Eject Box
Nozzle Changer Nozzle Station
Feeder Pallet H01/H02 Head (M3) Nozzle Station
Waste Tape Processing Unit H04(S) Head Nozzle Station

Operation Panel G04 Head Nozzle Station
Cover H08/H12(S)/H12HS/V12 Head Nozzle Station
FUJI Intelligent Feeder
FUJI Single Stick Feeder
Vibratory Stick Feeder PCU, PCU-2

(Pallet Change Unit)
Tray Feeder
Tray Feeder (M) MCU

(Module Change Unit)
Tray Feeder (L)
Waste Tape Processing Unit
Reject Parts Conveyor (M)
Reject Parts Conveyor (L) 01MEC-0306Ef

2.17.2 Standard machine configuration, M6-2/M6-2SP
Module XY-Robot
Placing Head Nozzle
H01 Head
H02 Head
H04 Head H04S Head
H08 Head H08Q Head H08M Head H08MQ Head
H12Head H12S Head H12HS Head H12SQ Head H12HSQ Head V12 Head
OF Head
G04 Head
GL Head
Mark Camera Panel height detection function
Parts Camera
Conveyor Backup Pin
Double Conveyor Vacuum Backup Pin Unit
Single Conveyor Soft Backup Pin
Extended Conveyor Auto PCB Support
Parts Eject Box
Nozzle Changer Nozzle Station
Feeder Pallet H01/H02 Head (M6-2) Nozzle Station
Waste Tape Processing Unit H04(S) Head Nozzle Station
Operation Panel H08M Head Nozzle Station
H08/H12(S)/H12HS/V12 Head Nozzle Station

Cover
OF Head Nozzle Station
FUJI Intelligent Feeder
G04 Head Nozzle Station
FUJI Single Stick Feeder
Vibratory Stick Feeder

Waste Tape Processing Unit
Tray unit-L Tray Feeder
Reject Parts Conveyor (M)
Tray unit-LT Tray Feeder (M) Reject Parts Conveyor (L)
Tray unit-LTC Tray Feeder (L)
Tray unit-M PCU, PCU-2
(Pallet Change Unit)
MCU
: M6-2SP module non-supported units (Module Change Unit)
01MEC-0307Ei

X-axis/Y-axis (M3-2 type)
XS-axis (M3-2 type)

Parts camera
Nozzle station X-axis/Y-axis (M6-2 type)
Module
servo box
Operation panel
CYCLE STOP READY ON GROUP START STOP POWER
MANUAL
OK
MONITOR
EMERGENCY
CANCEL
STAND BY
FUJI
Parts supply base
Module control box

Feeder pallet
Module CPU box
Waste tape processing unit 01MEC-0494E

2.17.3 Standard machine configuration, base

Base Module Clamper
Vacuum Pump (for parts pickup)

2M-2 Base
Waste Tape Box
4M-2 Base
Vacuum Unit (for vacuum backup pin unit)
01MEC-0309E
2M-2 Base
Base control box 1 Hub
Panel transfer interface L Fan3
Panel transfer interface R
Vacuum pump
Noise filter control box
Breaker box Remote I/O PCB 1
XS interlock PCB
Base control box
Thermal fuse
Main switch
Breaker box 2 01MEC-0241E
4M-2 Base
Base control box 1
Panel transfer interface L

Hub
Panel transfer interface R Fan 1
Base CPU box
Base control box 2
Breaker
Fan 2
Noise filter
Thermal fuse
Vacuum pump
control box
Main switch
Breaker box 1 Remote I/O PCB 1
Remote I/O PCB 2
Breaker box 2 XS interlock PCB 1
XS interlock PCB 2
01MEC-0242E

MEMO:

QD144-17 3. Functions of Each Component
3. Functions of Each Component

This section explains the functions of the major components.
3.1 Base
Bases are the foundations upon which the modules are mounted. Different types of bases
can have different amount of modules mounted upon them. Use a special base for modules
with a triple conveyor.
2M-2 base 4M-2 base
01MEC-0312E
3.1.1 2M-2 Base

A maximum of two M3-2 modules can be mounted on this base. If only M6-2(SP) modulse
are mounted, then the maximum number is one.
3.1.2 4M-2 Base

A maximum of four M3-2 modules can be mounted on this base. If only M6-2(SP) modules
are mounted, then the maximum number is two.

3. Functions of Each Component QD144-17
3.2 Modules
Each module comprises an XY-robot, panel conveyor, panel clamper, feeder pallet, and
vision system cameras. The XY-robot has a holder in which to mount the placing head.
Two sizes of modules are available and a module change unit can be used to quickly
remove and replace modules.
M3-2 Module
M6-2 Module
M6-2SP Module
01MEC-0313Eb
3.2.1 M3-2 Module

This module is 320 mm wide and takes up one "position" on the base. In the module there
is an X-axis moved by a servo motor and ball screw, a Y-axis moved by a linear motor, and
also an XS-axis on the XY-robot.
3.2.2 M6-2 Module

This module is 645 mm wide and occupies two "positions" on the bases. The module is
equipped with an X-axis driven by servo motors and ball screws, and a Y- axis driven by a
linear motor.
3.2.3 M6-2SP Module

This module is 645 mm wide and occupies two "positions" on the bases. The module is
equipped with an X-axis driven by servo motors and ball screws, and a Y- axis driven by a
linear motor. The conveyor is the same as the M6-2 module. In comparison to the M6-2
module, parts can be placed with a high degree of accuracy. Furthermore, a multi-wafer unit
can be attached to the module.

3.3 Placing Head

The placing head is responsible for carrying the parts from the feeder to the panel. Multiple
head types are available to support the placement of various part types. These heads can
be easily exchanged between modules.
H01 Head H02 Head H04(S) Head
H08 Head H12(S) Head H12HS Head
V12 Head H08M Head
NXTPHD015Eg
Note: For details on the OF head, refer to the "NXT/AIM OF Head Instruction Manual". For the
G04 head, refer to the "G04/G04Q Head Instruction Manual". For the H08M/H08MQ
heads, refer to the "H08M Head Instruction Manual". For the H08Q, H12SQ, and H12HSQ
heads, refer to the "Heads with Part Side Recognition Instruction Manual".

3.3.1 H01 head

This placing head has a position for a 1 nozzle and can handle a wide range of different
sized parts. When this head is used, a compatible nozzle station type must be used.
3.3.2 H02 head

This placing head has a position for up to two nozzles and can handle a wide range of
different sized parts. When this head is used, a compatible nozzle station type must be
used.
3.3.3 H04(S) head

This placing head has positions for up to four nozzles. This head is designed to mostly
place small to medium size components. The H04 and H04S heads are separate heads
with different specifications. When these heads are used, a compatible nozzle station type
must be used. The term H04(S) is used in this manual to refer to both head types.
3.3.4 H08 head

This placing head has positions for up to eight nozzles. This head is designed to mostly
place small components. When this head is mounted in a module, a compatible nozzle
station must be used.
3.3.5 H12(S) head

This placing head has positions for up to twelve nozzles. This head is designed to mostly
place small chips and can do so at even higher speed than the H08 head. When this head
is mounted in a module, a compatible nozzle station must be used. The nozzle station for
this head is the same nozzle station used for the H08 head. The H12 head and the H12S
head are separate heads with different specifications. However, the term H12(S) is used
in this manual to refer to both head types.
3.3.6 H12HS head

place small chips and can do so at even higher speed than the H12S head. The nozzle
station for this head is the same nozzle station as that used for the H08 head.
3.3.7 V12 head

place small chips and can do so at even higher speed than the H12HS head. This head
also has a camera for parts which can be used to determine the shape and direction of parts
picked up by the nozzles and also has a parts side recognition camera.
3.3.8 H08M head

This placing heads has positions for up to eight nozzles. These heads are appropriate for
high speed placing of small and medium sized parts and are even capable of placing wide
parts. Use H08M heads in M6-2, M6-2SP modules that have a P05 parts camera attached
in them. When this head is mounted in a module, a compatible nozzle station must be used.

3.4 Nozzle Changer

These units hold the nozzle station which in turn holds the replacement nozzles for the head
mounted in the module. The nozzle station is attached to the top of the nozzle changer and
can be easily changed. The nozzle changer is the same regardless of the nozzle station
used.
The nozzle station types are different based on the following three factors.
・The module type
・The placing head type
・The device unit type being used (such as feeder pallet, tray unit)
Note: Examples of some of the available nozzle stations are shown in the illustration below.
Nozzle station
Nozzle station <H08/H12(S)/H12HS/V12 type>
<H01/H02, M3-2 type>
Nozzle station
<H01/H02 type for tray unit-L/LT/LTC>
Nozzle station
<H01/H02, M6-2(SP) type>
Nozzle changer
Nozzle station
<H04(S) type>
Nozzle station
<H01/H02 type for tray unit-LT/LTC>
Nozzle station
<H04(S) type for tray unit-LT/LTC>
Nozzle station
<H08M type>
Nozzle station
<H04(S) type for tray unit-L/LT/LTC> 01MEC-1030Eb

3.5 Parts Supply System

3.5.1 Feeder pallet
These units hold the intelligent feeders, single stick feeders, and tray unit-M and are
attached to the front of the module. The feeder pallet for the M3-2 module is capable of
holding 20 8 mm feeders (7-inch reel holders), while the feeder pallet for the M6-2 is
capable of holding 45 8 mm feeders (7-inch reel holders).
Note: Up to 44 feeders (8 mm) with 7-inch reel holders can be loaded on M6-2SP modules.
3.5.2 Tray unit-L

The tray unit-L is a unit that supplies tray parts. It can be exchanged with a feeder pallet
for use on M6-2(SP) modules.
3.5.3 Tray unit-LT

The tray unit-LT is a unit that supplies tray parts. In addition to trays, up to 7 feeders (8 mm
feeders with 7-inch reel holders) can be set on this unit. It can be exchanged with a feeder
pallet for use on M6-2(SP) modules.
3.5.4 Tray unit-LTC

The tray unit-LTC is a unit that supplies tray parts. In addition to trays, up to 19 feeders (8
mm feeders with 7-inch reel holders) can be set on this unit. It can be exchanged with a
feeder pallet for use on M6-2(SP) modules.
3.5.5 Tray unit-M

This unit supplies parts on trays. The tray unit-M can be mounted on a feeder pallet in an
M6-2(SP) module.
3.6 Vision System

3.6.1 Parts camera
The parts camera is used to identify the shape and direction of parts which have been
picked up by the nozzles. There are five types of parts camera: standard type, high
resolution type, P03, P05, and sidelight type.
3.6.2 Mark camera

The mark camera is mounted on the XY-robot and is used to read the marks on the panel
required by the machine for positioning.

3.7 Panel Conveyance

3.7.1 Single conveyor
This unit is mounted in the module and loads the panel from the previous machine and
unloads it to the next machine when the panel is completed. This conveyor has one lane
and the lane width is automatically adjusted to match the panel being produced. There is
a motor driven panel clamper. There is also a hybrid calibration unit.
3.7.2 Double conveyor

This unit is mounted in the module and loads the panel from the previous machine and
unloads it to the next machine when the panel is completed. This conveyor has two lanes
and the lane width is automatically adjusted to match the panel being produced. There are
separate motor driven panel clampers for each lane. There is also a hybrid calibration unit.
3.7.3 Triple conveyor

This unit is mounted on the M3-2 module and loads the panel from the previous machine
and unloads it to the next machine when the panel is completed. This conveyor has three
lanes and the lane width is automatically adjusted to match the panel being produced.
There are separate motor driven panel clampers for each lane. There is also a hybrid
calibration unit. A special base is required for modules with triple conveyors.
3.7.4 M6-2 extended conveyor

This unit is mounted on the M6-2 module and loads the panel from the previous machine
and unloads it to the next machine when the panel is completed. This conveyor has one
lane and the lane width is automatically adjusted to match the panel being produced. There
is a motor driven panel clamper. There is also a hybrid calibration unit. The M6-2 extended
conveyor module can only be loaded on a dedicated 2M-2 base specially designed for the
M6-2 extended conveyor module.
3.8 Control System

3.8.1 Operation panel
The operation panel is equipped with the buttons required for operating the module and is
used to display instructions, the machine condition, and vision processing images.
3.8.2 Module CPU box

The control circuitry for running the module is located in this box. This box is responsible
for communicating with the base CPU box.
3.8.3 Module servo box

This box is located near the rear bottom of the modules and contains the servo amplifiers
and control boards used for controlling the servo axes in that module.
3.8.4 Base CPU box

This box has the control circuitry for running the machine and is responsible for managing
and communicating with the modules mounted on that base.

3.9 Other
3.9.1 Panel height detection function
This function improves the quality of produced panels by updating the parts placement
height after measuring the amount of warpage in the panel.

QD144-17 4. Sensor Positions
4. Sensor Positions
This section displays the position of the various sensors in the NXT-2 and the I/O listing.
Caution: Performing IO output operations may damage the machine depending on the machine
status. Always consult a service engineer from either Fuji or a Fuji agent before performing
IO output operations.
4.1 How to check I/Os

To check sensor I/Os (input and output signals), the [Equipment Check] software tool is
necessary. The screen below displays when [Equipment Check] is started. Select the
desired unit and check the I/Os.
Note: Refer to the “Equipment Check” section in the “NXT-2 Software Tools” chapter of the NXT
II System Reference for details on [Equipment Check].
01SYS-0346E
The following diagrams display the sensors labeled with numbers. These numbers
correspond with the address related information in the table.

4. Sensor Positions QD144-17
4.2 Base Sensors

4.2.1 2M-2 base
3 4
6 52
9 10
2
1
8
7 12
5
55 11
56 51
53
54
49
50 60
59
58
57
85
01MEC-0288a

4.2.2 4M-2 base
3 4
52
6 9 10
15 16
2 52
1
21 22
8
7 12
5
14
13
55 11 18
56 20
53
54 19 24
17
49
50 60 23
59
58
57
64
63 68
67
62
61 65
85
66
51
86
01MEC-0289a

4.2.3 Base module related inputs

Signal Name Module 1 Module 2 Module 3 Module 4
Clamp check 1 RX000 7 RX008 13 RX010 19 RX018
Unclamp check 2 RX001 8 RX009 14 RX011 20 RX019
Clamp position check 3 RX002 9 RX00A 15 RX012 21 RX01A
Docking check 4 RX003 10 RX00B 16 RX013 22 RX01B
Front unclamp check 5 RX004 11 RX00C 17 RX014 23 RX01C
Rear unclamp check 6 RX005 12 RX00D 18 RX015 24 RX01D
Waste tape box 85 RX007 86 RX007
presence check
4.2.4 Base inputs

No. Address Signal Name
49 X006 Air check
50 X007 Parts vacuum OK
51 X009 Parts thermal fuse OK
52 X017 Base cooling fan OK
4.2.5 Base module related outputs

Signal Name Module 1 Module 2 Module 3 Module 4
Clamp 53 RY000 57 RY008 61 RY010 65 RY018
Unclamp 54 RY001 58 RY009 62 RY011 66 RY019
Front, rear clamp 55 RY002 59 RY00A 63 RY012 67 RY01A
Front, rear unclamp 56 RY003 60 RY00B 64 RY013 68 RY01B

4.3 Placing Head Sensors

4.3.1 H01 head
5 6 *
11 *
8
7
9
10 3 *
2 *
NXTSEN003d

Number
1 X100 Pressure check
2* X103 Pin unclamp check
3* X104 Pin clamper upper limit check
4 X110 Nozzle pickup check
5 X111 Vacuum break check
6* X112 Pin clamper lower limit check
7 Y100 Part pickup on
8 Y101 Vacuum break
9 Y102 Nozzle pickup on
10 Y103 Nozzle vacuum break
11* Y108 Clamper down
*: For the optional automatic back-up pin function

4.3.2 H02 head

*
22
17
3 *
18
15
20 9
21 8
1 *
16
14 2 *
19
13 5
12
11 4
10 01MEC-0188a

Number
4 X103 Pressure check 2
5 X104 Pressure check 1
6 X110 Nozzle presence check 2
7 X111 Nozzle presence check 1
8 X112 Vacuum break check 2
9 X113 Vacuum break check 2
10 X128-12F Device presence check 2
11 X128-137 Device presence check 1
12 Y100 Part pickup check 2
13 Y101 Nozzle cleaning 2
14 Y102 Nozzle cleaning 1
15 Y103 Vacuum break 1
16 Y104 Part pickup 1


Number
17 Y108 Nozzle pickup 1
18 Y109 Nozzle discard 1
19 Y10A Vacuum break 2
20 Y10C Nozzle discard 2
21 Y10D Nozzle pickup 2
22* Y10E Clamper down

4.3.3 H04(S) head
8 *
9
4
10
2 *
1 *
3 *
6
**
5 NXTSEN016e

Number
4 X103 Nozzle lowering lever off check
5** X104 Nozzle presence check
6 X109 Lever returned check (origin)
7 X111 Part pickup check (red)
9 Y101 Vacuum break
10 Y103 Nozzle cleaning

4.3.4 H08 head
8 *
7 9
10
4 2 *
1 *
3 *
6
5
NXTSEN004d

Number
5 X104 Nozzle presence check
9 Y101 Vacuum break

4.3.5 H12(S) head
8 *
7 9
10
2 *
4
1 *
3 *
5 NXTSEN021d

Number
9 Y101 Vacuum break

4.3.6 H12HS head
8 *
7 9
10
2 *
1 *
3 *
5
01MEC-0193

Number
9 Y101 Vacuum break

4.3.7 V12 head
10
8 *
2 *
4
1 *
3 *
6
5 01MEC-0690

Number
9 Y101 Vacuum break

4.3.8 H08M head
10
11
12
7
8
9
5
14
15
13
16
3
9
5 01MEC-1272

6 X108 Upper transport height check sensor
8 X10A Lower transport height check sensor
9 X10B IPS back raised check sensor
10 X10C Syringe returned check sensor
11 X110 Vacuum check (orange)
X111 Vacuum check (red)
12 * Y100 Clamper down
13 Y101 Vacuum break
15 Y10C Lower transport height command
Note: * denotes the machines equipped with an auto back-up pin (option).

4.4 Module Base Sensors
M6-2 Module
M6-2SP Module
1
2 4
M3-2 Module
1
2
3
01MEC-0316Eb
N0. Address Signal Name

Number
1 RX000 Part vacuum pressure OK
2 RX002 Air OK
3 RX01D Paired module unlock check (M3)
4 X01A Module base cooling fan OK
5 RX017 Reject parts box set check

4.5 XY-Robot Sensors

4.5.1 M3-2 module
1
2
3
NXTSEN006

Number
1 X005 XS-axis interlock 1
4 RX00B Y-axis linear motor temperature OK

4.5.2 M6-2/M6-2SP module
01MEC-0257a

Number
1 RX00B Y-axis linear motor temperature OK

4.6 Nozzle Changer Sensors
4
5
1
2
3
8
10
12
7
9
11
NXTSEN007

Number
1 RX003 Nozzle changer 1 upper limit 1 check
2 RX004 Nozzle changer 1 upper limit 2 check
3 RX005 Nozzle changer 1 lower limit check
4 RX006 Nozzle changer 1 table shutter closed check
5 RX007 Nozzle changer 1 table shutter open check
6 RX009 Nozzle changer 1 docking check
7 RY000 Nozzle changer 1 up 1
8 RY001 Nozzle changer 1 down 1
9 RY002 Nozzle changer 1 up 2
10 RY003 Nozzle changer 1 down 2
11 RY004 Nozzle changer 1 table shutter open
12 RY005 Nozzle changer 1 table shutter close

4.7 Feeder Pallet Sensors
M3-2 Module
2
M6-2 Module
6
7 5
4 1
2 3
6
7
8
5
4 8
1
3
01MEC-0317E

Number
1 RX010 Side 1 - feeder pallet set check (R)
2 RX011 Side 1 - feeder pallet set check (L)
3 RX012 Side 1 - feeder pallet check
4 RX015 Side 1 - feeder pallet clamp check
5 RX016 Side 1 - feeder pallet unclamp check
6 RY010 Side 1 - feeder pallet clamp
7 RY011 Side 1 - feeder pallet unclamp
8 X01B Pallet base cooling fan OK

4.8 Waste Tape Processing Sensors
M6-2 Module M3-2 Module
1
1
2
2
01MEC-0318E

Number
1 RX019 Side 1 - tape cutter stroke end
2 PX01A Side 1 - tape cutter origin position
3 RY012 Side 1 - tape cutter tape cut

4.9 Single Conveyor Sensors

4.9.1 M3-2 module
3 5
1
4
01MEC-0320

Number
1 CX000 Lane 1 conveyor panel left
2 CX001 Lane 1 conveyor panel right
3 CX005 Lane 1 backup pin detection
4 - Conveyor panel check 1 amplifier

5
1
2
01MEC-0252

Number

4.10 Double Conveyor Sensors

4.10.1 M3-2 module
11
10
9
8
4
6
7
4
1
3
1
6
7
5
2
3
2 01MEC-0319

Number
3 CX005 Lane 1 back-up pin detection
6 CX00D Lane 2 adjustable conveyor back-up pin
detection
7 CX00F Lane 2 reference conveyor backup pin
detection
8 - Lane 1 conveyor panel left amplifier
9 - Lane 1 conveyor panel right amplifier


11
4 10
9
6 8
7
4
1
3
1
6
7
5
2
3
2 01MEC-0251

Number
6 CX00D Lane 2 adjustable conveyor back-up pin
detection
7 CX00F Lane 2 reference conveyor backup pin
detection

4.11 Triple Conveyor Sensors

4.11.1 M3-2 module
14
9
7
11
13
11
4
6 15
4
10
1
3 8
1
12
13
12
5
6
5
2
3
2
01MEC-0662

Number
6 CX00D Lane 2 back-up pin detection
* The triple conveyor has a controller for lanes 1 and 2 and a controller for lane 3. The
address for lane 1 and lane 3 is the same.

4.12 M6-2 extended conveyor Sensors

1
1 3
3 2
2
01MEC-1201

Number

4.13 Hybrid Calibration Unit Sensors

<M3-2 Single conveyor> <M3-2 Double conveyor>
2
2
3 3
1
<M3-2 Triple conveyor>
<M6-2 Single conveyor>

<M6-2SP Single conveyor>
<M6-2 Double conveyor>
<M6-2SP Double conveyor>
1
3
01MEC-0843Ea

Number
1 RX00C Hybrid calibration pick up check
2 RX006 Hybrid calibration pickup vacuum ON
3 RX007 Hybrid calibration pickup vacuum OFF

4.14 Panel height detection function sensor
2
2
1
PH2 sensor
01MEC-1236E

Number
1 RY00C PH2 SENSOR ZERO CONFIGURATION
2 RY00D PH2 SENSOR LASER STOP

4.15 Tray Unit-L

4.15.1 Safety components
1
4 2
NXTMTU018

Number
1 IN00 Upper door closed check
2 IN01 Rear door closed check
3 IN02 Lower door closed check
4 IN04 Emergency stop
5 IN1E Supply complete

4.15.2 Tray tower components

8
1 9
2
6
13
11
14
7
12
10
3
8
5
4
15
NXTMTU019a

Number
1 IN1D Pallet clamp close check
2 IN1C Pallet clamp open check
3 IN15 Lower pallet clamp close check 1-2
4 IN14 Lower pallet clamp open check 1-2
5 IN27 Tray discharge check
6 IN28 Tray height check 1
7 IN29 Tray height check 2
8 IN2B Pallet storage check
9 IN2C Upper pallet check
10 IN2D Lower pallet check
11 OUT20 Pallet clamp
12 OUT21 Pallet unclamp
13 OUT25 Lower pallet clamp open/closed
14 OUT1D Upper removal area LED
15 OUT1E Lower removal area LED

4.15.3 Shuttle components
5
6
7
NXTMTU020a

Number
1 IN20 Shuttle reverse check
2 IN21 Shuttle clamp open check
3 IN22 Shuttle clamp close check
4 OUT22 Shuttle pallet clamp open/closed
5 IN18 TY-axis tray height check sensor 3
6 IN19 TY-axis tray height check sensor 2
7 IN2A TY-axis tray height check sensor 1

4.15.4 Reject parts conveyor
4 3
NXTMTU021

Number
1 IN11 NG parts full check (center)
2 IN12 NG parts full check (side)
3 IN13 NG parts C/V count
4 OUT18 NG C/V on

4.15.5 Remover components

1
2
3
5
6
NXTMTU105

Number
1 IN10 Empty tray pickup check
2 IN23 Remover lifter raised check
3 IN24 Remover lifter lowered check
4 IN26 Remover presence check
5 OUT23 Raise/lower remover lifter
6 OUT27 Remover vacuum on

4.16 Tray Unit-LT

Tray unit-LT
01MEC-0222a

Number
No. Machine Signal Name

Address
Number
4 X206 Upper magazine complete switch
5 X209 Lower magazine complete switch


9
Tray unit-LT
5
6
2 7
8 9
4
9
10
1
01MEC-0223

Number
1 IN1F Lower magazine lock
2 IN1E Upper magazine lock
3 IN1C Upper magazine set
4 IN1D Lower magazine set
5 IN22 Upper magazine tray height (L)
6 IN23 Upper magazine tray height (R)
7 IN24 Lower magazine tray height (L)
8 IN25 Lower magazine tray height (R)
9 IN21 Pallet position check
10 IN20 Magazine interference check

Tray unit-LT 4
5
1
8
7
6
01MEC-0224a

Number
1 OUT20 Shuttle pallet clamp
2 IN10 Shuttle retracted check
3 IN12 Shuttle unclamp check
4 IN11 Shuttle clamp check
5 IN2E NG parts box set check
6 IN13 Shuttle tray height check (L)
7 IN14 Shuttle tray height check (M)
8 IN15 Shuttle tray height check (H)

4
Tray unit-LT
01MEC-0225

Number
1 IN02 Jog mode

4.17 Tray Unit-LTC

Tray unit-LTC
1
2
4
5
01MEC-0501a

Number
No. Machine Signal Name

Address
Number
4 X206 Upper magazine complete switch
5 X209 Lower magazine complete switch


Tray unit-LTC 7
9
10
7
6
1 8
01MEC-0502a

Number
1 IN1F Lower magazine lock
2 IN1E Upper magazine lock
3 IN1C Upper magazine set
4 IN1D Lower magazine set
5 IN22 Upper magazine tray heiht
6 IN24 Lower magazine tray heiht
7 IN21 Pallet position check
8 IN20 Magazine interference check
9 - Shuttle tray height monitoring (middle) amplifier
10 - Shuttle tray height monitoring (lower) amplifier

4
Tray unit-LTC
1
5
6
01MEC-0503a

Number
1 OUT20 Shuttle pallet clamp
2 IN10 Shuttle retracted check
3 IN12 Shuttle unclamp check
4 IN11 Shuttle clamp check
5 IN14 Shuttle tray height check (M)
6 IN13 Shuttle tray height check (L)

4
Tray unit-LTC
1
01MEC-0504

Number
1 IN02 Jog mode

4.18 Tray Unit-M
14
4
8
13
11
6
10
7
12
NXTMTU067a


Number
1 IN02 Tray presence check
2 IN03 Clutch ON check
3 IN04 Clutch OFF check
4 IN05 Door closed check
5 IN06 Magazine closed check
6 IN07 SUPPLY PARTS button input
7 IN10 COMPLETE button input
8 IN11 TZ-axis collision check
9 IN12 Tray stopper ON check
10 IN13 CHANGE PARTS button input
11 IN14 Tray forward/back deceleration check
12 IN15 Tray stopped forward check
13 IN16 Tray back check
14 - Unit clamp check

MEMO:

QD144-17 5. Basic Operation
5. Basic Operation
5.1 Pulling Out/Returning a Module
Modules can be pulled forward to allow access to the items within the module. This is
required when changing head or nozzle stations. This also allows cleaning and lubrication
of the module to be performed easier.
Note: When performing paired production, the paired modules are attached together. Pull both
modules forward because they are attached together.
CAUTION
A module should never be pulled out with an tray unit-L/LT/LTC
attached to it. It is possible that machine damage may occur under
such circumstances. First, remove the tray unit-L/LT/LTC and then
pull the module forward.
When pulling forward or pushing in modules with a tray unit-M, tray

type feeders, or a reject parts conveyor set in the module, do so
slowly and carefully. Also, check the state of the parts after
completing the action. There is a danger that parts may shift or
jump out of their trays if the module is moved too quickly.
5.1.1 Pulling out a module

1. With the module not operating, push MANUAL to display the manual commands.
2. Use scissors to cut any cover tape that is hanging down from feeders that are set on the
feeder pallet.
Feeder
Cover tape
01MEC-0966E

5. Basic Operation QD144-17
3. When the module and waste tape processing unit are the type that support the tray unit-
LT air blow exhaust, remove the plugs from the sockets in the front cover and remove
the air tubes.
Caution: Store the air tubes in the base so that they do not get caught between the module and the
base when the module is pulled forward.
Cover
Soket
Plug
01MEC-0849E
4. Use the arrow keys to highlight the cleaning pictogram.
Cleaning
01MEC-0001E
5. Ensure that when the module moves forward that nothing will be struck or pinched by
the module. When safe to unclamp the module, push OK and the module is
automatically unclamped. When the module is unclamped it moves a short distance
forward.
Note:
• If the module is not unclamped, check the cause based on the error message that
displays.
• M3-2 modules will not be unclamped if the XS-axis for that module or the neighboring
modules are in an unsafe position (i.e., protruding into another module). There are
three sensors on the back of the XY-robot. Move the XS-axis so that two of the
sensors are on at the same time (the center sensor and one of the side sensors).

6. Grip the handle for the module and squeeze to release the module brake and gently pull
the module forward until the module hits the stopper.
Note: When performing paired production, pull both modules forward at the same time.
WARNING
There is a limit to the number of modules that can be pulled out safely
at the same time. (Maximum: Two M3-2 modules on a 4M-2 base.)
If the maximum is exceeded, the entire machine may fall over to the
front, possibly resulting in serious physical harm.
CAUTION
Do not insert fingers or other body parts into the gap between the
machine side cover and base, because they could be injured when the
module is pulled out.
When pulling forward or returning a module, move the module gently

and slowly so it will not strike the stopper. It is possible that the
machine position may move if the module strikes the stopper.

5.1.2 Returning a module

1. For the M3-2 module, ensure that the XS-axis or any other items are not protruding from
the module before returning the module. If the axis is protruding, move the axis to a
safe position before returning the module.
2. Grip the handle for the module and squeeze to release the module brake and gently
push the module back.
WARNING
When pulling out or pushing in a module, do not insert hands or other

body parts in between modules. If caught between modules, fingers
or other body parts could be cut or severed
CAUTION
When pulling forward or returning a module, move the module gently

and slowly so it will not strike the stopper. It is possible that the
machine position may move if the module strikes the stopper.
3. Stop pushing when the module reaches the end of the possible movement and it cannot
be pushed back more. At this point, the machine will automatically clamp the module.
If no error occurs and the module is not automatically clamped, gently pull the module
forward a short distance and then push back into position.
LT air blow exhaust, connect the air tube plugs that stick out from waste tape duct to the
sockets in the front cover of the module.
Cover
Socket
Plug
Waste tape duct inside base

01MEC-0850E

5.2 Removing/Inserting a Module

A MCU (module change unit) is used to remove and insert modules.
5.2.1 Preparing to remove a module

Perform the following procedures before removing a module.
Removing the front base cover

Remove the front base cover from the front of the module.
Cover
NXTOPE219E
Note: If the front base cover is left attached to the module and the procedures to remove the
module are performed, the cover and MCU will hit each other and be damaged.
Removing bucket type feeder pallets

If using bucket type feeder pallets, remove the feeder pallet. Refer to section 5.3
"Removing/Loading a Feeder Pallet (PCU)" for details.
Feeder pallet
(bucket type)
NXTOPE220E

Note: If the MCU already has a M3-2 on it and the MCU is to be attached to a base that has a
module in line with an already mounted module on the MCU, remove the feeder pallet from
the module on the base.
M3-2 module
M3-2 module to
be removed
Feeder pallet of remaining module

(in the example, bucket type).
In order to prevent interference,
remove the feeder pallet from the
remaining module before
MCU (module change unit) attaching the MCU.
01MEC-0321E
Removing a tray unit-L/LT

If a tray unit-L/LT is set in the module, then remove this unit. Refer to section 5.5 "Inserting/
Removing a Tray Unit-L" for details.
Caution: Remove any tray unit-L/LT units from the modules next to the module being removed. The
MCU and tray unit-L/LT will interfere with each other.
Clearing pair module production mode

If pair module production is being performed, then clear this mode. Refer to the "NXT II
System Reference" manual for details.

5.2.2 Removing a Module from the Machine

2. Use scissors to cut any cover tape that is hanging down from feeders that are set on the
feeder pallet.
Feeder
Cover tape
01MEC-0966E
LT air blow exhaust, remove the plugs from the sockets in the front cover and remove
the air tubes.
Caution: Store the air tubes in the base so that they do not get caught between the module and the
base when the module is pulled forward.
Cover
Soket
Plug
01MEC-0849E
4. Attach the MCU (Module Changeover Unit) to the machine base.

Caution: Do not perform work such as putting modules on the base or removing modules with only
one guide in the base hole. The MCU may become damaged if only one guide is used. Be
sure to perform this work with both MCU guides in the holes on the base.
a. Turn the handle on the MCU to align the height of the guides with the holes on the
machine base.

b. Ensure that the lock knob is set to "LOCK".
c. Gently slide the MCU guides forward into the holes on the base.
WARNING
When mounting the MCU, ensure that no one is between the MCU
and machine base. A person could be crushed to death if caught
between the MCU and base.
CAUTION
When handling the MCU, watch out for corners and protrusions.
Base
MCU (Module Changeover Unit)
Alignment hole
Guide
Lower Raise
Handle NXTOPE001Ea
5. Level the MCU if necessary.
a. Turn the handle as shown in the diagram below to lift the front casters off the floor.
Handle NXTOPE120E

b. Turn the handle to lower the lifter and secure the MCU as shown below. Adjust the
lifter height while watching the spirit level until the upper surface of the MCU is level.
Lifter Handle
NXTOPE002E
Spirit level
Lifter
Handle NXTOPE114Ea
6. Pull out the module halfway from the machine base.
a. Turn the MCU knob to "UNLOCK".
Knob
NXTOPE027E
b. With the module not operating, push MANUAL to display the manual commands.

c. Use the arrow keys to highlight the cleaning pictogram.
Cleaning
01MEC-0001E
d. Ensure that when the module moves forward that nothing will be struck or pinched
by the module. When safe to unclamp the module, push OK and the module is
forward.
Note: If the module is not unclamped, check the cause based on the error message that displays.
M3-2 modules will not be unclamped if the XS-axis for that module or the neighboring
modules are in an unsafe position (i.e., protruding into another module).
e. Grip the handle for the module and squeeze to release the module brake and gently
pull the module forward until the module hits the stopper. This position should match
up with the line on the MCU.
NXTOPE003
WARNING
Do not modify the module stopper mechanism on the base or

remove the module without mounting the MCU first, because the
module could fall from the base causing severe injury or death.

CAUTION
machine side cover and base, because they could be injured when
the module is pulled out.

gently and slowly so it will not strike the stopper. It is possible that
the machine position may move if the module strikes the stopper.
Note: If removing the neighboring M3-2 module at the sametime onto the MCU, repeat the steps
above.
7. Disconnect the air and power supply from the module.
a. Push and hold the POWER button on the module pulled forward to put it asleep.
b. Open the door at the bottom of the module.

Note: This door is aligned with the cut out section of the MCU when the module is stopped at the
correct position.
c. Disconnect all of the connectors for the air and electrical items and disconnect the
cable bear from the module.
d. There is a lever in the connector area. Pull this lever forward and down in order to
allow the module to move past the line on the MCU.
e. Close the module door. Ensure that cable bear is down and out of the way so it will
not interfere with any items when the module is pulled forward.
Note: M6-2(SP) modules must have the steps above performed for both sides.

8. Pull the module fully onto the MCU.
a. Grip the handle for the module and squeeze to release the module brake and gently
pull the module until it is fully on the MCU.
Note: If removing the neighboring M3-2 module at the same time onto the MCU, repeat the steps
above.
M6-2
M3-2
01MEC-0322
CAUTION
Do not push on the shield plate guide in the module. The plate
shape may change if it is pushed on.
Shield plate guide
01MEC-0439E

b. Turn the knob to "LOCK" after removing the module in order to secure the module on
the MCU.
Knob
NXTOPE006Eb
c. From the base side, gently pull the cable bears so they are no longer in the MCU.
CAUTION
When working in front of the base, ensure that clothing or arms are
not caught on the guide pins on the top of the base to prevent the
risk of injury.
9. Lower the MCU wheels to the floor (when the MCU was leveled in step 5).
a. Turn the handle to raise the lifter and lower the rear casters to the floor.
Handle NXTOPE019Ea
b. Rotate the other handle to lower the front casters to the floor.
Handle NXTOPE020Ea

10.Dettach the MCU with module from the machine base.
a. Grip the MCU handles and squeeze the release lever to release the MCU from the
base.
Note: This operation cannot be done if the lever on the side of the MCU is still at UNLOCK.
WARNING
Do not rotate the module lock knob to UNLOCK when a module is

loaded on the MCU. If the module moves on the MCU, it could
pinch and sever fingers, and if it falls from the MCU it could cause
severe injury or death.
Release handle
NXTOPE007Eb
b. Gently pull the MCU away from the base.
CAUTION
Always be ready to apply the caster brake when handling the MCU.
Always use the caster brake when stopping an MCU loaded with a
module.

5.2.3 Inserting a module into the machine

If the module currently has a end side cover and the module is not going onto the end that
requires the cover, the cover should be removed before attempting these procedures. If
the module is to be mounted on the end of a base that requires a side cover, then the side
cover should be mounted before fully inserting the module into the machine. (Refer to
section 8.16 "Attaching/Removing the Module Side Covers".)
1. Attach the MCU with module to the machine base.

Caution: Do not perform work such as putting modules on the base or removing modules with only
one guide in the base hole. The MCU may become damaged if only one guide is used. Be
sure to perform this work with both MCU guides in the holes on the base.
a. Turn the handle on the MCU to align the height of the guides with the holes on the
machine base.
b. Gently slide the MCU guides forward into the holes on the base until the MCU locks
in the base.
WARNING
When mounting the MCU, ensure that no one is between the MCU
and machine base. A person could be crushed to death if caught
between the MCU and base.
CAUTION
When handing athe MCU, watch out for corners and protrusions.
2. Level the MCU if necessary.
a. Turn the handle to lift the front casters off the floor.
b. Turn the handle to lower the lifter and secure the MCU. Adjust the lifter height while
watching the spirit level until the upper surface of the MCU is level.
3. Push the module halfway onto the machine base.
a. From the base side, gently insert the cable bears between the module and the MCU
in the correct place and push the bear under the module until the end of the cable
bear is in the cut out section on the MCU.
b. Change the lever on the side of the MCU from LOCK to UNLOCK.

c. Grip the handle for the module and squeeze to release the module brake and gently
push the module toward the base until the line position marked on the MCU is
reached.
WARNING
• When pushing a module onto the base, check that no one is

behind the module, to prevent injuries.
• When pulling out or pushing in a module, do not insert hands or

other body parts in between modules. If caught between modules,
fingers or other body parts could be cut or severed.
d. Stop the module at the marked line position on the MCU (the module can be moved
past this position so be careful).
CAUTION
Do not push on the shield plate guide in the module. The plate
shape may change if it is pushed on.
Shield plate guide
01MEC-0439E

4. Connect the air and power supply to the machine.
a. Open the door at the bottom of the module.

Note: This door is aligned with the cut out section of the MCU when the module is stopped at the
correct position.
b. There is a lever in the connector area. Push this lever back and up in order to allow
the module to move back past the line on the MCU.
c. Connect the cable bear to the module and then connect all of the connectors for the
air and electrical items.
d. Close the module door. Ensure that cable bear and wires are safely positioned so
when the module is pushed back, there will be no interference.
M3-2 Module M6-2 Module
Cable bear
Cable bear
Air hoses
Communication
cable (6-pin)
Sensor cable
(50-pin) Power cable
(4-pin)
Knob
Cable bear bracket
01MEC-0323E

5. Push the module fully onto the machine base.
a. Push POWER on the operation panel to turn on the power for the module.
b. For the M3-2 module, ensure that the XS-axis or any other items are not protruding
from the module before returning the module. If the axis is protruding, move the axis
to a safe position before returning the module.
c. Grip the handle for the module and squeeze to release the module brake and gently
push the module toward the base.
WARNING


CAUTION

d. When the limit of the movement is reached, release the handle and the module will
be automatically locked into position.
6. Lower the MCU wheels to the floor (when the MCU was leveled in step 2).
a. Turn the handle to raise the lifter and lower the rear casters to the floor.
b. Rotate the other handle to lower the front casters to the floor.
7. Detach the MCU from the machine base.
a. Change the lever on the side of the MCU from UNLOCK to LOCK.
b. Grip the MCU handles and squeeze the brake to release the MCU from the base.
Note: This operation cannot be done if the lever on the side of the MCU is still at UNLOCK.
c. Gently pull the MCU away from the base.

LT air blow exhaust, connect the air tube plugs that stick out from waste tape duct to the
sockets in the front cover of the module.
Cover
Socket
Plug

01MEC-0850E
5.2.4 Loading M3(S) and M6(S) modules onto an NXT-2 base

When loading M3(S) or M6(S) modules onto 2M-2 or 4M-2 bases, the air coupler on the
standard base cable bear must be exchanged for the S module air coupler (supplied
separately). Remove the air supply hose outside of the machine before exchanging the
couplers.
<Standard air coupler> <S module air coupler>

<S module air coupler>
Drawing no. : AA7HA**
Part name : coupler
Qty. on M3 (S) : 1
Qty. on M6 (S) : 2
01MEC-0559E

5.3 Removing/Loading a Feeder Pallet (PCU)

A PCU (pallet change unit) is used in order to perform the following procedures.
It is possible to change from a feeder pallet to another type of device.

Note: The instructions provided here are for an M6-2(SP) module but the procedure for M3-2
modules is the same.
5.3.1 Removing a feeder pallet

1. Ensure that the module is displaying the main screen on the operation panel.
2. Prepare the PCU by adjusting the height of the PCU to match that of the machine.
Rotate the handle on the PCU until the indicator on the PCU matches the conveyance
height of the machine.
<For standard feeder pallets> <For bucket type feeder pallets>
For M3-2 modules

For M3-2 modules
Handle
Handle
Match the panel conveyance

height.
01MEC-0495E

3. Gently move the PCU forward so the PCU guides are inserted into the holes on the NXT
base. The guides are automatically locked into position.
Slide
NXT base
Guide
Alignment hole
NXTOPE190Ea
Note: Due to conditions such as the flooring, there are cases in which the guides do not align with
the alignment holes in the base. Before pushing the PCU into the base, ensure that the
guides height match that of the base alignment holes and if needed, rotate the handle to
adjust the height until they match.
4. Squeeze the slide lock release lever and move the PCU body forward toward the NXT
base.
Note: The lock is only released when the slide lock release lever is squeezed.
Slide lock
release lever
NXTOPE191E
5. Push MANUAL to display the manual commands.
6. Use the arrow keys to select the unit exchange pictogram and then push OK.

7. Select the pallet exchange pictogram and then push OK.
Pallet exchange
01SYS-0151E
8. Push OK to unclamp the feeder pallet.
01SYS-0152
9. Raise the pallet lock release lever and then gently pull the feeder pallet onto the PCU.
Feeder pallet
Pallet lock
release lever
NXTOPE192E
Note: When the feeder pallet is fully pulled onto the PCU, it is automatically locked.

10.Squeeze the slide lock release lever and gently pull the PCU body with the feeder pallet
away from the NXT.
Slide lock
release lever
NXTOPE193E
11.Squeeze the guide lock release lever and gently pull the PCU away from the NXT.
Guide lock release lever

NXTOPE194E
12.After the feeder pallet has been removed, guidance to attach the feeder pallet is
displayed.

5.3.2 Loading a feeder pallet

1. Ensure that the operation panel is displaying the main screen.
2. Prepare the PCU with the feeder pallet by adjusting the height of the PCU to match that
of the machine. Rotate the handle on the PCU until the indicator on the PCU matches
the conveyance height of the machine.
PCU
Match the panel conveyance

Handle height.
NXTOPE016Eb
3. Gently move the PCU forward so the PCU guides are inserted into the holes on the NXT
Slide
NXT base
Guide
Alignment hole
NXTOPE190Ea
Note: Due to conditions such as the flooring, there are cases in which the guides do not align with
the alignment holes in the base. Before pushing the PCU into the base, ensure that the
guides height match that of the base alignment holes and if needed, rotate the handle to
adjust the height until they match.

4. Squeeze the slide lock release lever and gently move the PCU body with the feeder
pallet forward into the NXT.
Note: The lock is only released when the slide lock release lever is squeezed.
Slide lock
release lever
NXTOPE0195E
5. Raise the pallet lock release lever and then gently push the feeder pallet fully onto the
feeder pallet base.
Pallet lock
release lever
NXTOPE0196E
Note: When the feeder pallet is fully pushed into the module, it is automatically locked.

6. Squeeze the slide lock release lever and gently pull the PCU body away from the NXT.
Slide lock
release lever
NXTOPE197E
7. Squeeze the guide lock release lever and gently pull the PCU away from the NXT.
NXTOPE198E
8. Push MANUAL and the main screen is displayed on the operation panel.

5.4 Removing/Loading a Feeder Pallet (PCU-2)

A PCU-2 (pallet change unit) is used to perform the following procedures. It is possible to
change from a feeder pallet with feeders loaded to another type of device.
Perform the following procedures in preparation for using a PCU-2.
a. Set a guide for the PCU under the base.
b. The height of the PCU-2 is measured and recorded for each place it is to be used
Note: a is a required procedure, however b is a procedure recommended by Fuji to improve the
efficiency of loading and removing a feeder pallet. Even if b is not performed, the feeder
pallet can still be attached and removed without difficulty.
5.4.1 Cautions when using the PCU-2

It is important to note the following cautions when using the PCU-2.
a. Do not use the PCU-2 in locations where the PCU guide has not been attached.
b. Do not use the PCU-2 between the 2 and 3 modules on a 4M base or between bases.
c. Do not change the height of the PCU-2 when the PCU-2 is inserted in the PCU guide.
d. Before inserting the PCU-2, pull out any electrical or air cords that may be under the
base.
e. Remove the PCU guide when using a tray unit-L/LT/LTC.
f. When using a PCU-2 with a tray feeder-M set in the feeder pallet of an M3-2, fully
retract the tray shuttle.
g. Do not attach or remove a feeder pallet when a tray unit-M is attached to the feeder
pallet.
h. When a W08a feeder is set at the right end of the feeder pallet, set the feeder pallet
with the reel holder raised.
i. The PCU-2 and PCU guide are built to suit a machine conveyance height of either
900 mm or 950 mm. Use a PCU-2 and PCU guide suited to the respective machine
conveyance height.

5.4.2 Attaching the PCU guide

Attach a PCU guide to the base when using a PCU-2.
PCU guide
01MEC-1045E
Prepare the required jigs for attaching the PCU guide to the base. This section contains
information regarding installing the PCU guide with and without a jig.
Caution: The PCU guide can only be installed on the base between modules 1 and 2, and between
modules 3 and 4.
Attaching the PCU guide using a jig

The PCU guide installation jig (option) is required for this operation.
01MEC-1041
1. Remove the front base covers from the front of the modules.
Cover
NXTOPE219E
2. Take out the waste tape box.

3. Remove the lower cover under the waste tape box.

Note: Depending on when the machine was purchased, there is a cover that supports the PCU
guide, and a cover that does not. If the cover does not support a PCU guide, exchange it
for a cover that does when attaching the PCU guide.
Cover that supports

the PCU guide
Cover that does not support

the PCU guide
Cover
01MEC-1040E
4. Set the jig on the base. Set the jig positioning pins and ensure that they are on the inside
of the two rails.
Jig Rails
Positioning pins
Jig
01MEC-1042E
5. Check the height and levelness of the bottom surface of the base. There is a stepped
section at the bottom left and right of the jig that has a 2 mm high gap. This 2 mm is the
reference height. Check if there is a 2 mm gap at both the left and right side of the base
surface.
Bottom surface
of base
2 mm 2 mm
Stepped section
01MEC-1043E

6. If one or both of the gaps is not the reference height of 2 mm, perform the following
procedures.
a. Measure and record the variation from the reference height (higher or lower) with a
ruler.
b. There is a stopper bolt at the top of the PCU guide. Loosen the nut of the stopper bolt
on the side(s) that deviates from the reference height.
c. Change the height of the stopper bolt in the direction of the deviance by the amount
of deviation, and then tighten the nut. (For example, raise the stopper bolt 1 mm if
the jig on the left side is 1 mm higher than the reference amount, and lower the
stopper bolt if the jig on the right side is 0.5 mm less than the reference height.)
Note: The height of the stopper bolts when shipped is 14.5 mm. In addition, one revolution of a
bolt moves it up or down 1 mm.
Left side of jig Bottom surface of base

Stopper bolt height
1 mm Right side of jig when shipped
Reference height
14.5 mm
Reference height
Raise 1 mm 0.5 mm
Lower 0.5 mm
PCU guide
Stopper bolt
01MEC-1044E
7. If both the left and right side fall within the reference height from the base, then there is
no need to adjust the PCU guide. However, when using a PCU guide with a stopper bolt
height that has been changed at another location, adjust so the stopper bolt height is
14.5 mm.
8. Remove the bracket that is attached to the PCU guide, and insert the PCU guide under
the base. When it is inserted under the base, reattach the bracket, and tighten the bolts.
Bracket
01MEC-1060E

9. Turn the three height adjustment bolts on the PCU guide to raise the PCU and align the
installation position. Move the PCU guide so that the front part of the PCU guide slots
into the bottom of the base, and the left and right side of the PCU guide slots into the
bottom of the jig.
Front position
Bracket
Side position
Height adjustment bolt 01MEC-1046E
10.With the PCU guide position matching, align the PCU guide attachment height. Turn the
three height adjustment bolts until the top surface of the front stopper bolts meet with
the bottom surface of the base, and the bracket installation holes at the rear meet the
base holes.
Caution: From the position of the stopper bolts at the side of the PCU guide making contact with the
base, there is the danger of the base denting if the height adjustment bolts are turned any
more and the PCU guide raised. Take care not to push too hard on the base.
11.Tighten the adjustment bolt at the front of the PCU guide, and secure using the nut. The
PCU guide is secured onto the bottom panel of the base.
Top surface of the adjustment bolt
Adjustment bolt
01MEC-1047E

12.Loosen the bolts used to attach the bracket in step 8, then align the holes of the base
and the bracket and secure using bolts.
Bracket
Adjustment bolt
Height adjustment bolt

01MEC-1048E
13.Remove the jig.
14.Turn the three height adjustment bolts, check that the lower surface of the bolt touches
the floor, and tighten the lock nuts.
15.Attach the lower cover that supports the PCU guide and insert the waste tape box.
16.Attach the covers for the front of the modules.

Attaching the PCU guide without using a jig

1. Remove the front base covers from the front of the modules.
Cover
NXTOPE219E
3. Remove the lower cover under the waste tape box.

Note: There is a cover that supports the PCU guide, and a cover that does not. If the cover does
not support a PCU guide, exchange it for a cover that does when attaching the PCU guide.
Cover that supports

the PCU guide
Cover that does not support

the PCU guide
Cover
01MEC-1040E
4. Use a ruler to measure the distance between the top surface of the rails on the base and
bottom of the base. Measure the distance from both the left and right rails. Permissible
range: 364 mm to 366 mm.
Left rail
Right rail
Measured distance
Measured distance
Bottom surface of base 01MEC-1054E

5. If one or both of the measured values left and right are outside the permissible range,
perform the following procedures.
a. There is a stopper bolt at the top of the PCU guide. Loosen the nut of the stopper
bolt on the side(s) that deviates from the tolerance value height.
b. If the measured value does not meet the permissible range, raise the stopper bolt
only the amount required to reach it. Conversely, if the range is exceeded, lower it
the amount required to reach it. Then tighten the nut. (For example, raise the
stopper bolt 1 mm when the distance from the left rail is 363 mm, and lower the
stopper bolt 1 mm when the distance from the right rail is 367 mm.)
Note: The height of the stopper bolts when shipped is 14.5 mm. In addition, one revolution of a
bolt moves it up or down 1 mm.
Stopper bolt height

Measured value: 363 mm when shipped
14.5 mm
Raise 1 mm
Measured value: 367 mm
Lower 1 mm
Stopper bolt PCU guide

01MEC-1055J
6. If the measurement values fall within the reference height, then there is no need to
adjust the PCU guide. However, when using a PCU guide with a stopper bolt height that
has been changed at another location, adjust so the stopper bolt height is 14.5 mm.
7. Remove the bracket that is attached to the PCU guide, and insert the PCU guide under
the base. When it is inserted under the base, reattach the bracket, and tighten the bolts.
Bracket
01MEC-1060E

8. Turn the three height adjustment bolts on the PCU guide to raise the PCU and align the
installation position. Move the PCU guide so that the front part of the PCU guide slots
into the bottom of the base. Use a ruler to position the PCU guide so that the gap
between the bottom surface of the base and the side of the PCU guide is not less than
234 mm and not more than 236 mm.
Note: When attaching a PCU guide between modules 1 and 2 on a 4M-2 base, the gap is from
the left side of the base.
Front position
Side position
Measurement
distance
Side of PCU guide Height adjustment bolt
Side of base bottom surface
01MEC-1056E
9. With the PCU guide position matching, align the PCU guide attachment height. Turn
the three height adjustment bolts until the top surface of the front stopper bolts meet with
the bottom surface of the base, and the bracket installation holes at the rear meet the
base holes.
10.Tighten the adjustment bolt at the front of the PCU guide, and secure using the nut. The
PCU guide is secured onto the bottom panel of the base.
Top surface of the adjustment bolt
Adjustment bolt
01MEC-1047E

11.Loosen the bolts used to attach the bracket in step 7, then align the holes of the base
and the bracket and secure using bolts.
Bracket
Adjustment bolt
Upper surface of the stopper bolt

01MEC-1061E
12.Turn the three height adjustment bolts, check that the lower surface of the bolt touches
the floor, and tighten the lock nut.
13.Attach the lower cover that supports the PCU guide and insert the waste tape box.
14.Attach the covers for the front of the modules.

When temporarily removing the PCU guide

When using a feeder pallet and tray unit-L/LT/LTC on a module, the PCU guide must be
temporarily removed when the tray unit is being used. The following method allows for easy
removal and reattachment of the PCU guide when necessary.
Note: This method only applies if the PCU guide and the location where it is to be attached are
the same. When attaching the PCU guide to a different location, it is necessary to position
and align the PCU guide.
1. Mark the position on the base where the PCU guide is attached.
Note: In regards to marking the base, Fuji recommends the following method. If marking is not
performed, follow the PCU guide installation procedures above the next time the PCU guide
is being attached.
2. Loosen the adjustment bolts at the front of the PCU guide.
3. Remove the bolts on the top surface of the bracket at the rear of the PCU guide, loosen
the three height adjustment bolts, and remove the PCU guide. That completes removing
the PCU guide.
Bracket
Base
PCU guide
Mark Height adjustment bolt

Adjustment bolt
01MEC-1049E
4. To reattach the PCU guide, turn the three height adjustment bolts and match the front
of the PCU guide with the position marked in procedure 1.
5. With the PCU guide position matching, align the PCU guide attachment height. Turn the
three height adjustment bolts until the height where the top surface of the front stopper
bolts meet with the bottom surface of the base, and height of the bracket installation
holes at the rear.
6. Tighten the adjustment bolts at the front of the PCU guide, and secure using the nut,
then secure the PCU guide bracket at the rear.
7. Turn the three height adjustment bolts, check that the lower surface of the bolts touch
the floor, and tighten the lock nuts.

5.4.3 Checking the PCU-2 height

If the conveyance height of the machine changes due to floor undulations, or the place
where it is being used changes, checking the height of the PCU-2 guide may be necessary.
By performing the following procedures beforehand, attaching or removing feeder pallets
can be made easier.
Note: The following procedures are not necessary procedures. However, if the following
procedures are not performed, every time the PCU-2 is used the height has to be checked,
and the PCU-2 height changed to a suitable height.
1. Prepare the PCU-2. Remove the lever stored with the PCU-2, and insert the height
adjustment lever.
Caution: Store the lever in the PCU-2 after using it to avoid misplacing it.
Note: The height change lever position is decided by the conveyance height of the machine. Use
the blue or green lever position when using a PCU-2 that supports a machine conveyance
height of 900 mm, and orange when using a PCU-2 that supports a machine conveyance
height of 950 mm.
Lever
Conveyance height Blue Green Orange

900 895~ 910~ 925~
950 930~ 945~ 960~
(mm)
Label
Height adjustment
lever 01MEC-1037E
2. Blue, green, and orange labels are attached at the height change lever change position.
Switch the lever position to blue when using a PCU-2 that supports a machine
conveyance height of 900 mm, and to green when using a PCU-2 that supports a
machine conveyance height of 950 mm.
Green
Blue Orange
Height adjustment
lever
Label 01MEC-1038E

3. Bring the PCU-2 to the front of the PCU guide, and slowly insert the leading rollers of
the PCU-2 into the grooves of the PCU guide. If the rollers and the PCU guide do not
align and the PCU-2 cannot be inserted, switch the height change lever position to green
when using a PCU-2 that supports a machine conveyance height of 900 mm, and to
orange when using a PCU-2 that supports a machine conveyance height of 950 mm,
and insert the PCU-2.
Caution: Insert the PCU-2 gently.
The tolerance for the reference conveyance height of 900 mm or 950 mm is from -5 mm to
+15 mm. Check the machine conveyance height even if the rollers and PCU guide match
after the height has been changed.
Rollers PCU guide groove
01SYS-0449E
4. When the PCU-2 is inserted into the PCU guide, check the color of the PCU-2 height
change lever position. Also, place a label of the same color at a spot on the base that
can easily be seen in order to know the height change lever position when using the
PCU-2.
Note: Fuji recommends using a label to identify the height used. However, any method that can
easily identify the height when the PCU-2 is used is fine.
Label
01MEC-1050E

5.4.4 Removing feeder pallets

Note: The illustrations below are of a PCU-2 that supports an M3-2 standard feeder pallets. The
procedures are the same for M6-2(SP) modules.
1. Ensure that the module from which the feeder pallet is to be removed is displaying the
main screen on the operation panel.
2. Match the height of the PCU-2 with the height of the location used. To change the
height, remove the lever stored with the PCU-2, and insert on the height adjustment
lever.
• If the height of the PCU-2 was checked beforehand at the location using height
identification labels or so on, change the height of the PCU-2 to match it.
• If the height of the PCU-2 was not checked beforehand, check the PCU-2
height, and change the height if appropriate. Refer to procedures 1 to 3 of
section 5.4.3 "Checking the PCU-2 height" for the method.
Lever

900 895~ 910~ 925~
950 930~ 945~ 960~
(mm)
Label
Height adjustment
lever 01MEC-1037E
3. Bring the PCU-2 to the front of the PCU guide, and gently insert the leading rollers of the
PCU-2 into the grooves of the PCU guide.
01SYS-0449E

4. Gently slide the PCU-2 forward so the PCU-2 guides are inserted into the holes on the
01SYS-0450E
Guides
6. Use the arrow keys to select the unit exchange pictogram and then push OK.
7. Select the pallet exchange pictogram and then push OK.
Pallet exchange
01SYS-0151E
8. Push OK to unclamp the feeder pallet.
01SYS-0152

9. Pull out the feeder pallet. After the feeder pallet has been pulled out, hold the handle of
the feeder pallet and check that the feeder pallet is locked into the PCU-2.
Note: Do not step on the foot pedal when checking that the feeder pallet is locked.
Feeder pallet handle
Foot pedal 01MEC-1051E
10.Squeeze the lever and gently pull the PCU-2 away from the base.
Caution: Do not grip the lever until it is confirmed that the feeder pallet is locked into the PCU-2.
Lever
01SYS-0453E
11.After the feeder pallet has been removed, guidance to attach a feeder pallet is displayed.

5.4.5 Attaching feeder pallets

2. Match the height of the PCU-2 with the height of the location used. To change the
height, remove the lever stored with the PCU-2, and insert on the height adjustment
lever.
• If the height of the PCU-2 was checked beforehand at the location using height
identification labels or so on, change the height of the PCU-2 to match it.
• If the height of the PCU-2 was not checked beforehand, check the PCU-2
height, and change the height if appropriate. Refer to procedures 1 to 3 of
section 5.4.3 "Checking the PCU-2 height" for the method.
Lever

900 895~ 910~ 925~
950 930~ 945~ 960~
(mm)
Label
Height adjustment
lever 01MEC-1037E
3. Bring the PCU-2 to the front of the PCU guide, and gently insert the leading rollers of the
PCU-2 into the grooves of the PCU guide.
01SYS-0449E

4. Gently slide the PCU-2 forward so the PCU-2 guides are inserted into the holes on the
Guides
01MEC-1052E
5. Press the foot pedal and insert the feeder pallet onto the module. After inserting, hold
the handle of the feeder pallet and check that the feeder pallet is locked into the module.
Feeder pallet handle
Foot pedal 01MEC-1053E
6. When the feeder pallet has been correctly clamped, the operation panel returns to
displaying guidance for pulling the module forward. Check that the screen is displaying
guidance for pulling the module forward.
01SYS-0152

7. Squeeze the lever and gently pull the PCU-2 away from the base.
Caution: Do not press the lever until the feeder pallet locks into the module.
Lever
01SYS-0456E
8. Push MANUAL and the main screen is displayed on the operation panel.

5.5 Inserting/Removing a Tray Unit-L
CAUTION
• Do not move the tray unit-L or attach/remove it from a module

when tray parts are set in the drawers inside the unit. It is possible
that the parts will shift or be jarred from their tray cavities.
• Be gentle when attaching or removing the tray unit-L so as to not
shock the mechanical components. It is possible that machine
damage may occur under such circumstances.
5.5.1 Preparation
Before inserting the tray unit-L into a module, ensure that the waste tape duct, waste tape
box, and reject parts box are not present and the parts camera is located in the side camera
position. The nozzle station also should be replaced with the one for the tray unit-L.
Waste tape box
NXTMTU007E
2. Remove the feeder pallet. Refer to section 5.3 "Removing/Loading a Feeder Pallet
(PCU)" for details.

NXTOPE194E

3. Pull out the module. (Refer to section 5.1 "Pulling Out/Returning a Module" for details.)
4. Remove the cover for the feeder setting area.
Cover
NXTMTU050E
5. Remove the screws securing the waste tape duct and remove the duct.
Duct
Screw
NXTMTU002E
6. If the separated reject parts box (option) is attached, remove the sensor connectors and
then remove the separated reject parts box.
01MEC-1183

7. Remove the reject parts box from the module.
8. Shift the position of the parts camera to the right side in the module. (Refer to section
8.1 "Replacing the Parts Camera" for details.)
9. Replace the nozzle station to the one for tray unit-L.

Caution: When using nozzle changers that support the station type brush unit (option), before
attaching the nozzle station, remove the bracket that holds the brush unit rubber pad. Place
the removed bracket in the empty space next to the nozzle changer, ensuring that the
bracket does not stick up higher than the conveyor height. Store the removed bolts and
washers in a safe place.
Reject parts box
Nozzle station for tray unit L
Bracket
Parts camera
NXTMTU003Ed
10.Return the module in the base. (Refer to section 5.1 "Pulling Out/Returning a Module"
for details.)
NXTMTU004

5.5.2 Inserting a tray unit-L into the module

1. Position the tray unit in front of the machine.
2. Use the handle to adjust the height of the tray unit until the rollers on the unit are
approximately the same height as the grooves on the part supply base.
Handle
Tray unit rollers Part supply base groove
NXTMTU014E
3. Gently push the tray unit fully into the machine. Once the tray unit is fully inserted into
the module, it is automatically clamped by the module.
WARNING
When pushing the tray unit into the machine, ensure that no one is
between the tray unit and machine base. A person could be
seriously injured or crushed to death if caught between the tray
unit and machine.
CAUTION
For tray unit-L units with a tray remover, hook the removal
prevention chain in the base alignment hole and then push the tray
unit-L fully into the machine. If the chain is left unhooked, then the
chain may become jammed between the tray unit and the base and
thus preventing the unit from fitting properly or being clamped.
NXTMTU006a

5.5.3 Removing a tray unit-L from the module

3. Use the arrow keys to select the unit exchange pictogram and push OK. The screen
changes to display the exchange options.
Unit exchange
01SYS-0080E
4. Ensure that the pallet exchange pictogram is already selected and push OK to unclamp
the tray unit-L.
Pallet exchange
01
5. For tray unit-L units with a tray remover, unhook the removal prevention chain from the
alignment hole in the base.
6. Release the caster brakes and gently pull the tray unit-L away from the machine.
NXTMTU035
7. Lock the casters to prevent the tray unit-L from moving accidentally.

5.5.4 Preparation for loading a feeder pallet

If inserting a feeder pallet after removing the tray unit-L, follow the steps below.
2. Change the position of the parts camera as necessary. (Refer to section 8.1 "Replacing
the Parts Camera" for details.)
Note: If the parts camera position is changed, the machine automatically performs auto-
calibration measurements. (Set nozzle jig(s) in the nozzle station because the machine
requires them for auto-calibration.)
3. Set the reject parts box in the position next to the parts camera.
4. Set the waste tape duct in position and secure it with bolts.
Duct
Screw
NXTMTU002E
5. Attach the cover for the feeder setting area.
Cover
NXTMTU050
6. Push the module back into its original position and it will be clamped. From this point,
the feeder pallet can be loaded in the module.

5.6 Inserting/Removing a Tray Unit-LT
CAUTION
• Do not move the tray unit-LT or attach/remove it from a module

• Be gentle when attaching or removing the tray unit-LT so as to not
5.6.1 Preparing the base

Installing the main switch ON/OFF unit
With a tray unit-LT attached to the main switch side of a 2M-2 or 4M-2 base, the main switch
cannot be reached to be turned ON or OFF. For this reason, the main switch ON/OFF unit
must be attached.
Caution: The main switch ON/OFF unit covers the positioning holes for the PCU and MCU. Remove
the unit before exchanging feeder pallets or modules.
Waste tape box
NXTMTU007E
(PCU)", section 5.4 "Removing/Loading a Feeder Pallet (PCU-2)" for details.
01MEC-1093

3. Remove the cover from the underside of the main switch on the base.
Main switch
Cover
01MEC-0565E
4. Using the same holes as the cover, attach the main switch on/off unit with the new
screws and washers attached.
Main switch
Main switch
ON/OFF unit
01MEC-0557E
5. Turn on and off the main switch on/off unit to confirm that the main switch on the base
turns on and off.
OFF
ON
01MEC-0558

5.6.2 Preparing the module

Before inserting the tray unit-LT into a module, ensure that the waste tape duct and reject
parts box are not present and the parts camera is located in the side camera position. The
nozzle station also should be replaced with the one for the tray unit-LT.
There are two types of waste tape duct sets that handle waste tape when using a tray unit-
LT. One set uses the standard lower duct (which does not need to be exchanged and can
be used for units other than a tray unit-LT). The other set uses a lower duct that is dedicated
for a tray unit-LT (which needs to be exchanged when not using a tray unit-LT). Perform the
appropriate work depending on the type of unit present.
Standard lower duct

The preparation work for attaching a tray unit-LT should be performed on modules that
have air coupler sockets attached to the front cover.
01MEC-1199
1. Remove the cover below the waste tape box.
01NST-1455
2. Loosen the bolts and then remove the lower front module cover.
01NST-1462

Cover
NXTMTU05
5. Remove the screws securing the upper waste tape duct and then remove it.
Duct
Screw
NXTMTU002E
6. Attach the upper waste tape duct for use with the tray unit-LT.
Duct
Screw
01MEC-0561E
01MEC-1183
8. Remove the reject parts box from the module.
9. Shift the position of the parts camera to the right side in the module. (Refer to section

10.Replace the nozzle station to the one for tray unit-LT.
Reject parts box

Nozzle station
for tray unit-LT
Parts camera
01MEC-0154Ea
for details.)
NXTMTU004
12.Remove the module lower front cover.
01MEC-1188
13.There are two valves inside the cover. Turn the handles of the valves to adjust them to
the appropriate position. Turn the valves so they are in the same position and then
attach the cover.
When using a tray unit-LT When not using a tray unit-LT 01MEC-0846E

14.Attach the waste tape chute for the tray unit-LT.
a. Insert the waste tape chute A into the module.
b. Use screws to attach the waste tape chute B to the chute A.
A
B
01MEC-1189
15.Attach the waste tape box guide for the tray unit-LT.
a. Set the waste tape box guide for the tray unit-LT in the base.
Note: There is a sensor in the base. If the waste tape box guide is not set accurately in the base,
the waste tape processing unit will not operate.
b. Run the air couplers attached to the end of the air hoses for the tray unit-LT waste
tape box guide through the hole in the waste tape chute and attach them to the
sockets on the module front cover.
01MEC-1190
16.Attach the waste tape box for the tray unit-LT to the right side of the waste tape box
guide. It is fixed into position by magnets.

17.Attach the cover tape chute for use with the tray unit-LT.
01MEC-1191
18.Attach the external waste tape box for the tray unit-LT.
a. Loosen the nuts on the bolts for adjusting the height of the external waste tape box
for the tray unit-LT.
b. Adjust the height of the external waste tape box by turning the height adjusting bolts
so that the external waste tape box opening matches the waste tape box opening.
c. Fit the opening of the external waste tape box over the opening for the waste tape
box for the tray unit-LT and attach to the base with magnets.
01MEC-1191
19.Attach the lower front module cover.

Lower duct specially for the tray unit-LT

Cover
NXTMTU05
Duct
Screw
NXTMTU002E
4. Remove the waste tape processing unit. (Refer to section 8.4 "Replacing the Waste
Tape Processing Unit" for details.)
5. Remove the screws securing the lower waste tape duct and then remove it.
Duct Screw
01MEC-0562E

6. Attach the lower waste tape duct for use with the tray unit-LT.
Duct
Screw
01MEC-0563E
7. Attach the waste tape processing unit. (Refer to section 8.4 "Replacing the Waste Tape
Processing Unit" for details.)
8. Attach the upper waste tape duct for use with the tray unit-LT.
Duct
Screw
01MEC-0561E
01MEC-1183

10.Remove the reject parts box from the module.
11.Shift the position of the parts camera to the right side in the module. (Refer to section
12.Replace the nozzle station to the one for tray unit-LT.
Reject parts box

Nozzle station
for tray unit-LT
Parts camera
01MEC-0154Ea
for details.)
NXTMTU004
14.Attach the waste tape duct and then set the waste tape box into the base.
Note: A sensor is installed at the area where the waste tape box is attached to the base. If the
waste tape box is not fully inserted back into position, the waste tape processing unit does
not operate.

(fixed base part)
Waste tape duct

inside base Waste tape box
01MEC-0779Ea

If the module and the waste tape duct support air blow, perform the following work.
15.Remove the four screws and remove the module front cover.
Cover
01MEC-0847E
16.There are two valves inside the cover. Turn the handles of the valves to adjust them to
the appropriate position. Turn the valves so they are in the same position and then
attach the cover.
When using a tray unit-LT When not using a tray unit-LT 01MEC-0846E
17.Set the waste tape duct inside the base.

(fixed base part)
Waste tape duct

inside base
01MEC-0844E

18.Connect the air tube plugs that stick out from waste tape duct to the sockets in the front
cover of the module.
Cover
Socket
Plug
Waste tape duct

inside base 01MEC-0848E
19.Insert the waste tape box into the base. Attach the external waste tape box after
attaching the tray unit-LT.
Waste tape box
External waste tape box
01MEC-0845E

5.6.3 Inserting a tray unit-LT into the module

1. Position the tray unit-LT in front of the machine.
2. Use the handle to adjust the height of the tray unit-LT until the rollers on the unit are
Handle

01MEC-0152E
3. Gently push the tray unit-LT fully into the machine. Once the tray unit-LT is fully inserted
into the module, it is automatically clamped by the module.
WARNING
When pushing the tray unit-LT into the machine, ensure that no one
is between the tray unit-LT and machine base. A person could be
seriously injured or crushed to death if caught between the ttray
unit-LT and machine.
01MEC-0575
LT air blow exhaust, attach the external waste tape box.

5.6.4 Removing a tray unit-LT from the module

Unit exchange
01SYS-0080E
the tray unit-LT.
Pallet exchange
01SYS-0151E
5. Release the caster brakes and gently pull the tray unit-LT away from the machine.
01MEC-0576
6. Lock the casters to prevent the tray unit-LT from moving accidentally.

After removing a tray unit-LT, perform the preparations in order to attach a feeder pallet.
Attach the feeder pallet by following the steps in section 5.6.2 "Preparing the module"in
reverse.

5.7 Inserting/Removing a Tray Unit-LTC
CAUTION
• Do not move the tray unit-LTC or attach/remove it from a module

• Be gentle when attaching or removing the tray unit-LTC so as to
not shock the mechanical components. It is possible that machine
5.7.1 Preparation
Before inserting the tray unit-LTC into a module, ensure that the waste tape duct, waste
tape box, and reject parts box are not present and the parts camera is located in the side
camera position. The nozzle station also should be replaced with the one for the tray unit-
LTC.
There are two types of waste tape duct sets that handle waste tape when using a tray unit-
LTC. One set uses the standard lower duct (which does not need to be exchanged and can
be used for units other than a tray unit-LTC). The other set uses a lower duct that is
dedicated for a tray unit-LTC (which needs to be exchanged when not using a tray unit-
LTC). Perform the appropriate work depending on the type of unit present.
Standard lower duct

Waste tape box
NXTMTU007E
01MEC-1093

1. Remove the cover below the waste tape box.
01NST-1455
2. Loosen the bolts and then remove the lower front module cover.
01NST-1462
Cover
NXTMTU050E
Duct
Screw
NXTMTU002E

6. Attach the upper waste tape duct for use with the tray unit-LTC.
Duct
Screw
01MEC-0882E
01MEC-1183
8. Insert the provided jumper connectors into the sensor connectors on the module.
9. Remove the parts reject box from its stand.
11.Replace the nozzle station to a tray unit-LTC type.
Stand
Reject parts box
Nozzle station for tray unit LTC
Parts camera
01MEC-0884E
12.Attach the tray unit-LTC cover to the left of the parts camera.

13.Attach the reject parts box stand onto the cover and then set the box onto the stand.
Stand
Cover
Reject parts box
01MEC-0885E
for details.)
NXTMTU004
15.Attach the waste tape chute for the tray unit-LTC.
a. Insert the waste tape chute A under the module and attach it to the base using bolts.
b. Attach the waste tape chute B to the chute A.
01MEC-1195

16.Remove the two screws on the front cover of the module and use those holes to attach
the brush.
01MEC-1194
17.Attach the waste tape box guide for the tray unit-LTC.
a. Loosen the butterfly screws for the tray unit-LTC waste tape box guide and set in the
base.
b. Position the plate under the waste tape box guide so it is under the base lower plate
and then tighten the butterfly screws.
Note: There is a sensor in the base. If the waste tape box guide is not set accurately in the base,
the waste tape processing unit will not operate.
01MEC-1193
18.Attach the lower front module cover.

Lower duct specially for the tray unit-LTC

Waste tape box
NXTMTU007E
01MEC-1093
Cover
NXTMTU05
Duct
Screw
NXTMTU002E

7. Remove the screws securing the lower waste tape duct and then remove it.
Duct Screw
01MEC-0562E
8. Attach the lower waste tape duct for use with the tray unit-LTC.
Duct
Screw
01MEC-0881E
9. Attach the waste tape processing unit. (Refer to section 8.4 "Replacing the Waste Tape
Processing Unit" for details.)
10.Attach the upper waste tape duct for use with the tray unit-LTC.
Duct
Screw
01MEC-0882E

11.If the separated reject parts box (option) is attached, remove the sensor connectors and
01MEC-1183
12.Insert the provided jumper connectors into the sensor connectors on the module.
13.Remove the parts reject box from its stand.
15.Replace the nozzle station to a tray unit-LTC type.
Stand
Reject parts box
Nozzle station for tray unit LTC
Parts camera
01MEC-0884E
16.Attach the tray unit-LTC cover to the left of the parts camera.

17.Attach the reject parts box stand onto the cover and then set the box onto the stand.
Stand
Cover
Reject parts box
01MEC-0885E
for details.)
NXTMTU004
19.Attach the waste tape duct into the base.

Note: A sensor is installed at the area where the waste tape box is attached to the base. The
waste tape processing unit will not operate if the tray unit-LTC is not attached to the module
and the waste tape box is not set in position.

(fixed base part)
01MEC-0883E

5.7.2 Inserting a tray unit-LTC into the module

1. Position the tray unit-LTC in front of the machine.
2. Use the handle to adjust the height of the tray unit-LTC until the rollers on the unit are
Handle

01MEC-0505E
3. Gently push the tray unit-LTC fully into the machine. Once the tray unit-LTC is fully
inserted into the module, it is automatically clamped by the module.
WARNING
When pushing the tray unit-LTC into the machine, ensure that no
one is between the tray unit-LTC and machine base. A person
could be seriously injured or crushed to death if caught between
the ttray unit-LTC and machine.
01MEC-0575

5.7.3 Removing a tray unit-LTC from the module

Unit exchange
01SYS-0080E
the tray unit-LTC.
Pallet exchange
01SYS-0151E
5. Release the caster brakes and gently pull the tray unit-LTC away from the machine.
01MEC-0507
6. Lock the casters to prevent the tray unit-LTC from moving accidentally.

After removing a tray unit-LTC, perform the preparations in order to attach a feeder pallet.
Attach the feeder pallet by following the steps in section 5.7.1 "Preparation"in reverse.

5.8 Removing/Attaching a Placing Head

5.8.1 Important points when removing and attaching heads
Take account of the following points when removing or attaching heads.
a. When removing or attaching heads, do so only following the procedures in the

manual. When the head is removed or attached under the following conditions, if the
power to the machine is on during the procedure, a 3A1F error will occur.
Caution: If this error occurs, this head can no longer be used. In this case, contact your Fuji
representative.
• CYCLE STOP was pushed to stop operation.
• The head was moved using the head positioning command.
• EMERGENCY STOP was pushed to cut the 200V power.
• The side door was opened.
b. The shaft of the Y-axis linear motor has a very strong magnetic field. Be careful that
the field does not pull the head towards the shaft and contact the head.
Caution: If the head contacts the shaft, stop using the head and contact your Fuji representative.
Linear motor coil
Linear motor shaft
X-axis gear cover

Linear scale 01MEC-0324Eb
c. If removing and attaching the head is difficult only holding the head by the handle with
one hand, use the other hand to support the head from below. Do not strain yourself
by trying to carry the entire weight of the head in one hand, and be careful not to
strike the head against the machine.
01MEC-1223

5.8.2 Removing a placing head

Placing heads can be easily removed from the machine. This makes it easier to perform
maintenance on the head and to change the head type when required.
2. Use the arrow keys to highlight the unit exchange pictogram and push OK.
Unit exchange
01SYS-0080E
3. Use the arrow keys to highlight the head exchange pictogram.
Head exchange
01MEC-0002E
4. Push START and the head moves to the removal position and power to the head is
turned off.
Note: If a tray unit-L/LT/LTC is attached to the module, the guidance screen changes to display
guidance for removing the tray unit-L/LT/LTC at this point. Follow the directions provided
to remove the tray unit-L/LT/LTC and then continue on to the next step.
forward.
Note: If the module is not unclamped, check the cause based on the error message that displays.
M3-2 modules will not be unclamped if the XS-axis for that module or the neighboring
modules are in an unsafe position (i.e., protruding into another module).

WARNING

safely at the same time. (Maximum: Two M3-2 modules on a 4M-2
base.) If the maximum is exceeded, the entire machine may fall
over to the front, possibly resulting in serious physical harm.
CAUTION


7. When using a V12 head or a head with the part side recognition function and operating
with the conveyor maximum panel width set to 230 mm or less, the head position must
be changed. (Refer to section 5.8.4 "Important points when using V12 heads and heads
with the part side recognition function" for details.)
8. Disconnect the connectors from the head. For the V12 head, remove connector 1 first,
then connector 2, and finally connector 3.
<V12 Head> Connector3

Connectors 1 2
Connector1
3
Connector2
01MEC-0838E

9. Raise the lever and push to the left. Holding the handle, gently remove the head as
shown in the illustration below.
Lever
Placing head
NXTPHD003b
For modules with a PH2 sensor, do not tilt the placing head too far when removing it. The
placing head may hit the PH2 sensor.
CAUTION
Be careful not to hit the PH2 sensor when removing or attaching the
placing head. Hitting the head against the sensor or other part may
cause damage.
Placing head
PH2 sensor 01MEC-1237E

CAUTION
When performing maintenance inside the module, the head or shaft

could be damaged by the magnetic field generated by the linear
motor in the Y-axis. Keep the head away from the shaft of the Y-
axis. Also, the head should always be in the exchange position
(away from the linear motor) when attaching or removing the head.
Do not hit the linear scale when exchanging the head and
performing maintenance. If the linear scale is damaged then errors
will occur and production may not be possible. In this case it will
be necessary to replace the linear scale.
Linear motor coil
Linear motor shaft
X-axis gear cover

10.Set the removed head in the optional head maintenance stand in order to prevent
damage when working on the head.

5.8.3 Attaching a placing head

2. Use the arrow keys to highlight the exchange pictogram.
3. Push OK and the selection screen is displayed.
4. With the head exchange pictogram selected, push START. The head is moved to the
removal location and the power to it is cut. When this is completed, the screen
automatically changes.
Note: If a tray unit-L is attached to the module, the guidance screen changes to display guidance
for removing the tray unit-L at this point. Follow the directions provided to remove the tray
unit-L and then continue on to the next step.
the module. When safe to unclamp the module, push OK and the module is unclamped.
When the module is unclamped it moves a short distance forward.
CAUTION
the module is pulled out or unclamped.
Note:
displays.
CAUTION



7. For the following placing heads, rotate the R-axis so that the arrow marks are aligned.
• Heads: V12, H12HS, H12(S), H08, H08M, H04(S), H12HSQ, H12SQ, H08Q,
H08MQ
Note: The position of the arrow depends on the head.
01MEC-1182
8. Ensure that there is no objects or dust on the attaching surfaces of the placing head and
the holder. Use a dry cloth to remove any foreign objects.
Placing head Head holder
01MEC-0158Ea
9. While holding the head handle, insert the clamp joints into the grooves on the head
holder, and while holding the lever down to the left, push the head into position and
release the lever.
Lever
Placing head
Press the head down firmly

against the head holder.
Head
Head
holder
01MEC-0325E

For modules with a PH2 sensor, do not tilt the placing head too far when removing it. The
placing head may hit the PH2 sensor.
CAUTION
Be careful not to hit the PH2 sensor when removing or attaching the
placing head. Hitting the head against the sensor or other part may
cause damage.
CAUTION
When performing maintenance inside the module, the head or shaft
could be damaged by the magnetic field generated by the linear
motor in the Y-axis. Keep the head away from the shaft of the Y-
axis. Also, the head should always be in the exchange position
(away from the linear motor) when attaching or removing the head.
Linear motor coil
Linear motor shaft
X-axis gear cover

10.Return the connectors to their original positions. For the V12 head, attach connector 3
first, then connector 2, and finally connector 1.
<V12 Head> Connector3

3 2
Connector1
1
Connector2
Connectors
01MEC-0839E

Note:
1. If a placing head with a different serial number from the previous head is attached, set
nozzle jigs in the nozzle station. Refer to section 5.8.5 "Setting nozzle jigs" for more
details.
2. If the handle for the head is a strap-type, ensure that the strap is flat against the head.
Interference or damage to the machine will occur if the strap is not flat against the head
when the head is attached.
Strap-type
handle
01SYS-0187E
11.Ensure that the XS-axis or any other items are not protruding from the module before
returning the module. If the axis is protruding, move the axis to a safe position before
returning the module.
12.Grip the handle for the module and squeeze to release the module brake and gently
WARNIG


CAUTION


13.Stop pushing when the module reaches the end of the possible movement and it cannot
be pushed back more. At this point, the machine will automatically clamp the module.
If no error occurs and the module is not automatically clamped, gently pull the module

5.8.4 Important points when using V12 heads and heads with the
part side recognition function
When using a V12 head or a head with the part side recognition function and operating with
the conveyor maximum panel width set to 230 mm or less, there is a danger of the head
colliding with the conveyor rail.
In this case, use the following procedure to change the head exchange position before
removing or attaching the placing head.
1. Remove the nozzle station.
2. Pull the XY-slider by hand so that the placing head moves above the nozzle changer.
Caution: Do not pull the placing head or the handle on the placing head.
XY slide
01NST-1005Ea
Note: As a rough indicator, move the head so that the mark camera edge aligns with the conveyor
rail edge.
Mark camera
Placing head
Conveyor rail
01NST-1006Ea

3. Place an item such as a cushion or air mat on top of the nozzle changer.
Cushion
01NST-1007Ea
Note: Cushions or air mats are not supplied with the machine. When removing or attaching the
head, prepare a suitably sized cushion so that the head when tilted during removal or
attachment process does not hit the nozzle changer.

5.8.5 Setting nozzle jigs

Prepare a nozzle station that is compatible with the placing head to be attached. Set the
same number of nozzle jigs in the nozzle station as there are holders on the head. Follow
the procedures below to set the nozzle jigs in the nozzle station.
1. Remove the nozzle station from the module.
2. Slide the plate on the prepared nozzle station and insert the same number of nozzle jigs
as there are holders on the head into the nozzle station. The actual position for the
nozzle jigs is not important as long as the quantity is correct.
Socket Nozzle jig
Plate
For H08/H12(S) For V12 head

/H12HS heads
Nozzle jig ID J01 J06

For H01/H02 heads For H04(S) heads For H08M heads
Nozzle jig ID J03 J02 J23

01MEC-1032Ea
CAUTION
When setting nozzles in the nozzle station, align the cutout on the
nozzle with the alignment pin in the nozzle station and make sure
that the pin goes into the cutout. If they are not aligned, nozzle
exchange errors occur.
Socket
Cutout Pin NXTNZC024E

3. Move the lever on the left side of the nozzle changer towards the front of the module and
then insert the rear part of the nozzle station first and then push down on the front end
of the station.
Nozzle station
(1)
Lever (3)
(2)
NXTNZC003Eb
CAUTION
Be careful to not put your hands underneath the nozzle station

when setting it in the machine.
4. Return the lever back to its original position.
5. Confirm that the nozzle station is fully seated on the nozzle changer.

5.9 Removing/Attaching a Nozzle Station

Nozzle stations are easy to remove and switch between the different types. If a different
type of placing head is attached to a module, the old nozzle station must be replaced with
a nozzle station that is compatible with the new head type
Caution: When performing this work on a nozzle station which can hold 32 nozzles (ND32C or
ND32D), be careful not to place any load on the brush itself. The bracket holding the brush
may bend if a load is applied.
ND32C or ND32D
Brush
01MEC-1092E
5.9.1 Removing
2. Use the arrow keys to highlight the unit exchange pictogram and then push OK.
Unit exchange
01SYS-0080E
3. Use the arrow keys to highlight the nozzle exchange command.
Nozzle exchange
01MEC-0003E
4. Push START and nozzles on the head are automatically ejected to the nozzle station.
Note: If a tray unit-LT is attached to the module, the guidance screen changes to display guidance
for removing the tray unit-L/LT/LTC at this point. Follow the directions provided to remove
the tray unit-L/LT/LTC and then continue on to the next step.

forward.
CAUTION
The module moves forward several centimeters when the OK

button is pushed. Be careful of this so to avoid personal injury and
mechanical damage.
Note:
displays.
WARNING

safely at the same time. (Maximum: Two M3-2 modules on a 4M-2
base.)
If the maximum is exceeded, the entire machine may fall over to the
front, possibly resulting in serious physical harm.
CAUTION
When pulling out or pushing in a module, do not insert hands or



7. Move the red lever on the left side of the nozzle station towards the front of the module
and pull upwards on the front half of the station to remove it.
Nozzle station
(2)
(1)
Lever
NXTNZC002Eb

5.9.2 Attaching
1. With the module pulled out, move the red lever on the left side of the nozzle station
towards the front of the module and insert the rear part of the station first and then push
down on the front end of the station.
Nozzle station
(1)
Lever (3)
(2)
NXTNZC003Eb
CAUTION
Be careful to not put your hands underneath the nozzle station

when setting it in the machine.
2. Return the lever back to its original position.
3. Confirm that the nozzle station is fully seated on the nozzle changer base.
4. Ensure that the XS-axis or any other items are not protruding from the module before
returning the module. If the axis is protruding, move the axis to a safe position before
returning the module.
6. Stop pushing when the module reaches the end of the possible movement and it cannot
be push back more. At this point, the machine will automatically clamp the module. If
no error occurs and the module is not automatically clamped, gently pull the module

5.10 Exchanging Backup Plates (When Performing

Dual Lane Production with Lane 2 Brought
Forward)
When performing dual lane production with lane 2 brought forward, set backup plates that
match the size of the panel being conveyed.
For the M6-2(SP) modules, the backup plate for lane 1 is divided into two pieces. It is
possible to exchange backup plates for M3-2 and M6-2(SP) modules without tools.
Only the backup plate for lane 1 is exchanged. As for the backup plate for lane 2, the
forward/back slide position is adjusted without exchanging the backup plate.
M6-2(SP) Module
When performing production
with lane 2 forward
Lane 2 backup plate
Lane 2 backup plate
Lane 1 backup plate (standard) Lane 1 backup plate

(for performing production
with lane 2 forward)
01MEC-0207Ea
There are three lane 1 backup plate types for the different panel sizes. Exchanging the
backup plate for lane 2 is not required because there is only one type available for this lane.
Lane 1 backup plate type Possible panel size (mm) for

lane 1 conveyance
165 for lane 2 forward production 48 to 165
200 for lane 2 forward production 48 to 200
Standard 48 to 280

5.10.1 Procedure
1. When the shaft for the linear motor cools to room temperature, set the protective covers
on the shaft.
Linear motor coil
Linear motor shaft
Linear scale
Protective covers 01MEC-0255Ea
WARNING
• Contact with the shaft or coil section of the Y-axis linear motor in a
module could cause burns. Do not make contact with the shaft or coil
section immediately after production is stopped.

modules. People with a heart pacemaker should stay clear of the shaft
and coil sections of the linear motor (maintain a distance of 400 mm or
more). Pacemakers may malfunction because of the magnetic field.
CAUTION
• Do not push or pull on the body of the head or use the handle on the
head to move the XY robot position.
• Do not push on the X-axis gear cover. Otherwise the gear cover may
be deformed.
• Be careful of the magnetic attraction and do not bring metal items

such removed backup plates and tools near the linear motor of a
module. The magnetic force can pull metal objects and this can result
in damage and injury.
• Damage to items may occur due to the magnetic field generated by a

linear motor. Keep magnetic cards, wristwatches and other precision
machines away from the linear motor (do not bring within 55 mm).
• Do not hit the linear scale when exchanging the head and performing
maintenance. If the linear scale is damaged then errors will occur and
production may not be possible. In this case it will be necessary to
replace the linear scale.

3. Use the arrow keys to highlight the unit exchange pictogram, and push OK.
Unit exchange
01SYS-0080E
4. The guidance for removing the tray unit is displayed when the tray unit is equipped, then
remove the tray unit.
NXTMTU035
5. The guidance for pulling out the module is displayed, then pull forward the
module.(Refer to section 5.1 "Pulling Out/Returning a Module" for details.)
a. Push OK and the module is automatically unclamped. When the module is

unclamped it moves a short distance forward.
b. Grip the handle for the module and squeeze to release the module brake and gently
pull the module forward until the module hits the stopper.
6. If there are any backup pins on the backup plates, then remove them.
7. Use the arrow keys to highlight the backup plate exchange command, and push OK.
Lane 2 backup plate exchange 01SYS-0082E

8. Push START and the follow-up rail for lane 1 and the reference rail for lane 2 are moved
towards the front of the module.
01MEC-0331
9. Exchange the backup plates (2 plates) for lane 1 by following the sub steps below.
a. Slide the backup plate for lane 2 towards the back of the module. (It is not necessary
to remove the plate.)
01MEC-0286
b. Lift up the rear side of a lane 1 backup plate. Pull the plate a little forward and the
remove it from the bottom plate. Remove both backup plates (2 plates) from the
module.
(1)
(2)
01MEC-0208

c. Get the new backup plates for lane 1. Set the front side of the plates on the bottom
plate and then push down on the rear side of the plates.
Caution: Before installing the backup plates, wipe the top and bottom surface of the backup plates
and the top surface of the bottom plates with a clean cloth and check there are no parts or
foreign items around the area of the plates.
Note: The plates are positioned correctly when they click into place.
(2)
(1)
01MEC-0210
d. Pull forward the plate for lane 2 until it is touching the plates for lane 1.
Note: The plate is positioned correctly when it clicks into place.
01MEC-0263
10.When removing the backup plate for lane 2, lift up the right side of the plate and then
push to the left and forward to remove it.
Caution: Before installing the backup plates, wipe the top and bottom surface of the backup plates
and the top surface of the bottom plates with a clean cloth and check there are no parts or
foreign items around the area of the plates.
(2)
(1)
01MEC-0256
11.Push OK.

12.Return the module. (Refer to 5.1 Pulling Out/Returning a Module for details.)
a. Grip the handle for the module and squeeze to release the module brake and gently
push the module back. Stop pushing when the module reaches the end of the
possible movement and cannot be pushed back any further.
b. At this point, the machine will automatically clamp the module. If no error occurs and
the module is not automatically clamped, gently pull the module forward a short
distance and then push back into position.
13.Insert the tray unit into the module, if so equipped.
NXTMTU006a
14.Push MANUAL to exit from manual command mode.
15.Push START and the conveyor is automatically adjusted to the panel width for the job.

5.11 Attaching/Removing a Tray Unit-M

The tray unit-M can be used on M6-2(SP) modules on one side or two sides. The positions
for these on the feeder pallet are called position A and B. The tray unit-M is set in slot 10
for position A and slot 35 for position B.
Note: When just attaching one tray unit-M, then attach it at position B.
Mounted on one side Mounted on both sides
Position A Position B
Position B
NXTMTU096Ea
It is possible to attach and remove the tray unit-M more efficiently by using the optional tray
unit-M change unit.
Handles
Lock knob
Leveling plate
01NST-0395E
WARNING
Use two or more people to lift, carry, and position the tray unit-M.
Be sure to firmly grip the right and left handles. Injury and machine
damage can occur if the tray unit is dropped.

Handle NXTMTU065E
CAUTION
• Do not move the tray unit-M or attach/remove it from a module

• Be gentle when attaching or removing the tray unit-M so as to not
• Stop the machine before attaching or removing a tray unit-M.
There is a possibility that the machine can be damaged if the tray
unit-M is removed or attached while the machine is producing.
• When a tray unit-M is loaded on a change unit, the center of
balance is high so it is not stable. When loading a tray unit-M on a
change unit for some reason, be careful to not tip it over. Injury and
machine damage can occur in such a case.
5.11.1 Preparation
• Shift the part camera position in the middle of the module when using the tray
unit-M. (Refer to section 8.1 "Replacing the Parts Camera".)
• Set a tray unit-M tape duct. (Refer to section 5.11.6 "Setting a tray unit-M tape
duct or cover".)
• Remove all trays from the tray unit-M magazine.

5.11.2 Attaching procedure

1. Pull out the module halfway. (Refer to section 5.1 "Pulling Out/Returning a Module".)
2. While performing the following operation by using two or more people, firmly grip the
right and left handles and pick up the unit in a level manner and position close to the
feeder pallet on the module.
WARNING
3. Use the labels for the slot numbers on the feeder pallet as a reference to position the
tray unit-M. (Position A: Slot 10, Position B: Slot 35)
Guides
PosA PosB
10 35
Feeder pallet
01NST-0396E
4. In this condition, horizontality push the tray unit-M forward on the feeder pallet. Firmly
push in the unit until the connectors between the tray unit-M and the feeder pallet are
together.
NXTMTU058a

5. Lower the clamp lever in the middle section of the shuttle unit to secure the tray unit-M
to the feeder pallet.
Clamp lever
01NST-0390E
6. Push the module fully back onto the base to return it. (Refer to section 5.1 "Pulling Out/
Returning a Module".)
5.11.3 Attaching procedure (with an optional change unit)

(1) Setting a tray unit-M on a change unit
1. Lock the casters on the wheels for safety.
2. On the empty change unit, pull and the turn the red lock knob until it is touching the
hanger like that shown in the picture below. (In this state, the lock pin for the upper
surface of the change unit is free.)
Lock knob (red)

Lock pin
Hanger
01NST-0392E

3. Load the tray unit-M on the left and right rails on the change unit.
Tray unit-M rails
Unit rails 01NST-0391E
4. Slide the tray unit-M all the way towards the handles on the change unit. The tray unit-
M is automatically locked. The red lock knob automatically moves to the lock position.
Handles
Lock knob (red)
UNLOCK
LOCK
01NST-0383E
(2) Attaching a tray unit-M to a module from the change unit

2. Position the change unit with the tray unit-M loaded on it close to the front of the feeder
pallet.
3. Adjust the height of the change unit by turning the height adjusting handle until the front
connectors on the shuttle are higher than the connectors on the feeder pallet. (You can
refer to the scale label as a reference. The scale used is based on the panel
conveyance height.)
Shuttle front end
Scale label
980
960
940
920 Feeder pallet

900 connector area
880
01NST-0385E

4. Use the labels for the slot numbers on the feeder pallet as a reference to position the
tray unit-M. (Position A: Slot 10, Position B: Slot 35)
Guides
PosA PosB
10 35
Feeder pallet
01NST-0396E
5. Use the height adjusting handle to adjust the height of the unit until the lower surface of
the shuttle (A) on the tray unit-M is level with the upper surface of the feeder pallet (B).
At this height, the connectors on the tray unit-M and feeder pallet can connect.
Shuttle area on tray unit-M
Adjust the height of (A)

the unit so that both
surfaces are level to (B)
connect together.
Feeder pallet in a module
01NST-0386E
(At this time, set the enclosed leveling plate in a slot in the magazine (any slot is fine) and
check the levelness of the unit.)
Mirror
Leveling plate
Level
01NST-0387E

6. Push the tray unit-M fully onto the feeder pallet in the module from the change unit.
WARNING
Correctly insert the guide on the bottom of the tray unit-M into the
slot on the feeder pallet.
If the guide is not in the slot, the tray unit-M is not clamped to the
feeder pallet and can drop causing injury and machine damage.
01MEC-0305
7. In this condition, horizontality push the tray unit-M forward on the feeder pallet. Firmly
push in the unit until the connectors between the tray unit-M and the feeder pallet are
together.
8. Lower the clamp lever in the middle section of the shuttle unit to secure the tray unit to
the feeder pallet.
Clamp lever
01NST-0390E
9. Pull and then turn the red lock knob until it is in the position against the hanger like that
shown in the picture below. Then lift up the lock lever (2) and then gently pull the change
unit away from the tray unit.

(1)
(2)
01NST-0389
10.Push the module fully back onto the base to return it.
5.11.4 Removal procedure

2. Open the door and then remove all trays set in the tray unit.
Tray
NXTMTU068E

3. Raise the clamp lever in the middle section of the shuttle unit to unclamp the tray unit.
Clamp lever
01NST-0394E
4. While performing the following operation by using two or more people, firmly grip the
right and left handles and horizontality pull the tray unit away from the feeder pallet. Set
the removed tray unit-M in a stable, safe location where it will not fall or be knocked over.
WARNING
5. Push the module fully back onto the base to return it.
5.11.5 Removing procedure (with an optional change unit)

2. On the empty change unit, pull and the turn the red lock knob until it is touching the
hanger like that shown in the picture below. (In this state, the lock pin for the upper
surface of the change unit is free.)
Lock knob (red)

Lock pin
Hanger
01NST-0392E
3. Set the change unit under the front half of the tray unit-M.

4. Turn the height adjusting handle until the rails on the change unit contact the rails on the
bottom of the tray unit-M.
Tray unit-M rails
Unit rails 01NST-0391E
5. Push the change unit towards the tray unit-M until the two units are fully connected. The
red lock knob automatically moves to the lock position.
Lock knob (red)
UNLOCK
LOCK
01NST-0393E
6. Raise the clamp lever in the middle section of the shuttle unit to unclamp the tray unit.
Clamp lever
01NST-0394E
7. Gently pull the change unit with the tray unit-M loaded away from the module.
8. When finished moving the unit, lock the casters on the wheels for safety.
CAUTION
When a tray unit-M is loaded on a change unit, the center of balance

is high so it is not stable. When loading a tray unit-M on a change
unit for some reason, be careful to not tip it over. Injury and
machine damage can occur in such a case.

5.11.6 Setting a tray unit-M tape duct or cover

The dedicated waste tape duct or cover must be used when tray unit-M(s) are mounted in
the module. Use the tray unit-M waste tape duct when mounting a unit on one side, and use
the waste tape cover when mounting units on both sides.
Duct and cover
Name Shape Usage
Tray unit-M waste tape Mounting on one side

duct (position B)
01MEC-0218
Waste tape cover Mounting on both sides

(positions A and B)
01MEC-0219
Procedure
CAUTION
The duct or shaft could be damaged by the magnetic field
generated by the linear motor in the Y-axis. Keep the duct away
from the shaft of the Y-axis when using a M6S module.
Linear motor coil
Linear motor shaft
X-axis gear cove

Linear scale 01MEC-0324E

1. Remove the bolts securing the standard type duct and then remove the duct.
Duct
Screw
NXTMTU002E
2. Set the tray unit-M compatible waste tape duct or the waste tape cover and use the bolts
from the previous tape duct to fix the item.
Duct
(When mounting a unit on one side)
Screw
Cover
(When mounting units on both sides)
Screw
NXTMTU056E

5.11.7 Exchanging the separated reject parts box

When using a tray unit-M on a module with a separated reject parts box, the box needs to
be replaced by a special dummy cover.
1. Remove the separated reject parts box.
01MEC-1184
2. Insert the dummy cover for use with a tray unit-M so that the bumps on the cover go in
the holes on the stand for the box.
01MEC-1185

QD144-17 6. Preventive Maintenance
6. Preventive Maintenance
6.1 About Preventative Maintenance
Preventative maintenance involves such tasks as regular inspections, cleaning and
lubrication, and is indispensable for the purpose of avoiding machine errors, and ensuring
that the machine performs according to the design specifications. Please ensure to adhere
strictly to the following guidelines when performing preventative maintenance procedures.
• The preventive maintenance items noted here are mainly directed towards
maintenance staff. However, there are certain tasks whose responsibility lies
with the operators.
• This section lists only those maintenance items related to the machine itself.
Please refer to the "FUJI Intelligent Feeder Manual" for details on feeder
maintenance.
• A maintenance manual related only to head maintenance (the Machine Head

Maintenance Manual) is available. Contact your Fuji representative for details.
6.1.1 Maintenance frequency

Fuji recommends that preventative maintenance tasks be performed at 1 day (within 24
hrs), 1 week (160 hrs), 2 week (320 hrs), 1 month (700 hrs), 3 month (2,000 hrs), 6 month
(4,000 hrs), 1 year (8,000 hrs) and 12,000 hour intervals. Furthermore, it is also
recommended that maintenance be performed periodically after long periods of continuous
operation, and at those times when experiencing production related problems on the
machine. (Refer to section 6.2 "Maintenance Checklist".) The maintenance periods listed
in the manual are a guide. There may be cases in which maintenance periods are shorter
depending on the machine environment and the status of the machine.

6. Preventive Maintenance QD144-17
6.1.2 Points of caution

• Follow the prescribed procedures for performing preventative maintenance only
after stopping the machine. At all other times, perform maintenance after
turning OFF the machine power, disconnecting the air supply and releasing
existing air from the air-hose.
• Do not direct compressed air inside the machine/modules when performing

maintenance, as scattered small chips or foreign objects may result in damage
to the machine during operation.
• When working on a removed placing head, it should be set on a head

maintenance stand (option item) or placed on its side on a work stand.
• Do not use an air gun or similar tool to blow pressurized air into the vacuum
pressure supply opening on the rear side of the placement head. Doing so can
damage the internal section of the head and cause it to malfunction.
Air pressure supply opening
Vacuum pressure supply opening

01MEC-0886E

6.1.3 Required equipment

Note: The jigs below are options.
Jig Nozzle cleaning drill AWPJ8100 Used to clean the inside of

nozzles
Jig 0603 Nozzle cleaning jig AA4XY01 Used to clean the inside of
nozzles
Jig Fuji grease gun kit AWPJ8201 Used to apply lubricant to

grease fittings
Jig Parts camera cleaning kit Used to clean the parts

Cleaning paper (A4565T)
camera glass
Vacuum pickup tool (A21010)
Wiper (AA14X00)
Cleaner (K3018H)
NXTPCA012Eb
Jig Head maintenance stand AA0AM** Used to clean and lub the
placing head
NXTPHD027a

Jig Filter cleaning basket K1325C Used to clean the head filters.
NXTPHD028
Jig H01 Q-axis gear fixing jig PM28083 Used when removing the H01
head sleeve assembly.
NXTPHD104
Jig Nozzle changer lubirication jig AA4CM** Used when lubricating the
nozzle changer without holes.
Jig Syringe O-ring lubrication jig Used to lubricate the O-ring in

AA40R**, AA79X** the syringe of the V12,
H12HS, H12(S), H08, H08M
and H04(S) heads.
AA40R** is for H04(S), H08,

H12(S), H12HS and V12
heads
AA79X** is for H08M heads
㪘㪘㪋㪇㪩㪁㪁㪘㪘㪎㪐㪯㪁㪁 NXTPHD122b
Jig Head Cleaner QK00C** Used for cleaning the syringes

on the V12, H12HS, H12(S),
H08, H08M and H04(S) head.
01MEC-0523
Jig Mechanical valve sliding resistance Used for inspecting the

measuring head AA6KN** mechanical valve O-rings on
the V12, H12HS, H12(S),
01MEC-0567

Jig Mechanical valve O-ring exchange tool Used for exchanging the
PM072M* mechanical valve O-rings on
the V12, H12HS, H12(S),
01MEC-0566
Jig Nozzle filter removal jig PM0GLZ* Used to remove the nozzle
filter on the H04(S), H08M
heads.
02NST-0059
Jig Nozzle filter insertion jig AB164** Used to insert the nozzle filter
on the H04(S), H08M heads.
02NST-0060
Jig Filter installation jig for nozzles with rubber Used to install filters in
pads 2MGKNJ00050* nozzles on the H04(S) head
01MEC-1165
Jig Single-end wrench PB00EY* Used for removing the

mechanical valve on the V12
head.
01NST-0882
Jig Syringe S61439 Used to lubricate syringes and

syringe gears on the V12
head.
This syringe can also be used

01NST-0952a for lubricating other heads.
When using different types of

grease, use a different syringe
for each type of grease.
Jig Torque driver (AA9ZT**) Used for removing the

mechanical valve on the V12
head.
Jig Torque driver 2AGKHJ0013** Used attaching mechanical

valve push plateson the H08M
head.
01NST-1097

Tools Metric spanner set -
Metric Allen wrench set -
Flat head screwdriver -
Phillips screwdriver -
Torque wrench -
Lubricants Daphne Eponex No.2 (Idemitsu) Manufacturer type number:

K3031M (2.5 kg)
MDV235-ZB (Kuroda) Manufacturer type number:

K3032K (30 g)
Mobilith SHC460WT (Mobil) Manufacturer type number:

K3036W (380 g)
NS7 (NSK) or Multemp SRL (Kyodo Yushi) NS7 Manufacturer type

number: K3035K (80 g)
Multemp SRL Manufacturer
type number: K3031X (400 g)
Biral T&D (Biral Lubricants Norway A/S) Manufacturer type number:

H5116A
VG-EP No. 1 (Wako Chemical) Manufacturer type number:

K60192
G501 (Shinetsu) Manufacturer type number:

K30315
Other Vacuum cleaner -
Cloth Ensure to use a soft, clean

cloth.
Cotton swab -
Soft brush -
Vacuum pickup tool For removing rejected parts
Industrial ethanol Used to clean the conveyor

belt
Used to clean nozzles
Ultrasonic cleaner Used to clean nozzle filters
Neutral detergent Used to clean nozzle filters
Tension meter For checking belts.
Safety goggles Used for cleaning the syringes

on the V12, H12HS, H12(S),
Push-pull gauge Used for inspecting the

mechanical valve O-rings on
the V12, H12HS, H12(S),

6.1.4 Applying grease

There are several methods for applying grease such as applying grease to grease fittings,
using a brush, spraying from a can. The procedures to be used to apply grease depending
on the location are explained step-by-step later in this chapter. This section explains the
two typical grease application methods that are used.
Note: A Fuji grease gun is used for calculating the amount of grease to be applied. One shot from
the grease gun (1 pump) is approximately 0.6 cc. Use the number of shots as an
approximate guide when applying grease. Clean off any extra grease that comes out.
Typical lubrication methods

Applying grease to grease fittings
1. Wipe off any filth from the ball screws and LM guides with a clean cloth.
2. Use the grease gun from the Fuji grease gun kit (AWPJ8201) to apply the required
number of shots to the grease fitting on the ball screws/LM guides.
3. Wipe off any excess grease off from the ball screw/LM guide with a clean cloth.
4. Manually move the unit to work in the grease on the ball screws/LM guides. (Move one
full stroke)
5. Wipe off any excess grease with a clean cloth again.
Applying grease with a brush (or spray can)

1. Wipe off any filth from the ball screws and LM guides with a clean cloth.
2. Use the grease gun from the Fuji grease gun kit (AWPJ8201) to apply the required
number of shots directly to a brush and then apply the grease to the applicable area on
the unit. Spread the grease evenly with the brush.
3. When spraying, directly spray the grease on the unit.
4. Wipe off any excess grease from the unit with a clean cloth.
5. Manually move the unit to work in the grease on the ball screws/LM guides. (Move one
full stroke)
6. Wipe off any excess grease with a clean cloth again.
Important points when lubricating

• Do not use a dirty cloth to remove grease when performing lubrication. Using a
dirty cloth may cause damage to parts. Be sure to use a clean cloth.
• Do not apply grease to areas other than those specified. This may result in
damage. If grease gets on any unspecified areas, remove it with a clean cloth.
• Only use the specified grease. Using other greases may cause machine
damage.
• Before lubricating. remove any old grease by wiping items with a clean cloth.
• After lubricating, remove any excess grease by wiping items with a clean cloth.

6.2 Maintenance Checklist

CLN: indicates cleaning LUB: indicates lubrication CHK: indicates checking EXG:
indicates exchanging.
The times listed in this chart are only recommendations. Actual work time may differ. The
time required for personnel to pull modules forward or load and unload units may add to the
total work time required.
6.2.1 Maintenance performed by operators when the machine is

waiting to produce
Maintenance Locations
Every 3 months
Every 6 months
Time Required
(within 24 hrs)
(2000 hrs)
(4000 hrs)
(8000 hrs)
(160 hrs)
(700 hrs)
irregular
Monthly
Weekly
Yearly
(min.)
Daily
Reject parts Remove parts CLN - - - - - - 1

box *14
Waste tape Clean waste tepe box CLN - - - - - - 1
box *15
Reject parts Remove rejected parts - - - - - - CLN, 0.1
conveyor *1
Tray unit-L Remove rejected parts - - - - - - CLN, 0.1
*1
Remove empty trays - - - - - - CLN, 2
*2
Tray unit-LT Remove rejected parts - - - - - - CLN, 0.1
*1
Clean waste tape box CLN - - - - - - 3
*15
Remove parts from the CLN - - - - - - 1
reject parts box *14
Tray unit-LTC Remove rejected parts - - - - - - CLN, 0.1
*1
Clean waste tape box CLN - - - - - - 1
*15
Module top Clean top cover - - - - - - CLN 1
cover
Hybrid Clean marks and - - - - - - CLN 1
calibration unit jig parts
*1: Performed when the box is full of parts

*2: Performed when the box is full of trays
*14: Every 24 hours
*15: Every 8 hours

6.2.2 Maintenance performed by maintenance personnel

Every 2 weekly
Every 3 months
Every 6 months
Time Required
12,000 hrs
(2000 hrs)
(4000 hrs)
(8000 hrs)
(160 hrs)
(320 hrs)
(700 hrs)
irregular
Monthly
Weekly
Yearly
(min.)
Nozzle Nozzle - - - - - - - CLN 10
, *3
Filter (H04S nozzles) - - - - - - - EXG 10
, *13
Nozzle Nozzle station holders CLN - - - - - - - 5
station Brush unit filter - - - - CLN - - - 5
Brush on brush unit - - - - - CLN - - 5
Nozzle Up/down shafts - - - - - LUB - - 5
changer
Part Feeder pallet CLN - - - - - - - 1
supply Connector between pallet - - - - - - - CLN 10
and part supply base , *4
H01 head Nozzle vacuum filter - - CLN - - - - CHK 10
, *5
Exchanging nozzle clamp - - EXG - - - - - 5
pins, cleaning nozzle pickup ,
surface CLN
Flange filter - - CLN - - - - - 10
Sleeve assembly - - - - CLN - - - 10
Q-axis gears - - - - - - LUB - 10
Z-axis ball screw - - - - - - LUB - 10
Z-axis LM guide - - - - - - LUB - 10
H02 head Nozzle vacuum filter - - CLN - - - - CHK 10
, *5
Exchanging nozzle clamp - - EXG - - - - - 5
pins, cleaning nozzle pickup ,
surface CLN
Flange filter - - CLN - - - - - 10
Q-axis gears - - - - - - LUB - 10
Z1, Z2-axes ball screws - - - - - - LUB - 10
Z1, Z2-axes LM guides - - - - - - LUB - 10

Every 2 weekly
Every 3 months
Every 6 months
Time Required
12,000 hrs
(2000 hrs)
(4000 hrs)
(8000 hrs)
(160 hrs)
(320 hrs)
(700 hrs)
irregular
Monthly
Weekly
Yearly
(min.)
H04 head Placing head vacuum filter - - CLN - - EXG - - 20
Inside of syringe - - CLN - - - - - 15
Circumference of syringes - - LUB - - - - - 10
and O-ring inside syringe
Q-axis gear (lower, syringe - - LUB - - - - - 5
side)
Mechanical valve - - CHK - - - 5,
O-ring EXG 20
Arm rotation axis for moving - - - - LUB - - - 5
mechanical valves
Z-axis guide shaft - - - - - - LUB - 10
Cam followers for moving - - - - - - LUB - 10
mechanical valves
Q-axis gear - - - - - - LUB - 5
(upper, motor side)
R-axis gear - - - - - - LUB - 5
H04S Placing head vacuum filter - - CLN - - EXG - - 20
head Inside of syringe - - CLN - - - - - 15
side), Syringe gears
O-ring EXG 20
mechanical valves
mechanical valves
Q-axis gear - - - - - - LUB - 5
(upper, motor side)
R-axis gear - - - - - LUB - 5

Every 2 weekly
Every 3 months
Every 6 months
Time Required
12,000 hrs
(2000 hrs)
(4000 hrs)
(8000 hrs)
(160 hrs)
(320 hrs)
(700 hrs)
irregular
Monthly
Weekly
Yearly
(min.)
H08 head Placing head vacuum filter - - CLN - - EXG - - 20
side)
O-ring EXG 40
mechanical valves
mechanical valves
Q-axis gear - - - - - - LUB - 5
(upper, motor side)
R-axis gear - - - - - - LUB - 5
H12(S) Placing head vacuum filter - - CLN - - EXG - - 20
side)
O-ring EXG 60
Arm rotation axis for moving - - - - CLN - - - 5
mechanical valves
mechanical valves
Q-axis gear - - - - - - LUB - 5
(upper, motor side)
R-axis gear - - - - - - LUB - 5

Every 2 weekly
Every 3 months
Every 6 months
Time Required
12,000 hrs
(2000 hrs)
(4000 hrs)
(8000 hrs)
(160 hrs)
(320 hrs)
(700 hrs)
irregular
Monthly
Weekly
Yearly
(min.)
H12HS Placing head vacuum filter - - CLN - - EXG - - 20
O-ring EXG 60
mechanical valves
Q-axis gear - - - - LUB - - - 5
(upper, motor side)
R-axis gear - - - - LUB - - - 5
mechanical valves
V12 head Mirrors in the prism box CLN - - - - - - - 5
Glass cover on the prism CLN - - - - - - - 5
Placing head vacuum filter - - CLN - - EXG - - 20
O-ring EXG 60
mechanical valves
Q-axis gear - - - - LUB - - - 5
(upper, motor side)
R-axis gear - - - - LUB - - - 5
mechanical valves
Grooved cam grooves - - - - - - LUB - 5

Every 2 weekly
Every 3 months
Every 6 months
Time Required
12,000 hrs
(2000 hrs)
(4000 hrs)
(8000 hrs)
(160 hrs)
(320 hrs)
(700 hrs)
irregular
Monthly
Weekly
Yearly
(min.)
H08M Syringe edge - LUB - - - - - - 20
head Placing head vacuum filter - - CLN - - EXG - - 20
O-ring EXG 40
mechanical valves
Q-axis gear - - - - LUB - - - 5
(upper, motor side)
R-axis gear - - - - LUB - - - 5
mechanical valves
Conveyor CZ-axis ball screw - - - - - - LUB - 15
Ballscrews for width change - - - - - - LUB - 10
Belt tension - - - - - - CHK CHK 10
, *6
Conveyor belt - - - - - - - CLN -
, *6
Soft backup pin - - - - - - - CLN -
, *9
CZ-axis belt tension - - - - - - - CHK -
, *10
Panel conveyance motor - - - - - - - CHK -
belt tension , *6
Width change motor belt - - - - - - - CHK -
tension , *11
XY-robot Linear motor cooling fan - - - CLN - EXG - - 5
<M3-2> filter
X-axis gear - - - LUB - - - - 5
X-axis LM guide - - - - LUB - - - 5
Y-axis ball screw - - - - LUB - - - 5
Y-axis LM guide - - - - LUB - - - 5
XS-axis gear - - - LUB - - - - 5
XS-axis ball screw - - - - LUB - - - 5
XS-axis LM guide - - - - LUB - - - 5
XY-axis flat cable - - - LUB LUB - - - 10

Every 2 weekly
Every 3 months
Every 6 months
Time Required
12,000 hrs
(2000 hrs)
(4000 hrs)
(8000 hrs)
(160 hrs)
(320 hrs)
(700 hrs)
irregular
Monthly
Weekly
Yearly
(min.)
XY-robot Linear motor cooling fan - - - CLN - EXG - - -
<M6-2/ filter
M6-2SP> X-axis gear *15 - - - LUB - - - - 5
X-axis LM guide - - - - LUB - - - 5
X-axis ball screw - - - - LUB - - - 5
Y-axis LM guide - - - - LUB - - - 5
XY-axis flat cable - - - LUB LUB - - - 10
Mark Half mirror inside light unit - - - - - CLN - - 3
camera
Parts Glass cover CLN - - - - - - - 2
camera Glass inside light unit CLN - - - - - - - 2
Lens - - - - - CLN - - 2
Waste LM guide - - - - - - LUB - 20
tape Cutter - - - - - - - CLN 20
processin , *7
g unit
Duct - - - - - - - CLN 15
*8
Brush - - - - - - - EXG 20
*14
Machine Inside module CLN - - - - - - - 2
body Base/module support - - - LUB - - - - 5
surface
Air regulator - - - - - CLN - - 15
Mist separator - - - - - - CLN - 15
Vacuum pump filter - - - - - - CLN - 15
Reject Conveyor belt - - CLN - - - - - 5
parts
conveyor
Tray unit- Reject parts conveyor belt - - CLN - - - - - 5
L Shuttle belt - - CLN - - - - - 5
Air filter - - - - - - CLN - 5
TZ-axis ballscrew - - - - - - LUB - 10
Lifter gear - - - - - - LUB - 10
TZ-axis belt tension - - - - - - CHK - 10
TY-axis belts (for shuttle) - - - - - - CHK - 10
tension
TY-axis belt (for motor gear) - - - - - - CHK - 10
tension
Tray drawer bottom surface - - - - - - CHK - 1
sheet EXG 5

Every 2 weekly
Every 3 months
Every 6 months
Time Required
12,000 hrs
(2000 hrs)
(4000 hrs)
(8000 hrs)
(160 hrs)
(320 hrs)
(700 hrs)
irregular
Monthly
Weekly
Yearly
(min.)
Tray unit- Slots, connectors CLN - - - - - - - 1
LT Reject parts conveyor belt - - CLN - - - - - 5
Shuttle belt - - CLN - - - - - 5
TZ1/TZ2-axis ballscrew - - - - - - LUB - 10
TZ1/TZ2-axis belt tension - - - - - - CHK - 10
tension
tension
sheet EXG 5
Tray unit- Slots, connectors CLN - - - - - - - 1
LTC Reject parts conveyor belt - - CLN - - - - - 5
Shuttle belt - - CLN - - - - - 5
TZ1/TZ2-axis ballscrew - - - - - - LUB - 10
TZ1/TZ2-axis belt tension - - - - - - CHK - 10
tension
tension
sheet EXG 5
Tray unit- Shuttle belts - - - - CLN - - - 5
M Magazine belts - - - - CLN - - - 10
TY-axis clutch - - - - - - LUB - 10
TZ-axis belt tension (belt on - - - - - - CHK - 10
the magazine side)
TZ-axis belt tension (motor - - - - - - CHK - 10
side)
TY-axis belt tension (for the - - - - - - CHK - 10
clutch)
TY-axis belt tension (motor - - - - - - CHK - 10
side)
PCU Movable parts on the PCU - - - - - - - LUB 10
, *12
PCU-2 Movable parts on the PCU- - - - - - - - LUB 10
2 , *12
*3: Every 150,000 pickups or when a pickup error occurs

*4: When a pallet clamp error occurs
*5: When a nozzle vacuum pressure error occurs or filters are extremely dirty

*6: When a conveyor error occurs

*7: When a cutter operation problem occurs
*8: When a tape feeder error occurs
*9: When backup pins require cleaning
*10: When a panel clamp error occurs
*11: When a conveyor width change error occurs
*12: When problems occur with operation
*13: Every 2 to 3 weeks, or when pickup errors occur.
*14: Refer to section 6.11.17 "Replacing the Brush on Waste Tape Processing Units"
*15: This action is not required for M6-2SP modules.

6.3 Daily Maintenance (Within 24 hrs)

6.3.1 Cleaning the waste tape box (Every 8 hrs)
Clean the inside of the waste tape box for feeder pallets and tray unit-LT/LTCs.
Caution: The scheduled period for this work is every 8 hours, but depending on production conditions
such as the number of feeders used, there are cases in which it is necessary to change this
period. Use a period that is appropriate for the production conditions.
1. Pull out the waste tape box.
2. Use scissors to cut any cover tape that is hanging down from feeders.
3. Remove any waste tape that has accumulated in the waste tape box for feeder pallets
and tray unit-LT/LTCs.
Waste tape box
NXTBAS004E
4. If anything is in the area where the waste tape box is put, remove it.
Note: A sensor is attached inside the base. The waste tape processing unit will not operate
unless the waste tape box for feeder pallets has been returned to the correct position in the
base.

6.3.2 Cleaning the reject parts box (Every 24 hrs)

Note: When the separated reject parts box is present, clean it in the same manner as below.
When removing the separated reject parts box, remove all four reject parts boxes together.
1. Pull out the module. (Refer to section 5.1 "Pulling Out/Returning a Module".)
2. Pull up and remove the reject parts box.
3. Empty the reject parts box.

Caution: Be sure that the reject parts box is fully seated (placed completely back in position so it does
not stick up) when putting it back. If the reject parts box is not fully seated, it is possible that
items such as the head may strike and be damaged and/or damage the reject parts box.
Reject parts box
Seat
NXTBAS005Eb
6.3.3 Cleaning the reject parts box on the tray unit-LT (Every 24 hrs)
1. Remove the tray unit-LT from the machine. (Refer to section 5.6 "Inserting/Removing a
Tray Unit-LT".)
2. Pull up and remove the reject parts box.
3. Empty the reject parts box.

Caution: Be sure that the reject parts box is fully seated (placed completely back in position so it does
not stick up) when putting it back. If the reject parts box is not fully seated, it is possible that
items such as the head may strike and be damaged and/or damage the reject parts box.
01MEC-1143

6.4 Weekly Maintenance (Every 160 Hrs)

6.4.1 Cleaning the nozzle station
2. Remove the nozzle station. (Refer tosection 5.9 "Removing/Attaching a Nozzle Station"
for details.)
3. Slide the plate over and remove all nozzles.
4. Use a vacuum cleaner to remove any dirt or foreign objects from inside the nozzle
sockets.
5. Use a cotton swab to clean the surfaces of fluorescent stickers.
Plate
Nozzle sockets NXTNZC005E

6.4.2 Cleaning the feeder pallet

1. Remove the feeder pallet. (Refer to section 5.3 "Removing/Loading a Feeder Pallet
(PCU)" for details.)
2. Use a vacuum cleaner to remove foreign objects and dust from the feeder slots and
pallet connectors. If necessary, use a soft brush to carefully remove any remaining
items.
3. Ensure to clean any foreign objects or dust from the part supply base roller grooves prior
to returning the feeder pallet to the machine.
Feeder pallet
Feeder connectors
Slots
Part supply base

Roller groove
Roller groove
NXTDPL013Ed

6.4.3 Cleaning the glass cover on the parts camera

2. Set the wiper with a paper of the parts camera cleaning kit. Use it to remove any dirt or
foreign objects from the glass cover.
Note: Do not apply too much pressure when cleaning the glass surface in order to avoid breaking
the glass.
Wiper
Cover glass surface
NXTPCA008Ea
Note: Refer to the illustration below for setting the cleaning paper on the wiper.
Cleaning paper 3
NXTPCA009E

6.4.4 Cleaning the glass cover inside parts camera lighting unit
2. Use the cleaner of the parts camera cleaning kit to remove any dirt or foreign objects
from the glass cover inside the unit. Use the vacuum pickup tool for large objects that
the cleaner could not remove.
3. Use the wiper with a cleaning paper to wipe off any dirt or stain on the glass cover.
Note: Refer to section 6.4.3 "Cleaning the glass cover on the parts camera" for setting the
cleaning paper on the wiper.
Note: Do not apply too much pressure when cleaning the glass surface in order to avoid breaking
the glass.
Cleaner
Wiper
Vacuum pickup tool Glass surface

NXTPCA010Ea
Note: Use the brush nozzle with the cleaner. Do not use other types of the nozzle, as it could
damage the glass.
Cleaner (K3018H)
Nozzle with brush
Small size nozzle

Standard size nozzle
(not used)
(not used)
NXTPCA0011E

6.4.5 Cleaning inside the module
WARNING
module could cause burns. Do not contact the shaft or coil section
immediately after production is stopped.

modules. People with a heart pacemaker should stay clear of the
shaft and coil sections of the linear motor (maintain a distance of
400 mm or more). Pacemakers may malfunction because of the
magnetic field.
CAUTION
• Do not push or pull on the head body or use the handle on the
• Do not push on the X-axis gear cover. Otherwise the gear cover
may be deformed.
• When working close to the linear motor (within 55 mm) do not use
ordinary metal tools. Use only nonmagnetic tools.
• Damage to items may occur due to the magnetic field generated

by a linear motor. Keep magnetic cards, wristwatches and other
precision machines away from the linear motor (do not bring within
55 mm).
• Do not hit the linear scale when exchanging the head and
Linear motor coil
Linear motor shaft
X-axis gear cov

Linear scale 01MEC-032

2. Use a vacuum cleaner to remove any foreign objects or dirt scattered inside the module.
NXTBAS006
3. Use a dry cloth to carefully remove grease from areas other than those specified.

6.4.6 Cleaning the tray unit-LT feeder slots and connectors

Use a vacuum cleaner to remove foreign objects and dust from the feeder slots and
connectors. If necessary, use a soft brush to carefully remove any remaining items.
Connectors
Feeder slots
01MEC-0441E
6.4.7 Cleaning the tray unit-LTC feeder slots and connectors

Use a vacuum cleaner to remove foreign objects and dust from the feeder slots and
connectors. If necessary, use a soft brush to carefully remove any remaining items.
Connectors
Feeder slots
01MEC-0508E

6.4.8 Cleaning the mirrors on the V12 head

It is necessary to use a cotton swab when cleaning the mirrors in the mirror box.
Mirrors
01NST-0863E
Procedure
1. Remove the placing head. (Refer to section 5.8 "Removing/Attaching a Placing Head"
for details.)
2. Remove the cover from the bottom of the mirror box.

Note: When the cover is removed, parts which have dropped into the mirror box may fall out.
Cover
01NST-0861E

3. Use the cotton swab to clean the mirrors (3) in the mirror box.
Caution: Do not push hard on the mirrors.
Cotton swab
Mirror
Mirrors
01NST-0862E
Note: Use the cleaner (K3018H) from the parts camera cleaning kit to remove any foreign items.
4. Insert the tip of the cover in the mirror box slot and then secure the cover in place.
Cover tip
01NST-0886E

6.4.9 Cleaning the prism glass on the V12 head

It is necessary to use a cotton swab when cleaning the prism glass.
for details.)
2. Use a cotton swab to remove any foreign items that have become attached to the prism
glass or LEDs.
Glass cover LED
01MEC-1125E

6.5 2 Weekly Maintenance (Every 320 Hrs)

6.5.1 Lubricating the syringe, Q-axis gear (lower syringe side) and
O-rings on the V12 head
Required grease Application location Amount (cc)
VG-EP No. 1 (Wako Chemical) (1) Syringes 0.02
Biral T&D (2) Q-axis gear teeth 0.336

(Biral Lubricants Norway A/S)
(3) Syringe gear teeth 0.005
MDV235-ZB (Kuroda) (4) O-rings inside syringe -
Note: The listed lubrication amount for the syringe and syringe gear is the amount for one syringe.
It is recommended to use the syringe (S61439) to apply grease when only a small amount
is required. Use the scale markings on the syringe to apply the correct amount of grease.
for details.)
2. Remove the side cover from the head.
01MEC-1279
3. Turn the R-axis, and move the syringe to be lubricated to the position shown in the
diagram below. Move the syringe up and down in this position.
4. Move the syringe up and down and if the upward movement of the syringe is not smooth,
apply Biral T&D to the syringe (1) using a clean cloth (or cotton swab). Then, confirm
that the movement of the syringe is smooth.
Syringe up and down movement position
1 01NST-0864Eb
5. Use a clean cloth (or cotton swab) to wipe clean the syringe (1). This includes removing
the Biral T&D applied in step 3 above.

6. Apply 0.01 cc of VG-EP No. 1 to a cotton swab or flat brush and apply this to the upper
section of the syringe (1) while holding up the spring.
Caution: Use a lubrication syringe when lubricating syringe 1 on the V12 head. Be sure to apply the
appropriate amount.
7. Lower the syringe and apply 0.01 cc of VG-EP No. 1 to the lower part of syringe (1).
8. Move the syringe (1) up and down to lubricate.
9. Wipe off any excess grease with a clean cloth (or cotton swab).
10.Lubricate all of the syringes.
11.Wipe off any foreign matter and old grease from the Q-axis gear (2) and each syringe
gear (3) with a cotton swab.
12.Use a cotton swab soaked in Biral T&D, and apply it to the Q-axis gear (2) while turning
the gear by hand to lubricate the gear teeth.
13.Put some Biral T&D in a container and use the syringe to pick up a small amount of the
lubricant.
14.Use the syringe to apply 0.005 cc (about one drop) of the Biral T&D to each syringe gear
(3).
15.Move the syringe gears (3) up and down, and manually turn the Q-axis to work in the
lubricant.
2
Approx. 1 drop
01NST-0865Eb
16.Lubricate the O-ring in the syringes with MDV235-ZB grease by following the substeps
below.
a. Put the specified grease in the jar and then put the lid with the rods in it back on the
jar.
b. Remove the rod for H08/H12 head from the jig.
Syringe O-ring lubrication jig

(AA40R**)
Rod
(for H08/H12)
Jar
NXTPHD120Ec

c. Wipe the excess grease off end of the rod with a clean cloth.
Wipe here Grease

Rod
Excess grease
01MEC-0013Ja
d. Insert the rod into the syringe. Use the groove as a guide for the depth. Once the rod
is inserted, lightly rotate it to apply the grease to the O-ring (4).
Note: Use a clean cloth to remove any grease from the top of the syringe.
Rod
Wipe here Excess grease
Syringe O-ring (4)
Groove
01NST-0866E
e. Put the rod back in the jig to apply more grease and then continue to lubricate the
other syringes on the head.
17. Attach the side cover from the head.
Cautions regarding the Syringe O-ring lubrication jig

1. Use a clean cloth to wipe off any excess grease around the holes where the rods are
inserted.
Wipe here
dia.
dia.
: for H04
: for H08/H12
01MEC-0012Eb
2. Make sure that the sizes of rod and hole match before inserting the rod.
3. When there is grease inside the jig (jar), keep it away from direct sunlight and store it in
a cool place.

6.5.2 Lubricating the syringe edge on the H08M head
Required grease Application location Amount(cc)
Biral T&D (1) Syringes 0.002

Note: The listed lubrication amount for the syringe is the amount for one syringe.
for details.)
2. Lower the syringe, and use a cloth to wipe any excess grease from the syringe edge.
3. Apply 0.002 cc of the lubricant Biral T&D to a dry cloth and apply it to the edge of the
syringe.
4. Lubricate all of the syringes in the same manner.
01NST-1784

6.6 Monthly Maintenance (Every 700 Hrs)

6.6.1 Cleaning the reject parts conveyor unit
1. Remove the reject parts conveyor. (Refer to section 8.3 "Replacing the Reject Parts
Unit" for details.)
2. Clean the surface of the conveyor belt with a clean, dry cloth.
Reject parts conveyor belt
NXTRPC006Eb
6.6.2 Cleaning the tray unit-L shuttle belts (reject parts, tray drawer)
1. Remove the tray unit. (Refer to section 5.5 "Inserting/Removing a Tray Unit-L" for
details.)
2. Clean the surfaces of the conveyor and shuttle belts with a dry, clean cloth.
Tray drawer
shuttle belts
Reject parts
conveyor belt
NXTMTU026E

6.6.3 Cleaning the tray unit-LT shuttle belts (reject parts, tray
drawer)
1. Remove the tray unit-LT. (Refer to section 5.6 "Inserting/Removing a Tray Unit-LT" for
details.)
Reject parts conveyor belt Tray drawer shuttle belts
01MEC-0442E
6.6.4 Cleaning the tray unit-LTC shuttle belts (reject parts, tray
drawer)
1. Remove the tray unit-LTC. (Refer to section 5.7 "Inserting/Removing a Tray Unit-LTC"
for details.)
Tray drawer shuttle belts

Reject parts conveyor belt
01MEC-0509E

6.6.5 Cleaning the placing head vacuum filters

About the filter cleaning basket
Cleaning the filters is easier when using the special filter cleaning basket. When using this
basket, put in the filters along with any cases and put the basket in an ultrasonic cleaning
machine to clean them. The quantities of filters that can be put in the basket are provided
below.
• H04(S), H08, H12(S), H12HS, V12, H08M head: Maximum 40 filters
• H01, H02 head: Maximum 20 filters
NXTPHD028
<H01 head>
for details.)
2. Using the small-type blade screw driver, loosen and remove the filter cases and filters.
Filter case
Filter
Drawing number : XH0056*(Rev.2, 3)
: XH0094*(Rev.4)
Filter case
Filter NXTPHD013Ec
3. Wash the filter cases and filters in neutral detergent solvent, or replace if excessively
dirty.
Note: Put the filters while still in the case in the optional filter cleaning basket (K1325C). Clean
them by soaking them in neutral detergent in an ultrasonic cleaning machine for 5 minutes.

<H02 head>
for details.)
2. Using the small-type blade screw driver, loosen and remove the filter cases and filters.
Holder A Nozzle pick-up
Filter case
Filter
(Drawing number:
XH0094*)
Holder B Nozzle pick-up
Holder A Parts pick-up
Filter
Filter case (Drawing number: XH0094*)
Filter Filter case
(Drawing number:
XH0094*)
Holder B Parts pick-up
Filter
(Drawing number: XH0094*)
Filter case
01MEC-0462E
dirty.
<H04(S) head>
for details.)
2. Slide the aluminum lock-ring to the right and remove the filter cases (with filter inside).
Filter cover Filter case

(filter inside)
DWG No.:AA0AL**
NXTPHD018Ea
dirty.

<H08 head>
for details.)
Filter case
(filter inside)
DWG No.:AA0AL**
Filter cover NXTPHD006Ed
dirty.
<H12(S)/H12HS head>
for details.)
Filter cover
Filter case
(filter inside)
DWG No.:AA19H**
01MEC-0194Eb
dirty.

<V12 head>
for details.)
Filter cover
Filter case
(filter inside)
DWG No.:AA19H**
01NST-0872Eb
dirty.
<H08M head>
for details.)
Filter cover
Filter case
(filter inside)
DWG No.:AA19H**
01NST-1086E
dirty.

6.6.6 Placing head nozzle clamp pin replacement and nozzle pick-
up surface cleaning
<H01/H02 head only>
for details.)
2. Pinch the nozzle clamp pin fixing tabs with needle nose pliers to make removal easy.
Nozzle clamp pin

Nozzle pickup
surface
Mark
NXTPHD038Ea
Caution: Do not touch the 4 marks on the nozzle pickup surface.
3. Remove the nozzle clamp pin.
Nozzle pickup surface
NXTPHD039E
Caution: Be careful to not damage the nozzle pickup surface.
4. There are two pins used to clamp the nozzle. Repeat these procedures to remove the
second pin.

5. Clean the nozzle pickup surface. Gently wipe with cleaning paper to remove items from
the surface.
Nozzle pickup surface
Mark
NXTPHD041Ea
Caution: Be careful to not damage the nozzle pickup surface.
6. Attach the new nozzle clamp pins. Use an item that matches the inside diameter of the
pin in order to be able to securely push in the pin into place.
Nozzle clamp pin

Drawing number: PH0027*
NXTPHD040E
Caution: Be careful to not damage the clamp items on the clamp pins.

6.6.7 Cleaning the placing head flange filter

<H01/H02 head only>
For H01 heads that do not have the filter in the flange unit, it is necessary to clean the sleeve
assembly. (Refer to section section 6.8.1 "Cleaning the H01 head sleeve assembly <for
heads without flange filter>" for details.)
Flange
Filter
NXTPHD105E
for details.)
2. Remove the filter lock and then gently pull out the filter from the head.
Filter Flange
(AA1FZ0*)
NXTPHD116E
Hook
3. Use an air gun to clean the filter.

6.6.8 Cleaning the placing head syringes

<H04(S)/H08/H12(S)/H12HS/V12/H08M head>
It is necessary to use the head cleaner (QK00C**) when cleaning syringes.
CAUTION
Head Cleaner is designed to clean H04(S), H08, H12(S), H12HS,
V12, and H08M heads. Do not use this unit to clean other types of
heads. Using it to clean heads other than above heads may result
in damage to them.
Caution: If syringes are not periodically cleaned, there are cases in which good production results
cannot be obtained due a large accumulation of dust.
1. Connect an air hose to the head cleaner to supply air.
01MEC-0523
for details.)
3. Remove the side cover from the head. It is not necessary to remove the cover from V12
and H08M heads.
H04(S) head H08 head
Cover Cover
H12HS head
H12(S) head
Cover
Cover
01MEC-0589Ea

4. Ensure that there no objects or dust on the attaching surfaces of the placing head and
the holder. Use a clean dry cloth to remove any foreign objects.
Placing head clamp parts Parts where attached on holder
01MEC-0526E
5. While holding the head handle, insert the clamp joints into the grooves on the holder.
Pull the lever on the syringe cleaning unit forward and down to secure the placing head.
Placing head
Press the head down

firmly against the holder.
Placing head
Holder
01MEC-0527E

6. Place a cloth under the head. Alternatively, set a box covered with a cloth under the
head.
Caution: Use a box size that does not interfere with the head. Remove the box when attaching or
removing a head.
01MEC-0545a
7. Set the filter cases without filters in the head. Refer to section 6.6.5 "Cleaning the placing
head vacuum filters" for details.
8. Check the following items.
• The air pressure is between 0.4 MPa to 0.5 MPa.
• All of the filter cases are locked in place.
• All of the mechanical valves are in the upper position.

Note: The illustration below shows a H08 head, but perform the same work for the H04(S),
H12(S), H12HS, V12 and H08M heads.
Filter locked Filter unlocked
01MEC-0548E
9. Open the air valve to supply air to the head.
Valve closed Valve opened 01MEC-0528E

10.For the V12 head, rotate the R-axis to move the syringe to be cleaned to the position
shown in the diagram. Move the syringe up and down in this position.
<V12 head>
Syringe up and down

movement position
01MEC-0797E
11.Lower only one of the mechanical valves to supply air to the syringe. While supplying
air to the syringe, move the syringe up and down until foreign matter stops coming out.
Caution: Clean only one syringe at a time because the effectiveness of the cleaning is reduced due
to the air pressure dropping when air is supplied to multiple syringes at the same time.
CAUTION
Wear protective goggles when performing this work. It is possible

that items can be blown into the eyes from the syringe when the
mechanical valve is lowered.
01MEC-0549
12.Replace the empty filter cases with cases that have filters. Refer to section section 6.6.5
"Cleaning the placing head vacuum filters" for details.
13.Wipe off any foreign objects clinging to the side of the syringe with a clean dry cloth.
Lubricate the syringes at the same time as cleaning them. Refer to section 6.5.1
"Lubricating the syringe, Q-axis gear (lower syringe side) and O-rings on the V12 head",
section 6.6.9 "Lubricating the placing head circumference of syringes, Q-axis gear
(lower, syringe side), and syringe O-rings" for details on lubricating the syringes.
14.When all the syringes have been cleaned, while holding the head handle, lift the lever
on the syringe cleaning unit and then remove the head from the unit. Reattach the side
cover back on the head.

6.6.9 Lubricating the placing head circumference of syringes, Q-

axis gear (lower, syringe side), and syringe O-rings
<H04(S) head>
Biral T&D (2) Q-axis gear (lower, syringe side) 0.124

(3) Syringe gear (H04S head only) 0.02
for details.)
5. Use a cotton swab or brush to apply 0.035 cc of VG-EP No. 1 to the upper part of syringe
(1).
9. Lubricate all of the syringes.
gear (3) with a clean cloth.
(2) Cover
(1)
(1)
NXTPHD022Eb

11.Apply a thin coat of the Biral T&D to the Q-axis gear teeth (2) with a clean cloth.
12.Rotate the Q-axis gear (2) by hand to lubricate the gear teeth.
13.For H04S heads, apply Biral T&D to the syringe gear teeth (3).
14.Move the syringe gear (3) up and down and rotate the Q-axis gear (2) by hand to
lubricate the gear teeth.
(2)
(3)
01MEC-0653
below.
jar.
b. Remove the rod for lubricating the O-ring on the H04 head from the jar.

(AA40R**)
Rod (for H04)
Jar
NXTPHD118b
Wipe here Grease
Excess grease Rod
01MEC-0011Ea

is correctly inserted, lightly rotate it to apply the grease to the O-ring.
Rod
Wipe here Excess grease
Syringe
Groove
(4) O-ring
01MEC-0654E
e. Put the rod back in the jar to apply more grease and then continue to lubricate the

<H08 / H12(S) / H12HS head>

H08 head
Biral T&D (2) Q-axis gear 0.272

(Biral Lubricants Norway A/S) (lower, syringe side)
H12(S) / H12HS head
Biral T&D (2) Q-axis gear 0.336

(3) Syringe gear 0.02
(H12HS head only)
for details.)
5. Use a cotton swab or brush to apply 0.01 cc of VG-EP No. 1 to the upper part of syringe
(1).
(1)
(1)
NXTPHD016b

11.Apply a thin coat of the Biral T&D to the Q-axis gear teeth (2) with a clean cloth.
12.For H12HS heads, apply Biral T&D to the syringe gear teeth (3).
H08 H12(S)/H12HS
(2)
(2)
(3)
<H12HS>
01MEC-0440a
below.
jar.
b. Remove the rod for lubricating the O-ring on the H12/H08 head from the jar.

(AA40R**)
Rod
(for H08/H12)
Jar
NXTPHD120Ec
Wipe here Grease

Rod
Excess grease
01MEC-0013Ja

is inserted, lightly rotate it to apply the grease to the O-ring.
Rod
Excess grease
Wipe here
Syringe
Groove
(4) O-ring
NXTPHD121Ec
e. Put the rod back in the jar to apply more grease and then continue to lubricate the

1. Use a clean cloth to wipe off any excess grease around the holes where the rods are
inserted.
Wipe here
dia.
dia.
: for H04
: for H08/H12
01MEC-0012Eb
2. Make sure that the sizes of rod and hole match before inserting the rod.
3. When there is grease inside the jar, keep it away from direct sunlight and store it in a
cool place.

<H08M head>
Biral T&D (2) Q-axis gear (lower, syringe side) 0.054

(Sugai Chemical Industry)
(3) Syringe gear 0.022
for details.)
lower the syringe and only apply Biral T&D to the lowered part of the syringe (1) using a
clean cloth (or cotton swab). Then, confirm that the movement of the syringe is smooth.
4. Apply 0.05 cc of VG-EP No. 1 to a cotton swab or flat brush and apply this to the upper
section of the syringe (1) while holding up the spring.
(1)
(1)
01NST-1089
9. Wipe off any foreign matter and old grease from the Q-axis gear (2) and each syringe

10.Apply a thin coat of the Biral T&D to the Q-axis gear teeth (2) with a clean cotton swab.
11.Apply a thin coat of the Biral T&D to the syringe gear teeth (3) with a clean cotton swab.
(3) (2)
01NST-1090
13.Lubricate the O-ring in the syringes with MDV235-ZB grease by following the steps
below.
a. Put the specified grease in the jar and then put the lid with the rod in it back on the jar.
b. Remove the rod for lubricating from the jig.

(AA79X**)
Rod
Case
01MEC-0447E
Wipe here
Rod
Excess grease
01MEC-0448E

is correctly inserted, lightly rotate it to apply the grease to the O-ring (4).
Rod
Wipe here
Excess grease
Syringe (4) O-ring
Groove
01MEC-1273E
e. Put the rod back in the jig to apply more grease and then continue to lubricate the
other O-rings in the syringes of the head.

1. Use a dry cloth to wipe off any excess grease around the holes where the rods are
inserted.
Wipe here
01MEC-0450E
2. When there is grease inside the jig, keep it away from direct sunlight and store it in a
cool place.

6.6.10 Checking the placing head mechanical valve O-rings

<H04(S)/H08/H12(S)/H12HS/V12/H08M head>
Measure the up and down sliding resistance of the mechanical valve and decide whether
the O-rings are good or need to be replaced.
1. Attach the mechanical valve sliding resistance measuring head (AA6KN**) to a push-
pull gauge.
Note: Use a push-pull gauge that has a maximum load value of 10 N.
for details.)
3. Set the measuring head on the mechanical valve and read the maximum value on the
push-pull gauge from moving the valve up and down.
4. Measure all of the mechanical valves. If any measurements fall out of the permissible
range of 0.4 N to 2.0 N, then exchange the O-rings for that mechanical valve. Refer to
section 6.10.12 "Replacing and lubricating the placing head mechanical valve O-rings"
for procedures on exchanging these items.
0.4 N ~ 2.0 N
Resistance measuring head
Push-pull gauge
Mechanical valve
01MEC-0573E

6.7 3 Monthly Maintenance (Every 2000 Hrs)

6.7.1 Machine lubrication (base, module support surfaces)
Daphne Eponex No. 2 (Idemitsu) (1) Base support blocks 0.6
(2) Module support blocks 0.4
Note: 1 shot from the grease gun from the Fuji grease gun kit is approximately 0.6 cc. Use
approximate amounts when supplying grease.
2. Wipe off any filth from the base support blocks (1) and the module support blocks (2).
3. Apply 0.6 cc of Daphne Eponex No. 2 to a brush.
4. Spread the grease on the base support blocks (1).
6. Spread the grease on the module support blocks (2).
7. Wipe the excess grease off with a clean cloth.

Note: Applying grease as outlined above will result in both the upper and lower surfaces of the
support blocks (8) being lubricated.
(1)
(2) NXTBAS008b
Note: The example used above is of an M6-2(SP) module, however, the same lubrication process
also applies to the M3-2 module.
8. Return the module to the machine. (Refer to section 5.1 "Pulling Out/Returning a
Module".)

6.7.2 Cleaning the linear motor cooling fan filter
Linear motor coil section
Linear motor shaft
Linear scale X-axis gear cover

Cooling fan filter 01MEC-0437Eb
WARNING

magnetic field.
CAUTION
may be deformed.

55 mm).

1. Wait until the shaft for the linear motor cools to room temperature and then set the
protective covers on the shaft.
2. Remove the filter mounting bolts (two) from the front side of the XY robot.
Cooling fan filter
Drawing no. : AA8CS**

Part name : filter
01MEC-0438Eb
3. Remove the filter from the cooling fan.
4. Use compressed air to clean the filter. If the filter is very dirty, replace it with a new filter.

6.7.3 Lubricating the X-axis gears

The grease gun kit is required to lubricate several items.
WARNING

modules. People with a heart pacemaker should stay clear of the shaft
and coil sections of the linear motor (maintain a distance of 400 mm or
more). Pacemakers may malfunction because of the magnetic field.
CAUTION
• Do not push or pull on the head body or use the handle on the head to
move the XY robot position.
be deformed.

Wait until the shaft for the linear motor cools to room temperature and then set the
Linear motor shaft
Linear scale
X-axis gear cover
Protective cover 01MEC-0326Ea

<M3-2 modules>
Mobilith SHC460WT (Mobil) (1) X-axis gear 0.5
(6) XS-axis gear 0.5
2. Turn off the main switch of the machine.
<X-axis/Y-axis>
Linear motor shaft
Linear scale
Protective cover
X-axis gear cover <XS-axis>
Use brush XS-axis gear cover

01MEC-0590Ea

Lubricating the X-axis
4. Remove the X-axis gear cover and the XS-axis gear cover.
5. Wipe off any filth from the X-axis gears (1) with a clean cloth.
6. Apply 0.5 cc of Mobilith SHC460WT to a brush.
7. Use the brush to apply the grease evenly to the X-axis gear teeth (1).
8. Move the head holder right and left in the X-axis direction (ten full strokes) to lubricate
the ballscrew and LM guides evenly.
CAUTION
Do not push or pull on the head body or use the handle on the head
to move the XY robot position.
Do not push on the X-axis gear cover. Otherwise the gear cover
may be deformed.
9. Wipe off any excess grease with a clean cloth.
Lubricating the XS-axis
10.Wipe off any filth from the XS-axis gears (2) with a clean cloth.
11.Apply 0.5 cc of Mobilith SHC460WT to a brush.
12.Use the brush to apply the grease evenly to the XS-axis gear teeth (2).
13.Move the XS-axis unit right and left in the XS-axis direction (ten full strokes) to lubricate
CAUTION
may be deformed.
14.Wipe off any excess grease with a clean cloth.
15.Reattach the X-axis gear cover and the XS-axis gear cover.
16.After lubricating, check that no grease has spilled onto the top of the parts camera,
nozzle station, conveyor or the Y-axis linear scale. If grease has spilled onto any of
these areas, wipe it off using a lint free clean dry cloth.
Caution: Do not apply too much pressure when cleaning the units to avoid causing any damage.
17.Remove the protective cover from the linear motor shaft.
18.Return the module to the machine. (Refer to section 5.1 "Pulling Out/Returning a
Module".)

<M6-2 modules>
Mobilith SHC460WT (Mobil) X-axis gear 0.5
4. Remove the X-axis gear cover.
Linear motor shaft
Protective cover
Linear scale
XS-axis gear cover
Use brush 01MEC-0591E
5. Wipe off any filth from the X-axis gears with a clean cloth.
7. Use the brush to apply the grease evenly to the X-axis gear teeth.
8. Move the head holder right and left in the X-axis direction (ten full strokes) to lubricate
CAUTION
may be deformed.

10.Reattach the X-axis gear cover.
nozzle station, conveyor, Y-axis linear scale, the top of the coplanarity sensor (option)
or the coplanarity sensor linear scale. If grease has spilled onto any of these areas, wipe
it off using a lint free clean dry cloth.
Coplanarity sensor linear scale
Linear motor shaft
Module".)

6.7.4 Lubricating the Y-axis flat cable and rollers
WARNING

shaft and coil sections of the linear motor (maintain a distance of 400
mm or more). Pacemakers may malfunction because of the magnetic
field.
CAUTION
• Do not push or pull on the head body or use the handle on the head
be deformed.

Linear motor coil
Linear motor shaft
X-axis gear cover


G501 (Shinetsu) (K30315) M3-2 (1) Y-axis flat cable (LH) 0.4
(2) Y-axis flat cable (RH) 0.2
(3) Rollers 0.6
M6-2/ (4) Y-axis flat cable 0.7

M6-2SP
(5) Rollers 0.5
The amount of lubrication shown in the table is the amount required for one module.
A M6-2(SP) module is used as the example in the explanation below.
1. Pull the module forward. (Refer to section 5.1 "Pulling Out/Returning a Module".)
Linear motor shaft
Linear scale
X-axis gear cover
4. Remove the module top cover. (Refer to section 8.15 "Removing the Module Top
Cover").
5. Wipe the flat cables and rollers with a clean cloth.
6. Check the condition of the filament tape (silver tape 30 mm in width) wrapped around
the flat cables. If you see any problems such as peeling, loosening, or damage, stop the
work and contact your Fuji representative about it.
Note: Filament tape is wrapped around the different cables as follows. M3-2 modules: X-axis flat
cables, 1 location; Y-axis flat cables (left side), 5 locations. M6-2(SP) modules: X-axis flat
cables, 2 locations; Y-axis flat cables, 5 locations. Check all locations.

7. Apply the specified grease to the flat cables with a brush. (For the amount of grease,
refer to the table shown in this section.)
• Apply lubrication to the surfaces that make contact with the flat cable, such as
the rollers and cable support tray. Apply lubricant to areas that are able to move
during Y-axis operation.
• Do not apply lubrication to the area surrounding each flat cable securing bracket
in a range of 50 mm.
M3-2 module (2)

(1)
(3)
Brackets
Y-axis
Bracket
Cable support tray

01MEC-1062E
M6-2 module (4)

M6-2SP module
(5)
Brackets
Y-axis
Bracket
Cable support tray

01MEC-1063Ea

8. After lubricating, check that no grease has spilled onto the top of the parts camera,
Linear motor shaft
9. After performing lubrication, attach the top cover by reversing the procedures used
when removing the top cover.
Module".)

6.8 6 Monthly Maintenance (Every 4000 Hrs)

6.8.1 Cleaning the H01 head sleeve assembly <for heads without
flange filter>
If there is no flange filter, clean the head sleeve assembly.
Flange
Filter
01MEC-0663E
When preparing to clean the head sleeve assembly, it is highly recommended to have 2
spares of each of spare part shown below.
1. Vacuum pad (H1339A)

2. O-ring (A5202W)
3. Spring (PZ0933*)
NXTPHD112E
for details.)
2. Put a 2.5 mm Allen wrench in the hole at the top of the head and use it to turn the
ballscrew until the Z-axis has been fully lowered.
Wrench
NXTPHD106E

3. Remove the head side cover.
Cover
NXTPHD107E
4. Remove the bolts shown in the diagram and then move the bracket.
Bolts
Bracket
Bolts
NXTPHD108E
Note: A short ended 2.5 mm Allen wrench is required to remove these bolts.
5. Set the Q-axis gear fixing jig in the holes in the Q-axis gear.
Q-axis gear
Q-axis gear fixing jig
NXTPHD109E
Gear holes (the jig pins fit in here)

6. Lock the Q-axis in place and using an 8 mm spanner, loosen the sleeve assembly.
Sleeve assembly
Spanner (8 mm)
NXTPHD110E
7. Remove the sleeve assembly from the placing head.
Sleeve assembly
NXTPHD111E
Note: There are cases when the vacuum pad comes off. Be careful to not lose it.
8. Take apart the sleeve assembly.
Vacuum pad
Sleeve assembly
O-ring
Spring
Cap
NXTPHD113E

9. Use an air gun to remove any grime from the spring and internal section of the sleeve
assembly. Use a cloth to clean and wipe off any grime that was not removed.
Sleeve assembly Spring
NXTPHD114E
10.After cleaning the parts, lubricate the sleeve assembly O-ring and spring. Then put back
together the sleeve assembly. Push the shaft with the vacuum pad attached and ensure
that the up and down movement is smooth.
Used grease: MDV235-ZB (Kuroda)

(Manufacture type: K3032K)
Vacuum pad
Sleeve assembly
O-ring
Spring
Cap
Shaft
NXTPHD115Eb
11.Follow the removal steps in reverse order to reattach the sleeve assembly back into the
H01 head.

6.8.2 Cleaning the tray unit-M

1. Remove the tray unit-M from the machine. (Refer to section 5.11 "Attaching/Removing
a Tray Unit-M" for details.)
2. Clean the surfaces of the shuttle and magazine belts with a dry, clean cloth.
Magazine belt Shuttle belt
NXTMTU073E

6.8.3 Lubricating H04(S)/H08/H12(S)/H12HS/V12/H08M head arm

rotation axis for moving mechanical valves
Daphne Eponex No. 2 (Idemitsu) Arm rotation axis 0.002
Note: It is recommended to use the syringe (S61439) to apply grease when only a small amount
for details.)
2. Wipe off any foreign matter from the arm rotation axis using an item such as a cotton
swab.
3. Use an item such as a cotton swab to apply 0.002 cc of Daphne Eponex No. 2 grease
to the arm rotation axis and the other moving parts around it.
Arm
NXTPHD042E
4. Turn the arm rotation axis several times to spread the lubricant.
5. Wipe off any excess grease with a clean cotton swab.

6.8.4 Lubricating the Q-axis gear and R-axis gear on the H12HS
head
Mobilith SHC460WT (Mobil) (1) Q-axis gear (upper, 0.138

motor side)
(2) R-axis gear 0.224
for details.)
2. Remove the cover.
3. Wipe off any foreign matter and old grease from the Q-axis gear (1) and the R-axis gear
(2) with a clean cloth.
5. Use the brush to apply the grease evenly to the Q-axis gear teeth (1) .
7. Use the brush to apply the grease evenly to the R-axis gear teeth (2).
8. Rotate the Q-axis gear (1) and the R-axis gear (2) by hand to lubricate the gear teeth
evenly.
Cover
1
01MEC-0904E

6.8.5 Lubricating the Q-axis gear and R-axis gear on the V12 head
Mobilith SHC460WT (Mobil) (1) Q-axis gear (upper, motor side) 0.138
for details.)
evenly.
10.Attach the side cover on the head.
01NST-0884b

6.8.6 Lubricating the Q-axis gear and R-axis gear on the H08M head
for details.)
2. Remove the top cover.
evenly.
10.Attach the top cover.
Cover
(1)
(2)
01NST-1094E

6.8.7 XY-robot lubrication

The grease gun kit is required to lubricate several items.
WARNING

field.
CAUTION
be deformed.

Wait until the shaft for the linear motor cools to room temperature and then set the
Linear motor shaft
Linear scale
X-axis gear cover

<M3-2 modules>
NS7 (NSK) or Multemp SRL (Kyodo (1) X-axis ballscrew 0.3

Yushi)
(2) X-axis LM guides 0.9
(3) Y-axis LM guides 0.9
(4) XS-axis ballscrew 0.3
(5) XS-axis LM guides 1.2
The amount of lubricant in the table is equal to about one ballscrew or one LM guide block.
4. Wipe off any filth from the X-axis ballscrew with a clean cloth.
5. Wipe off any filth from the X-axis LM guide rails with a clean cloth.
6. Use the grease gun to apply 0.3 cc of NS7 or Multemp SRL to the grease fitting of the
X-axis ballscrew (1).
X-axis LM guides (2).
10.Move the head holder right and left in the X-axis direction (ten full strokes) to lubricate
CAUTION
may be deformed.
11.Wipe off any excess grease from the ballscrew and the LM guides with a clean cloth.

<X-axis/Y-axis>
3
Linear motor shaft
3
Linear scale
1 2
Protective cover
<XS-axis>
5
4
5
Use grease gun
Use brush
01MEC-0155Eb
Lubricating the XS-axis
12.Wipe off any filth from the XS-axis ballscrew (4) with a clean cloth.
13.Wipe off any filth from the XS-axis LM guide rails with a clean cloth.
14.Apply 0.3 cc of NS7 or Multemp SRL to a brush.
15.Use the brush to apply the grease evenly to the XS-axis ballscrew (4).
16.Use the grease gun to apply 1.2 cc of NS7 or Multemp SRL to the grease fitting of the
XS-axis LM guides (5).

18.Move the XS-axis unit right and left in the XS-axis direction (ten full strokes) to lubricate
CAUTION
may be deformed.
Lubricating the Y-axis
20.Wipe off any filth from the Y-axis LM guides with a clean cloth.
Y-axis LM guides (3).
23.Move the Y-axis unit up and down in the Y-axis direction (ten full strokes) to lubricate
CAUTION
may be deformed.
24.Wipe off any excess grease from the LM guides with a clean cloth.
nozzle station, conveyor or the Y-axis linear scale. If grease has spilled onto any of
these areas, wipe it off using a lint free clean dry cloth.
Module".)

<M6-2/M6-2SP modules>
NS7 (NSK) or Multemp SRL (Kyodo (1) X-axis ballscrew 0.3

Yushi)
(2) X-axis LM guides 0.6
(3) Y-axis LM guides 0.6
The amount of lubricant in the table is equal to about one ballscrew or one LM guide block.
Linear motor shaft 3
3
Protective cover
3
2
Use grease gun 01MEC-0420Eb
4. Wipe off any filth from the X-axis ballscrew with a clean cloth.
5. Wipe off any filth from the X-axis LM guide rails with a clean cloth.
X-axis ballscrew (1).
X-axis LM guides (2).

10.Move the head holder right and left in the X-axis direction (ten full strokes) to lubricate
CAUTION
may be deformed.
Lubricating the Y-axis
12.Wipe off any filth from the Y-axis LM guides with a clean cloth.
Y-axis LM guides (3).
15.Move the Y-axis unit up and down in the Y-axis direction (ten full strokes) to lubricate
CAUTION
may be deformed.
16.Wipe off any excess grease from the LM guides with a clean cloth.

Linear motor shaft
Module".)

6.8.8 Lubricating the XY-robot flat cables
WARNING

field.
CAUTION
be deformed.

Linear motor coil
Linear motor shaft
X-axis gear cover


G501 (Shinetsu) M3-2 (1) X-axis flat cable and cable 1.0
(K30315) support tray
(2) Y-axis flat cable (left side) 1.2

and cable support tray
(3) Y-axis flat cable (right side) 0.8

and cable support tray
M6-2/ (4) X-axis flat cable and cable 1.2

M6-2SP support tray
(5) Y-axis flat cable and cable 3

support tray
A M6-2(SP) module is used as the example in the explanation below.
Linear motor shaft
Linear scale
X-axis gear cover
4. Remove the module top cover. (Refer to section 8.15 "Removing the Module Top
Cover").
5. Wipe the flat cables with a clean cloth.
6. Check the condition of the filament tape (silver tape 30 mm in width) wrapped around
the flat cables. If you see any problems such as peeling, loosening, or damage, stop the
work and contact your Fuji representative about it.
Note: Filament tape is wrapped around the different cables as follows. M3-2 modules: X-axis flat
cables, 1 location; Y-axis flat cables (left side), 5 locations. M6-2(SP) modules: X-axis flat
cables, 2 locations; Y-axis flat cables, 5 locations. Check all locations.

7. Apply the specified grease to the flat cables with a brush. (For the amount of grease,
refer to the table shown in this section.)
• Apply lubrication to the surfaces that make contact with the flat cable, such as
the cable support tray, as well as between the flat cables where they overlap.
Apply lubricant to areas that are able to move during X-axis and Y-axis
operation.
• Do not apply lubrication to the area surrounding each flat cable securing bracket
in a range of 50 mm.
Caution: If you separate cables in order to apply grease between them, be sure to return them to
their original state afterwards.
M3-2 module
Y-axis
(2) (3)
Cable support tray Bracket
Brackets
(1) Cable support tray
(1)
(1)
Bracket
X-axis
Cable support tray
01MEC-0434Ea
M6-2 module Y-axis (5)

M6-2SP module (5)
(5)
Cable support tray Bracket
Brackets
(4) Cable support tray
(4)
(4)
Bracket
X-axis
Cable support tray
01MEC-0435Eb

8. After lubricating, check that no grease has spilled onto the top of the parts camera,
Linear motor shaft
9. After performing lubrication, attach the top cover by reversing the procedures used
when removing the top cover.
Module".)

6.8.9 Cleaning the filter on the brush unit station type

1. Pull the module forward. (Refer to section 5.1 "Pulling Out/Returning a Module" for
details.)
2. Remove the filter from the opening on the left side of the module.
Note: The diagram below shows an M6-2(SP) module, but the filter is in the same place on M3-2
modules.
Filter
Air hoses
01MEC-1033E
3. Remove the air hoses from the filter.
4. Rotate the end of the filter case and remove the filter element.
Filter case
Filter element
Filter case Protrusions
Cutout
01MEC-1034E
5. Use an air gun to remove any foreign objects from the filter. Replace the filter if it is
excessively dirty.
6. Insert the filter element into the filter case, then align the protrusions in one end of the
filter case with the cutouts in the other end of the filter case and rotate the end of the
filter case until it locks into place.
7. Follow the removal procedure in reverse to reattach the filter.

6.9 Yearly Maintenance (Every 8000 Hrs)

6.9.1 Cleaning the air regulator
2. Remove the cover from the base.
3. Turn OFF the air supply at the air inlet valve, and allow the air pressure in the air piping
to decompress.
4. Push down on the lock knob, turn the filter case and remove.
5. Clean the filter case using a neutral detergent.
6. Clean the filter element using a high-pressure air-gun, or replace if excessively dirty.
Cover
Filter regulator
Mist separator
O-ring
Fiter element
Drawing number : H3028C
Lock knob
Filter case
NXTBAS021Ea

6.9.2 Cleaning the half mirror of the mark camera light source
2. Place cleaning paper (A4565T) or a lens-cleaning cloth over a cotton swab and wipe the
half mirror of the mark camera light source.
Half mirror Mark camera
Cleaning paper (A4565T)
01MEC-0025Ea

6.9.3 Cleaning the parts camera lens

2. Turn off the NXT machine by turning the main switch off.
WARNING
• Always turn the machine main switch OFF before performing this
work.
WARNING

magnetic field.
CAUTION
may be deformed.

55 mm).

Linear motor shaft
Linear scale
X-axis gear cover
4. Loosen and remove the four (4) screws securing the cover using a driver.
Screws (M3 x 4)
Cover
NXTPCA003E
5. Gently remove the cover and then disconnect the two electrical connectors.
Note: The wiring position shown in the illustration below is different for P05 part cameras.
Connectors
NXTPCA005E

6. Use an Allen wrench to loosen and remove the four stud bolts. Gently remove the
lighting unit.
Stud bolt
(4 mm Allen wrench required)
Stud bolt identification
No groove 1 groove 2 grooves 3 grooves

(Standard and (High reso- (Sidelight (P05 camera)
P03 camera) lution camera) type camera)
Lighting unit
Lens 01MEC-0201Eb
7. Use cleaning paper (A4565T) to remove any foreign items and to clean the lens.
Lens
01MEC-0967E
Caution: Do not apply too much pressure when cleaning the lens in order to avoid damaging it.
8. Follow the removal steps in reverse order to reassemble the parts camera unit.
Caution: When attaching the lighting unit in the machine, be careful to not pinch wires under the
lighting stand legs or bolts. A pinched wire may cause a short.
9. Remove the protective cover from the linear motor shaft.
10.Turn on the main switch and turn on the module.
11.Push the module back to its original position. (Refer to section 5.1 "Pulling Out/

6.9.4 Lubricating the nozzle changer up/down shafts
Biral T&D Up/down shafts 0.9

(Biral Lubricants Norway A/S) (with lubrication holes)
Up/down shafts 1.8

(without lubrication holes)
There are nozzle changers that have lubrication holes for the shafts and there are nozzle
changers without these lubrication holes. The procedures for lubricating the shafts are
different depending on this condition. Use the procedure that is applicable for the type of
nozzle changer present.
Lubrication hole Lubrication points label
Lubrication hole
NXTNZC029E
Nozzle changer with lubrication holes Nozzle changer without lubrication holes
For a nozzle changer with lubrication holes
1. Pull forward the module. (Refer to section 5.1 "Pulling Out/Returning a Module".)
2. Remove the nozzle station.
Nozzle station
(2)
(1)
Lever
NXTNZC002Eb

3. Apply 0.9 cc of lubricant (Biral T&D) to each of the lubrication holes.
NXTNCZ030
For a nozzle changer without lubrication holes

For nozzle changers without the lubrication holes, use a jig to apply lubricant to the up/down
shafts.
Jig (AA4CM0*)
Lubricate shafts
AIMNZC009E
1. Use the nozzle station exchange command in manual mode to remove the nozzle
station. Refer to section 5.9 "Removing/Attaching a Nozzle Station" for details on
performing this action.
Note: When the nozzle station exchange command is used, the nozzle changer is raised and
exposes the locations on the shafts to be lubricated.
2. In order to not get any grease on the parts camera, cover the parts camera with some
type of cover such as cloth.
3. Push the jig firmly against the top of the nozzle changer while pushing in the direction of
the arrows shown below depending on the shaft being lubricated. With the jig in place,
insert the nozzle of the Biral T&D lubricant into the jig and apply a small amount of
lubricant (approximately 0.5 seconds).
Caution: It is necessary to use the tube supplied with the Biral T&D (2.2 mm in diameter). If a
different diameter tube is used, then the proper amount of lubricate cannot be applied or
the lubricant will not go to the correct place.
Note: If the jig strap is placed around the hand when using the jig, then the jig cannot be dropped
while using it.
Lubricate the back side nozzle

Tube attached Back side

to Biral T&D Shaft Jig
Nozzle
changer
Jig
Front side
AIMNZC006E
Lubricate the front side nozzle
Tube attached
Back side
to Biral T&D
Nozzle
changer
Shaft Jig
Jig
Front side
AIMNZC007E
4. Reattach the nozzle station. Refer to section 5.9 "Removing/Attaching a Nozzle Station"
for details.
5. Return the module to the machine and when production is started, the nozzle changer
is automatically lowered.

6.9.5 Replacing the placing head vacuum filters <H04(S), H08,

H12(S), H12HS, V12 and H08M heads>
Replace the placing head vacuum filters with new ones. (Refer to section 6.6.5 "Cleaning
the placing head vacuum filters".)
6.9.6 Replacing the linear motor cooling fan filter

Check the filter for dirt. If the filter is very dirty, replace it with a new filter. (Refer to section
6.7.2 "Cleaning the linear motor cooling fan filter" for removal procedure.)
6.9.7 Replacing the brush on the station type brush unit

1. Remove the nozzle station to which the brush unit is attached.
2. Using a flat head screwdriver, remove the coupler connecting the air hose to the brush
part.
3. Remove the two screws and then remove the brush.
Positioning pin
Brush Coupler 01MEC-1091E
4. Set the new brush on the positioning pin. Reattach the brush unit using the previous
procedures in reverse.

6.10 12000 Hr Maintenance

6.10.1 Cleaning the mist separator filter
3. Turn OFF the air supply at the air inlet valve, and allow the air pressure in the air piping
to decompress.
4. Rotate the filter element assembly and remove.
Caution: Install the filter element assembly so that the section with the opening for the filter faces
upwards.
Cover
Filter regulator
Mist separator
Element assembly
Drawing number : H3028B
NXTBAS022Ed

6.10.2 Cleaning the vacuum pump filter

2. Turn off the main switch.
4. Allow the pressure in the vacuum supply piping to decompress.
5. For a 2M-2 base, use the following sub steps to remove the vacuum filter.
a. Loosen the bolt under the filter case and then remove the filter case.
b. Remove the filter element.
2M-2 base
Vacuum pump
Vacuum pump
Filter element
Drawing number : H3022B
Filter case
Bolt
01MEC-0293Eb
6. For a 4M-2 base, use the following sub steps to remove the vacuum filter.
a. Push down on the lock knob and turn the filter case and then remove.
b. Turn the filter element holder to remove it and then take the filter element out.

4M-2 base
Cover
Vacuum pump
Filter element
Drawing number : H62915
Filter case Knob
01MEC-0294Eb
7. Wash the filter case with neutral detergent.

6.10.3 Cleaning the tray unit-L fan filter
CAUTION
Do not perform this work while the fan is operating. It is possible

that hands or other body parts can be injured by the fan.
Do not perform this work during production. Because the brake

cover is removed, it is possible for hands or other body parts to
become caught and injured in the TZ-axis items.
1. Remove the two M5 bolts from the brake cover and then remove the cover.
2. Remove the fan filter holder.
3. Remove the filter for the fan.
4. Use compressed air to clean the filter. If the filter is very dirty, replace it with a new filter.
Brake cover
Fan filter cover
Filter
M5 bolts
NXTMTU047E
5. Return the filter and the filter cover and reattach the brake cover using the M5 bolts.

6.10.4 Lubricating the H01 head
Mobilith SHC460WT (Mobil) (1) Q-axis gear 0.1
Daphne Eponex No. 2 (Idemitsu) (2) Z-axis ballscrew 0.117
(3) Z-axis LM guide 0.292
for details.)
2. Wipe off any foreign matter and old grease from the Q-axis gear (1) with a clean cloth.
4. Use the brush to apply the grease evenly to the Q-axis gear teeth (1).
5. Rotate the Q-axis (1) by hand to lubricate the gear teeth evenly.
6. Wipe off any foreign matter and old grease from the Z-axis ballscrew (2) with a clean
cloth.
8. Use the brush to apply the grease evenly to the Z-axis ball screw (2).
9. Wipe off any foreign matter and old grease the Z-axis LM guide rail (3) with a clean cloth.
10.Apply 0.292 cc of Daphne Eponex No. 2 to a brush.
11.Use the brush to apply the grease evenly to the surface of the rail of the Z-axis LM guide
(3).
12.Move the Z-axis up and down by hand to lubricate the ballscrew and LM guide evenly.
1
3
NXTPHD011b

Mobilith SHC460WT (Mobil) (1) Q-axis gears 0.1
Daphne Eponex No. 2 (2) Z1-axes ball screws 0.117

(Idemitsu)
(2) Z2-axes ball screws 0.117
(3) Z1-axes LM guides 0.292
(3) Z2-axes LM guides 0.292
There is a brake on top of the placing head to prevent the Z-axes from dropping. When
moving the Z-axes during these procedures, squeeze the Z-axes brake using your fingers
to release the brake (refer to the diagram).
for details.)
2. Remove the cover that is covering the Z-axes brake area.
3. While holding the ball nuts for the Z-axes ball screws, squeeze both sides of the Z-axes
brake using your fingers to release the brake and gently move the axes to their lowest
positions (fully extended).
4. Wipe off any foreign matter and old grease from the Q-axes gears (1) with a clean cloth.
6. Use the brush to apply the grease evenly to the Q-axis gear teeth (1).
7. Rotate the Q-axes gears (1) by hand to work in the grease evenly.
8. Wipe off any foreign matter and old grease from the Z1- and Z2-axis ball screws (2) with
a clean cloth.
10.Use the brush to apply the grease evenly to Z1 and Z2-axis ball screws (2). Apply 0.117
cc of grease to each of the Z1 and Z2-axis ball screws.
11.While holding the ball nuts for the Z-axes ball screws, squeeze both sides of the Z-axes
brake using your fingers to release the brake and gently move the axes to their highest
positions (fully retracted).
12.Wipe off any foreign matter and old grease from the Z1- and Z2-axis LM guides (3) with
a clean cloth.
13.Apply 0.292 cc of Daphne Eponex No. 2 to a brush.
14.Use the brush to apply the grease evenly to the surface of the rails of the Z1 and Z2-axis
LM guides. Apply 0.292 cc of grease to each of the Z1 and Z2-axis LM guides.
Caution: If grease gets on the flange, remove it with a clean cloth.
15.Manually move the Z-axes up and down several times to work in the grease.

17.Attach the cover for the Z-axes brake back on the placing head.
Cover
Z1-axis Z2-axis
Z-axes drop
prevention brake
2
2
1
1
1
Z1- and Z2-axes ball nuts

Flange
3
3
3
Apply to the entire 3
surface of the rail sides
Z1- and Z2-axes LM guides 01MEC-0461Ea


<Gears, Z-axis>
Daphne Eponex No. 2 (1) Z-axis ballscrew 0.082

(Idemitsu)
(2) Z-axis guide shaft 0.078
(3) Cam followers for moving 0.005

mechanical valves
Mobilith SHC460WT (4) Q-axis gear (upper, motor side) 0.18

(Mobil)
for details.)
2. Remove the side cover.
3. Rotate the R-axis until the triangle marks on the holder and on the head are aligned.
Caution: Do not turn the R-axis while the Z-axis is lowered.
4. Wipe off any foreign matter and old grease from the Z-axis ball screw (1) and the Z-axis
guide shaft (2) with a clean cloth.
6. Use the brush to apply grease evenly to the Z-axis ballscrew (1).
8. Use the brush to apply grease evenly to the Z-axis guide shafts (2).
9. Move the Z-axis up and down by hand to lubricate the ballscrew and the guide shaft
evenly.
11.Use an item such as a cotton swab to wipe off any foreign matter from the cam followers
(3).
12.Use an item such as a cotton swab to apply 0.005 cc of Daphne Eponex No.2 to the
interior and circumference of the cam followers (3).
13.Wipe off any excess grease with a clean cotton swab.
14.Wipe off any foreign matter and old grease from the Q-axis gear (4) and the R-axis gear
16.Use the brush to apply the grease evenly to the Q-axis gear teeth (4) .
18.Use the brush to apply the grease evenly to the R-axis gear teeth (5).

19.Rotate the Q-axis gear (4) and the R-axis gear (5) by hand to lubricate the gear teeth
evenly.
3
3
NXTPHD020c

6.10.7 Lubricating the H04S head

<Gears, Z-axis>
NS7 (NSK) or Multemp SRL (1) Z-axis ballscrew 0.082

(Kyodo Yushi)
Daphne Eponex No. 2 (2) Z-axis guide shaft 0.078

(Idemitsu)
mechanical valves
for details.)
2. Remove the side cover.
5. Apply 0.82 cc of NS7 or Multemp SRL to a brush.
evenly.
(3).

evenly.
3
3
NXTPHD020c

6.10.8 Lubricating the H08/H12(S) head

<Gears, Z-axis>
Daphne Eponex No. 2 (1) Z-axis ballscrew 0.07

(Idemitsu)
(2) Z-axis guide shaft 0.063 <H08>,
0.059 <H12(S)>

mechanical valves
Mobilith SHC460WT (4) Q-axis gear (upper, motor side) 0.138

(Mobil)
for details.)
7. Apply Daphne Eponex No.2 to a brush. Use 0.063 cc for H08 heads, and 0.059 cc for
H12(S) heads.
evenly.
(3).

evenly.
5
4
3
3
NXTPHD010g

6.10.9 Lubricating the H12HS head
NS7 (NSK) or Multemp SRL (Kyodo Yushi) (1) Z-axis ballscrew 0.058
Daphne Eponex No. 2 (Idemitsu) (2) Z-axis guide shaft 0.064
(3) Cam followers for 0.004

moving mechanical valves
for details.)
evenly.
(3).

01MEC-0195c

6.10.10 Lubricating the V12 head
NS7 (NSK) or Multemp SRL (1) Z-axis ballscrew 0.058

(Kyodo Yushi)
Daphne Eponex No. 2 (2) Z-axis guide shaft 0.064

(Idemitsu)
mechanical valves
(4) Grooved cam grooves 0.01
for details.)
evenly.
11.Attach the side cover on the head.
1
2
01NST-0883a

(3).
Arm for moving 3

mechanical valves
01NST-0885E
15.Move a syringe close to the entrance of the grooved cam grooves (4).
16.Use a cotton swab to apply 0.01 cc of Daphne Eponex No.2 to the grooved cam groove
(4) entrance.
17.Work in the grease into all of the grooved cam grooves at the syringe cam followers by
turning the R-axis by hand more than 90 degrees back and forth.
Syringe
Grease application area
Cam follower
Grooved cam grooves(4)
01NST-0951E
18.Wipe off any excess grease that may have collected around the syringes with a clean
cloth.

6.10.11 Lubricating the H08M head
NS7 (NSK) or Multemp SRL (Kyodo Yushi) (1) Z-axis ballscrew 0.086
Daphne Eponex No. 2 (Idemitsu) (2) Z-axis guide shaft 0.082
(3) Cam followers for 0.004

moving mechanical valves
for details.)
2. Remove the front cover.
evenly.
(3).
14.Attach the front cover.

(3)
(2)
(1)
01MEC-1274

6.10.12 Replacing and lubricating the placing head mechanical valve

O-rings
<H04(S)/H08/H12(S)/H12HS head>
MDV235-ZB (Kuroda) (K3032K) Mechanical valve O-rings 0.003
It is not possible to remove the mechanical valves for heads with serial number 00590 and
prior. Contact your Fuji representative to perform maintenance on these heads.
for details.)
3. Remove the bolts from the mechanical valve retainers for the valves to exchange, and
then remove the retainers.
4. Gently pull up on the mechanical valves and take them out.

Note: The illustration below shows a H08 head, but perform the same work for the H04, H12(S),
and H12HS heads.
Mechanical valve
Cover
Bolt tightening torque:

0.35 Nm
Mechanical valve retainer
NXTPHD009Ed

5. By using something such as fingernails, pull up on the O-ring for the mechanical valve.
Then insert the pointed end of the mechanical valve O-ring exchange tool (PM072M*)
in the created gap and then remove the O-ring. Remove all six O-rings in the same
manner.
O-ring (A5054X)
O-ring exchange tool
Mechanical valve 01MEC-0569Ea
6. Slide the new O-rings on the mechanical valve O-ring exchange tool from the pointed
end. Insert the mechanical valve into the O-ring exchange tool. Align a position on the
mechanical valve that has an O-ring groove with the end of the tool and then slide an O-
ring into the groove. Repeat for all 6 O-rings.
Mechanical valve
O-ring
Groove
01MEC-0571E
7. Apply 0.003 cc of MDV235-ZB to a brush.
8. Use the brush to lightly grease the surface of the O-rings on the mechanical valve.
9. Return the mechanical valve back to its position, set the valve retainer and then secure
with the bolt by tightening it to a torque of 0.35 Nm.
Caution: Do not overtighten. If overtightened the threads for the bolt on the head will be damaged
and the head will need to be replaced.

6.10.13 Replacing and lubricating the V12 head mechanical valve O-

rings
Procedure
for details.)
2. Remove the bolts from the mechanical valve retainer, and then remove the bottom cover
and the retainer.

0.16 Nm
Mechanical valve
O-rings (6)
Drawing number : A5053C

0.20 Nm

Bottom cover Washer 01NST-0877Eb
3. Push down the mechanical valve.
4. Use an Allen wrench with a jig spanner (PB00EY*) or a torque driver (AA9ZT**) to
remove the bolt and then separate the pusher plate from the plunger.
Note: A short head type 1.5 mm width Allen wrench must be used.
Pusher plate
Plunger Allen wrench
Jig spanner
Torque driver
01NST-0876Ea

5. Pull out the plunger from the rotory holder in a downward direction.
6. By using something such as fingernails, pull up on the O-ring. Then insert the pointed
end of the mechanical valve O-ring exchange tool (PM072M*) in the created gap and
then remove the O-ring. Remove all six O-rings in the same manner.
Plunger 01NST-0878Ea
end. Insert the plunger into the O-ring exchange tool. Align a position on the plunger
that has an O-ring groove with the end of the tool and then slide an O-ring into the
groove. Repeat for all 6 O-rings.

Groove
Plunger
O-ring
Drawing number
: A5053C
01NST-0879Ea
8. Apply 0.003 cc of MDV235-ZB to a brush.
9. Use the brush to lightly grease the surface of the O-rings.
10.Insert the plunger back into the rotary holder from the bottom.

11.Attach the pusher plate to the plunger using torque driver (AA9ZT**) to tighten the bolt
to the specified torque (0.16 Nm).
Caution: Be sure to use the appropriate amount of torque when tightening each bolt. It is possible
to damage the hole for the bolt if you do not use the correct torque.
Note: Adhesive is applied to the securing bolts to prevent them from loosening. Bolts that have
been removed two or three times can be reused, but replace bolts that have been removed
many times.
Bolt tightening torque

0.16 Nm
Pusher plate
Plunger Allen wrench
Torque driver
(AA9ZT**)
01NST-0887Eb
12.Secure the bottom cover and mechanical valve pusher with the securing bolt and tighten
to the appropriate torque.(Bolt tightening torque : 0.20Nm)
to damage the holes for the bolts on the placing heads if you do not use the correct torque.
Note: Adhesive is applied to the securing bolts to prevent them from loosening. Bolts that have
many times.

6.10.14 Replacing and lubricating the H08M head mechanical valve O-

rings
for details.)
2. Mechanical valves are comprised of a pusher plate and a plunger. Use an Allen wrench
to remove the bolt and then separate the pusher plate from the plunger.
Pusher plate
Plunger
Allen wrench
01NST-1098E
3. Remove the mechanical valve retainer bolt and then remove the retainer.
4. Gently pull up on the mechanical valve and take it out.
Plunger
Bolt 01NST-1099E

5. By using something such as fingernails, pull up on the O-ring. Then insert the pointed
end of the mechanical valve O-ring exchange tool (PM072M*) in the created gap and
then remove the O-ring. Remove all six O-rings in the same manner.
Plunger 01NST-0878Ea
end. Insert the plunger into the O-ring exchange tool. Align a position on the plunger
that has an O-ring groove with the end of the tool and then slide an O-ring into the
groove. Repeat for all 6 O-rings.

Groove
Plunger
O-ring
Drawing number
: A5053C
01NST-0879Ea
7. Apply 0.003 cc of MDV235-ZB to a brush, and use the brush to lightly grease the surface
of the O-rings.
8. Insert the plunger back to its position in the head, set the valve retainer and then secure
with the bolt by tightening it to the proper torque. (Tighten to a torque of 0.35 Nm.)
Plunger

0.35 Nm 01NST-1101E

9. Remove the top cover.
10.Attach the pusher plate to the plunger and temporarily lightly tighten the bolt.
11.Align the holes in the Q-axis and R-axis gears and tighten the bolt using torque driver
2AGKHJ0013** to tighten the bolt to the specified torque (0.16 Nm).
Adhesive is applied to the securing bolts to prevent them from loosening. Bolts that have
many times.
Cover
Torque driver
Q-axis gear

0.16 Nm
Pusher plate
R-axis gear
Plunger
01NST-1100E

6.10.15 Lubricating the conveyor
NS7 (NSK) or Multemp SRL (1) Ballscrews for width change 3.75
(Kyodo Yushi)
(2) CZ-axis ballscrews 0.9
The lubrication amount given in the table is for one entire ball screw.
<M3-2 module single conveyor>
(1)
(1)
(2)
3 places 01MEC-0412Ea

<M3-2 module double conveyor>
(1)
(1)
(2)
<M3-2 module triple conveyor>

(1)
(1)
(1)
(2)

<M6-2 module single conveyor>

(1)
(1)
(1)
(1)
(2)
4 places 01MEC-0213Ec
Note: The procedure for the extended conveyor is the same as for the M6-2 module single
conveyor. Perform the work after removing the conveyor cover. Refer to section 8.25
"Removing the Conveyor Cover on M6-2 extended Conveyor Modules"for details.
(1)
<M6-2 module double conveyor>
(1)
(1) (1)
(1)
(1)
(2)
8 places 01MEC-0212Ec

Procedure
3. For double conveyors, remove the backup plates. (Refer to section 5.10 "Exchanging
Backup Plates (When Performing Dual Lane Production with Lane 2 Brought
Forward)".)
Lubricating the ballscrews
4. Wipe off any filth from the ballscrews (1) with a clean cloth.
5. Apply 3.75 cc of NS7 or Multemp SRL to a brush for the width changing ball screws.
Spread the grease evenly with the brush. Apply grease to each of the ball screws.
6. Move the adjustable rail up and down (one full stroke) by hand to lubricate the
ballscrews.
7. Wipe off any excess grease from the ballscrews with a clean cloth.
Lubricating the CZ-axis ballscrews
8. Pull on the drive belt to rotate and raise the CZ-axis.
9. Wipe off any filth from the CZ-axis ballscrews (2) with a clean cloth.
10.Apply 0.9 cc of NS7 or Multemp SRL to a brush.
11.Spread the grease on the CZ-axis ballscrews (2).
12.Pull on the drive belt to rotate and move the CZ-axes up and down (one full stroke) by
hand to lubricate the axes.
13.Wipe off any excess grease from the CZ-axes with a clean cloth.
14.For double conveyors, attach the backup plates. (Refer to section 5.10 "Exchanging
Backup Plates (When Performing Dual Lane Production with Lane 2 Brought
Forward)".)
Module".)

6.10.16 Checking the conveyor belt tension

There are two types of conveyor belts (ones with a black exterior and ones with a white
exterior) and the type present in the machine depends on when it was purchased. Check
the color of the belt being inspected and refer to the appropriate belt tension value based
on the belt color.
1. Prepare the tension meter.
2. Pull the module forward.
3. When measuring the tension of the belt for the M3-2 conveyor, remove the screw
securing the belt cleaner and remove the cleaner. This is only necessary for the M3-2
conveyor. (Refer to section 7.3 "Replacing the Conveyor Belt Cleaner".)
Belt cleaner
<M3-2 module>
01MEC-0579E
4. Measure the belt tension using the tension meter positioned at the locations below. If
the tension is outside the permissible range, use the tension pulley to adjust the tension
until it is within range.
Black conveyor belt tension
<Single, Double conveyor>
M3-2 and M6-2(SP) Tension when adjusting Permissible tension

modules (Hz) (Hz)
Lane 1 284 - 344 201 - 344
Lane 2 205 - 245 145 - 245
White conveyor belt tension
<Single, Double conveyor, M6-2 extended conveyor>
M3-2 and M6-2(SP) Tension when adjusting Permissible tension

modules (Hz) (Hz)
Lane 1 233.1 - 284.9 65 - 285
Lane 2 171 - 209 48 - 209

<Triple conveyor>
M3-2 modules Tension when adjusting Permissible tension

(Hz) (Hz)
Lane 1 Reference side 248.4 - 303.6 69 - 304
Lane 1 Followup side 307.8 - 376.2 86 - 376
Lane 2 234 - 286 65 - 286
Lane 3 215.1 - 262.9 60 - 263
Note: Stretching of the conveyor belt occurs during operation. If the tension exceeds the
permissible range, then adjust the tension to be within the range of the “Tension when
adjusting” column.
<M3-2 module>
Measuring position
Measuring
position Tension pulley
Lane 2 Lane 1 01MEC-0362E
<M6-2 module> Tension pulley

<M6-2SP module>
Measuring Measuring position

position
Lane 2 Lane 1 01MEC-0363Ea
In addition, clean the belt cleaner.
<M3-2 module>
Belt cleaner
01MEC-0364E
<M6-2 module>
<M6-2SP module>
Belt cleaner
01MEC-0365Ea

6.10.17 Lubricating the waste tape processing unit
Daphne Eponex No. 2 (Idemitsu) LM guides 0.19
WARNING
Do not insert fingers or any other body parts in the waste tape
processing duct. There could be injury from the sharp cutter
(blade).
2. Wipe off filth from the LM guides with a clean cloth.
3. Use the grease gun to apply 0.19 cc of Daphne Eponex No.2 to the grease fittings of
each of the LM guide blocks.
5. Move the slider unit up and down (one full stroke) by hand to lubricate the LM guides.
LM guide blocks
01MEC-0410E
7. Attach the waste tape processing unit to the module. (Refer to section 8.4 "Replacing
the Waste Tape Processing Unit" for details.)

6.10.18 Lubricating the tray unit-L

<TZ-axis ballscrews>
Daphne Eponex No. 2 (Idemitsu) TZ-axis ballscrews 0.54
1. Remove the tray unit-L from the machine. (Refer to section 5.5 "Inserting/Removing a
Tray Unit-L".)
2. Remove the tray unit-L covers. (Refer to section 8.20 "Detaching and Attaching the Tray
Unit-L Cover".)
3. Wipe off any filth from the TZ-axis ballscrews with a clean cloth.
4. Use the grease gun to apply 0.54 cc of Daphne Eponex No.2 to the grease fittings of
each of the TZ-axis ball screws.
5. Rotate the TZ-axis by hand (move the magazine rack up and down, one full stroke) to
lubricate the ballscrews.
Note that the TZ-axis is locked when power is off, therefore for this operation it is
necessary to loosen the coupling of the brake unit. (Refer to section 8.20 "Detaching and
Attaching the Tray Unit-L Cover" for details.)
NXTMTU037
7. Attach the tray unit-L covers. (Refer to section 8.20 "Detaching and Attaching the Tray
Unit-L Cover".)
8. Insert the tray unit-L to the machine. (Refer to section 5.5 "Inserting/Removing a Tray
Unit-L".)

<Lifting gears>
Daphne Eponex No. 2 (Idemitsu) Lifting gears 0.92
1. Remove the tray unit-L from the machine. (Refer to section 5.5 "Inserting/Removing a
Tray Unit-L".)
2. Remove the tray unit-L covers. (Refer to section 8.20 "Detaching and Attaching the Tray
Unit-L Cover".)
3. Wipe off any filth from the lifting gears with a clean cloth.
5. Use the brush to apply the grease evenly to gears of the lifter.
Handle
NXTMTU040Ea
6. Turn the handle several turns by hand to lubricate the gears.
8. Attach the tray unit-L covers. (Refer to section 8.20 "Detaching and Attaching the Tray
Unit-L Cover".)
9. Insert the tray unit-L to the machine. (Refer to section 5.5 "Inserting/Removing a Tray
Unit-L".)

6.10.19 Checking and adjusting the tray unit-L belt tension

Obtain the tension meter necessary to measure the tension of the various belts before
starting these procedures. In addition, remove the tray unit-L from the machine. (Refer to
section 5.5 "Inserting/Removing a Tray Unit-L" for details.)
<TZ-axis belt tension>

1. Measure the belt tension in the middle of the longest span of the belt as indicated below.
Ensure that the tension is within the specified range.
Belt tension Specified value (Hz)
TZ-axis 44 - 48
NXTMTU038a
2. If the tension is outside of this range, adjust the belt tension until it is within the correct
range. Lightly loosen the pulley fixing bolts and then use the adjusting bolt to adjust the
tension. Ensure that the tension is still within range after retightening the pulley fixing
bolts.
Adjusting bolt
Pulley fixing bolts

NXTMTU039E

<TY-axis belt shuttle tension>

TY-axis (Shuttle) 37 - 40
NXTMTU041a
range. Lightly loosen the tension pulley fixing bolts. Loosen the lock nut on the
adjusting bolt and then use the adjusting bolt to adjust the tension. Ensure that the
tension is still within range after retightening the tension pulley fixing bolts.
Adjusting bolt
Lock nut
Tension pulley
fixing bolts
NXTMTU042E

<TY-axis motor gear belt tension>

TY-axis motor gear 361 - 399
NXTMTU043a
range. Lightly loosen the motor bracket fixing bolts. Loosen the lock nut on the
tension is still within range after retightening the motor bracket fixing bolts.
Adjusting bolt
Lock nut
Motor bracket fixing bolts NXTMTU044E

6.10.20 Checking and replacing the tray unit-L tray drawer bottom
surface sheet
Checking the tray drawer bottom surface sheet
1. Remove the tray drawer bottom surface sheet to be checked.
2. A sheet is attached to the bottom surface of the tray drawer. Check that the sheet is not
torn or damaged. If the sheet is torn or damaged, replace the sheet.
3. Check all tray drawers.
01MEC-1225
Replacing the tray drawer bottom surface sheet

If the tray drawer bottom surface sheet is torn or damaged, replace the sheet.
1. Turn the tray drawer over, and remove the sheet to be replaced.
2. Clean the surface where the sheet was attached with degreaser or other cleaning agent
to remove any oil or other foreign matter.
3. Remove the cover tape from the back of the sheet, and then attach the new sheet to the
tray drawer bottom surface in the position shown below.
Caution: Make sure there are no air bubbles or foreign matter under the sheet when attaching it. Use
a tool like a spatula to prevent air bubbles.
8.5mm
8.5mm
Sheets
90mm 90mm Drawing number : PZ0862*
01MEC-1226E

6.10.21 Lubricating the tray unit-LT moving parts

<TZ1/TZ2-axis ballscrews>
Daphne Eponex No. 2 (Idemitsu) TZ1/TZ2-axis ballscrews 0.5
Tray Unit-LT".)
2. Remove the tray unit-LT covers. (Refer to section 8.22 "Removing Tray Unit-LT
Covers".)
4. Use the grease gun to apply 0.5 cc of Daphne Eponex No.2 to the grease fittings of each
of the TZ-axis ball screws.
Tray unit-LT
01MEC-0227
6. Attach the tray unit-LT covers. (Refer to section 8.22 "Removing Tray Unit-LT Covers".)
7. Insert the tray unit-LT to the machine. (Refer to section 5.6 "Inserting/Removing a Tray
Unit-LT".)

<Lifting gears>
Tray Unit-LT".)
2. Remove the tray unit-LT covers. (Refer to section 8.22 "Removing Tray Unit-LT
Covers".)
Handle
01MEC-0228E
8. Attach the tray unit-LT covers. (Refer to section 8.22 "Removing Tray Unit-LT Covers".)
9. Insert the tray unit-LT to the machine. (Refer to section 5.6 "Inserting/Removing a Tray
Unit-LT".)

6.10.22 Checking and adjusting the tray unit-LT belt tension

starting these procedures. In addition, remove the tray unit-LT from the machine. (Refer to
section 5.6 "Inserting/Removing a Tray Unit-LT" for details.)
<TZ1/TZ2-axis belt tension>

Ensure that the tension is within the specified value.
TZ1-axis 58 - 63
TZ2-axis 58 - 63
Tray unit-LT
TZ1
TZ2
01MEC-0229b
bolts.

Tray unit-LT
Fixing bolts
(TZ2)
Fixing bolts
(TZ1)
Tension pulley
Adjusting bolt
01MEC-0230E

<TY-axis belt tension (shuttle)>

TY-axis (shuttle) 37 - 40
Tray unit-LT
01MEC-0231a
Tray unit-LT
Tension pulley
Adjusting bolt
Lock nut
Fixing bolts
01MEC-0232E


Tray unit-LT
01MEC-0233b
Tray unit-LT
Adjusting bolt
Lock nut
Motor bracket fixing bolts 01MEC-0234E

6.10.23 Checking and replacing the tray unit-LT tray drawer bottom
surface sheet
30MEC-0298

8.5mm
8.5mm
Sheets
94mm 94mm Drawing number : PZ0862*
30MEC-0299E

6.10.24 Lubricating the tray unit-LTC moving parts

<TZ1/TZ2-axis ballscrews>
Daphne Eponex No. 2 (Idemitsu) TZ1/TZ2-axis ballscrews 0.5
1. Remove the tray unit-LTC from the machine. (Refer to section 5.7 "Inserting/Removing
a Tray Unit-LTC".)
2. Remove the tray unit-LTC covers. (Refer to section 8.24 "Removing Tray Unit-LTC
Covers".)
4. Use the grease gun to apply 0.5 cc of Daphne Eponex No.2 to the grease fittings of each
of the TZ-axis ball screws.
Tray unit-LTC
01MEC-0510
6. Attach the tray unit-LTC covers. (Refer to section 8.24 "Removing Tray Unit-LTC
Covers".)
7. Insert the tray unit-LTC to the machine. (Refer to section 5.7 "Inserting/Removing a Tray
Unit-LTC".)

<Lifting gears>
1. Remove the tray unit-LTC from the machine. (Refer to section 5.7 "Inserting/Removing
a Tray Unit-LTC".)
2. Remove the tray unit-LTC covers. (Refer to section 8.24 "Removing Tray Unit-LTC
Covers".)
Handle
01MEC-0511E
8. Attach the tray unit-LTC covers. (Refer to section 8.24 "Removing Tray Unit-LTC
Covers".)
9. Insert the tray unit-LTC to the machine. (Refer to section 5.7 "Inserting/Removing a Tray
Unit-LTC".)

6.10.25 Checking and adjusting the tray unit-LTC belt tension

starting these procedures. In addition, remove the tray unit-LTC from the machine. (Refer
to section 5.7 "Inserting/Removing a Tray Unit-LTC" for details.)
<TZ1/TZ2-axis belt tension>

TZ1-axis 95 - 104
TZ2-axis 95 - 104
Tray unit-LTC
TZ2
TZ1
01MEC-0512
bolts.

Tray unit-LTC
Fixing bolts
(TZ2)
Fixing bolts
(TZ1)
Adjusting bolt
Tension pulley
01MEC-0513E

<TY-axis belt tension (shuttle)>

TY-axis (shuttle) 37 - 40
Tray unit-LTC
01MEC-0514
Tray unit-LTC Tension pulley
Adjusting bolt
Lock nut
Fixing bolts
01MEC-0515E


Tray unit-LTC
01MEC-0516
Tray unit-LTC
Adjusting bolt
Lock nut
Fixing bolts
01MEC-0517J

6.10.26 Checking and replacing the tray unit-LTC tray drawer bottom
surface sheet
01MEC-1227

8.5mm
Sheets
94.5mm Drawing number : PZ0862*
01MEC-1228E

6.10.27 Lubricating the tray unit-M (TY-axis clutches)
Daphne Eponex No. 2 (Idemitsu) TY-axis clutches 0.06
2. Remove the covers of the tray unit-M.
Covers
01MEC-0425Ea
3. Wipe off any filth from the TY-axis clutch with a clean cloth.

5. Use the brush to apply the grease evenly to the area where the TY-axis clutches come
together.
Clutches
Lubricate the area where

the clutches come together.
NXTMTU076E
7. Attach the covers of the tray unit-M.

6.10.28 Lubricating the tray unit-M (tray stoppers)
Daphne Eponex No. 2 (Idemitsu) Tray stopper pins 0.115
Tray stopper pin drive shaft 0.375
2. Remove the covers of the tray unit-M.
Covers
01MEC-0425Ea
Lubricating the stopper pins (10)
3. Wipe off any filth from the stopper pins with a clean cloth.
5. Use the brush to apply the grease evenly to the areas indicated below.
Apply a thin layer to the side

that does not contact the tray.
Tray stopper
Tray
Magazin belt
01MEC-0426E

Lubricating the drive shaft
7. Wipe off any filth from the stopper pin drive shaft with a clean cloth.
9. Use the brush to apply the grease evenly to the drive shaft.
10.Manually move the drive shaft right and left to lubricate the shaft.
Stopper pin
push shaft
01MEC-0430E
12.Attach the covers of the tray unit-M.

6.10.29 Checking and adjusting the tray unit-M belt tension

starting these procedures. In addition, remove the tray unit-M from the machine. (Refer to
section 5.11 "Attaching/Removing a Tray Unit-M" for details.)
<TZ-axis belt tension (motor side)>

Ensure that the tension is 245.0 ± 10.0 Hz.
TZ-axis belt
245.0 10.0 Hz
NXTMTU077E
range. Lightly loosen the motor fixing bolts and then use the adjusting bolt to adjust the
tension. Ensure that the tension is still within range after retightening the motor fixing
bolts.
Adjusting bolt
Motor fixing bolts NXTMTU078E

<TZ-axis belt tension (belt on the magazine side)>

TZ-axis belt
60.0 3.0 Hz
NXTMTU079E
bolts.
Adjusting bolt
Pulley fixing bolts

NXTMTU080E

<TY-axis belt tension (for the clutch)>

TY-axis belt
225.0 20.0 Hz
NXTMTU081E
Tension pulleys
NXTMTU082E

<TY-axis belt tension (motor side)>

363.0 20.0 Hz
TY-axis belt
NXTMTU083E
range. Lightly loosen the motor fixing bolts and then use the adjusting bolt to adjust the
tension. Ensure that the tension is still within range after retightening the motor fixing
bolts.
Adjusting bolt
NXTMTU084E
Motor fixing bolts

6.11 Irregular Maintenance

6.11.1 Removing rejected parts (reject parts conveyor, tray unit-L/
LT/LTC)
Perform when required
It is possible to remove rejected parts during production. If the module stops because the
reject parts conveyor becomes full, remove the parts from the conveyor and restart
production.
1. Use the vacuum pickup tool to remove the parts from the reject parts conveyor.
NXTMTU048

6.11.2 Removing empty trays (tray unit-L)

1. Remove the empty trays.
Empty tray Stopper Empty tray Empty tray box NXTMTU049Ea
Note:
1. Empty trays should be removed by hand, regardless of whether they are removed from t
tray box or a stopper. It is possible to remove the empty trays while the machine is
producing.
2. If the bolts on the bottom of the stopper are loosened, it is possible to slide the stopper
forwards and backwards. Adjust the stopper position as desired.
Bolts
Stopper
NXTMTU115E

6.11.3 Cleaning the Module Top Cover

If the top cover on the module becomes dirty then it should be cleaned.
1. A dry cloth or paper towel should be used to clean the top cover. They should be wiped
lightly to remove dirt .
CAUTION
There is the danger of the windows on the top cover losing their
anti-static effectiveness if they are cleaned with a wet cloth or
chemicals, or if they are wiped too hard.
top cover top cover
windows windows
M6-2 Module
M3-2 Module M6-2SP Module
01MEC-0578Ea

6.11.4 Cleaning hybrid calibration marks and jig parts

Clean these items before performing hybrid calibration
Cleaning procedure
1. Pull the module forward. Refer to section section 5.1 "Pulling Out/Returning a Module"
for details.)
2. Remove any dust or foreign matter from the four marks on the hybrid calibration stand
with a cotton swab.
Caution: Do not use water or detergent to clean this area. Also, be careful not to scratch the marks.
3. Remove any dust or foreign items from the surface of the jig parts that are set on the
hybrid calibration stand with a cotton swab.
Caution: Do not use water or detergent to clean these items. Also, be careful not to scratch the jig
parts.
Jigu part (GGAJ040*)

Jigu part (AA7SA**)
Hybrid calibration stand

01MEC-0835E

6.11.5 Cleaning the nozzles

Clean the nozzles after 150,000 pickups have been performed. The cleaning method for
standard nozzles (without rubber) and nozzles with rubber tips is different.
<Standard nozzles>
Selecting the correct drill bit for the nozzle size
The internal diameter of the nozzle tip is sometimes different than the back of the nozzle.
Refer to the chart below and select the appropriate drill for the area to be cleaned. Nozzle
damage can occur if an incorrect drill size is used.
Cleaning the tip of the nozzle Cleaning the back of the nozzle
Nozzle Drill Nozzle Drill
NXTNZC047E
Nozzle Drill diameter Nozzle Drill diameter

diameter diameter
(etched Nozzle Nozzle Nozzle Nozzle

on the top Tip Back Tip Back
of the
nozzle)
H08/H12(S)/H12HS/V12 H01/H02
dia. 0.3 (Ultrasonic cleaning) dia. 1.0 dia. 0.6 dia. 0.35
dia. 0.4 dia. 0.16 (for 0603) dia. 1.3 dia. 0.9
dia. 0.7 dia. 0.35 dia. 1.8 dia. 0.9
dia. 1.0 dia. 0.6 dia. 0.35 dia. 2.5 dia. 1.9 dia. 1.35
dia. 1.3 dia. 0.9 dia. 0.6 H08M
dia. 1.8 dia. 0.9 dia. 0.6 dia. 0.4 dia. 0.16 (for 0603)
dia. 2.5 dia. 1.9 dia. 0.6 dia. 0.7 dia. 0.35
H04(S) dia. 1.0 dia. 0.6 dia. 0.35
dia. 2.5 dia. 1.9 dia. 0.6 - - -

Cleaning procedure
1. Remove the nozzles from the nozzle station.
2. While holding the nozzle correctly, use the correct size of drill on the nozzle cleaning jig
for the nozzle in question to clean the nozzle tip area and back area. Refer to the chart
in the section "Selecting the correct drill bit for the nozzle size" on the next page. In
addition, disassemble the H01/H02 1.0 mm nozzle and clean the nozzle end.
Note: Hold the nozzle at the ceramic part of the tip as shown below when cleaning nozzles with
the drill jig. If the sleeve of the nozzle is held (as shown below) to clean the nozzle, the
connection to the ceramic part of the nozzle may become loose or damaged.
Nozzle held correctly

<1.0 mm nozzle for the H01/H02 head>
Remove the o-ring and then remove the pin.
Flange
Spring
Jig (AWPJ8100)
Nozzle held incorrectly Pipe
Pin
O-ring
NXTNZC045Ea
3. Use a cotton swab or clean cloth soaked in cleaning solution (ethyl alcohol or isopropyl
alcohol) to gently rub away any dirt from the 2D codes on the nozzle. Use an air-gun to
blow away any remaining cleaning solution.
4. Confirm that the nozzle pipe moves up and down smoothly. Check by pushing the end
of the nozzle with a push-pull gauge and confirm that movement occurs with a force of
20 gf or less. In addition, check the flange surface of H01 head nozzles for indentations,
bulges, or burrs.
Caution: Do not use the nozzle if the nozzle pipe does not move smoothly or requires more than 20
gf to move, because this may negatively affect production.

5. Set the nozzles back in the nozzle station. Ensure that the pipes for the nozzles are
lowered. In addition, wipe any oil off the flanges for H01/H02 head nozzles.
Pipe sticking out

Pipe lowered
Nozzle station
Incorrect Correct NXTNZC046E
Note: Because the needles are extremely thin for the 0603 nozzle cleaning jig, it is possible to
exchange just the needle if it becomes damaged. Refer to the table below for ordering the
special needle needed to replace any damaged ones.
Nozzle diameter Drawing number Part name

(target parts mm
[inch])
0.4 mm (0603 [0201]) PB75690 Needle
0.7 mm (1005 [0402]) PB75700 Needle
<Nozzles with rubber tips>

Applicable nozzles
Head type Ring type Pad type
H01, H02 and H08M heads dia. 2.5 dia. 3.7G - dia. 20.0G
H04(S) head dia. 2.5 dia. 3.7G - dia. 15.0G
H08, H12(S), H12HS and V12 heads dia. 2.5 dia. 3.7G, dia. 5.0G
Note: The OF head uses the same size as H01 and H02 heads. The G04 head uses only ring type
nozzles that are between 2.5G and 10.0G diameter.
Cleaning procedure
2. Use an air gun to remove any dust on the exterior and interior of each nozzle.
3. Use a cotton swab or clean cloth soaked in cleaning solution (ethyl alcohol or isopropyl
alcohol) to gently wipe away any dirt from the rubber section of the nozzle.
Pad type Ring type

Rubber section Rubber section
01MEC-0933E

Cleaning with an ultrasonic cleaner

Follow the conditions below when using an ultrasonic cleaning unit to clean nozzles.
• Cleaning equipment: 60W or more for eyewear use or precious metal cleaning
• Cleaning fluid: Ethanol or isopropyl alcohol based cleaning fluids
• Cleaning time: 15 minutes
• Do not use an ultrasonic cleaner to clean nozzles with 2D code labels (stickers). It is only
possible to use the ultrasonic cleaner for nozzles which have laser etched 2D codes.
• To ensure that the cleaning fluid used does not damage the nozzle coating, it is
recommended to test 1 or 2 nozzles before cleaning all of the nozzles.
• Immediately after cleaning, use an air gun to remove any excess cleaning fluid from the
nozzles. Furthermore, carefully maintain the cleanliness of the cleaning fluids to ensure
that the nozzles do not become dirty from the cleaning fluid itself.
• When cleaning nozzles with rubber tips, do not immerse the rubber section in cleaning
solution (this includes water). The rubber will degrade and may cause problems during
production. If using the ultrasonic cleaner to clean nozzles with rubber tips, set the nozzles
so that the rubber section protrudes above the level of the cleaning solution and ensure they
don't fall over when the cleaner vibrates.
Example of how to set nozzles for cleaning

Rubber section
Cleaning fluid
Wire mesh (or other material with holes) 01MEC-0934E

6.11.6 Cleaning H04(S) nozzles with filters and replacing nozzle

filters
There are two types of H04 head nozzles, those with filters and those without filters.
Perform the following work on nozzles with filters only.
Clean dia. 2.5 or smaller nozzles every 2 weeks, and dia. 3.7 or larger nozzles every 3
weeks. Clean all nozzle types when errors occur. If filters are excessively dirty, replace
them with new ones.
Caution: Replace periods may differ depending on operating conditions and machine environment.
Procedure
2. Use an air gun to blow air into the locations indicated in the diagram below to remove
dust and other foreign objects.
<Nozzles of dia. 2.5 or less> <Nozzles of dia. 3.7 or more>
Slot Slot
Moving part Moving part
of nozzle tip of nozzle tip
Guide Guide 01MEC-1035E
3. For nozzles with rubber pads, use a cotton swab or clean cloth soaked in cleaning
solution (ethyl alcohol or isopropyl alcohol) to gently wipe away any dirt from the rubber
section of the nozzle.
4. If the filter is particularly dirty, replace it with a new filter. Refer to the filter replacement
method on the next page for how to remove the filter.
5. If necessary, use the nozzle cleaning drill to clean the nozzle interior.
Note: Refer to section 6.11.5 "Cleaning the nozzles" for details on how to clean the nozzle with
the drill.
6. If necessary, use an ultrasonic cleaner to clean the nozzle.

Caution: When using an ultrasonic cleaner, remove the filter inside the nozzle. Also, so that filters
do not get submerged in cleaning solution, set the nozzle for cleaning in the same manner
as for nozzles with rubber pads. Refer to "section 6.11.5 "Cleaning the nozzles"for
important points regarding using an ultrasonic cleaner to clean nozzles with rubber pads.
7. Install a new filter. Refer to the filter replacement method on the next page for how to
install the filter.
Caution: For nozzles with filters, be sure that filters are attached before using these nozzles.
8. Ensure that the nozzle tip moves smoothly by pushing the tip with your finger.
Caution: For nozzles with rubber pads, do not hold the rubber pad section.
9. Set the nozzles back in the nozzle station.

<Filter replacement method>

The filter replacement method is different depending on the nozzle size and whether or not
the nozzle has a rubber pad. Use the method that best suits your needs.
H04(S) head nozzles
Group 1 Φ1.0, Φ1.8, Φ2.5, Φ2.5G
Group 2 Φ3.7, Φ5.0, Φ7.0, Φ10.0, Φ15.0
Group 3 Φ3.7G, Φ5.0G
Group 4 Φ7.0G, Φ10.0G, Φ15.0G
Installing group 1 filters

a. Use the nozzle filter removal jig (PM0GLZ**) to remove the filter from the nozzle.
01MEC-1168
b. Set a new filter at the rear of the nozzle.
c. Use the [Φ3.7, Φ5, Φ5G] side of the nozzle filter insertion jig (AB164**) to push the
filter into the pocket on the nozzle.
Ǿ㧟㧚㧣㧳
㧼㨞㨑‫ޓ‬㧿㨑㨠
Ǿ㧣㧳㨪
Ǿ㧣㨪㧘
‫ޓޓ‬Ǿ㧡㧳
Ǿ㧟㧚㧣㧘Ǿ㧡㧘
01MEC-1166


a. Use the nozzle filter removal jig (PM0GLZ**) to remove the filter from the nozzle.
01MEC-1164
b. Set a new filter at the tip of the nozzle.
c. Use the side of the nozzle filter insertion jig (AB164**) that matches the nozzle size
to push the filter into the pocket on the nozzle.
Note: Use the [Φ3.7 ,Φ5, Φ5G] side for Φ3.7, Φ5.0 nozzles and the [Φ7~,Φ7G~] side for
Φ7.0, Φ10.0, Φ15.0 nozzles.
Ǿ㧟㧚㧣㧳
‫ޓޓ‬Ǿ㧡㧳
Ǿ㧣㧳㨪
Ǿ㧣㨪㧘
01MEC-1167


a. Use tweezers or similar tool to remove the rubber pad from the nozzle tip.
01MEC-1169
b. Use the nozzle filter removal jig (PM0GLZ**) to remove the filter from the rubber pad.
01MEC-1170
c. Attach the rubber pad onto the protruding section of the filter installation jig for
nozzles with rubber pads (2MGKNJ00050*).
01MEC-1171
d. Insert a new filter into the hole from the back of the filter installation jig for nozzles
with rubber pads.
Ǿ㧣㨪㧘
e. Use the [Pre Set] side of the nozzle filter insertion jig (AB164**) to push the filter into
the rubber pad. Ǿ㧣㧳㨪
‫ޓޓ‬Ǿ㧡㧳
Ǿ㧟㧚㧣㧳
Ǿ㧡㧳
Ǿ㧟㧚
㧣㧘Ǿ㧡㧘
01MEC-1172

6. Preventive Maintenance Ǿ㧣㨪㧘 QD144-17
Ǿ㧣㧳㨪
‫ޓޓ‬Ǿ㧡㧳
Ǿ㧟㧚㧣㧳
f. Continue pushing the filter insertion jig so that the rubber pad is entirely removed
from the filter installation jig.
㧳
Ǿ㧡㧘
01MEC-1173
g. Insert the rubber pad with the filter into the tip of the nozzle.
Ǿ㧣㨪㧘
h. Use the [Pre Set] Ǿ㧣㧳㨪
side of the nozzle filter insertion jig to push the rubber pad into the
‫ޓޓ‬Ǿ㧡㧳
Ǿ㧟㧚㧣㧳
nozzle.
㧡㧳
Ǿ㧟
㧘Ǿ㧡㧘
01MEC-1161
i. Check that the rubber pad is installed correctly inside the nozzle. The rubber pad
should protrude 0.05 to 0.25 mm past the edge of the nozzle for Φ3.7G and Φ5.0G
nozzles.
Protruding distance 01MEC-1175E


a. Use tweezers or similar tool to remove the rubber pad and shim (1 or 2 shims) from
the nozzle tip.
Note: There may not be a shim inside.
Be careful not to lose the shims because they are used when installing the rubber pad.
01MEC-1176
b. Use the nozzle filter removal jig (PM0GLZ**) to remove the filter from the nozzle.
01MEC-1177
c. Insert a new filter into the nozzle.
d. Use the [Φ7~, Φ7G~] side of the nozzle filter insertion jig (AB164**) to push the filter
into the pocket on the nozzle.
Ǿ㧟㧚㧣㧳
‫ޓޓ‬Ǿ㧡㧳
Ǿ㧣㧳㨪
Ǿ㧣㨪㧘
01MEC-1167

e. Push the shim and rubber pad into the nozzle.

Note: Insert the same quantity of shims that were originally inside the nozzle.
01MEC-1178
f. Check that the rubber pad is installed correctly inside the nozzle. Ensure that the
rubber pad protrudes past the edge of the nozzle and is within the range listed below.
Nozzle Protrusion amount
Φ7.0G 0.05 mm to 0.25 mm
Φ10.0G 0.10 mm to 0.40 mm
Φ15.0G 0.20 mm to 0.60 mm
Protruding distance 01MEC-1179E

6.11.7 Cleaning H08M nozzles with filters and replacing nozzle filters
Recommended frequency
Clean dia. 2.5 or smaller nozzles every 2 weeks, and dia. 3.7 or larger nozzles every 3
weeks. Clean all nozzle types when errors occur. If filters are excessively dirty, replace
them with new ones.
Caution: Replace periods may differ depending on operating conditions and machine environment.
Procedure
2. Use an air gun to blow air into the locations indicated in the diagram below to remove
dust and other foreign objects.
<Nozzles of dia. 2.5 or less> <Nozzles of dia. 3.7 or more>
Slot Slot
Filter
Slot Slot
Spring Guide Spring Guide
Filter
01NST-1771E
3. For nozzles with rubber pads, use a cotton swab or clean cloth soaked in cleaning
solution (ethyl alcohol or isopropyl alcohol) to gently wipe away any dirt from the rubber
section of the nozzle.
4. If the filter is particularly dirty, replace it with a new filter. Refer to the filter replacement
method on the next page for how to remove the filter.
5. If necessary, use the nozzle cleaning drill to clean the nozzle interior.
Note: Refer to section 6.11.5 "Cleaning the nozzles" for details on how to clean the nozzle with
the drill.
6. If necessary, use an ultrasonic cleaner to clean the nozzle.

Caution: When using an ultrasonic cleaner, remove the filter inside the nozzle. Also, so that filters
do not get submerged in cleaning solution, set the nozzle for cleaning in the same manner
as for nozzles with rubber pads. Refer to "section 6.11.5 "Cleaning the nozzles"for
important points regarding using an ultrasonic cleaner to clean nozzles with rubber pads.
7. Install a new filter. Refer to the filter replacement method on the next page for how to
install the filter.
Caution: For nozzles with filters, be sure that filters are attached before using these nozzles.
8. Ensure that the nozzle tip moves smoothly by pushing the tip with your finger.
Caution: For nozzles with rubber pads, do not hold the rubber pad section.
9. Set the nozzles back in the nozzle station.

<Filter replacement method>

The method of replacing filters differs for nozzlesφ2.5 and smaller and nozzles φ3.7 and
larger. Please use the method appropriate to the nozzle size.
Note: This applies to nozzles with rubber pads and MELF nozzles.
Replacing filters of nozzles φ2.5 and smaller

1. Use the nozzle filter removal jig (PM0GLZ**) to remove the filter from the nozzle.
01NST-1772
2. Set a new filter at the rear of the nozzle.
3. Use the [Φ3.7, Φ5, Φ5G] side of the nozzle filter insertion jig (AB164**) to push the filter
into the pocket on the nozzle.
Ǿ㧟㧚㧣㧳
Ǿ㧣㧳㨪
Ǿ㧣㨪㧘
‫ޓޓ‬Ǿ㧡㧳
01NST-1773

Replacing filters of nozzles φ3.7 and larger

Note: The illustration is of a φ3.7 and a φ15.0G nozzle. The shape of the nozzle tip differs
depending on the nozzle size and whether or not the nozzle has a rubber pad, however the
filter replacement method is the same.
1. Use the nozzle filter removal jig (PM0GLZ**) to remove the filter from the nozzle.
Ǿ Ǿ)
01NST-1774
2. Set a new filter at the nozzle tip.
3. Use the side of the nozzle filter insertion jig (AB164**) that matches the nozzle size to
push the filter into the pocket on the nozzle.
Note: Use the [φ7~,φ7G~] section for φ7.0, φ10.0, φ7.0G, φ10.0G nozzles, and the [φ3.7G]
section for φ3.7G nozzles, and the [φ3.7, φ5, φ5G] section for other nozzles.
Ǿ
Ǿ㧟㧚㧣㧳
Ǿ㧣㧳㨪
Ǿ㧣㨪㧘
‫ޓޓ‬Ǿ㧡㧳
Ǿ)
Ǿ㧟㧚㧣㧳
Ǿ㧣㧳㨪
Ǿ㧣㨪㧘
‫ޓޓ‬Ǿ㧡㧳
01NST-1775

6.11.8 Cleaning the feeder pallet and part supply base connector
When a pallet clamp error occurs
Clean the following areas if a warning message displays at the machine.
2. Use a vacuum cleaner to remove any dirt or foreign objects clogging both sides of the
connector.
Connector
Feeder pallet
Part supply base
NXTDPL014Eb
6.11.9 Checking and replacing the placing head vacuum filters <H01/
H02 heads>
When nozzle vacuum errors occur, check to see if the head vacuum filters are dirty. If it is
extremely dirty, replace them with new ones. (Refer to section 6.6.5 "Cleaning the placing
head vacuum filters".)
6.11.10 Checking the conveyor belt tension

Check the conveyor belt tension when the panel stopping position is not stable or when
panel conveyance errors occur. (Refer to section 6.10.16 "Checking the conveyor belt
tension".)

6.11.11 Cleaning the conveyor belt and belt cleaner

Cleaning the conveyor belt
The conveyor belt should be cleaned when a problem like one of the following occurs.
• Flux gets on the conveying surface of the conveyor belt and sticks to panels
during conveyance.
• The panel stopping position is unstable and panel conveyance errors occur.
2. Turn off the machine.
3. Soak a soft cloth with industrial ethanol and wipe away any dirt or foreign objects off the
belt. Clean the entire length of the belt by turning the hexagonal shaft.
4. Apply some lubricant (Biral T&D) to a clean cloth and apply a small amount of the
lubricant to the entire length of the bottom surface of the belt (the side with teeth) by
turning the hexagonal shaft.
Note: We recommend to lubricate at the beginning of each work week.
Bottom surface
Conveying
surface
Hexagonal shaft
01MEC-0010Ea
Cleaning the belt cleaner

Clean the conveyor belt cleaner when the panel stopping position is not stable or when
panel conveyance errors occur.
2. Turn the main machine OFF.
3. Remove the belt cleaner. (Refer to section 7.3 "Replacing the Conveyor Belt Cleaner".)
4. Remove any foreign matter from the brush and block of the belt cleaner.
M3-2 module M6-2 module M6-2 extended

M6-2SP module conveyor module
Brush
Brush
Brush
Block Block 01MEC-0906Eb

6.11.12 Cleaning the soft backup pins

The soft backup pins should be cleaned in cases such as when flux remains on the tips of
the soft backup pins and sticks to the panel during conveyance.
Procedure
Use a soft dry cloth to wipe any dirt or foreign items from the backup pins.
Replace the soft backup pins when it is no longer possible to clean them thoroughly.
Note: Do not use liquids which contain neutral detergents when cleaning soft backup pins
because some of the material used to make the backup pins is water soluble.
01MEC-0009

6.11.13 Checking the CZ-axis belt tension

If panel clamping errors occur, then check the conveyor belt.
Specified tensions for M3-2 module conveyors
Symbols in Adjustment Allowable Notes

illust tension tension
A 32 -52 25 - 52 For single conveyors
B 146 - 166 94 - 166 For double conveyors
C 86 - 106 58 - 106 For double conveyors
D 155 - 175 99 - 175 For triple conveyors
<Single conveyor>
Tension
meter
(A)
01MEC-0414Ea
<Double conveyor>
Tension
meter
(C)
(B)
01MEC-0413Ea

<Triple conveyor>
(D)
Tension meter
(D)
(D)
01MEC-0648E
Specified tensions for M6-2 module conveyors

A 53 - 73 38 - 73 -
B 35 - 55 27 - 55 For single conveyors
Note: The procedure for the M6-2 extended conveyor is the same as for the M6-2 module single
<Single conveyor>
Tension pully
(B)
(B)
Tension meter (A) Tension meter
01MEC-0214Ea

<Double conveyor>
Tension pully
(A)
(A)
Tension meter
01MEC-0216Ea
Adjustment procedure
1. Obtain a tension meter.
2. Measure the belt tension at the center of the belt span and check if the measured
tension is within the allowable range.
3. If the measured tension is out of the range, adjust the belt tension by following the sub
steps.
a. Loosen the fixing bolts of the tension pully bracket.
b. Turn the adjusting bolt so that the tension comes in the specified value.
Fixing bolt
Tension pully Fixing bolt

bracket
Adjustment bolt
01MEC-0215Ea
c. Tighten the fixing bolts of the tension pully bracket.
d. Measure the belt tension again, and be sure the tension is within the allowable range.

6.11.14 Checking the conveyor motor belt tension

Belt tension on single and double conveyor M3-2 modules

A 388 - 408 233 - 408 For lane 1 conveyance
B 388 - 408 233 - 408 For lane 2 conveyance
C 399 - 419 234 - 419 For changing lane 2

reference rail position
D 161 - 181 97 - 181 For changing lane 1 position
E 399 - 419 234 - 419 For changing lane 2

adjustable rail position
<Single conveyor>
A
D
: Measuring position
01MEC-0416Ea
<Double conveyor>
A C
B E
01MEC-0415Ea

Belt tension on triple conveyor M3-2 modules
Symboles in Adjustment Allowable Notes

illust tension (Hz) tension (Hz)
A 236 - 256 148 - 256 For changing lane 3

C 333 - 353 206 - 353 For lane 1 conveyance
D 236 - 256 148 - 256 For changing lane 2

E 291 - 311 181 - 311 For lane 3 conveyance
F 291 - 311 181 - 311 For changing lane 1

<Triple conveyor> A D
B E
C F
01MEC-0649E
Note:
• The upper fixing bolts (marked with a black circle in the above diagram) for the third
level motor (the topmost motor) are M4 x 12 Allen bolts.
• The fixing bolts for the first and second level motors are special hexagon bolts. A 6
mm open ended spanner is required to loosen them.
Caution:
• The bolts indicated in the dotted box in the above diagram are 77 mm in length, and
the other bolts are 95 mm in length. If the wrong length bolts are used, then there is
a danger of interference occurring.

Belt tension on M6-2 module conveyor

A 189 - 209 113 - 209 For lane 1 conveyance
C 268 - 288 161 - 288 For changing lane 2

reference rail position
D 291 - 311 175 - 311 For changing lane 1 position
E 268 - 288 161 - 288 For changing lane 2

Note: The procedure for the M6-2 extended conveyor is the same as for the M6-2 module single
<Single conveyor>
A
D
01MEC-0418Ea
<Double conveyor>
C
A
B
E
01MEC-0417Ea

Adjustment procedure
1. Obtain a tension meter.
2. Measure the belt tension at the center of the belt span and check if the measured
tension is within the allowable range.
3. If the measured tension is out of the range, adjust the belt tension by following the sub
steps.
a. Loosen the motor fixing bolts.
b. Loosen the adjusting bolt lock nut.
c. Turn the adjusting bolt so that the belt tension comes in the specified value.
Fixing bolts
Lock nut
Adjusting bolt
Fixing bolts
01MEC-0419E
d. Tighten the motor fixing bolts.
e. Tighten the adjusting bolt lock nut.
f. Measure the belt tension again, and be sure the tension is within the allowable range.

6.11.15 Cleaning the waste tape cutter

Clean this unit if a warning message displays at the machine about the cutter movement
not being good.
WARNING
Avoid injury by keeping fingers clear of the entrance to the waste

tape processing unit duct.
2. Use an air-gun to clear the tape cutter of any waste tape and parts. Also, remove any
materials that are stuck to the blades (such as splicing tape).
Cutter
NXTWTC010Ea
6.11.16 Cleaning the waste tape processing unit duct

Perform the following cleaning procedures when feeder indexing errors occur.
WARNING

2. Use an air-gun to clear the duct of any waste tape and parts. Also, remove any materials
that are stuck to the duct (such as splicing tape).
Duct
NXTWTC008Ea

6.11.17 Replacing the Brush on Waste Tape Processing Units

This work is only required for B type waste tape processing units which have a brush
attached. Replace the brush if pieces of tape cut in the duct of the waste tape unit are stuck
to the brush.
Note: Refer to section 7.28 "Replacing the Movable Blades on Waste Tape Processing Units" for
how to tell the difference between the A type and B type waste tape processing units. The
B type waste tape processing unit may not have a brush attached, depending on the date
of manufacture. This work is not required if there is no brush.
For M3-2 module
Brushes
For M6-2 module

For M6-2SP module
01MEC-1096Ea
WARNING


2. Set the waste tape unit on the blade adjustment jig. Insert the unit into the grooves and
secure it into position.
Blade adjustment jig
01MEC-0598E
3. Remove the brush. The brush is attached with double-sided tape.
4. Clean the surface where the brush was attached with degreaser or other cleaning agent
5. Remove the cover tape from the double-sided tape and then attach the new brush to the
waste tape processing unit.
For M3-2 module
Attachment surface
Attachment surface
For M6-2 module

For M6-2SP module
01MEC-1097Ea

6.11.18 Lubricating the PCU (Pallet Change Unit)

Lubricate the PCU when the levers for the handles on each side of the unit do not move
smoothly or when the PCU does not operate correctly while changing feeder pallets.
PCU for standard feeder pallets
Required grease Application location Amount

(cc)
Daphne Eponex No. 2 (1) Grooves at front and back sliders (4 locations) 0.3
(Idemitsu)
(2) Screw to lower or raise the unit 0.3
(3) Gear to lower or raise the unit 0.3
(4) Front side spring 0.3
(5) Sliding section at front side slider (2 locations) 0.3
(6) Support pins for guide (2 locations) 0.3
(7) Sliding section for lower slider at center 0.3
(8) Sliding section for lower slider at left side 0.3

(3 locations)
(9)Pipe support area at lower left and right sides 0.3
(10) Around slide lock pin at lower left and right 0.3
sides (2 locations)
(11)Sliding section for top pin 0.3

(For M3-2 modules, there are 4 locations at the
left, right and center, for M6-2 modules there are 2
locations at the left and right.)
1. Wipe off any dirt from the lubrication points with a clean cloth.
3. Apply grease to the sliding sections of the lubrication points.
• When lubricating the screw to lower or raise the unit (item 2), apply grease after
raising the unit by turning the height adjustment handle.
• When lubricating item 6, the pin (item 11) and the pipe support area (item 9),
apply grease around the gap of the sliding sections.
• (When lubricating the sliding sections on the sliders (items 5, 7 and 8), apply
grease to the sliding surface while moving the slider. If grease cannot be
applied to the sliding surface, apply grease to the area surrounding the sliding
parts.
4. Move each lubrication point to spread the grease evenly.

PCU for standard feeder pallets
Lever
(11)
(9)
(10) (6) (4)
(5)
(8)
(7) (1)
(3)
(2)
(9)
Handle
(10)
01MEC-0968E

PCU for bucket type feeder pallets

(cc)
Daphne Eponex No. 2 (1) Grooves at front and back sliders (4 locations) 0.3
(Idemitsu)
(2) Screw to lower or raise the unit 0.3
(3) Gear to lower or raise the unit 0.3
(4) Front side spring 0.3
(5) Sliding section at front side slider (2 locations) 0.3
(7) Sliding section for lower slider at center 0.3
(8) Sliding section for lower slider at left side 0.3

(3 locations)
(9)Pipe support area at lower left and right sides 0.3
(10) Around slide lock pin at lower left and right 0.3
sides (2 locations)
(11) Cam follower support pin on plate 0.3

(12)Around pallet lock pin on plate (2 locations) 0.3
(13) Stopper support pin on plate 0.3

• When lubricating the screw to lower or raise the unit (item 2), apply grease after
raising the unit by turning the height adjustment handle.
• When lubricating the support pin (item 6 and 13) and the pipe support area (item
9), apply grease around the gap of the sliding sections.
• (When lubricating the sliding sections on the sliders (items 5, 7 and 8), apply
grease to the sliding surface while moving the slider. If grease cannot be
applied to the sliding surface, apply grease to the area surrounding the sliding
parts.

PCU for bucket type feeder pallets
(12) (11)
(1)
(6) (4)
(5)
Lever
(9)
(10)
(8)
(13)
Handle
(3) (2)
(9)
(7)
(10)
01MEC-0969E

6.11.19 Lubricating the PCU-2 (Pallet Change Unit)

Lubricate the PCU-2 when the PCU-2 does not operate correctly while changing feeder
pallets.
PCU-2 for standard feeder pallets

(cc)
Daphne Eponex No. 2 (1) Main body upper and lower drive shaft 0.3
(Idemitsu) (2 locations)
(2) Upper and lower drive gears 0.3
(3) Guide point section (2 locations) 0.3
(5) Roller sliding surfaces (6 locations) 0.3
(6) Caster upper and lower drive shaft (2 locations) 0.3
(7) Height change lever supporting pin 0.3
• Applying grease to the upper and lower drive shafts (item 1and 6) after
positioning the height change lever to the blue label.
• To lubricate the upper and lower drive gears (item 2), remove the cover and
apply grease to the gear teeth.
• To lubricate the support pin (item 4 and 7) , apply grease around the gap of the
sliding sections.
• (To lubricate the rollers (item 5), apply grease in the gap between the side
surface of the rollers and the axes.

PCU-2 for standard feeder pallets
(3)
(4)
Cover
(2)
(1)
(5)
(5)
(5)
(6) (7)
01MEC-1057E

PCU-2 for bucket type feeder pallets

(cc)
Daphne Eponex No. 2 (1) Main body upper and lower drive shaft 0.3
(Idemitsu) (2 locations)
(2) Upper and lower drive gears 0.3
(3) Guide point section (2 locations) 0.3
(5) Roller sliding surfaces (6 locations) 0.3
(6) Caster upper and lower drive shaft (2 locations) 0.3
(7) Height change lever supporting pin 0.3
(8) Cam follower support pin on plate 0.3

(9) Around pallet lock pin on plate (2 locations) 0.3
(10) Stopper support pin on plate 0.3

• Applying grease to the upper and lower drive shafts (item 1and 6) after
positioning the height change lever to the blue label.
• To lubricate the upper and lower drive gears (item 2), remove the cover and
apply grease to the gear teeth.
• To lubricate the support pin (item 4, 7, 8 and 10) , apply grease around the gap
of the sliding sections.
• (To lubricate the rollers (item 5), apply grease in the gap between the side
surface of the rollers and the axes.

PCU-2 for bucket type feeder pallets
(8) (9)
(10)
(3)
(4)
Cover
(2)
(1)
(5)
(5)
(5)
(6) (7)
01MEC-1058E

QD144-17 7. Replacing Consumable Parts
7. Replacing Consumable Parts

7.1 About Consumable Parts
Consumable parts are parts that deteriorate during the course of operating the machine and
these parts must be paid for even if the machine is still under warranty.
Refer to the appropriate parts list for the machine or unit for consumable part information.
7.2 Replacing Conveyor Belts

7.2.1 Recommended frequency
Replace when damage to the belt results in panel conveyance errors.
7.2.2 Procedure
It is necessary to replace both the reference side and adjustable side conveyor belts at the
same time.
Note: In the descriptions below, a double conveyor for a M6-2(SP) module conveyor is shown.
The procedure for exchanging the conveyor belt is the same for the M6-2(SP) module
single conveyor, the M6-2 extended conveyor, and the M3-2 module conveyor. For M6-2
extended conveyor modules, remove the conveyor cover before performing this work.
Refer to section 8.25 "Removing the Conveyor Cover on M6-2 extended Conveyor
Modules"for details.
1. Move the conveyor rail to the replacement position for the side on which the belt is being
replaced.
01MEC-0259
3. Turn the main switch off.

7. Replacing Consumable Parts QD144-17
4. Loosen the two front and central set screws of the lane 1 and lane 2 hexagonal shafts,
and slide the hexagonal shafts back far enough to allow the belt to be removed.
Set screws
Hexagonal shafts NXTBAS011Eb
5. Loosen the tension pulley.
Conveyor belt
Tension pulley
NXTBAS012Ea
6. Remove the panel guides and the panel retainer plates.

Caution: The bolts that secure the panel retainer plate have collars on them. Be careful that the
collars do not fall off.
Panel guide
(adjustable side)
Panel retainer plate
Panel guide
(reference side)
NXTBAS014Eb

7. For the M6-2 extended conveyor, remove the panel guides at the left, right, and center.
a. Remove the bolts and then remove the sensor cover.
b. Remove the bolts and then remove the panel guides.
01MEC-1180
8. Remove the clamp plate and replace the conveyor belt. Adjust the conveyor belt to the
prescribed tension using the tension pulley. Refer to section 6.11.10 "Checking the
conveyor belt tension" for more details.
Conveyor belt
Clamp plate
NXTBAS015E
Note: Attach the conveyor belt compatible with the optional thin panel conveyor with the raised
section of the belt on the clamp plate side.
Conveyor belt Belt guide
Raised section
Clamp plate
AIMBAS074E
9. Attach the clamp plate.

10.Attach the panel guides. When attaching the M6-2 extended conveyor sensor cover and
panel guide, they should be positioned as explained below.
• The sensor should not stick out from the cover when attaching the sensor cover.
01MEC-1181
• The panel guides (b) on the left and right should be attached based on the
position of the center guide (a). Make sure that the panel contacting surfaces (d)
of the guides on left and right sides are aligned with the center guide and that
the ends of the guides (c) are flush against each other. Confirm that panels can
be moved along the guide without getting caught.
a
c b a b c
b
d
01MEC-1200
11.Attach the panel retainer plate on the reference rail.
a. Set the panel retainer plate at the attachment position, insert the collars and then
tighten the bolts. Tighten the bolts to a torque of 1.0 Nm.
b. Confirm that the panel retainer plate opens and closes smoothly.
Note: If the movement is not smooth, check the collar and the tightening torque of the bolts.

12.Align the holes for the set screw in the hexagonal shafts with the hole in the shafts. Next,
fit the end of the hexagonal shafts over the shafts until the positioning line, then insert
the set screws.
Note: Align the hexagonal shafts with the shafts so that the set screws can be inserted.
Shaft hole Position line
Hexagonal shafts
Set screw
Shafts 01MEC-1098E

7.3 Replacing the Conveyor Belt Cleaner

When panel conveyance errors occur.
7.3.2 Procedure
Note: For M6-2 extended conveyor modules, remove the conveyor cover before performing this
work. Refer to section 8.25 "Removing the Conveyor Cover on M6-2 extended Conveyor
3. Replace the belt cleaner. When mounting the new belt cleaner, the end of the brushes
should push in about 1.0 mm from the edge of the conveyor belt.
<M3-2 module>
Bolt torque: 0.8 Nm Belt cleaner

(Single conveyor: 2 places)
(Double conveyor: 4 places) About 1.0 mm
(Triple conveyor: 6 places) 01MEC-0366Eb
㧨M6-2/M6-2SP module㧪
About 1.0 mm
Belt cleaner
(Double conveyor: 4 places)
(Single conveyor: 2 places)
Bolt torque: 0.8 Nm
About 1.0 mm
Bolt torque: 0.8 Nm
Belt cleaner
(M6-2 extended conveyor: 2 places) 01MEC-0367Ed
4. Turn on the main switch and turn on the module.
5. Push the module back to its original position. (Refer to section 5.1 "Pulling Out/

7.4 Replacing Panel Clamper Stopper Bolts

When panel clamp errors occur
7.4.2 Procedure
Note: For M6-2 extended conveyor modules, remove the conveyor cover before performing this
work. Refer to section 8.25 "Removing the Conveyor Cover on M6-2 extended Conveyor
3. Remove the panel clamper by removing the two bolts holding it in place. Be careful to
not lose the springs.
Stopper bolt
Panel clamper
Stopper
Bolt
Springs
Bolt 01MEC-0261E
Note: The reference rail for a M3-2 module is shown in the diagram above. The items for the
adjustable rail are removed the same way. In addition, there are 4 pins for a M3-2 module
and 6 for a M6-2(SP) module.

4. Replace the stopper bolts. Using a micrometer to measure the position, secure the new
stopper bolt in place at the specified distance from the top of the clamp plate.
Clamp plate
Bolt length
(L)
Stopper bolt
01MEC-0262E
Conveyor rail Bolt length in mm
Double conveyor Adjustable rail on lane 1 51.93 +/- 0.02
Reference rail on lane 1 52+/- 0.02

Reference and adjustable
rails on lane 2
Single conveyor Reference and adjustable 52 +/- 0.02

M6-2 extendedconveyor rails
Triple conveyor
5. Return the springs back to their original locations and reattach the clamper.
7. Push the module back to its original position. (Refer to section 5.1 "Pulling Out/

7.5 Replacing the Module Servo Amplifier Battery

7.5.1 Battery type
Drawing number H10212
Part name Battery
Type JZSP-BA01
Guarantee period *1 Three years (Temperature 40 degrees, no-operation) *2
*1: The guarantee period is started from the date of manufacture.
*2: The battery life may be shortened depending on the environment in which it is used.

Read the alarm that appears at the operation panel of the machine to determine the
appropriate procedure.
Alarm Details
Seek Number: 3A21 Battery low (Replace the battery as soon as possible using
the procedure in this section.)
Seek Number: 3A1F Backup data lost (Contact your Fuji Representative. The
origin of the servo motor must be reset when replacing the
battery.)
7.5.3 Procedure
CAUTION
Do not use a battery other than the specified battery.
Perform battery exchange with the power to the servo amp on. If
the battery is removed without the power being on, the backup data
is deleted and it will be necessary to reset the origin position of the
motor.
Properly dispose of the used battery according to local regulations.
1. Ensure that the module is turned on.
2. While holding the bottom rear cover for the module to ensure that it does not drop,
remove the four bolts for this cover with a plus driver and gently remove the cover.

Rear cover
Servo box
01MEC-0287E
3. While holding the fan, remove the four allen bolts for the fan and then let the fan hang
down. Do not disconnect the fan wiring.
4. To be able to provide power to the servo amplifier, begin production of a job and then
immediately stop production.
a. Push the START button to begin production.
b. As soon as the head begins to move, push CYCLE STOP. Power is now supplied to
the servo amp.
5. Gently move the cables in the back area of the module and locate the battery case for
the axis that needs the new battery.
6. Open the battery case and replace the battery.
Fan
Servo amplifier
battery case
Battery
NXTBAS007Ea
7. Reattach the fan.
8. Reattach the rear cover.

7.6 Replacing the Placing Head Battery

7.6.1 Battery type
Drawing number H1021H
Part name Battery
Type ER6VLY
Guarantee period *1 Four years (Temperature 40 degrees, no-operation) *2

Read the alarm that appears at the operation panel of the machine to determine the
appropriate procedure.
Alarm Details
Seek Number: 3A21 Battery low (Replace the battery as soon as possible using
the procedure in this section.)
Seek Number: 3A1F Backup data lost (Contact your Fuji Representative. The
origin of the servo motor must be reset when replacing the
battery.)
7.6.3 Procedure
Replace the battery with power being supplied to the placing head.
Remove the placing head from the module and then remove the battery cover. Attach the
placing head to the module. Use the cleaning command in manual mode and then replace
the battery with the power on.
As a countermeasure to static electricity, put on an electrostatic discharge wristband (with

a resistance of 1 megaohm or greater).
The connection points for the wrist strap (labeled EARTH BONDING POINT) are located
on the front and back of the base.
Note: For 2M-2 bases with a serial number of 189 or prior, and 4M-2 bases with a serial number
of 798 and prior, there is no wrist strap connection point on the back of the base. Use the
earth bracket inside the base instead.
CAUTION
Do not use a battery other than the specified battery.
Perform battery exchange with the power to the placing head on. If
the battery is removed without the power being on, the backup data
is deleted and it will be necessary to reset the origin position of the
motor.

CAUTION
If procedures are performed with static electric charge still present,

the electrical components on boards may be damaged.
1. Use the placing head exchange command in manual mode to remove the placing head
from the module. (Refer to section 5.8 "Removing/Attaching a Placing Head").
2. Remove the battery cover from the placing head (Refer to the diagram below). Do not
remove the battery yet.
3. With the battery cover removed, attach the placing head to the module. Return the
module. (Refer to section 5.8 "Removing/Attaching a Placing Head".)
4. To be able to provide power to the servo amplifier, begin production of a job and then
immediately stop production.
a. Push the START button to begin production.
b. As soon as the head begins to move, push CYCLE STOP. Power is now supplied to
the servo amp.
5. Use the cleaning command in manual mode to pull out the module. (Refer to the
Chapter 6 “Manual Mode Commands” in the NXT System Reference manual.)
6. With the placing head still attached to the module, remove the harness connector of the
old battery and then remove the battery itself. Attach the new battery to the placing head
and then connect the harness connector. (Refer to the diagram below.)
7. Return the module. (Refer to section 5.8 "Removing/Attaching a Placing Head".)
8. Push CANCEL and MANUAL. The monitor displays the main screen.
9. Using the method used in Step 1, remove the placing head and then attach the cover.

<H01 Head>
Battery
(Drawing No. : H1021H)
Cover
NXTPHD012Ea
<H02 Head>
Battery
01MEC-0191E

<H04(S) Head>
Battery
Cover
NXTPHD019Ea
<H08 Head>
Battery
Cover
NXTPHD008Eb

<H12(S) Head>
Battery
Cover
NXTPHD044E
<H12HS Head>
Battery
Cover
01MEC-0199E

<V12 Head>
Battery
01MEC-0731E
<H08M Head>
Battery
01MEC-1275E

7.7 Replacing the Module CPU Battery

A battery retains the data listed below when the main switch for the machine is turned off.
However, the following data is deleted when the main switch is turned off and the battery
has no power.
a. Module calibration data
• Matrix data, Feeder pallet levelness data, and auto-calibration values.
• Module camera calibration data (only when there is no parts camera in the
module)
b. Module configuration settings
c. Production information
• Current job name, Production information, Profiler information, and completed

sequences.
Perform the preparation procedures in order to ensure that the necessary data is available
and then proceed to change the battery.
7.7.1 Battery type
Drawing number H1019M
Part name Battery
Type CR2450
Guarantee period *1 Seven years (Temperature 40 degrees, no-operation) *2

Replace the battery upon the occurrence of a battery alarm.

7.7.3 Preparation procedures

Information cannot be acquired from the machine while there is a battery alarm occurring.
It is recommended to always keep a backup of calibration data and a record of module
configuration settings.
Note: Calibration data is stored on a disc that comes with the machine. Record the module
configuration settings. Refer to the Accessory Software section in the NXTII System
Reference for how to display the module configuration settings.
1. Confirm that you have the floppy disk containing the calibration data. Matrix data, feeder
pallet levelness data, and module camera calibration data.
2. Make sure that you have the record containing module configuration settings.
3. Eject all nozzles from the head by using the manual mode command.
4. Remove any panels that are in the module.
5. Set the nozzle jigs for the type of head in the module in the nozzle station. Set the same
number of nozzle jigs as there are holders on the head.
6. Have the replacement battery and an electrostatic discharge wrist strap (with an internal
resistance of 1 megaohm and above) prepared and ready to be used.

7.7.4 Procedure for replacing the battery
CAUTION
• Do not use a battery other than the specified battery.

• After replacing the battery, do not attempt to run the module. It is

possible for items in the module to collide because calibration data
for the module is not correct.
a. Start Accessory Software. Select the module to be pulled out and then click
[Calibration].
01MEC-0030E
b. Click [When the module CPU box battery has expired].
01MEC-0031E

c. Click [Unclamp module].
01MEC-0032E
d. Pull the module forward. (Refer to section 5.1 "Pulling Out/Returning a Module".)
3. Disconnect the cables from the CPU box. (Refer to section 8.6 "Replacing the Module
CPU Box" for details.)
4. As a countermeasure to static electricity, put on an electrostatic discharge wristband

(with a resistance of 1 megaohm or greater).The connection points for the wrist strap
(labeled EARTH BONDING POINT) are located on the front and back of the base..
CAUTION
It is possible that electrical items in the CPU box will be damaged if

the person performing the work is not grounded to prevent
electrostatic.
5. Remove the four screws which secure the CPU board.
01MEC-0341

6. Gently pull out the CPU board.
01MEC-0342
7. Replace the battery. Pull up on the front of the battery in order to remove it from the
battery holder. To set the new battery, set the rear of the battery in the battery holder
and then gently push down on the front of the battery.
Battery (CR2450)
01MEC-0343E
8. After replacing the battery, follow the procedures in reverse to return the CPU box back
in the module.

7.7.5 Making all settings after changing the battery

After changing the battery, the following items must be performed.
a. Register matrix data
b. Register feeder pallet levelness data
c. Register module camera calibration data (only when there is no parts camera in the
module)
d. Remeasure calibration data
e. Transmit the job
f. Specify module configuration settings
Procedure
All calibration data can be registered using Accessory Software.
1. Switch on the power to the machine. A battery error message is displayed.
Module <<Normal Mode>>

Fuji_VM Version V02.61
Boot Error occurred
Fuji Machine Mfg. Co., Ltd.
ErrorCode :0x8000EB19
Booting system
SubErrorCode :0x00000001
Battery Error(Module)
DIO Initialize Done
CUnet Initialize Done
Panel Initialize Done
IO Shell Initialize Done
:
:
:
01MEC-0029
Note: If a battery error message is not displayed and the machine starts normally, perform the
diagnostic command and wait for the following pictogram to appear.
01MEC-0037

2. Start Accessory Software. Select the module to be pulled out and then click [Calibration].
01MEC-0030E
3. Click [When the module CPU box battery has expired].
01MEC-0031E
4. Click [Register calibration data].
01MEC-0033E

5. Click [Start].
01MEC-0034E
After the machine restarts, check that the operation panel displays that the module can
receive calibration data.
01MEC-0035
6. Register the calibration data. Click [Browse] and then specify the storage location of
each calibration data file.
Note: If feeder pallet measurement has not been performed for a module, it is not necessary to
register the feeder pallet measurement data.
01MEC-0036Ea
7. After all of the necessary data has been specified, click [Start].
8. Switch the power off and then on.

9. Module configuration settings have been initialized. Use Accessory Software to reset
these settings.
10.Transmit a job from Fuji Flexa.
11.At the [Calibration] page in machine accessories for the module, click [Remeasure
Calibration Data] to remeasure the calibration data. (Refer to the Accessory Software
Online Manual.)
a. Switch on the power to the machine 30 minutes before performing the following
measurement to warm up the parts camera.
b. Set the jig nozzles in the nozzle station.
c. Push START to begin auto calibration.

7.8 Replacing the Base CPU battery

A battery retains the network data when the main switch for the machine is turned off.
However, this data is deleted when the main switch is turned off and the battery has no
power.
Perform the preparation procedures in order to ensure that the necessary data is available
and then proceed to change the battery.
7.8.1 Battery type
Drawing number H1019M
Part name Battery
Type CR2450
Guarantee period *1 Seven years (Temperature 40 degrees, no-operation) *2

Replace the battery upon the occurrence of a battery alarm.

Information cannot be acquired from the machine while there is a battery alarm occurring.
It is recommended to always keep a record of the network settings.
Note: The network settings can be checked using the information command in manual mode.
1. Use the manual mode Information command to display the network settings for the
machine. The following is a list of the network settings that is required.
• IP address • Subnet mask • Default gateway

• Other settings such as DNS server.
2. Have the replacement battery and an electrostatic discharge wrist strap (with an internal
resistance of 1 megaohm and above) prepared and ready to be used.

7.8.4 Procedure for replacing the battery
CAUTION
• Properly dispose of the used battery according to local

regulations.
1. Turn off the main switch and then remove the cables connected to the CPU box.
Refer to section 8.10 "Replacing the Base CPU Box" for details.

CAUTION
It is possible that electrical items in the CPU box will be damaged if

the person performing the work is not grounded to prevent
electrostatic.
3. Remove the four screws which secure the CPU board.
01MEC-0344

4. Gently pull out the CPU board.
01MEC-0345
5. Replace the battery. Pull up on the front of the battery in order to remove it from the
battery holder. It set the new battery, set the rear of the battery in the battery holder and
then gently push down on the front of the battery.
Battery (CR2450)
01MEC-0343E
6. After replacing the battery, follow the procedures in reverse to return the CPU box back
in the base.

7.8.5 Making all settings after changing the battery

After changing the battery, the network settings for the base must be specified.
Procedure
1. Turn on the main switch for the machine.
2. When the battery error message is displayed, press OK. The Network setting screen is
displayed.
Note: If a battery error message is not displayed and the network settings screen is displayed,
proceed to the next step.
If the [Network Settings] screen fails to display, even when the OK button is pushed, and a
[Module and base are unable to communicate.] error screen appears, use the
“TcpIpSetting” software tool to make the network settings. (Refer to the “TcpIpSetting”
section in chapter 8 “NXT-2 Software Tools” of the NXT II System Reference for details.)
Module <<Normal Mode>>

Fuji_VM Version V02.61
Boot Error occurred
Fuji Machine Mfg. Co., Ltd.
ErrorCode :0x8000EB0D
Booting system ...
SubErrorCode :0x00000000
Battery Error(Base)
DIO Initialize ... Done
CUnet Initialize ... Done
Panel Initialize ... Done
IO Shell Initialize Done
:
:
:
01MEC-0027
3. At the Network settings screen, set the IP address, subnet mask and default gateway.
01MEC-0028
4. Switch the power off and then on.
5. If you want to make further settings, such as DNS server or host name, use the
NetworkSetting Tool. Refer to the “NetworkSetting” section in chapter 8 “NXT-2
Software Tools” of the NXT II System Reference for details.

7.9 Replacing the Nozzle Station Fluorescent

Stickers
7.9.1 Replacement frequency
Replace if errors occur when the machine tries to detect the presence of a nozzle.
7.9.2 Procedure
1. Remove the nozzle station from the nozzle changer. (Refer to section 5.9 "Removing/
Attaching a Nozzle Station" for details.)
2. Remove all nozzles from the nozzle station.
3. Remove the fluorescent stickers and affix new stickers.
<H01/H02 type>
Fluorescent stickers Fluorescent stickers
Fluorescent
stickers
NXTNZC010c
<H04(S) type>
Fluorescent stickers
NXTNZC012Ea
<H08M type>
01NST-1084E

<H08/H12(S)/H12HS/V12 type>
1. When the station type brush unit (option) is attached, remove the bolts that attach it from
the bottom of the nozzle station and then remove the station type brush unit items.
Station type brush unit

Bolt
Nozzle station
01MEC-0860E
2. Remove the installation bolts and then remove the two blocks.
Bolt
Blocks
01MEC-0861E
3. Remove the two plates and then change the fluorescent stickers.
Plate
01MEC-0862E
4. Assemble the nozzle station in reverse order.

7.10 Replacing the Stickers on the V12 Head

When stickers appear dirty.
7.10.1 Type
Use the stickers below.
Drawin number Qty.
Sticker PS0356* 2
7.10.2 Replacement procedures

for details.)
2. Remove the old stickers from the head.
Stickers
01NST-0880E
3. Affix the new stickers on the head. Fit the edges of the stickers flush to the bottom
surface of the head.
Stickers
Fit the edges of the stickers

flush to the bottom surface.
01NST-0881E
Note: Ensure that the stickers have no air bubbles or foreign objects caught under the stickers.
When applying the stickers, make sure to wipe any grease from your fingers as well as the
application surface. If the application surface or the sticker has any grease or dirt on it, it
will peel off easily.

7.11 Replacing a Fuse on a Board inside a Module

A fuse check LED on the board turns off when a fuse on that board inside the module is
burnt out. Ensure that the fuse is burnt out before replacing it.

a resistance of 1 megaohm or greater).The connection points for the wrist strap (labeled
EARTH BONDING POINT) are located on the front and back of the base..
CAUTION

7.11.1 Module remote I/O boards

1. Remove the front cover that covers the remote I/O board.
Remote I/O board
Cover 01MEC-0264E
2. Put on the electrostatic discharge wrist strap.
3. Locate the burnt out fuse.
CAUTION
Be sure to turn off the machine power before replacing any fuses.
Replace fuses with fuses of the same capacity.
4. Turn off the power to the machine by turning the main switch off.

5. Remove the burnt out fuse (F1 or F3) from the remote I/O board and replace it.
Remote I/O Board LED1 LED3 Remote I/O Board LED1 LED3
When F1 is burnt out: LED1 turns off

F1 F3 F1 F3
When F3 is burnt out: LED3 turns off NXTBAS072Ja

7.11.2 Module interface board and module connector board

(inside the module control box)
Cover
Module control box
01MEC-0265E
CAUTION
5. Remove any burnt out fuses (F1 or F2) from the module interface board and replace
them.
6. Remove any burnt out fuses (F1, F2, F3 or F4) from the module connecting board and
replace them. Remove the holder cover when removing the fuses F1, F3, or F4.
Module connecting board

When F4 is burnt out: LED6 turns off LED3
F1 LED4
When F1 is burnt out: PL8 turns off LED5
When F2 is burnt out: PL9 turns off F2
LED6
PL9 PL8 F3
F1
F4
F2
Module interface board NXTBAS074E

7.12 Replacing a Fuse on the Base Remote I/O

Boards
The position of the remote I/O boards in the base is shown in the figure below. When a
fuse on the I/O board burns out, a fuse check LED for that fuse turns off. Confirm whether
or not a fuse is burnt out, before replacing the fuse. When replacing a fuse, the module
over the remote I/O board needs to be pulled forward.

EARTH BONDING POINT) are located on the front and back of the base.
CAUTION

Remote I/O board 1 (For module 1, 2)
Remote I/O board 2 (For module 3, 4)
2M-2 base 4M-2 base

Remote I/O board 1 Remote I/O board 1
Remote I/O board 2
01MEC-0266Ea
WARNING
There is a limit to the number of the modules that can be pulled out
at safely at the same time. (Maximum: Two M3-2 modules on a 4M-
2 base). If the maximum is exceeded, the entire machine may fall

7.12.1 Remote I/O board 1 <4M-2 base>

1. Remove the cover above the remote I/O board.
Base remote I/O board 1
Cover
01MEC-0267E
CAUTION
Remote I/O board 1

LED1
LED3
F1
When F1 is burnt out, LED1 turns off F3

When F3 is burnt out, LED3 turns off NXTBAS076E


Base remote I/O board 2
Cover
01MEC-0268E
CAUTION
Remote I/O board 2

LED1
LED3
When F1 is burnt out: LED 1 turns off F1

When F3 is burnt out: LED 3 turns off
F3
NXTBAS078E


Base remote I/O board Cover
01MEC-0269E
CAUTION
Remote I/O board 1

LED1
LED3
F1
When F1 is burnt out, LED1 turns off F3

When F3 is burnt out, LED3 turns off NXTBAS076E

7.13 Replacing a Fuse on a Base Control Interface

Board
The positions of the base control boxes are shown in the figure below. When a fuse on an
interface board in the base control box is burnt out, a fuse check LED for the fuse turns off.
Confirm whether or not the fuse is burnt out, before replacing the fuse. When replacing a
fuse, the module above the base control box needs to be pulled forward.

CAUTION

<2M-2 base> <4M-2 base>

Base control board 1 Base control board 1
Base control board 2
01MEC-0270Ea
WARNING
There is a limit to the number of the modules that can be pulled out
at safely at the same time. (Maximum: Two M3-2 modules on a 4M-
2 base). If the maximum is exceeded, the entire machine may fall

7.13.1 Base control Interface board 1 <4M-2 Base>

1. Remove the cover above the base control box 1.
Base control box 1

Cover
01MEC-271E
3. Check which fuse on the interface board has blown and then turn off the main power to
the machine.
CAUTION
4. Remove and replace the fuses (F1, F2, F3 and F4) on the interface board inside the
base control box. The fuses (M1F1, M1F2) in the base control box are held inside a
holder. Use a Phillips screwdriver to remove the holders and then replace the fuses.
F4 F3 F2 F1
M1F1
M1F2
PL64 PL63 PL62 PL0
F4 F3 F2 F1
When F1 is burnt out: PL0 turns off

Base control box
NXTBAS083Ec
Interface board

7.13.2 Base control Interface board 2 <4M-2 Base>

1. Remove the cover above the base control box 2.
Base control box 2
Cover
01MEC-0272E
the machine.
CAUTION
base control box. The fuses (F1) in the base control box are held inside a holder. Use
a Phillips screwdriver to remove the holders and then replace the fuses.
F4 F3 F2 F1
F1
PL64 PL63 PL62 PL0
F4 F3 F2 F1
When F1 is burnt out, PL0 turns off

When F4 is burnt out, PL64 turns off Base control box
NXTBAS088Ec
Interface board

7.13.3 Base control Interface board 1 <2M-2 base>

1. Remove the cover above the base control interface box.
Base control box 1

Cover
01MEC-0273E
the machine.
WARNING
base control box. The fuses (M1F1, M1F2) in the base control box are held inside a
holder. Use a Phillips screwdriver to remove the holders and then replace the fuses.
F4 F3 F2 F1
M1F1
M1F2
PL64 PL63 PL62 PL0
F4 F3 F2 F1

Base control box
NXTBAS083Ec
Interface board

7.14 Replacing the Thermofuse on the Vacuum Pump

7.14.1 Procedure
WARNING
Be sure to turn off the power to the machine before performing any
replacement work.
2. Remove the cover above the vacuum pump.
<2M-2 base> Thermofuse Cover
<4M-2 base>
Thermofuse
01MEC-0584E
3. Push down on the two levers on the thermal fuse side of the thermal fuse terminal box.
With these two levers being pushed down, remove the thermal fuse.
Fuse
Terminal
box
Lever
01MEC-0303E
4. When putting in the new fuse, push down on the two levers and insert the new thermal
fuse. Return the levers back up to lock the thermal fuse in place.
CAUTION

7.15 Replacing the Tray Unit-L Servo Controller

Battery
The internal memory of the MP2300 servo controller stores data required for operation of
the tray unit-L and a battery inside the controller helps maintain this data when power is not
supplied to the servo controller. To ensure the stable operation of the tray unit-L, replace
this battery every two years.
7.15.1 Battery type
Part name Battery
Type JZSP-BA01
Guarantee period 3 years with the machine power on for 8 hours

(estimated) per day
7.15.2 Procedure
CAUTION
• Replace the battery with the machine power on. It will be

necessary to reset the motor origin if the battery is replaced with
the machine power turned off.
• Properly dispose the used battery according to the local

regulations.
1. Turn on the power to the module and then attach the tray unit-L.
2. Loosen the screws for the control box cover, and then open the control box.
Control box NXTMTU022E

3. Ensure that the controller [RDY] LED green light is lit.
4. Gently remove the battery cover from the front of the controller.
Controller
Battery cover
NXTMTU023E
5. Detach the battery connector and remove the old battery. Attach and insert the new
battery.
RDY
ALM
TX
Battery
Maker: Yasukawa Electric
Model: JZSP-BA01
NXTMTU027E
6. Ensure that the [BAT] LED turns off after the new battery has been attached.
7. Reattach the battery cover.
8. Close and retighten the control box cover.

7.16 Replacing the Tray Unit-L Servo Axis Amplifier

Battery
Replace upon the occurrence of a battery alarm.
CAUTION


regulations.
7.16.2 Procedure
2. Open the battery case and replace the battery for the axis to be changed (TY- or TZ-
axis).
Battery
Model: JZSP-BA01
NXTMTU028E
3. Reattach the tray unit cover.

7.17 Replacing the Tray Unit-L Interface Board Fuse

A fuse check LED on the board turns off when a fuse on that board inside the tray unit-L is
burnt out. Ensure that the fuse is burnt out before replacing it.
7.17.1 Procedure
2. Loosen the screws for the control box cover, and then open the control box.
Tray unit-L interface board NXTMTU024E
CAUTION
5. Remove any burnt out fuses (34F1, 34F2, or 34F3) from the interface board and replace
them.
Fuse (34F3)
Type : DM05
Fuse (34F2)
Type : DM20
Fuse (34F1)
Type : DM20
NXTMTU025Ea

7.18 Replacing the Sponge Pad on the Tray Unit-L

Remover
A sponge pad is affixed to the bottom of the tray remover to preserve the vacuum. By
changing the sponge pad at the specified interval, it is possible to maintain stable pickup of
trays.
Note: These procedures are not necessary for tray units-L that do not have the tray remover.

Every year
7.18.2 Replacing procedure

1. Remove the tray unit-L from the machine. Refer to section 5.5 "Inserting/Removing a
Tray Unit-L" for details on removing a tray unit-L.
2. Push the lever and pull up on the remover.
Remover
Lever
NXTMTU106E
3. Gently peel off the old sponge pad from the bottom of the remover.
Note: Gently peel off the sponge pad to prevent changing the shape of the plate. If the shape of
the plate is changed, it may not be possible to maintain stable pickup of empty trays.
Replace the plate if the old sponge pad cannot be completely removed or if the plate
becomes bent.
4. Peel off the cover from the adhesive paper on the sponge pad and affix the sponge pad
to the bottom of the plate.
Plate
(PB6969*)
Sponge pad
(PJ1087*)
NXTMTU107E
Note: Be sure that the sponge pad shape is attached so that it matches the plate shape.

7.19 Replacing the Tray Unit-LT Servo Controller

Battery
the tray unit-LT and a battery inside the controller helps maintain this data when power is
not supplied to the servo controller. To ensure the stable operation of the tray unit-LT,
replace this battery every two years.
7.19.1 Battery type
Part name Battery
Type JZSP-BA01

(estimated) per day
7.19.2 Procedure
CAUTION


regulations.
1. Turn on the power to the module and then attach the tray unit-LT.
2. Remove the screws and then remove the front lower cover. (Refer to section 8.22
"Removing Tray Unit-LT Covers".)
Cover
01MEC-0585Ea

3. Ensure that the controller [RDY] LED green light is lite.
Controller
MP2300
Battery cover 01MEC-0586E
battery.
RDY
ALM
TX
Battery
Model: JZSP-BA01
NXTMTU027E

7.20 Replacing the Tray Unit-LT Servo Axis Amplifier

Battery
CAUTION


regulations.
7.20.2 Procedure
3. Open each of the battery cases in the control box and replace all the batteries with new
ones.
Battery
Cover Model: JZSP-BA01
01MEC-0587Ea
4. Reattach the tray unit cover.

7.21 Replacing the Tray Unit-LT Interface Board Fuse

A fuse check LED on the board turns off when a fuse on that board inside the tray unit-LT
is burnt out. Ensure that the fuse is burnt out before replacing it.
7.21.1 Procedure
Interface board
01MEC-0560E
CAUTION
5. Remove any burnt out fuses (T1F1 - 9) from the Interface board and replace them.
Fuse (TIF2~4) Fuse (TIF9)

Type : DM10 Type : DM10
Fuse (TIF1) Fuse (TIF5~8)

Type : DM16 Type : DM10 01MEC-0588E

7.22 Replacing the Tray Unit-LTC Servo Controller

Battery
the tray unit-LTC and a battery inside the controller helps maintain this data when power is
not supplied to the servo controller. To ensure the stable operation of the tray unit-LTC,
replace this battery every two years.
7.22.1 Battery type
Part name Battery
Type JZSP-BA01

(estimated) per day
7.22.2 Procedure
CAUTION


regulations.
1. Turn on the power to the module and then attach the tray unit-LTC.
2. Remove the waste tape box from the tray unit-LTC.
"Removing Tray Unit-LTC Covers".)
Cover
Waste tape box 01MEC-0887E

4. Ensure that the controller [RDY] LED green light is lite.
Controller
MP2300
Battery cover 01MEC-0589E
battery.
RDY
ALM
TX
Battery
Model: JZSP-BA01
NXTMTU027E

7.23 Replacing the Tray Unit-LTC Servo Axis

Amplifier Battery
CAUTION


regulations.
7.23.2 Procedure
1. Remove the waste tape processing duct (duct secured inside base) from inside the
base.

(fixed base part)
01MEC-0883E
2. Remove the screws and then remove the cover on the left lower section of the tray unit-
LTC. (Refer to section 8.24 "Removing Tray Unit-LTC Covers".)
01MEC-0891a

3. Turn on the power to the module and then attach the tray unit-LTC.
4. Remove the waste tape box from the tray unit-LTC.
"Removing Tray Unit-LTC Covers".)
6. Open each battery case beneath the cover and replace with new batteries. The TZ-axis
battery should be replaced by inserting your hand between the tray unit-LTC and module
or by inserting your hand into the front lower opening.
Battery
Model: JZSP-BA01
Cover TZ2-axis battery

01MEC-0892E
TY-axis battery TZ1-axis battery
7. Remove the tray unit-LTC from the module.
8. Attach the tray unit-LTC covers.

7.24 Replacing the Tray Unit-LTC Interface Board

Fuse
Replace fuses on the tray unit-LTC interface board after removing the unit from the module.
7.24.1 Procedure
1. Remove the screws and then remove the cover on the left lower section of the tray unit-
LTC.
Cover
Interface board
01MEC-0893Eb
2. Remove fuses (T1F1 to 9) from the interface board and then check each one visually to
see if they have burnt out. Return any fuses that are in good condition to their original
location.
Fuse (TIF2~4) Fuse (TIF9)

Type : DM10 Type : DM10
Fuse (TIF1) Fuse (TIF5~8)

Type : DM16 Type : DM10 01MEC-0588E
3. Replace any burnt out fuses with new ones.
CAUTION
4. Attach the cover.

7.25 Replacing the Tray Unit-M Interface Board Fuses

7.25.1 Procedure
Before performing these procedures, first remove the tray unit-M from the machine.
1. Loosen the screws and remove the cover.
Cover
Interface board
NXTMTU071E
2. Remove any burnt out fuses (M1F1, M1F2, M1F3) from the interface board and replace
them.
M1F3
M1F2
M1F1
Fuse (M1F3)
Type: DM32CDL (3.2A)
Fuse (M1F2) Fuse (M1F1)
Type: DM32CDL (3.2A) Type: DM20CDL (2A) NXTMTU072Ea
3. Reattach the side cover.

7.26 Replacing the Vacuum Pump's Inlet Valves/

Outlet Valves & Gaskets (for a 2M-2 base vacuum
pump)
The inlet valves, outlet valves and gaskets are consumable items, and should be replaced
by the new items provided in the vacuum pump maintenance kit.

Consumables should be replaced after every 10,000 hours of operation.
DOP-300SA Inlet valve rubber separator 4

Maintenance Kit
Inlet & outlet valves 12
Drawing number:
H5448D Backup outlet valves 4
Cup packing 4
Gaskets 4
Backup inlet valves 4
Connecting tubes 1
Tools Hex wrench set
Torque wrench 5mm hex socket-

head wrench
(torque settable to
8N•m)
Plus driver No.2
Other Cleaning solvent (Industrial Ethyl alcohol) For wiping clean
Paper wipe For wiping clean
Dust mask, gloves, oil-based marker pen -

7.26.3 Replacement procedure

Removing the vacuum pump
1. After pulling the base's right-most module out, turn the main switch off.
WARNING
Be sure that the machine's main power has been turned off before
attempting to remove the vacuum pump.
2. First, remove the 2 covers. Remove the 2 screws which secure the rail, then bend the
rail so that it will not interfere with the vacuum pump removal process.
Rail
NXTBAS064E
3. Remove the vacuum pump's terminal box cover, then disconnect the terminal block
power wiring (U: red, V: white, W: black, and ground wire).
U V W
NXTBAS173

4. Remove the thermal fuse bracket, then remove the vacuum pipe.
Thermal fuse bracket
Vacuum pipe
NXTBAS174E
5. Remove the 4 bolts that secure the vacuum pump, then lift the pump off the machine
base.
WARNING
Pump handling requires two or more personnel. To avoid back

injuries, etc., avoid strained postures when lifting the pump.
Mounting bolt
Handles
NXTBAS175E
WARNING
After stopping pump operation, allow the pump 30 minutes or more

to cool before beginning the replacement procedure. Failure to do
this could result in burns, as the pump interior is extremely hot
immediately after operation is stopped.

Disassembling the vacuum pump
WARNING
To prevent the ingestion of microscopic particles from worn

components, always wear a dust mask and gloves before
performing the following procedure.
1. Use a hex wrench to loosen the hex socket head bolt (M6 x L16) that secures the handle,
then remove the handle and plate.
Handle fixing bolts
Handle
Plate
NXTBAS221E
2. Stand the pump upright so that the head to be replaced can be removed vertically.
3. Remove the head cover as follows.
a. Use a hex wrench to loosen the 4 hex socket head bolts (M6 x L30) that secure the
head cover, then remove the bolts.
NXTBAS153

b. Pull the fitting joint forward with both hands, then remove the connecting tube and
the head cover. Pull the left and right fitting joints in an alternating and gradual
manner until they are removed.
NXTBAS154
4. Remove the cylinder as follows.
a. Use a permanent marker to mark the cylinder and casing before removing the
cylinder.
NXTBAS155
b. With gloves on, slowly turn the fan. Do not attempt this without gloves.
NXTBAS156

c. Lift the cylinder upward to remove it.
NXTBAS157
5. Remove the holder plate and the packing as follows.
a. Mark the holder plate at the casing's mark position.
NXTBAS158
b. Loosen the 4 countersunk screws (M5 x L12) in the holder plate. With a gloved hand,
hold the connecting rod in place when loosening the countersunk screws.
Holder plate
NXTBAS159E

c. Remove the holder plate.
Holder plate
NXTBAS160E
d. Remove the cup packing.
Cup packing
NXTBAS161E
e. Remove the inlet valve's rubber separator from the holder plate.
f. Wipe the holder plate clean using a cloth or paper wipe dampened with industrial
alcohol.

6. Remove the cylinder's small components as follows.
1. Inlet valve
2. Backup inlet valve
3. Inlet valve holder plate
4. Outlet valve holder plate
5. Backup outlet valve
6. Outlet valve
1 2 3 4 5 6
NXTBAS164E
a. Loosen the roundhead screw (M3 x L5) that secures the outlet valve holder plate.
Outlet valve holder plate
NXTBAS162E
b. Remove the outlet valve holder plate, the backup outlet valve, and the outlet valve.
c. Loosen the roundhead screw (M3 x L5) that secures the inlet valve holder plate.
Inlet valve holder plate NXTBAS163E
d. Remove the inlet valve holder plate and the inlet valve.
e. Wipe the entire cylinder clean using a cloth or paper wipe dampened with industrial
alcohol. Pay particular attention to cleaning the inlet/outlet valve mounting faces,
and the cup packing's vibrating face. When cleaning, use care to avoid wiping off the
mark.

Reassembling the vacuum pump

1. Set the new cup packing on the connecting rod with the cup's flange facing downward.
Cup packing
NXTBAS165E
2. Insert a new inlet valve rubber separator into the groove on the rear side of the holder
plate.
3. Align the holder plate mark, then tighten the 4 countersunk screws (M5 x L12).
Inlet valve rubber separator
Markings
NXTBAS166E

4. Mount the inlet valves on the cylinder as follows.
a. Place the 2 inlet valves on the cylinder, then place the inlet valve backup and inlet
valve holder plate on top of them.
b. While verifying that the inlet valve is not making contact with the groove's inner
perimeter, tighten the roundhead screw (M3 X L5) that secure the inlet valve holder
plate.
Note: Be sure that the orientation of the inlet valve holder plate is correct. The top of the inlet
valve holder plate must be set facing upward and the shorter direction (distance from center
of hole to end face) is facing the rounded side of the inlet valves.
Inlet valve holder plate

Upper side
Valve's rounded
side
Lower side (valve side)
NXTBAS167E
5. Mount the outlet valve on the cylinder as follows.
a. Place the outlet valve on the cylinder, then place the outlet valve backup and outlet
valve holder plate on top of it.
b. While verifying that the outlet valve is not making contact with the groove's inner
perimeter, tighten the roundhead screw (M3 x L5) that secures the outlet valve holder
plate.
NXTBAS168E
Outlet valve holder plate

6. Align the cylinder with the mark, then insert it into the cup packing.
Markings
NXTBAS169E
7. Replace the head cover gasket as follows.
a. Remove the old gasket from the head cover.
b. Clean the head cover by wiping it with industrial alcohol, then dry it with compressed
air.
c. Set the new gasket on the head cover.
Gasket
NXTBAS170E

8. Mount the head cover on the casing as follows.
a. Insert the head cover joint into the connecting tube and align the casing screw holes
with those in the head cover.
b. Tighten the 4 hex socket head bolts (M6 x L30) to a torque of 8N•m. (If replacing the
connecting tube, be sure that the tube is cut to the same pump length.)
Head cover
NXTBAS171E
9. Connect the connecting tube. (If replacing the connecting tube, be sure that the tube is
cut to the same pump length.)
Connecting
tube
NXTBAS172E
10.Lay the pump on its side, then mount the panel and handle.
Mounting the vacuum pump

1. Follow the removal procedure in reverse to mount the vacuum pump in the machine
base.
WARNING


7.27 Replacing the Vacuum Pump Valves and

Packings (for the 4M-2 pump (DOP-420SA))
The valves and gaskets are consumable items, and should be replaced by the new items
provided in the vacuum pump maintenance kit.

Consumables should be replaced after every 10,000 hours of operation.

Note: The maintenance kit used for the vacuum pump that was initially released with the NXT-2
is different than that for the current vacuum pump. Check the top part of the vacuum pump
to identify the type and then use the appropriate maintenance kit.
Initial vacuum pump Current vacuum pump

Maintenance kit drawing number: H62892 Maintenance kit drawing number: H5448E
01MEC-1270E
Maintenance kit
4 3 5
1 2 7 6 01MEC-0346a
No. Part names Qty.
1 Cup packings 4
2 Valves 8
3 S-100 O-rings 4
4 AS568-117 O-rings 2
5 Gaskets 2
6 Filters 4
7 Mufflers 2

Tools
01MEC-0347a
Name of tool Notes
Allen T-wrench 5 mm
Allen T-wrench 6 mm
Allen T-wrench 3 mm
Torque wrench 5 mm
Torque wrench 6 mm
Torque wrench 3 mm
Phillips screwdriver No. 2
Torque driver No. 2
Compressor For blowing air
Silicon grease -
Loctite 242 For fixing screws
Cloth For wiping clean
Industrial ethanol For wiping clean
Dust mask -
Gloves -
Safety goggles -

7.27.3 Replacement procedure

Removing the vacuum pump
1. After pulling the base's right-most module out, turn the main switch off.
WARNING
Be sure that the machine's main power has been turned off before
attempting to remove the vacuum pump.
2. Wait until the surface of the vacuum pump cools to room temperature.
WARNING
After stopping pump operation, allow the pump 30 minutes or more

to cool before beginning the replacement procedure. Failure to do
this could result in burns, as the pump interior is extremely hot
immediately after operation is stopped.
3. First, remove the 2 covers. Remove the 2 screws which secure the rail, then bend the
rail so that it will not interfere with the vacuum pump removal process.
Rail
NXTBAS064E
4. Remove the vacuum pump's terminal box cover, then disconnect the terminal block
power wiring (U: red, V: white, W: black, and ground wire).
U V W
30MEC-0154

5. Wrap the disconnected wires with something such as elastic tape to prevent from
touching metallic parts.
6. Disconnect the hoses from the vacuum pump.
7. Remove the four bolts that secure the vacuum pump. Grip the handles and lift the pump
off the machine base.
WARNING
Handle
Terminal box
01MEC-0962E
Disassembling the vacuum pump
WARNING
To prevent the ingestion of microscopic particles from worn
components, always wear a dust mask and gloves before
performing the following procedure.
1. Spread the clean cloth over the workbench and place the pump with the opening part
upward.
WARNING
The pump is heavy. Be careful to not pinch fingers or other body

parts when working on the pump. Failure to do so could result in
injury.

2. Remove the nuts and then remove the plates and rubber cushions.
Plate
Rubber cushion
Muffler
01MEC-0958E
3. Remove the two sets of mufflers from the vacuum pump.
4. Remove the cover bolts and take off the casing cover.
01MEC-0349
5. Remove the six pump head bolts, and then remove the pump head assembly.
Caution: Gently pull off the pump head assembly.
Pump head assembly
01MEC-0350Eb

6. Remove the three cover screws, and then remove the pump head cover.
Pump head cover
01MEC-0351Ea
7. Remove the gasket and two filters from the pump head.
Gasket Filters
01MEC-0352Ea
8. Replace the exhaust valves in the head by following the sub steps below. (2 locations)
a. Remove the screws with a Phillips screwdriver, and then remove the valve and the
valve retainer.
b. Clean the valve mounting surfaces and the valve retainer by wiping with a cloth with
industrial ethyl alcohol and then blowing with air.
Caution: Wear protective goggles when blowing with air.
c. Set new valve and return the removed valve retainer in the head.
Caution: Ensure that the valve is below the valve retainer.
d. Apply a small amount of Loctite 242 to the mounting screws and then lightly tighten
the screws.

e. Tighten the screw with a torque driver to 2.7 Nm.
Valve retainer
Valve
01MEC-0353Ea
9. Turn over the pump head and then exchange the air valves (2 locations) for the inlet
valve using the same method.
Caution: Ensure that the valve is below the valve retainer.
Valve retainer
Valve
01MEC-0354Ea
10.Replace the O-ring (S-100) as follows. (2 locations)
a. Remove the four mounting screws, and then take out the cylinder.
Cylinder
O-ring
01MEC-0355Ea
b. Clean the removed cylinder by wiping with a cloth with industrial ethyl alcohol and
then blowing with air.

c. Replace the O-ring with new one.
d. Apply a thin layer of silicone grease all around the O-ring.
e. Insert the cylinder into the pump head while aligning the bolt holes with those on the
head and lightly tighten the bolts.
Cylinder
01MEC-0357Ea
f. Tighten the screws with the torque driver to 4 Nm.
11.Turn over the pump head and attach a new gasket and two new filters.
Gasket Filters
01MEC-0352Ea
12.Tighten the head cover mounting screws.

13.Replace the cup packing. (2 locations)
a. Loosen the screw with a 5 mm Allen wrench, and then remove the retainer plate and
cup packing.
b. Clean the removed retainer plate by wiping with a cloth with industrial ethyl alcohol
and then blowing with air.
c. Set new cup packing and reconnect the removed plate to the connecting rod.
d. Apply a small amount of Loctite 242 to the mounting screw. Then temporarily tighten
the screw with an Allen wrench.
e. Tighten the screw with the torque wrench to 10 Nm.
Connecting rod
Cup packing
Retainer plate
01MEC-0358Ea
14.Replace the O-ring (AS568-117) with a new one.
01MEC-0359
Note: The O-ring might be found adhered to the backside of the head.

15.Reassemble the pump head.
a. While holding the connecting rod with one hand, align the cylinder and pump head
and then slowly insert the head cylinder into the casing.
b. Temporarily tighten the six mounting bolts.
c. Tighten the bolts with a torque wrench to 16 Nm in the order shown in the figure
below.
6
1 4
9 2 8
5 3
7
01MEC-0360a
16.As for the other pump head, use the same procedures to remove and replace the parts.
17.Ensure that the pump shaft rotates smoothly when turned by hand through the pump
opening.
18.Attach the cover to the casing and temporarily tighten it with the bolts.
19.Tighten the mounting bolts with a torque wrench to 10 Nm.
20.Attach a new muffler.
21.Attach the anti-vibration rubber pads to the bottom of the pump.
Mounting the vacuum pump

1. Follow the removal procedure in reverse to mount the vacuum pump in the machine
base.
WARNING

2. Follow the removal steps in reverse order to reassemble the parts camera unit.

7.28 Replacing the Movable Blades on Waste Tape

Processing Units
There are two types of waste tape processing units, type A and type B. The unit that the
machine has depends on the date of manufacture. Look at the unit identification number
on the barcode label attached to the top or side of the unit to determine the type of waste
tape processing unit.
Note: On A type units, the barcode label is on the top. On B type units, the barcode label is on
the top or the side, depending on the date of manufacture.
• A type units: TCM3A (for M3-2 module), TCM6A (for M6-2(SP) module)
• B type units: TCM3B (for M3-2 module), TCM6B (for M6-2(SP) module)
Barcode label For M3-2 module

(attached to the top)
Barcode label
(attached to the side)
For M6-2 module

For M6-2SP module
01MEC-0981Eb
CAUTION
Do not insert fingers or other body parts into the opening of the
waste tape processing unit. Doing so may result in injury.
Apart from when measuring the gaps between the blades, use an
item such as masking tape to cover the moving and fixed blades.
This is to prevent injury, because the blades are extremely sharp.

Use the following procedure to replace blades that are chipped or that no longer cut well.


A type
Jig Blade adjustment jig AA3HT**

(Option)
01MEC-0592
Materials Putty
Epoxy resin Drawing number:
S4014B
Hardening agent
Spatula 01MEC-0602E
Tools Metric Allen wrench set
Flat head screwdriver
Hammer (copper or rubber)
Other Scales
Feeler gauges (to measure gap widths) Thickness : 0.02mm, 0.06mm
Gloves (rubber or cloth)
Degreaser
B type
Jig Blade adjustment jig AA3HT**

(Option)
01MEC-0592
Shim 0.02mm 2MGKPK0021
Tools Metric Allen wrench set
Metric spanner set
Phillips screwdriver
Other Feeler gauges (to measure gap widths)

Thickness : 0.02mm, 0.06mm, 0.10mm

7.28.3 Procedure for A type

Removing the movable blades
1. Remove the waste tape processing unit from the machine. Refer to section section 8.4
"Replacing the Waste Tape Processing Unit" for details.
2. Remove the bolts for the cover and then remove the cover.
Cover
01MEC-0594E
3. Remove the bolts for the slide cover and then remove the slide cover.
Slide cover
01MEC-0595E
4. Remove all the putty from the movable blades and slide cover. Use an item with a flat
tip such as a screwdriver to remove the putty. Place it against the putty and then tap it
with a hammer to remove the putty.
Putty
01MEC-0596E
5. After removing the putty, clean the surface.
6. Remove the bolts for the retainer of the blade to be removed and then remove the
retainer.
Movable blade retainer
01MEC-0597E

01MEC-0598E
8. Remove the bolts for the movable blade and then remove the blade.
Caution: The blade may fall when removed. Place a soft item under the unit to absorb the impact.
Item to absorb impact
01MEC-0599E
There is putty in the gap of the surface where the movable blade is attached. If the blade
cannot be removed just by removing the bolts, release the lock by pushing in the location
shown below and move the blade to the forward position. Use a copper or rubber hammer
to gently tap the blade in the area shown below to remove it.
Area to tap with a hammer

01MEC-0600E
9. Clean the surface where the blade was attached.
10.Perform the same procedure for all the blades that are to be replaced.

Attaching and adjusting new blades

11.Attach the new movable blade in a position offset from the fixed blade (so it pushes
down, as shown in the figure below). Tighten the bolts so that the blade can still be
moved when hit gently with a hammer.
Pressing down 01MEC-0593E
12.Release the lock and move the blade to the forward position.
13.Adjust the gap between the movable and fixed blades by using a copper or rubber
hammer to gently tap the movable blade. Insert feeler gauges while tapping with the
hammer until the feeler gauge with a thickness of 0.02 mm can be inserted, and the
feeler gauge with a thickness of 0.06 mm cannot be inserted. Confirm the gap in two
positions on each blade.
Feeler gauge Measurement positions
Fixed blade Movable blade

01MEC-0601E
14.Tighten the bolts properly and confirm that the gap is correct. If the gap is incorrect,
perform the adjustment procedure again from step 11.
15.Attach the movable blade retainer.

Applying putty
CAUTION
Wear protective items such as glasses, a mask, and rubber gloves

when handling the putty.
16.Put the epoxy resin and the hardening agent in a container for putty and mix them so
that the mixture is even. The ratio of epoxy resin to hardening agent should be 10:1.
• Approximate amounts
For one M3-2 module waste tape processing unit:
Epoxy resin = 9 g, Hardening agent = 0.9 g
For one M6-2(SP) module waste tape processing unit:
Epoxy resin = 18 g, Hardening agent = 1.8 g
Caution: After mixing the two substances together, use within 60 minutes.
Measure the amounts with scales before mixing the substances (for 10 parts epoxy resin,
make sure to use between 0.9 and 1.1 parts hardening agent).
Epoxy resin Drawing number:

S4014B
Hardening agent
Spatula 01MEC-0602E
17.Use a clean cloth and degreasing agent to clean the surfaces of the gap where the
movable blade is attached.
18.Use the spatula to apply the putty to the gap where the movable blade is attached, as
shown in the diagram below. If putty gets on any other areas, use a cloth to wipe the
area clean.
Gap
Movable blades
Examples of the applied putty
01MEC-0603E
19.Remove the waste tape processing unit from the blade adjustment jig and place on a
work surface.

20.Use a clean cloth and degreasing agent to remove any foreign matter from edge of the
slide cover and the movable blades.
Slide cover
Movable blades
Area to clean
01MEC-0604E
21.Apply the putty to the edge of the slide cover. Put as much putty on the edge as
possible.
Slide cover
Putty
01MEC-0605E
22.Attach the slide cover. Remove any putty that sticks out with a cloth.
Areas to remove putty

01MEC-0606J
23.The putty requires at least 12 hours at room temperature to harden.

24.When the putty has hardened, move the movable blade to the forward position by hand
to confirm operation, and then attach the cover. When securing the cover, attach the
bolts while pushing down on the fixed blade.
Cover
01MEC-0646E

7.28.4 Procedure for B type

Removing the movable blades
1. Remove the waste tape processing unit from the machine. Refer to section section 8.4
2. Disconnect the air hose that is connected to the duct.

Note: This work is not necessary if the type of unit being used does not have an air hose attached.
3. Remove the bolts for the cover and then remove the cover.
Duct
01MEC-0809Ea
4. Remove the bolts for the slide cover and then remove the slide cover.
Slide cover
01MEC-0810Ea
5. Remove the bolts holding the blades and exchange the movable blades with new ones.
The movable blades are available in sets (3 blades for M3-2 module and 5 blades for
M6-2(SP) module). When exchanging, exchange all of the movable blades at the same
time.
01MEC-0812a

Adjusting the gap between the fixed and movable blades

01MEC-0598E
7. Move the safety lever to release the lock and move the blades to the forward position.
01MEC-0811
8. Adjust the gap between the movable blade and scraper by using feeler gauges to check
the gap. Adjust so that a 0.02 mm thick feeler gauge can be inserted and a 0.10 mm
thick feeler gauge cannot be inserted. Check the gap at two locations for each blade.
Feeler gauge
Measurement positions
Movable blade Scraper 01MEC-0816E

9. If the gap is not acceptable, adjust the height of the scraper.
Scraper attachment screw
Base plate Shims

Scraper attachment screw
(4 positions for M3-2 module and
5 positions for M6-2(SP) module)
Scraper
Adjustment screws and nuts

10 positions for M6-2(SP) module) 01MEC-0800Eb
a. Loosen the scraper attachment screw and the nut for the adjustment screw in the
area where the gap is not acceptable.
b. Insert a shim of a suitable thickness between the scraper and the base plate near the
scraper attachment screw and then temporarily tighten the screw.
Note: The position of the shim in the diagram is just an example. The size and position of the
shim will depend on what adjustments need to be made.
c. Check the gap by using the method from step 8.
d. If the gap is not acceptable, use a shim with different thickness and then check the
gap again.
e. Perform steps a to d until the gap is correct. If the correct gap cannot be achieved
by changing the shim, rotate the adjustment screw and then adjust.
f. Tighten the scraper attachment screw and the nut for the adjustment screw and then
confirm that the gap is correct by measuring the gap in all the positions. If the gap is
not acceptable, perform the adjustment procedure again.

10.Adjust the gap between the movable blade and fixed blade by using feeler gauges to
check the gap. Adjust so that a 0.02 mm thick feeler gauge can be inserted and a 0.06
mm thick feeler gauge cannot be inserted. Check the gap at two locations for each
blade.
Caution: If a brush is attached to the blade, do not remove the brush. Insert the feeler gauge under
the brush.
Feeler gauge
Measurement positions
Brush
Fixed blade Movable blade 01MEC-0793Ea
11.If the gap is not acceptable, adjust the height of the fixed blade.
Fixed blade attachment screw

Adjustment screws and nuts
Base plate
Brush
Fixed blade
Shims
01MEC-0795Eb
a. Loosen the fixed blade attachment screw and the nut for the adjustment screw in the
area where the gap is not acceptable.
b. Insert a shim of a suitable thickness between the fixed blade and the base plate near
the fixed blade attachment screw and then temporarily tighten the screw.
Note: If a brush is attached to the blade, insert the shim from the side without the brush. The
position of the shim in the diagram is just an example. The size and position of the shim
will depend on what adjustments need to be made.

c. Check the gap by using the method from step 10.
d. If the gap is not acceptable, use a shim with different thickness and then check the
gap again.
e. Perform steps a to d until the gap is correct. If the correct gap cannot be achieved
by changing the shim, rotate the adjustment screw and then adjust.
f. Tighten the fixed blade attachment screw and the nut for the adjustment screw and
then confirm that the gap is correct by measuring the gap in all the positions. If the
gap is not acceptable, perform the adjustment procedure again.
12.Remove the waste tape processing unit from the blade adjustment jig and place on a
work surface.
13.Attach the securing bolts to the slide cover while pushing it in the direction shown by the
arrow in the diagram below.
Slide cover
01MEC-1095E
14.Attach the cover. When securing the cover, attach the bolts while pushing down on the
fixed blade.
15.Move the movable blade backwards and forwards and confirm that the slide cover does
not hit the duct.
Note: If the slide cover hits the duct, move the duct to a position where it does not get hit by the
slide cover.
16.Connect the air hose.

Note: This work is not necessary if the type of unit being used does not have an air hose attached.
Duct
01MEC-0794Ea
17.Attach the waste tape processing unit from the machine. Refer to section section 8.4

QD144-17 8. Replacing Parts
8. Replacing Parts
8.1 Replacing the Parts Camera
The parts camera cover, lighting, lens, and camera should be treated as one unit. It is not
possible to just replace an item on this unit without special equipment and training.
8.1.1 Required tools

Phillips screwdriver, metric Allen wrench set
8.1.2 Required time

Approximately 10 minutes are required to remove the existing light and camera units and
attach the new unit.
8.1.3 Procedure
WARNING
Always turn the machine main switch OFF before performing this
work.
WARNING
Contact with the shaft or coil section of the Y-axis linear motor in a
A strong magnetic field is generated by the Y-axis linear motor in

magnetic field.
CAUTION
may be deformed.

8. Replacing Parts QD144-17
CAUTION
When working close to the linear motor (within 55 mm) do not use
Damage to items may occur due to the magnetic field generated by

a linear motor. Keep magnetic cards, wristwatches and other
55 mm).
Linear motor shaft
Linear scale
X-axis gear cover
4. Loosen and remove the four (4) screws securing the cover using a driver.
Screws (M3 x 4)
Cover
NXTPCA003E

5. Gently remove the cover and then disconnect the two electrical connectors.
Note: The wiring position shown in the illustration below is different for P05 part cameras.
Connectors
NXTPCA005E
6. Use an Allen wrench to loosen and remove the four stud bolts. Gently remove the
lighting unit.
Stud bolt
(4 mm Allen wrench required)
Stud bolt identification
No groove 1 groove 2 grooves 3 grooves

(Standard and (High reso- (Sidelight (P05 camera)
P03 camera) lution camera) type camera)
Lighting unit
Lens 01MEC-0201Eb
Caution: When attaching the unit in the machine, be careful to not pinch wires under the lighting
stand legs or bolts. A pinched wire may cause a short.

7. Loosen and remove the 4 bolts as shown below using an Allen wrench in order to free
the camera unit.
Bolts (4 mm Allen wrench required)
Parts camera
NXTPCA006E
8. Disconnect both connectors at the bottom of the camera.
Connectors NXTPCA007E
9. Use the reverse procedure to attach the new unit.
10.When attaching the camera, pay attention to the following.
a. Set the camera unit at the direction which the cut-away portion of the camera unit is
facing the conveyor side.
Conveyor Cut-away
Front of the Machine 01MEC-1094E

b. Fit the positioning pin of the base in the U-groove of the camera unit (back side).
<Mark camera is mounted in the middle of the machine>

Mark camera
Pin and U-groove
AIMPCA007E
<Mark camera is mounted at the right hand side of

the machine> Mark camera
Pin and U-groove
AIMPCA008E
c. Make sure the direction of each part is right when assembling the lighting unit and
the cover onto the camera unit.
Note: The cutout size is the same size for the P05 parts camera lighting unit. Attach with the
attached board facing the operator side.
Mark camera Lighting unit Cover

Cut-away Large cut-away Screw hole
AIMPCA009E

8.2 Replacing the Mark Camera

The mark camera lighting, lens, and camera should be treated as one unit. It is not possible
to just replace an item on this unit without special equipment and training.

Metric Allen wrench set, 5.5 mm spanner
8.2.2 Required time

Approximately 10 minutes are required to remove the existing light and camera units and
attach the new unit.
8.2.3 Process
WARNING
Always turn the machine main switch OFF before performing this work.
3. If the rear of the camera unit has a bracket to prevent the connectors from being
disconnected, remove the bracket.
Bracket
01MEC-0772E
4. Remove the connectors from the rear of the camera unit.
Connectors
Mark camera
NXTMCA004E

5. Loosen the two (2) cap bolts and two (2) hex bolts, slide the camera unit backwards and
remove.
Hex bolts
(5.5 mm spanner required)
Cap bolts
(3 mm Allen wrench required) Mark camera
NXTMCA005Eb
Note: Under no circumstances should the the mark camera bolts or stoppers be loosened. (Refer
to the illustration below.)
Bolts
Stoppers
NXTMCA007Ea
6. Disconnect the connector for the mark camera lighting unit.
Connector NXTMCA002E

7. Loosen the four (4) bolts and remove the lighting unit.
Lighting unit
Bolts (3 mm Allen wrench required)

NXTMCA003E
8. Use the reverse procedure to attach the new unit.

Note: Slide the camera unit forward until the stoppers on the camera contact the lighting unit, then
tighten.
Stopper
Lighting unit Mark camera

NXTMCA006Eb

8.3 Replacing the Reject Parts Unit

8.3.1 Required time
Approximately 3 minutes are required to remove the existing unit and attach the new unit.
8.3.2 Procedure
1. When removing the reject parts conveyor, pull out the conveyor horizontally, while
pulling the clamp lever in the direction indicated in the diagram.
Clamp lever
NXTRPC004Ea

2. Align and slide the guide on the underside of the reject parts conveyor into one of the
feeder pallet slots.
Feeder pallet
Feeder pallet slot

Guide
NXTRPC002Ea
3. Slide the reject parts conveyor while pulling the clamp lever in the direction indicated in
the illustration below. Release the clamp lever when set properly in position.
Ensure that the connector on the reject parts conveyor is connected to the connector on
the feeder pallet.
Clamp lever
NXTRPC003Ea

8.4 Replacing the Waste Tape Processing Unit

It is necessary to remove the waste tape processing unit in cases such as when performing
maintenance on the unit.

Allen wrench set
8.4.2 Required time

Approximately 10 minutes are required to remove the existing unit and attach the new unit
(excludes the time required for work being performed on the unit such as lubrication.)
8.4.3 Procedure
3. Turn off the machine by switching the main switch to off.
WARNING
work.
4. Remove the attachment bolts followed by the duct.
Duct
Attachment bolt
NXTWTC002E

5. Remove the 4 bolts with an Allen wrench.
Waste tape disposal unit
NXTWTC004Eb
6. Disconnect the power cable connection from the right-hand side of the waste tape
processing unit. Pull the coupler in the direction of the arrow in the illustration to
disconnect the air hose.
Air hose
Power connector
Coupler NXTWTC005Eb
7. Slide the unit out of the machine using the handle on the right-hand side.
Note: The unit may drop on the ground, resulting in damage, if pulled out too far.
NXTWTC006

8. Lift the unit using the handles and carry to the maintenance stand.
Handles
Duct
NXTWTC007Eb
WARNING
Ensure not to put your hands inside the waste tape processing unit
when transporting the unit, as the cutter blade moves freely when
the unit is removed from the machine.
CAUTION
• Be careful not to drop the unit while carrying as it is extremely

heavy.
• Turn the unit upside down as shown and set on the maintenance
stand when working on the unit. Setting the unit on the
maintenance stand as is may result in damage to the duct due to
the weight of the unit.
9. After maintenance work has been completed, use the reverse procedure to return the
unit to the machine.
10.Attach the duct.

8.5 Replacing the Module Control Box

WARNING
work.
• When changing the module control box, ensure that no one

pushes in the module. The module may pinch, sever, or cause
serious injury.
CAUTION
• Hold the harness connectors when disconnecting the connectors.

Do not pull on the cables.
• Take care not to hook and pull the wiring harnesses when taking
out the control box.
• Confirm the connector names are right when reconnecting the

connectors.
• Take care not to pinch or damage the wiring harnesses when

installing the unit.
• It is possible that electrical items in the control box will be

damaged if the person performing the work is not grounded to
prevent electrostatic.

Phillips screwdriver, Allen wrench set

8.5.2 Procedure
2. Remove the screws (four), then remove the cover.
Module control box
Cover
NXTBAS029Ea
4. Remove the bolts (four) which fix the control box.
NXTBAS026
5. Disconnect the connectors in the black marked positions in the illustration below.
Connector board
Interface board CN
MCBCN
Connector panel 01MEC-0333E

6. Take out the control box from the module body.
Control box
NXTBAS028Ea
7. Check the model number on the new interface board. If the model number is
FH1511A0F or FH1366C0F, the dip switches must be set. Check the dip switch settings
for the board model number and module type and set them if necessary.
Note: Dip switch settings are unnecessary for interface boards with model numbers other than
FH1511A0F or FH1366C0F.
Dip switch
Interface board
Model number
FH1366C0F FH1511A0F
M3-2 module M3-2 module
ON ON
OFF OFF
ON ON
OFF OFF

ON ON
OFF OFF
ON ON
OFF OFF
M6-2SP module M6-2SP module

ON ON
OFF OFF
ON ON
OFF OFF
01MEC-1239E
8. Use the reverse procedure when installing the new control box.

8.6 Replacing the Module CPU Box

WARNING
work.
• When changing the module CPU box, ensure that no one pushes
in the module. The module may pinch, sever, or cause serious
injury.
CAUTION

out the CPU box.

connectors.

• It is possible that electrical items in the CPU box will be damaged

if the person performing the work is not grounded to prevent
electrostatic.

Phillips screwdriver, Flat head screwdriver, Allen wrench set

1. Confirm that you have the floppy disk containing the calibration data. Matrix data, feeder
pallet levelness data, and module camera calibration data (only for modules with no
parts camera) are used in this procedure. The disk comes with the machine.
Note: If the disk cannot be located or is damaged, perform the following procedures.
Save the module matrix data and module camera calibration data from the module on a
computer. In addition, record the feeder pallet levelness values for the module. This data
is displayed in the information command in manual mode. (Refer to the “Information
Command“ section in chapter 6 “Manual Mode Commands“ of the NXT II System
Reference manual for details.)

2. Record the module configuration settings. Use Accessory Software to display the
module configuration settings for the module in question. Refer to “Making module
configuration settings“ in the “Machine Accessories“ section in chapter 7 “Accessory
Software“ of the NXT II System Reference manual for details. Once all of the module
data has been checked and/or recorded, then proceed to the next step.
3. Eject all nozzles from the head by using the manual mode command.
4. Remove any panels that are in the module.
5. Set the nozzle jigs for the type of head in the module in the nozzle station. Set the same
number of nozzle jigs as there are holders on the head.
8.6.3 Procedure
Ensure that a backup of the matrix data and feeder pallet levelness data for each module
exists before performing this procedure.
2. Remove the screws (four on M3-2 modules, six on M6-2(SP) modules), then remove the
cover.
Module CPU box
Cover
NXTBAS031E
Note: For M6-2 modules, there are 6 screws.
4. Remove the bolts (six) which fix the CPU box.
01MEC-0607

5. Use a number 1 size Phillips head screwdriver and a flathead screwdriver to remove the
CPU box connecting cables from the locations marked in black below.
5 7
Cable 6 8
UART1-4
DIO
1
(Only on M6-2) CUNET RS232C LAN

PANEL LINK USB 1394PO
2
RGB IN
BAT
o
12V
HEAD
MARK PART1 PART2
TRIG OUT TRIG IN
I/O OUT IN
01MEC-0279Ea
6. Take out the CPU box from the module body, and detach the bracket from the CPU box.
CPU box
Bracket
NXTBAS034E
7. Use the reverse procedure when installing the new CPU box.
8. Turn on the power and confirm that the machine starts up correctly.
8.6.4 Making all settings after replacing the CPU box

After replacing the CPU box, perform module calibration and configuration settings. Refer
to step 2 onwards of section 7.7.5 "Making all settings after changing the battery" for details.

8.7 Replacing Boards in the Module CPU Box

The CPU board, vision processing board, and servo board in the CPU box can be replaced
individually.
WARNING
work.
• When changing boards in the module CPU box, ensure that no

one pushes in the module. The module may pinch, sever, or cause
serious injury.
CAUTION

connectors.

electrostatic.


1. When replacing the CPU board, refer to section 8.6.2 "Preparation procedures" and
perform the actions explained in that section.
4. Remove the screws (four on M3-2 modules, six on M6-2(SP) modules), then remove the
cover.
Module CPU box
Cover
NXTBAS031E


6. Use a number 1 size Phillips head screwdriver and a flathead screwdriver to remove the
CPU box connecting cables from the locations marked in black below.
5 7
Cable 6 8
UART1-4
DIO
1
(Only on M6-2) CUNET RS232C LAN

PANEL LINK USB 1394PO
2
RGB IN
BAT
o
12V
HEAD
MARK PART1 PART2
TRIG OUT TRIG IN
I/O OUT IN
01MEC-0279Ea
8.7.3 Replacing the CPU board

1. Use a number 1 Phillips screwdriver to remove the 4 four screws. Disconnect the cable
connecting the CPU board and the vision board. Open the levers and remove the CPU
board.
Connector
Lever
Lever 01MEC-0608J
2. Confirm that the dip switch settings on the new CPU board are correct.
Caution: If the settings are incorrect, it will not work correctly.
SW3 ON
OFF
SW2 ON
OFF
Dip switches
01MEC-0609E

3. Using the guides, insert the new CPU board into the CPU box. Tighten the screws.
Guides
01MEC-0610E
8.7.4 Replacing the vision board

1. Use a number 1 Phillips screwdriver to remove the 2 screws. Disconnect the cable
connecting the vision board and the CPU board. Open the levers and pull the vision
board halfway out.
Connector
Lever
Lever 01MEC-0611E
2. Disconnect the cable connecting the vision board and the ATX power source. Remove
the vision board.
Connector
01MEC-0612E
3. Using the guides, insert the new vision board halfway into the CPU box.
Guides
01MEC-0621E

4. Connect the vision board and the ATX power source with the correct cable and insert
the vision board fully.
5. Connect the vision board and the CPU board with the correct cable and tighten the
screws of the vision board.
8.7.5 Replacing the servo board

1. Use a number 1 Phillips screwdriver to remove the 4 screws, open the levers, and pull
the servo board tray out.
Lever
01MEC-0613E
2. Remove the 4 screws and replace the servo board.
Tray
01MEC-0614E
3. Using the guides, insert the servo board tray into the CPU box and tighten the screws.
Guide
01MEC-0615E
8.7.6 After replacing boards

1. Attach the CPU box connecting cables and cover.
3. If the CPU board has been replaced, perform module calibration and configuration
settings. Refer to section 7.7.5 "Making all settings after changing the battery" for
details.

8.8 Replacing the Base Control Box 1

WARNING
work.
• When working in an opening in the top of the base with the cover
off, ensure that no one pushes in the module. The module may
pinch, sever, or cause serious injury.
CAUTION

out the servo box.

connectors.




8.8.2 Procedure
1. Pull out the module, then turn off the power to the machine by turning the main switch off.
2M-2 base 4M-2 base
Base control box 1 Base control box 1

Cover
01MEC-0280Ea
4. Remove the bolts (four) which fix the control box.
NXTBAS050

Interface board
For 4M-2
01MEC-0334E
6. Take out the control box from the base.
NXTBAS048

8.9 Replacing the Base Control Box 2

WARNING
work.
CAUTION

out the servo box.

connectors.




8.9.2 Procedure
Base control box 2
Cover
01MEC-0281E
4. Remove the bolts (three) which fix the control box.
NXTBAS057a

Interface board
NXTBAS058Eb
6. Take out the control box from the base.
NXTBAS055

8.10 Replacing the Base CPU Box

WARNING
• Always turn the main switch OFF before performing this work.
CAUTION
out the servo box.

connectors.


electrostatic.


1. Use the manual mode Information command to display the network settings for the
machine. The following is a list of the network settings that is required. Refer to the
“Information Command“ section in chapter 6 “Manual Mode Commands“ of the NXT II
System Reference manual for details.
• IP address • Subnet mask • Default gateway

• Other settings such as DNS server.
2. Before replacing the CPU box or the memory card in the CPU box, confirm that you have
the floppy disk with the various calibration data for the machine. The final offset files are
used in this procedure. The disk is attached to the machine.
Note: If there are no problems with the old memory card, then exchange the new memory card in
the new CPU box with the old memory card.

8.10.3 Procedure
1. Pull out the module, turn off the power to the machine by turning the main switch off.
2. Remove the screws, then remove the covers.
4M-2 base
2M-2 base
Base control box 2 Base CPU box
Base CPU box
Cover 01MEC-0282Eb
3. First remove the base control box 1 and the base control box 2. (Refer to section 8.8.2
"Procedure" and section 8.9.2 "Procedure".)
4. Remove the bolts (two) which fix a section of the rail. Keep this part of the rail away from
the opening when working in the base.
Rail
NXTBAS064E
6. Remove the bolts (two) which fix the CPU box.
01MEC-0616J

5 7
DIO
6 8 1
UART1-4
CUNET RS232C LAN USB 1394PO

PANEL LINK
RGB IN
BAT
01MEC-0122a
8. Remove the memory card from the memory card board in the old CPU box and put into
the new base CPU box. Refer to section 8.11.4 "Replacing the memory card board".
9. Take out the CPU box from the base, and detach the bracket.
Bracket
NXTBAS069E
10.Use the reverse procedure when installing the new CPU box.
11.Turn on the power and confirm that the machine starts up correctly.

8.10.4 Settings after replacement

The following actions are necessary after exchanging the CPU box.
a. Configure network settings
b. Install machine application software
c. Transmit the final offset file (when replacing the CPU box memory card)
Note: If the memory card from the old CPU box was put into the new CPU box, there is no need
to send the offset files.
1. The network settings screen displays when the machine is started. Input the values you
wrote down. Refer to the “Making Network Settings“ section in chapter 3 “Machine Set
Up“ of the NXT II Setup manual for details.
2. Install the version of the machine application software that matches the modules (the
same version as the modules). Refer to “Upgrading machine control software“ in the
“Machine Accessories“ section in chapter 7 “Accessory Software“ of the NXT II System
Reference manual for details.
3. Send the final offset file to the modules. Refer to “Sending the final offset file to a
module“ in the “Machine Accessories“ section in chapter 7 “Accessory Software“ of the
NXT II System Reference manual for details.
Note: Also refer to “Installing the machine application software” and “Performing PAM at the
machine” in the online version of the Fuji Accessory Software Operation Manual.

8.11 Replacing Boards in the Base CPU Box

The CPU board and the memory card board in the CPU box can be replaced individually.
WARNING
• Always turn the machine main switch OFF before performing this work.
• When changing boards in the module CPU box, ensure that no one
pushes in the module. The module may pinch, sever, or cause serious
injury.
CAUTION
• Hold the harness connectors when disconnecting the connectors. Do
not pull on the cables.

connectors.
• It is possible that electrical items in the CPU box will be damaged if the
person performing the work is not grounded to prevent electrostatic.


1. When replacing the CPU board, refer to section 8.10.2 "Preparation procedures" and
perform the actions explained in that section.
4M-2 base
2M-2 base
Base control box 2 Base CPU box
Base CPU box
Cover 01MEC-0282Eb


6. Remove the CPU box connecting cables from the locations marked in black.
5 7
DIO
6 8 1
UART1-4
CUNET RS232C LAN USB 1394PO

PANEL LINK
RGB IN
BAT
01MEC-0122a
8.11.3 Replacing the CPU board

1. Remove the 4 screws, open the levers and remove the CPU board.
Lever
Lever 01MEC-0622E
2. Confirm that the dip switch settings on the new CPU board are correct.
Caution: If the settings are incorrect, it will not work correctly.
SW3 ON
OFF
SW2 ON
OFF
Dip switches
01MEC-0623E

3. Using the guides, insert the new CPU board into the CPU box and tighten the screws.
Guides
01MEC-0610E
8.11.4 Replacing the memory card board

1. Remove the 2 screws, open the levers and pull out the memory card board tray.
Lever 01MEC-0617E
2. Loosen the 2 screws on the memory card retainer.
Memory card retainer
01MEC-0624E
3. Remove the 4 screws and remove the memory card board from the tray.
Tray
01MEC-0618E

4. Release the lever and remove the memory card. Set the memory card in the new board.
Lever
Memory card
01MEC-0619E
5. Attach the memory card board to the tray, align the position of the memory card retainer
and tighten the screws.
Memory card retainer
01MEC-0624E
6. Using the guides, insert the memory card board tray into the CPU box and tighten the
screws.
Guide
01MEC-0620E
8.11.5 Procedure after replacement

1. Attach the CPU box connecting cables and cover.
3. IIf the CPU board has been replaced, perform steps for items a and b from section
8.10.4 "Settings after replacement". If the memory card on the memory board is
exchanged with a different memory card, then perform steps for item c.

8.12 Replacing the Vacuum Pump Control Box
WARNING
work.
CAUTION
out the servo box.

connectors.


8.12.2 Procedure
2M-2 base 4M-2 base
Vacuum control box Vacuum control box
Cover 01MEC-0283Ea

3. Disconnect the harness connectors from the bracket of the vacuum pump control box.
NXTBAS043
4. Remove the bolts (two) which fix the bracket of the vacuum pump control box.
NXTBAS044
5. Take out the vacuum pump control box with the bracket attached.
6. Use the reverse procedure when installing the new vacuum control box.

8.13 Replacing the DC Power Supply Unit on the

Feeder Pallet
Remove the feeder pallet prior to replacing the DC power supply unit on the part supply
base.
WARNING
work.
CAUTION


connectors.

8.13.2 M3-2 module

2. Remove the four bolts to remove the cover of the DC power supply unit from the part
supply base.
Cover
NXTBAS120E
DC power supply unit

3. Disconnect any connectors connected to the DC power supply unit.
Connectors
NXTBAS121E
4. Remove the four screws and then remove the DC power supply unit from the part supply
base and replace it.

NXTBAS122E

2. Remove the four bolts to remove the cover of the DC power supply unit from the part
supply base.
Cover

NXTBAS117E

3. Disconnect any connectors connected to the DC power supply unit.
Connectors
NXTBAS118E
4. Remove the four screws and then remove the DC power supply unit from the part supply
base and replace it.

NXTBAS119E

8.14 Replacing a Conveyer Controller

WARNING
work.
CAUTION

connectors.
• If procedures are performed with static electric charge still

present, the electrical components on boards may be damaged.

8.14.2 Replacing single and double conveyor controllers

A M6-2(SP) module is used as the example in the explanation below for replacing the
conveyor controller, but the same procedures are used for M3-2 modules.
1. Move the back rail for lane 2 forward.
2. Turn off the power supply.
3. Remove the two screws and then remove the cover.
<Double conveyor> Conveyor controller Cover
01MEC-0295E

<Single conveyor>
Conveyor controller Cover
01MEC-0296E
4. Remove the connectors marked by the black sections in the illustration below from the
conveyor controller.
<M3-2 module>
Controller for Double conveyor Controller for Single conveyor
CN6-3 CN9-3
C20
C21
C13 C13
CN6-3 CN6-2 CN6-1 CN8-2 CN10-1 CN10-2 CN10-1

CN1 CN1
b-4
d-4
b-4
b-3
d-3
b-3
CN9-2 CN9-2
b-2
d-2
b-2
CN3 CN3
b-1
d-1
b-1
a-4
c-4
a-4
CN4 CN4
a-3
c-3
a-3
CN2 CN2
a-2
c-2
a-2
a-1
c-1
a-1
CNB-1 CN9-1 CN5-1 CN5-2 CN5-3 CNB-1 CN9-1 CN5-1 CN5-2 CN5-3
01MEC-0123E
ON ON
1 2 3 4 5 1 2 3 4 5
<M6-2 module>
<M6-2SP module>
Controller for Double conveyor Controller for Single conveyor
CN6-3 CN9-3
C20
C21
C13 C13
CN6-3 CN6-2 CN6-1 CN8-2 CN10-1 CN10-2 CN10-1

CN1 CN1
b-4
d-4
b-4
b-3
d-3
b-3
CN9-2 CN9-2
b-2
d-2
b-2
CN3 CN3
b-1
d-1
b-1
a-4
c-4
a-4
CN4 CN4
a-3
c-3
a-3
CN2 CN2
a-2
c-2
a-2
a-1
c-1
a-1
CNB-1 CN9-1 CN5-1 CN5-2 CN5-3 CNB-1 CN9-1 CN5-1 CN5-2 CN5-3
ON ON
1 2 3 4 5 1 2 3 4 5 01MEC-0335Eb

5. Remove the four screws and then remove the conveyor controller and bracket.
<Double conveyor> <Single conveyor>

Conveyor controller Conveyor controller
Bracket Bracket
01MEC-0297E
6. Remove the screws and then remove the conveyor controller from the bracket and
replace it.
<Double conveyor>
Conveyor controller
Bracket
01MEC-0299E
<Single conveyor>
Conveyor controller
Bracket
01MEC-0300E
7. Return the controller to its original position using the removal procedure in reverse.
8. Adjust the controller after replacing it. Refer to section 8.14.4 "Adjusting the controller
after replacement"for details.

8.14.3 Replacing triple conveyor controllers

Preparation
1. Pull forward the module to the right of the module in which you want to replace the
3. Access the back of the module from the rear of the machine and check the conveyor
controller position.
4. Remove the four bolts from the top cover and then remove the cover.
A
Top cover
01NST-0501E
5. Remove the four fixing bolts (B) from the bracket.
Move to the front of the module
01NST-0502E
6. Without pulling hard on the cables, move the bracket gently towards the front of the
module.
7. Gently remove the conveyor controller for lane 3.

Caution: When replacing the conveyor controller for lane 1 and 2, it is necessary to at least
temporary remove the conveyor controller for lane 3 in order to have enough space to work
in.

When replacing the conveyor controller for lane 3

8. Remove the connectors marked by the black sections in the illustration below from the
C13
CN10-1
CN1
b-4
b-3
CN9-2
b-2
CN3
b-1
a-4
CN4
a-3
CN2
a-2
a-1
CNB-1 CN9-1 CN5-1 CN5-2 CN5-3
ON
1 2 3 4 5 01MEC-0650
9. Remove the bolts (C) for the bracket and conveyor controller for lane 3 and then remove
the conveyor controller.
Controller for lane 3
01NST-0503E
10.Ensure that dip switch 1 is on and all the others are off for the dip switch settings on the
new conveyor controller and then mount the new conveyor controller.
11.If just replacing the conveyor controller for lane 3, then perform the steps from 9 to 1 in
reverse to put the unit back together. If replacing the conveyor controller for lane 1 and
2, then proceed to step 12.

When replacing the conveyor controller for lane 1 and 2

12.Remove the fixing bolts (D) for the conveyor controller.
Controller for lane 1 and 2
01NST-0504E
13.Remove the connectors marked by the black sections in the illustration below from the
CN6-3 CN9-3
C20
C21
C13
CN6-3 CN6-2 CN6-1 CN8-2 CN10-1 CN10-2

CN1
b-4
d-4
b-3
d-3
CN9-2
b-2
d-2
CN3
b-1
d-1
a-4
c-4
CN4
a-3
c-3
CN2
a-2
c-2
a-1
c-1
CNB-1 CN9-1 CN5-1 CN5-2 CN5-3
ON
1 2 3 4 5 01MEC-0661
14.Ensure that dip switch 1 is on and all the others are off for the dip switch settings on the
new conveyor controller and then mount the new conveyor controller.
15.Perform the steps from 14 to 12 in reverse to put the conveyor controller for lane 1 and
2 back and then perform the steps from 10 to 1 in reverse to put the unit back together.
16.Adjust the controller after replacing it. Refer to section 8.14.4 "Adjusting the controller
after replacement"for details.

8.14.4 Adjusting the controller after replacement

The following actions are necessary after the controller has been replaced.
a. Upgrade the conveyor software
b. Calibrate the conveyor
c. Adjust the sensitivity of the conveyor sensors
Upgrading the conveyor software

1. Select manual mode at the machine and then use the diagnosis command. Refer to
"Manual Commands" in the NXT II System Reference manual for details.
2. Start Accessory Software.
3. Select the module(s) and then click [Remote operation].
4. Click [Update software].
01MEC-1229E
5. Click [Start updating]. The machine reboots automatically.
01MEC-1230E

6. A selection screen displays at the machine operation panel. Use the arrow keys to select
[Conveyor] and then OK.
01MEC-1238
7. After the update is complete, select [Reboot] to restart the machine.
Calibrating the conveyor

1. Check that EMEGENCY STOP has not been pushed.
2. Check that the main screen is displayed at the machine.
5. Click [Conveyor calibration].
01MEC-1231E
6. Click [Start]. Calibration begins.
01MEC-1232E
7. After calibration is complete, turn the main power off and on.

Adjusting the sensitivity of the conveyor sensors

1. Check that there are no panels or similar items blocking the beams between the
conveyor sensors.
4. Click [Conveyor sensor sensitivity adjustment].
01MEC-1233E
5. Click [Start].
01MEC-1234E

8.15 Removing the Module Top Cover

Allen wrench set
8.15.2 Procedure
1. Pull the module forward. (See section 5.1 "Pulling Out/Returning a Module".)
WARNING
Be sure to turn off the power to the machine before performing
work to remove the module top cover.
3. Open the front cover.
4. Remove the connector for the signal tower.
Connector
01MEC-0290E
5. Remove the bolts (4) which are securing the top cover.
Top cover
01MEC-0291E
6. Remove the module top cover. The top cover is held in place by a hook located in the
rear of the module. To remove the top cover, slide the cover forward and then lift up.
Top cover
Hook 01MEC-0017E

8.16 Attaching/Removing the Module Side Covers

Modules that are mounted on the ends of the base need side safety covers. These covers
are actually mounted on the modules itself. This means that if the module is to be moved
to another position on the base, the cover must be removed before attempting to insert the
module back in the machine at the new position.

8.16.2 Attaching
1. Pull out the module to allow access to the screws that go next to the safety connector.
2. Hold the side cover against the module and secure the cover by lightly tightening the
Allen bolts.
3. Using a plus screwdriver, secure the bottom half of the cover with screws.
4. Fully tighten the Allen bolts from step 2.
5. Return the module, and ensure that the safety connector is properly connected.
Safety connector
(Do not remove)
Allen bolt Screw 01-MEC-0374E
8.16.3 Removing
1. Pull out the module to disconnect the safety connect and allow access to the screw near
the bottom of the cover.
2. Using a plus screwdriver, remove the three screws near the bottom of the cover.
Note: Do not remove the safety connector from the cover.
3. While holding the cover to ensure that it does not drop, remove the four Allen bolts with
an Allen wrench.
4. Remove the side cover from the module.

8.17 Replacing the Cooling Fan

8.17.1 Module fan (upper side)
For M3-2 modules
Module fan
01MEC-0580E
1. Pull forward the module if necessary.

Note: It is necessary to remove the rear cover in order to replace the module cooling fan. Pull the
module forward when the seamless cover hides the screw used to secure the rear cover.
WARNING
replacement work.
3. Remove the four screws from the rear cover.
Rear cover
01MEC-0496E

4. Disconnect the connector and then remove the rear cover.
Rear cover
01MEC-0497E
5. Remove the four Allen bolts and then remove the cooling fan.
Bracket
Cooling fan
Guard
Allen bolt
01MEC-0581E
6. Attach the new fan and previous guard to the bracket and tighten the four Allen bolts.
7. Connect the connector for the wiring.
8. Reattach the rear cover to the module.

For M6-2/M6-2SP modules
Module fan
01MEC-0582E
WARNING
replacement work.
2. Remove the top cover from the module. (Refer to section 8.15 "Removing the Module
Top Cover" for detailed procedures on doing this.)
3. Remove the four screws and then remove the guard and fan.
Guard
Cooling fan
Connector
Bracket
01MEC-0583E
4. Disconnect the connector for the wiring.
5. Attach the new fan and previous guard to the bracket and then tighten the four screws.
6. Connect the connector for the new fan.
7. Attach the top cover to the module.

8.17.2 Module fan (lower side)

The replacement procedures are the same for the M3-2 modules and the M6-2(SP)
modules.
WARNING
replacement work.
2. Remove four screws to remove the rear side cover of the module. Disconnect the
connector for the wiring.
Cover
Module fan 01MEC-0274E
3. Remove the two bolts and then remove the fan mounting bracket from the rear side of
the module.
Mounting bracket
Fan NXTBAS113E
4. Disconnect any connectors to remove the fan and bracket from the module. Then,
remove the two screws and disassemble the fan and the bracket and replace the fan.
Connector
Fan
Bracket
NXTBAS114E

8.17.3 Base fan

WARNING
replacement work.
2. Remove the four screws to remove the rear side cover of the module.
Cover
Base fan 01MEC-0275E
3. Disconnect any connectors to remove the fan and the bracket from the module. Then,
remove the four screws and disassemble the fan and the bracket and replace the fan.
Cover Fan
Connector
NXTBAS116E

8.17.4 Fan for the DC power supply unit on the feeder pallet
<M6-2/M6-2SP Module>
Remove a feeder pallet prior to replacing the fan for the DC power supply unit on the feeder
pallet base.
WARNING
replacement work.
2. Remove the four bolts and disconnect any connectors for the fan and then remove the
cover of the DC power supply unit from the pallet base.
Fan
Cover
NXTBAS123E
3. Remove the four screws and remove the fan from the cover of the DC power supply unit
and replace the fan.
Fan
Connector
NXTBAS124E

<M3-2 Module>
Remove a feeder pallet prior to replacing the fan of the DC power supply unit on the feeder
pallet base.
WARNING
replacement work.
2. Remove the four bolts and disconnect any connectors for the fan and then remove the
cover of the DC power supply unit from the pallet base.
Cover
Fan
NXTBAS125E
3. Remove the four screws and remove the fan from the cover of the DC power supply unit
and replace the fan.
Fan
Connector NXTBAS126E

8.18 Replacing the Connector between the Feeder

Pallet and the Parts Supply Base
The feeder pallet and device base connectors are made up of several connectors put
together. When assembling the connectors ensure to follow the procedures below.
CAUTION
• Always turn the machine main switch OFF before removing or

attaching connectors.
• If the connectors are disassembled, confirm that the connectors

are correctly reassembled by referring the indicator lines on the
side of the connectors.

Allen wrench set
8.18.2 M3-2 module

2. A set of connectors (indicated in the figure below) is connected to the feeder pallet and
the part supply base.
Connector
(feeder pallet side)
Connector
(part supply base side)
NXTBAS096E
3. If the connectors are disassembled, confirm that they are correctly reassembled by
referring the indicator lines on the sides of the connectors.
Connectors (feeder pallet side)
Connectors (part supply base side)
Indicator lines
NXTBAS098E


2. A set of connectors (indicated in the figure below) is connected to the feeder pallet and
the part supply base.
Connecting connector Connecting connector

(feeder pallet side) (part supply base side)
NXTBAS095E
referring the indicator lines on the sides of the connectors.
Connectors (feeder pallet side)
Indicator lines
NXTBAS097E

8.19 Replacing the Connector for the Tray Unit-L and

Parts Supply Base
Follow the procedures below to reassemble the connectors for the tray unit-L.
CAUTION
• Always turn the machine main switch off before removing or
are correctly reassembled by referring to the indicator lines on the

Allen wrench set
8.19.2 Procedure
2. A set of connectors (indicated in the figure below) is connected to the tray unit-L and the
parts supply base.

(tray unit-L side) (part supply base side)
NXTMTU045E
referring to the indicator lines on the sides of the connectors.
Connectors (tray unit-L side)
Indicator lines
NXTMTU046E

8.20 Detaching and Attaching the Tray Unit-L Cover

8.20.2 Tray unit-L cover nomenclature

The following exploded view of the unit parts are numbered in the order that they should be
dismantled.
Detach the parts according to this order, and attach them in the reverse order.
4
8
AIMMTU010
1. Rear cover
2. Top cover
3. Front rails
4. Front cover
5. Upper right side cover
6. Upper left side cover
7. Front door
8. Lower right side cover
9. Lower left side cover

8.20.3 Detachment
WARNING
Always remove the tray unit from the machine before performing
this work.
Detach the covers from the tray unit in the following order.
1. Rear cover.
Remove the four screws, and then detach the rear cover.
Rear cover
AIMMTU011E
2. Top cover
a. Remove the two screws at the back.
b. Open the door at the front for the top cover, and then remove the bolts on the left and
right.
Note: These bolts are tightened together with the magnet catches.
Magnetic catch Magnetic catch
Top cover door
AIMMTU012Ea
c. Detach the top cover.

3. Front rails
Remove the four bolts holding the front rails (together with the front cover) from the
inside of the tray unit.
Front cover
Front rails
AIMMTU013E
4. Front cover
Detach the front cover together with the front rails when the four bolts holding both parts
are removed in the step above.
5. Upper right side cover

The upper right side cover is secured by bolts (7) from the outside of the tray unit, and
secured by a nut (1) from the inside of the tray unit. First, it is necessary to lower the
magazine rack and remove the nut from the inside of the tray unit. Use the procedures
listed below to lower the magazine rack.
a. Remove the brake cover from the bottom of the tray unit.
Brake cover
Bolts (M5 x 2)
01MEC-0019E

b. Remove the 3 bolts from the coupling of the brake unit.

Caution: The TZ-axis motor pulley(*) is located close to the brake unit. Do not mistakenly loosen the
bolts for the TZ-axis motor pulley.
Brake unit
Coupling
TZ-axis motor pulley(*)
01MEC-0020E
WARNING
The magazine rack will fall when the coupling is loosened. Do not
insert fingers or other body parts under the magazine rack, or
injury may occur.
c. The coupling is wedged firmly into place and cannot be removed by only removing
the bolts. The coupling can be pushed off by screwing the bolts that were just
removed into the other, unused holes of the coupling.
(1) Loosen and remove (2) Screw the bolts into

the bolts from the coupling. the unused holes.
01MEC-0021E
d. Manually lower the magazine rack so that the nut securing the side cover can be
accessed from inside the tray unit.

e. Remove the nut holding the upper right side cover from the inside of the tray unit.
AIMMTU014
f. Remove the seven bolts holding the cover on the outside of the unit, and then remove
the cover.
6. Upper left side cover.
a. Remove the two nuts holding the upper left side cover from the door hinge inside the
machine.
Front door
AIMMTU015E
b. Remove the six bolts holding the cover on the outside of the unit, and then remove
the cover.

7. Front door
a. Remove the four air hoses from the front door air cylinders.
b. Remove the four bolts from the front door hinges.
Front door
AIMMTU016E
c. Remove the front door.
8. Lower right side cover

Remove the bolts, and then remove the cover.
9. Lower left side cover

Remove the bolts, and then remove the cover.

8.20.4 Attachment
1. Attach the covers in the reverse order from their detachment.
2. Tighten the couplings with the magazine rack at its upper limit.
Torque for the coupling bolts: 4.0 Nm
Rectangular block
Coupling
Bolt
AIMMTU018E

8.21 Replacing the Connector for the Tray Unit-LT

and Parts Supply Base
Follow the procedures below to reassemble the connectors for the tray unit-LT.
CAUTION

Allen wrench set
8.21.2 Procedure
2. A set of connectors (indicated in the figure below) is connected to the tray unit-LT and
the parts supply base.

(tray unit-LT side) (part supply base side)
01MEC-0236E
Connectors (tray unit-LT side)
Indicator lines
01MEC-0237E

8.22 Removing Tray Unit-LT Covers

8.22.2 Tray unit-LT cover configuration

1
4
7
12
9
10
11 01MEC-0235a
1. Top left cover 7. Front cover
2. Top cover 8. Lower magazine door
3. Rear cover 9. Lower left cover
4. Right side cover 10. Lower middle cover
5. Left side cover 11. Lower right cover
6. Upper magazine door 12. Lower cover

8.22.3 Removing covers
WARNING
Always remove and attach covers on the tray unit-LT after

removing the unit from the machine.
Left side cover

1. Remove the rear cover.
Rear cover
01MEC-0463E
2. Remove the top left cover.
Top left cover
01MEC-0464E
3. Remove the lower left cover.
Lower left cover
01MEC-0465E

4. From the rear side of the unit, remove the four screws holding the left side cover.
Left side cover
01MEC-0467E
5. Remove the remaining nine screws holding the left side cover and then remove the
cover.
01MEC-0468

Right side cover

Rear cover
01MEC-0463E
2. If the bucket type reel holder is installed, then remove it so that the right side cover can
be removed.
Bucket type reel holder
01MEC-0469E
3. From the rear side of the unit, remove the four screws holding the right side cover.
Right side cover
01MEC-0470E

4. Remove the three screws holding the right side cover shown in the diagram below.
01MEC-0471
5. Remove the remaining eight screws holding the right side cover and then remove the
cover.
Note: It is not necessary to remove the access cover (shown in gray in the diagram below).
01MEC-0472

Front cover
1. Remove the screws from the front cover that are on the top, left side, and bottom.
Front cover
01MEC-0478E
2. Gently remove the front cover from the tray unit by pulling it towards you.
3. Remove all of the cable connectors connected to the cover.

Lower covers
Lower left cover
01MEC-0465E
2. Remove the lower right cover.
Lower right cover
01MEC-0474E
3. Remove the lower middle cover.
Lower middle cover
01MEC-0475E

4. Remove the eight screws holding the lower cover.
Lower cover
01MEC-0476E
5. Gently remove the lower cover from the tray unit by pulling it towards you.

8.23 Replacing the Connector for the Tray Unit-LTC

and Parts Supply Base
Follow the procedures below to reassemble the connectors for the tray unit-LTC.
CAUTION

Allen wrench set
8.23.2 Procedure
2. A set of connectors (indicated in the figure below) is connected to the tray unit-LTC and
the parts supply base.

(tray unit-LTC side) (part supply base side)
01MEC-0519E
Connectors (tray unit-LTC side)
Indicator lines
01MEC-0523E

8.24 Removing Tray Unit-LTC Covers

8.24.2 Tray unit-LTC cover configuration
1
2
3
5
6
12
11
10 01MEC-0894
1. Top left cover 7. Front cover
2. Top cover 8. Lower magazine door
3. Rear cover 9. Lower left cover
4. Right side cover 10. Lower middle cover
5. Left side cover 11. Lower right cover
6. Upper magazine door 12. Lower cover

8.24.3 Removing covers
WARNING
Always remove and attach covers on the tray unit-LTC after

removing the unit from the machine.
Left side cover

Rear cover
01MEC-0896E
2. Remove the top left cover.
Top left cover
01MEC-0464E
Lower left cover
01MEC-0895E

4. From the rear side of the unit, remove the four screws holding the left side cover.
Left side cover
01MEC-0467E
5. Remove the remaining nine screws holding the left side cover and then remove the
cover.
01MEC-0468

Right side cover

Rear cover
01MEC-0896E
2. If the bucket type reel holder is installed, then remove it so that the right side cover can
be removed.
Bucket type reel holder
01MEC-0903E
3. From the rear side of the unit, remove the four screws holding the right side cover.
Right side cover
01MEC-0897E

4. Remove the three screws holding the right side cover shown in the diagram below.
01MEC-0898
5. Remove the remaining eight screws holding the right side cover and then remove the
cover.
Note: It is not necessary to remove the access cover (shown in gray in the diagram below).
01MEC-0472

Front cover
1. Remove the screws from the front cover that are on the top, left side, and bottom.
Front cover
01MEC-0899E
2. Gently remove the front cover from the tray unit by pulling it towards you.
3. Remove all of the cable connectors connected to the cover.

Lower covers
Lower left cover
01MEC-0895E
2. Remove the lower right cover.
Lower right cover
01MEC-0900E
3. Remove the lower middle cover.
Lower middle cover
01MEC-0901E
4. Remove the eight screws holding the lower cover.

Lower cover
01MEC-0902E
5. Gently remove the lower cover from the tray unit by pulling it towards you.

8.25 Removing the Conveyor Cover on M6-2

extended Conveyor Modules
A cover is attached to the part of the conveyor that sticks out either side of M6-2 extended
conveyor modules. This cover should be removed to perform maintenance.
1. Open the side cover of the module.
01MEC-1186
2. Remove the bolts on the top of the cover.
3. Lift up the side of the cover next to module. Next, lift the cover up to remove it.
01MEC-1187
4. Follow the above procedure in reverse to attach the cover.

MEMO:

QD144-17 9. Measurement and Adjustment
9. Measurement and Adjustment

9.1 On machine PAM (Placement Accuracy
Measurement)
The following are explanations for on machine PAM (Placement Accuracy Measurement).
PAM measurement should only be performed under the directions of a Fuji engineer, Fuji
agent, or technician who has received training from Fuji in PAM measurement.
The jigs used for PAM measurements have changed from software V5.11. The jig plate
(AA01B**) and glass parts (PZ1460*) used until now cannot be used with V5.11. Use these
jigs only for software versions prior to V5.11.
9.1.1 Required parts

The following parts and jigs (options) are required for PAM measurements.
Required parts when using H01, H02, H04(S), H08M, G04 or OF heads
Use for version V5.11 or later
Single/ Jig Glass board PZ1459* Same for all heads

Double
Conveyor
NXTBAS185
Jig Jig plate AA94E** Same for all heads
01MEC-0625
Triple Jig Glass board PZ4405* Same for all heads

Conveyor
NXTBAS185
Jig Jig tray AA83E** 6 parts
01MEC-0626
Jig Attachment PM0CBS* 32 parts
01MEC-0627

9. Measurement and Adjustment QD144-17
Triple Feeder Tray Feeder -M With 2-inch tray adapter loaded

Conveyor
01MEC-0628
Shared Parts Glass parts PZ5240* Number of parts used

H01, OF: 32 parts , H02 : 64 parts
H04(S), H08M, G04 : 128 parts
Parts Glass parts PZ3891* Use when combining the P03

camera and G04 head
Number of parts used : 128 parts
Nozzle dia. 5.0 AA0HR** H01: 1 parts , H02: 2 parts
dia. 5.0 AA07B** H04: 4 parts
dia. 5.0 AA93X** H04S: 4 parts
dia. 5.0 AA8LZ** H08M: 8 parts
dia. 5.0 AA6TD** G04: 4 parts
dia. 5.0 AA1CG** OF: 1 part
Other Glass part double-sided 10 mm width, half transparent

tape (available on market)
Use for versions prior to V5.11
Jig Glass board PZ1459* For all types of placing head
NXTBAS185
Jig Jig plate AA01B** For all types of placing head
Parts Glass parts PZ1460* Number of parts used

H01, OF: 32 parts , H02 : 64 parts
H04(S), G04 : 64 parts

Nozzle dia. 7.0 AA080** H01: 1 parts , H02 : 2 parts
dia. 7.0 AA07C** H04: 4 parts
dia. 7.0 AA93Y** H04S: 4 parts
dia. 7.0 AA6TM** G04: 4 parts
dia. 7.0 AA1CH** OF: 1 parts
Other Glass part double-sided tape 10 mm width, half transparent

(available on market)
Required parts when using the H08, H12(S), H12HS or V12 heads
Single/ Jig Glass board PZ1459* Same for all heads

Double
Conveyor
NXTBAS185
Jig Jig plate AA94E** Same for all heads
01MEC-0625
Jig plate AA94E** Same for all heads
Triple Jig Glass board Z4405* Same for all heads

Conveyor
NXTBAS185
Shared Parts 1005 white parts 10,000 part / reel
Nozzle f 0.7 AA735** H08: 8 parts ,

H12S, H12HS, V12: 12 parts
Other White part double-sided tape #5605 (50 mm x 100 m),

T4067B transparent

9.1.2 About the sample job

The machine application CD-ROM has a sample job for on machine PAM. For jobs with
conditions, edit to match the configuration of the machine.
Caution: Do not change the part data or placement sequence.
Do not optimize.
Jobs for single and double conveyor machines

Head sample job
H01 PAM_H01_7mmGlass_Shuffle_ver4_S~GM6x2~4.JOB
H04S PAM_H04S_7mmGlass_Shuffle_ver4_S~GM6x2~4.JOB
H08M PAM_H08M-
(8 nozzle operation) 8N_7mmGlass_Shuffle_Ver5_S~GM6x2~4.JOB
H08M PAM_H08M-
(Single nozzle operation) 1N_7mmGlass_Shuffle_Ver5_S~GM6x2~4.JOB
G04 PAM_G04_7mmGlass_Shuffe_ver4_S~GM6x2~4.JOB
G04 PAM_G04_Glass_P03_Shuffle_ver4_S~GM6x2~4.JOB
(for the P03 camera)
OF PAM_OF_7mmGlass_Shuffle_ver4_S~GM6x2~4.JOB
H08 PAM_H08_1005_ver4_S~GM6x2~4.JOB
H12(S), H12HS PAM_H12S_1005_ver4_S~GM6x2~4.JOB
V12 PAM_V12_1005_Ver3_S~GM6x2~4.JOB
Note: The number of placements when using the H02 head is 64. For the H04, H04S, H08M and
G04 heads the number of placements is 128. There are only 32 glass parts, which is not
enough for these numbers of placements. Divide the placement sequence of the sample
job to create jobs with 32 placements each. Divide into two jobs for the H02 head and four
jobs for the H04, H04S, H08M and G04 heads to acquire data for the required number of
placements.
Head type sample job
H01 PAM_H01_Glass_Shuffle_ver4_S~GM6x2~4.JOB
H04S PAM_H04S_Glass_Shuffle_ver4_S~GM6x2~4.JOB
G04 PAM_G04_Glass_Shuffle_ver4_S~GM6x2~4.JOB
OF PAM_OF_Glass_Shuffle_ver4_S~GM6x2~4.JOB

H08 PAM_H08_1005_ver4_S~GM6x2~4.JOB
H12(S), H12HS PAM_H12S_1005_ver4_S~GM6x2~4.JOB
Note: There are 64 placements when measuring H02, H04, H04S and G04 heads. When there
are only 32 glass parts, this is insufficient for the required placement quantity. Divide the
placements in the sample job into 32 placements for two jobs. By dividing into two jobs, it
is possible to acquire data for the required amount of placements.
Jobs for machines with triple conveyors
Head sample job
H01 RL2_TFM-PAM_H01_7mmGlass_shuffle_ver6_S~GM6x2~4.JOB
H02 RL2_TFM-PAM_H02_7mmGlass_shuffle_*_ver6_S~GM6x2~4.JOB
H04 RL_TFM-PAM_H04_7mmGlass_shuffle_*_ver6_S~GM6x2~4.JOB
H04S RL_TFM-PAM_H04S_7mmGlass_shuffle_*_ver6_S~GM6x2~4.JOB
G04 RL_TFM-PAM_G04_7mmGlass_shuffle_*_ver6_S~GM6x2~4.JOB
H08 TFM-PAM_H08_1005_ver4_S~GM3x4~4.JOB
H12(S) TFM-PAM_H12S_1005_ver4_S~GM3x4~4.JOB
H12HS TFM-PAM_H12HS_1005_ver4_S~GM3x4~4.JOB
Note: For measurement using the glass parts for triple conveyor machines, 32 measurements are
made each time. The H02 head requires 64 measurements and H04/H04S/G04 heads
require 128 measurements, therefore measure twice for the H02 head and four times for
H04/H04S/G04 heads.
For jobs that use H02, H04, H04S, or G04 heads, the number of jobs that are needed for
the required number of measurements is used. Change the jobs in the order indicated by
the number that appears in place of the asterisk (*) in the job name and then perform
measurement.
9.1.3 Notes on performing on machine PAM

During PAM measurements, the following are important:
• PAM is not supported for double lane conveyance. When a job that uses both
lane 1 and 2 is specified, measurement can only be performed on lane 1. To
perform PAM on lane 2, send a job which only uses lane 2 to the machine.
• When measuring the glass parts at lane 2, use the pickup position which is
exactly 64 places in front of the jig.
• If "NaN" displays above the measured PAM results on the operation panel, this
indicates that a vision processing error may have occurred during the
measuring process. If "NaN" or blank lines are in the results file, ignore the
affected data.

9.1.4 Positioning backup plates on machines with a double

conveyor
When using a double conveyor, change the position of backup pins depending on the type
of backup plates in lane 1 and the lane to be used for measurement. Refer to section 5.10
"Exchanging Backup Plates (When Performing Dual Lane Production with Lane 2 Brought
Forward)" for details.
When using standard backup plates for lane 1

Position the backup plates in the same way as for normal production. PAM measurement
is possible at lane 1 and lane 2.
Note: When PAM measurement is performed at lane 1, lane 2 should also be clamped.
280
280
For lane 2
280
280
For lane 1
(standard) 01MEC-0629E
When using backup plates for production with lane 2 brought forward
and performing PAM at lane 1
Move the lane 2 backup plate right up to the lane 1 side.
280
280
For lane 2
280
280
For lane 1
(production with lane 2 brought forward) 01MEC-0630E
When using backup plates for production with lane 2 brought forward
and performing PAM at lane 2
Slide the lane 2 backup plate to the rear. Align the front edge of the backup plate with the
edge of the plate under the backup plate.

280
280
For lane 2
280
280
For lane 1
(production with lane 2 brought forward) 01MEC-0631E

9.1.5 Preparing ( Use for version V5.11 or later )

When measuring for H01, H02, H04(S), H08M, G04 or OF heads on
modules with single or double conveyors
1. Use stickers to cover the two rows of dots that are adjacent to the corner marks. This
is to prevent the corner marks from being read mistakenly. The tape should be placed
on the surface with the printing.
Tape
Tape
Tape
Tape
NXTBAS188Ea
2. Next, set the glass board with the printed surface face up on the jig plate and secure the
glass board with the holders at all 4 corners.
Glass board
Holders Jig plate
Holders
01MEC-0632E
3. Affix double-sided tape (semi-transparent, 10 mm wide) to the glass board. Leave five
rows uncovered at the bottom and then cover four rows of dots with a strip of tape. For
the next strip of tape, leave two rows uncovered and then cover another four rows. Do
not cover the four corner marks. The number of strips required for each head is given
below.
• For H01 or OF head: 5 strips For H02, H04(S), H08M or G04 head: 9 strips
Double-sided tape
2 rows
4 rows
5 rows
01MEC-0633E
Note: It is essential that nothing is trapped between the tape and the glass board including air
pockets.

4. Set the glass parts with their beveled edges face down in jig plate. For the H01 and OF
heads, set 32 glass parts from the first row. Set 64 parts for the H02 head and 128 parts
for the H04(S), H08M and G04 heads.
Jig plate
Glass parts
01MEC-0634E
Note: Ensure that the surfaces of the glass board and parts are kept clean at all times.
When measuring for H01, H02, H04(S), G04 or OF heads on modules

with triple conveyors
Tape
Tape
Tape
Tape
NXTBAS188Ea
2. Affix double-sided tape (semi-transparent, 10 mm wide) to the glass board. Leave five
rows uncovered at the bottom and then cover four rows of dots with a strip of tape. For
the next strip of tape, leave two rows uncovered and then cover another four rows. Do
not cover the four corner marks. The number of strips required for each head is given
below.
• For H01 or OF head: 5 strips For H02, H04(S) or G04 head: 9 strips
Double-sided tape
2 rows
4 rows
5 rows
01MEC-0633E
Note: Ensure that there are no air bubbles or foreign matter between the glass panel and the
double-sided tape.

3. Insert the 32 attachments (PM0CBS*) in the 6 jig trays (AA83E**). Insert 6 attachments
in 5 jig trays and 2 attachments in 1 jig tray.
Jig tray
Attachment
01MEC-0635E
4. Prepare a tray feeder-M with a 2-inch tray adapter loaded and set it in the module to be
measured. Refer to the Tray Feeder Instruction Manual for details regarding tray
feeders.
5. Set the 6 jig trays (AA83E**) on the tray adapter.
Tray feeder-M
Jig tray
01MEC-0636E
6. Set the 32 glass parts in the jig trays on the tray feeder. Set 6 parts in trays 1 to 5 and
2 parts in tray 6.
Glass parts
01MEC-0637E

Preparing to perform measurements for H08, H12(S), H12HS or V12

heads
Tape
Tape
Tape
Tape
NXTBAS188Ea
Glass board
Holders Jig plate
Holders
01MEC-0632E
3. Affix a strip of double-sided tape (50 mm wide with a minimum of 100mm in length)
across the bottom left corner of the glass board as shown below. Do not cover the
corner marks from step 1 with this tape.
pockets.
Double-sided tape
50 mm
more than 100 mm
50 mm
50 mm NXTBAS190Eb
4. Set the white 1005 parts on an 8 mm feeder and set the pitch to be 2 mm pitch and then
set on the module to be used for PAM measurements.

9.1.6 Preparing ( Use for versions prior to V5.11 )

Preparing to perform measurements for H01, H02, H04(S) or G04 heads
Tape
Tape
Tape
Tape
NXTBAS188Ea
Holders Glass board
Jig plate
Holders
NXTBAS201E
3. Affix the number of strips indicated below of double-sided tape (10 mm wide) with the
first strip of tape covering the top 4 rows of dots, and the remaining strips affixed as
shown below with a gap of 3 rows in between each strip. Do not cover the top right or
bottom left end corner marks from step 1 with this tape.
• For the H01 head: 5 strips For the H04(S) head: 9 strips
Double-sided tape
4 rows
3 rows
1 row
NXTBAS189Ea

4. Set the glass parts with their beveled edges face down in jig plate. For the H01 and OF
heads, set 32 glass parts from the first row. Set 64 parts for the H02 head and 128 parts
for the H04(S) and G04 heads.
Jig plate
Glass parts
NXTBAS191E
Preparing to perform measurements for H08, H12(S) or H12HS heads

Tape
Tape
Tape
Tape
NXTBAS188Ea
2. Next, set the glass board with the printed surface face up on the jig and secure the glass
board with the holders at all 4 corners.
Holders Glass board
Jig plate
Holders
NXTBAS201E

3. Affix a strip of double-sided tape (50 mm wide with a minimum of 100mm in length)
across the bottom left corner of the glass board as shown below. Do not cover the
corner marks from step 1 with this tape.
pockets.
Double-sided tape
50 mm
more than 100 mm
50 mm
50 mm NXTBAS190Eb
4. Set the white 1005 parts on an 8 mm feeder and set the pitch to be 2 mm pitch and then
set on the module to be used for PAM measurements.

9.1.7 Placing accuracy measurement (PAM) flow chart

PAM is performed for each head.
When measuring PAM, remeasure the calibration data for the module before performing
PAM.
To check the accuracy of a module where PAM has previously been performed, perform
PAM without deleting the final offset file of the relevant head. The final offset file should only
be deleted when the placement accuracy is not good before performing PAM.
When performing production with the hybrid calibration measurement function enabled,
perform PAM measurement with the hybrid calibration measurement function setting
enabled. Refer to the "Additional Information" section in chapter "4. Production" in the NXT
II System Reference for details.
Change to PAM mode
Perform PAM
Are PAM results No

OK?
Yes
Cancel PAM mode
(When creating the final

offset file easily) (When creating the final
offset file manually)
Select the easy create command and Select the manually create command
the final offset file is sent to the machine. and acquire PAM results.
Calculate PAM results
First time How many times was Second time or more

PAM performed?
"Output File (1/1)" to output "Output File (1/2)" to output

the final offset file the final offset file
Generate the binary file

and text file
Transmit the binary file for

calibrating the machine
(Repeat PAM) NXTPAM001b

9.1.8 Setting PAM measurement mode

There are two PAM measurement modes available (explained below). Select the mode
according to your purpose.
a. [PAM mode] - for measuring placement accuracy, calculating values for the final
offset file and sending to the machine.
b. [Accuracy check mode] - for confirming the accuracy of placement only. (Supported
from V5.11)
Note: The steps below are performed using Accessory Software. For further details, refer to
"Performing on machine PAM" in the online Accessory Software operation manual on line.
Checks before setting PAM mode

Check the following before setting the PAM mode
a. Transmit the job to the machine in normal mode.
b. Use the nozzle exchange command to return all nozzles currently held by the head
to the nozzle station.
c. Confirm that there are no backup pins set on the backup plates.
d. In the [Loader setting] category of [Machine Configuration] in Accessory Software,

set both [Maximum panel width for lane 1] and [Maximum panel width for lane 2] to
[50 mm to 280 mm].
Specifying the PAM mode

1. From the machine accessories page in Accessory Software, select the module for which
PAM measurement is to be performed and click [Remote operation].
2. Click [On machine PAM]. The page changes to display the available options.
01MEC-0638E
3. Click [Change to PAM mode] or [Change to accuracy check mode].
01MEC-0639E

4. Click [Start]. The mode change is sent to the selected module. If completed
successfully, the module changes to PAM mode.
01MEC-0008E
Note: When in PAM mode, the background color of the operation panel is dark brown.
To cancel PAM mode, click [Remote operation] - [On machine PAM] - [Cancel PAM mode].
Click [Start] and then [Close] to return the module to the normal operating display. Also be
aware that when the machine returns from PAM mode to production operation, the job is
deleted from the machine.
9.1.9 PAM measurements

Measure using the following procedure. If backup pins are set on the backup plate, remove
them before performing the procedure.
Note: If backup pins remain on the backup plate during PAM measurement, the jig will collide with
the pins.
1. Transmit the PAM job from Fuji Flexa to the machine. For [Accuracy check mode],
[CHECK] is displayed before the name of the job transmitted.
2. Set the necessary feeder on the module at the required slot.
a. When performing PAM using a H08, H12(S), H12HS or V12 heads, use the feeder
with white 1005 parts prepared earlier in the appropriate position and push set for the
feeder in the module.
b. When performing PAM using H01, H02, H04(S), H08M, G04 or OF heads on
machines with single or double conveyors, set an empty 12 mm feeder with 4 mm
pitch in the module and push the set button for that feeder position.
Note: For the H08M head, set 2 empty feeders.
c. When performing PAM using H01, H02, H04(S), G04 or OF heads on machines with
triple conveyors, set a tray feeder M-type on the module in the slot specified in the
job and push the set button for that feeder position.
d. When performing PAM on module with a tray unit-L/LT, skip this step.
3. Push START on all modules. Calibration is automatically performed and the conveyors
are automatically adjusted to be the correct size for the jig.
Note: It is necessary to push START on all modules. The conveyor width has to be correct on all
modules.
NXTOPE139

4. Upon completing calibration, the machine waits for panels to be loaded. Push CYCLE
STOP on all of the modules.
5. Push MANUAL on the module to perform PAM to display the manual commands.
6. Use the arrow keys to highlight the cleaning pictogram and then push OK. The module
is unclamped and moved forward a little. When unclamped, the module moves forward
a short distance and can pinch or severe any items between the module and the base.
01MEC-0007
7. Confirm that the surrounding is safe. Grip the handle for the module and squeeze to
release the module brake. Gently pull the module forward.
8. Set the jig plate (for modules with single or double conveyors) or the glass panel (for
modules with triple conveyors) in lane 1 on the module. When measuring H01, H02,
H04(S), H08M, G04, or OF head placement accuracy on machines with single or double
conveyors, set the jig plate with the glass parts set.
10.Push MANUAL on the machine to exit the manual commands and then push START.
The module then places parts and then measures the placing accuracy. Upon
completion, the jig plate is automatically unclamped.
Caution: If there are many parts to measure, the machine may appear to have stopped with the panel
clamped. However, the machine is actually outputting the measurement results during this
time. Do not insert hands or other body parts into the machine.
NXTOPE139
11.Wait until all operations are completed and the jig plate is unclamped, and then push
CYCLE STOP to return to the main screen.
12.Push MANUAL on the module to display the manual commands. Use the arrow keys to
highlight the panel removal pictogram and push OK.
13.Follow the guidance displayed on the screen to remove the jig plate and gently push the
module back.
14.Push MANUAL.

15.Write down the placement accuracy results displayed on the operation panel.
01MEC-0640
16.If the PAM results are outside the tolerance range, it is necessary to create a final offset
file. Refer to section 9.1.10 "Creating a final offset file" for details. The final offset file
cannot be created in [Accuracy check mode].
M3-2 module, M6-2 module (mm)

OF, H08, H01,
H04S
H12HS H04 H02,
H08M
V12 G04
Placement Cpk҈1.00 ±0.050 ±0.050 ±0.040 ±0.030
accuracy (3 ) Cpk҈1.33 ±0.066 ±0.066 ±0.053 ±0.040
M6-2SP module (mm) (mm)

H12HS H01, H02,
H08M
V12 G04
Placement Placement
accuracy (3 ) Cpk҈1.00 ±0.038 ±0.030 accuracy (3 ) ±0.010
NXTBAS202d
17.For the H01, H02, H04(S), G04 or OF heads, remove all glass parts from the tape and
place them back in the jig plate. For the H08, H12S, H12HS or V12 heads, remove the
tape along with all components placed on it when measuring white 1005 parts and affix
new tape on the glass board.
When measuring for H02, H04(S), or G04 heads on modules with triple
conveyors
In the following cases, in order to achieve the required number of placement points for
accurate measurement, it is necessary to measure multiple times. Change the job and
measure twice for H02 heads and four times for H04(S) and G04 heads. Refer to section
9.1.2 "About the sample job" for details.
a. When measuring for H02, H04(S), or G04 heads on modules with triple conveyors.
b. When measuring H02, H04(S) or G04 heads on machines with single or double
conveyors and there are only 32 glass parts

9.1.10 Creating a final offset file

With [PAM mode] a final offset file is created after the completion of PAM measurements.
There are two ways to create a final offset file, the easy creation method and the manual
creation method.
The easy creation method does not use Accessory Software and the final offset values can
be sent to the machine easily. Use the easy creation method except when it is strictly
necessary to use the manual method. The manual method should only be used when the
following is true.
a. Offset values are to be edited
b. When measuring for H02, H04(S), or G04 heads on modules with triple conveyors.
c. When measuring H02, H04(S), H08M or G04 heads on machines with single or
double conveyors and there are only 32 glass parts
Caution: Do not change the name of the final offset file. The file may not be able to be read by the
machine and the offset values will not be saved in the machine.
The final offset file cannot be created in [Accuracy check mode]. To acquire the
measurement results when using this mode, save the data in the same manner as for the
manual creation method.
Final offset file easy creation method

1. When the PAM results are displayed on the operation panel, use the arrow keys to
select the easy creation command and push OK. The final offset file will be created
momentarily and the main screen displayed.
01MEC-0641
2. When measuring again to confirm the accuracy, set the jig plate in the machine and
push START. Pushing START saves the final offset file in the machine and starts
measurement.
3. When PAM is complete, create a backup of the final offset file. Select [Calibration] -
[Delete and save offset file] in Accessory Software.
01MEC-0642E

4. Select the final offset file to backup and click [Save file].
01MEC-0643E
5. With the easy creation method, it is not necessary to transmit the file. The offset file is
saved in the machine automatically at any of the following points.
• When START is pushed with the machine in PAM mode
• When the machine is changed from PAM mode to production mode
• When the machine is restarted
Final offset file manual creation method

Note: The steps shown below are guidance to operations in Accessory Software. For further
details, refer to on machine PAM in the Accessory Software operation manual on line.
1. When the PAM results are displayed on the operation panel, use the arrow keys to
select the manual creation command and push OK. The main screen displays.
01MEC-0644
2. Check that the module that you wish to perform PAM on is selected and click [Remote
operation] - [On machine PAM].
01MEC-0638E

3. Click [Start Acquisition] to start the acquisition process.
01MEC-0645E
Note: [Start Acquisition] downloads the results from the machine to the server and then displays
a list of the acquired files. By saving a file from this list, the results are downloaded from
the server to the client computer. The results are used for correcting the placement
accuracy.
4. Right-click the file to download from the list that displays and click [Save Target As]. A
[Save As] dialog box is displayed.
NXTOPE156E
5. Specify the location to save the file and click [Save]. The results are saved to the
specified location.
Note: It is best to save each file to the desktop using an easily understood file name (such as
PAM1.dat).
6. When using PAM mode, edit the saved data and save in the machine as the final offset
file. Refer to section 9.1.11 "Combining multiple offset files into one" and section 9.1.12
"Correcting the placement accuracy (final offset file)" for details.

9.1.11 Combining multiple offset files into one

Under the following conditions, because offset files are created for each time
measurements were performed, it is necessary to combine the offset files into one. This
section explains how to combine multiple offset files into one. This procedure is not
required except in the following conditions.
The Excel file used in this operation is only available on the application CD for version V5.12
and later.
a. When measuring for H02, H04(S) or G04 heads on modules with triple conveyors.
b. When measuring H02, H04(S), H08M or G04 heads on machines with single or
double conveyors and there are only 32 glass parts
Procedure
1. Open the Excel file on the machine application CD.
• :\Documents\PAM\ CombineDatFile.xls
2. Click the [Select Files] button.
01MEC-0852
3. A file selection dialog box displays. Select the offset files to be combined and click
[Open].
01MEC-0853E

4. Check the number of files being combined and then click the [Combine Dat File] button.
01MEC-0854
5. A dialog box displays confirming whether you wish to save the combined offset file.
Click [Yes].
01MEC-0855E
6. A placement point offset file necessary for accuracy measurement is created. Use the
PAM data calculation Excel file to create the operational data. Refer to section 9.1.12
"Correcting the placement accuracy (final offset file)" for details.

9.1.12 Correcting the placement accuracy (final offset file)

Creating calculation data
1. Open the excel file for calculating PAM data which is located on the NXT installation CD.
• /Documents/PAM/PamToFinalOffset_v***.xls
Note: It is necessary to click [Enable Macros] in the displayed message box.
2. Select the language to use, click [Processing Start], then specify the PAM1.dat file that
is measured.
NXTOPE144Ea
Note: The .dat file naming system is as follows; select the target file checking by the module serial
No. and the head serial No. Those serial numbers can be confirmed on the information
command of the machine manual mode.
PAM01_M3_XNo01_H01_000020_HBCG.dat
Module nickname
Module serial number
Head type
Head serial number
Option
Option : HBCC is hybrid calibration measurement ON using 1005 parts for measurement
HBCG is hybrid calibration measurement ON using glass parts for measurement
NXTOPE241Eb
3. Click [Yes] in the dialog box after selecting the .dat file.
NXTOPE242E
4. The measured PAM results are loaded, calculated and displayed in the result and final
offset sheets.

Result sheet
The result sheet shows the placement accuracy (3 sigma) for the entire module, each angle
and each holder as well as the average placement accuracy for each angle and holder.
Values in red indicate that the value is outside the tolerance range.
• Click [CPK..] to change the CPK coefficient.
• Click [Print] to print the result sheet. Enter the user name and production
number. When the values of the results are outside the tolerance range, it is not
possible to print.
Final offset sheet

The manual final offsets (X, Y, Q) display by placement angles for each nozzle holder.
When the values of the results are outside the tolerance range, it is not possible to print.
NXTOPE244E
Outputting the correction file

1. Generate the correction file from the final offset sheet. The method differs depending
on the measurement and output conditions.
a. If performing PAM for the first time
• Click [Output File (1/1)].
NXTOPE245E

b. If performing PAM for the second time or more
• Click [Previous offset value] then [Output File (1/2)].
NXTOPE246E
c. If performing PAM for the second time or more, and changing the manual offset value
only for items which have exceeded a specified value.
• Click each range button, then input the desired value.
NXTOPE247

d. If performing PAM for the second time or more, and updating a percentage of the
measured results to the previous results.
• Click each [Reflection percentage] button, then input the desired value.
NXTOPE248
e. If performing PAM for the second time or more, and changing the manual offset value
only for certain items.
• Toggle the button (green) to OFF at the desired item.
NXTOPE249
Note:
1. If there are many items to change, select [ON] for those items which are not to be
changed.
2. If there are only a few items to change, select [All ON] and then change only those items
which are to be changed to [OFF].

• In order to cancel the previous offset value, click [Delete previous offset].
NXTOPE251E
2. Click [Output File (1/1)] or [Output File (1/2)] to generate successively the binary file and
the text file. The dialog boxes display the file path and file name, click [OK].
NXTOPE252E
Note: The file naming system is as follows;
M3_XNo1_H01_000020_HBCG_050822134648.bin(.txt)
Module nickname
Module serial number
Head type
Head serial number
Option
File creation date (YYMMDDHHMMSS)
*bin files do not have a creation date
Option: HBCC is hybrid calibration measurement ON using 1005 parts for measurement
HBCG is hybrid calibration measurement ON using glass parts for measurement
NXTOPE253Eb

3. In Accessory Software, transmit the binary file to the machine.
a. From [Machine Configuration], select the module to which to send the file.
b. Click [Calibration].
c. Click [Send offset file].
NXTOPE254E
d. Select the target file, then click [Send File].
NXTOPE255E
e. The final offsets are updated at the machine at either of the following times.
• When START is pushed with the machine in PAM mode.
• When the machine is changed from PAM mode to normal production mode.
• When the machine is rebooted.

9.1.13 Changing the type of PAM mode

There are three type of PAM modes available. These three types are [Place & Measure],
[Measure], and [Place]. The [Place & measure] mode is the default type. With this type of
mode, the parts are picked and placed on the module and then the placing accuracy is
measured on the module. If [Place] is specified, then the module only places the PAM parts
on the glass board. If [Measure] is specified, then the module only measures the placing
accuracy of previously placed PAM parts.
Follow the procedures below to change the type of PAM mode.
1. When in PAM mode, push MANUAL to display the manual commands.
01MEC-0004
2. Use the arrow keys to highlight the diagnosis pictogram and then push OK.
01MEC-0005a
3. The 3 modes are displayed on the operation panel. The one that is highlighted (green)
represents the current type of mode in use. Use the arrow keys to highlight a different
mode if necessary, and push OK to exit this screen.
01MEC-0006
4. Push MANUAL to return to the main screen.

9.2 Sensitivity Adjustment for the Conveyor Panel

Pass Sensor
For the panel pass sensor on the conveyor, there are cases in which an error displays when
the conveyor width is changed manually such as when a panel needs to be removed
because of some problem. When errors occur, follow one of the methods below to restore
the automatic adjustment. For sensor and sensor amp positions, refer to section 4. "Sensor
Positions".
a. Turn the ballscrew by hand for the conveyor to make the width narrower until a
positive values display in the sensor amplifiers. (Check the sensor amplifier and
when a positive value displays, the automatic sensitivity adjust function is restored).
b. Reset the sensor sensitivity using Accessory Software. (Refer to section 9.2.1
"Remote adjustment procedure" for details).
c. Manually reset the sensor sensitivity at the sensor amplifier on the machine. (Refer
to section 9.2.2 "On-machine adjustment procedure" for details).
9.2.1 Remote adjustment procedure

Reset the sensor sensitivity using Accessory Software. All conveyor sensors for the
module can be adjusted at once when using this method. Adjustment of the sensors using
Accessory Software is much easier to perform than on-machine adjustment, particularly
when many modules exist in a line.
1. Start Accessory Software and from Floor Monitor, click the machine name that has the
sensor to be adjusted. The machine Accessories log on page is displayed.
2. Select a user ID from the drop-down list.
3. Enter the password for the user and click [Log on].
4. Select the module on which to adjust the sensor and click [Remote Operation].
5. Click [Conveyor sensor sensitivity adjustment].
6. Ensure that there are no panels or any other items blocking any of the sensors and then
click [Start]. The sensitivity for the conveyor sensors for the selected module are
adjusted.

9.2.2 On-machine adjustment procedure

Manually reset the sensor sensitivity at the sensor amplifier on the machine.
WARNING

magnetic field.
• Do not look directly into the panel pass sensor laser. Eye damage
may be caused by the looking directly into the sensor laser. Wear
tinted protective glasses.
CAUTION
may be deformed.

55 mm).
Linear motor coil
Linear motor shaft
X-axis gear cover


2. Open the lid of the sensor amplifier that needs to be adjusted.
1 Lane 1 (front) conveyor sensor LH 4

3
2 Lane 1 (front) conveyor sensor RH 2 Mode button
1
3 Lane 2 (rear) conveyor sensor LH
4 Lane 2 (rear) conveyor sensor RH
3
1 Arrow button
Digital display
4
2
01MEC-0336Ea
3. Push button 1, and then button 2 within five seconds to set the input mode to light-on
(L-on).
2 1
01MEC-0337b
4. Next, set the sensitivity. Push MODE (3) for about three seconds, and then push it once
more to enter the setting mode. The sensitivity setting screen is opened.
MODE button (3)
or 01MEC-0338Ec
5. If [Std] is displayed, push either of the arrow buttons once to switch to [SEtP] mode. If
[SEtP] is displayed, this step is not necessary.
6. Push MODE once.
7. Push the arrow buttons to set the value to "-4P".
01MEC-0340
8. Push MODE for three seconds to register the value.
9. Close the lid for the sensor amplifier and return the module to its original position. (Refer
to section 5.1 "Pulling Out/Returning a Module".)

9.3 Module Vacuum Sensor

9.3.1 Procedure
1. Pull the module that needs to be adjusted forward. (Refer to section 5.1 "Pulling Out/
Returning a Module".) If the module is the first module on the base and has the side
cover on the left side, remove the side cover to gain access to the sensor position.
2. Locate the module vacuum sensor. It is positioned on the left lower front side. There
are two sensors at this position displaying numbers. The vacuum sensor is the sensor
closest to the front of the module.
Module pressure sensor

(PS6-103G-PWM-019)
Module vacuum sensor
(PS6-102V-PWM-020) 01MEC-0304Ea
3. Change the MODE switch to S1 using a precision minus screwdriver.
4. Use the screwdriver to adjust the SET1 switch until the value -59 displays.
Note: Changing the MODE switch only changes the display. If SET1 or SET2 are adjusted when
the value for that item is not being displayed, the value will still change.
5. Change the MODE switch to S2 with the screwdriver.
6. Use the screwdriver to adjust the SET2 switch until the value 00 displays.
7. Change the MODE switch back to ME to display the current vacuum value.
Note: If any of the switches are changed while the value for that switch is not being displayed, be
sure to adjust that value to be correct after displaying it.
8. If the side cover was removed, replace it and then return the module to its original
position. (Refer to section 5.1 "Pulling Out/Returning a Module".)

9.4 Module Pressure Sensor

9.4.1 Procedure
1. Pull the module that needs to be adjusted forward. (Refer to section 5.1 "Pulling Out/
Returning a Module".) If the module the first module on the base and has the side cover
on the left side, remove the side cover to gain access to the sensor position.
2. Locate the module pressure sensor. It is positioned on the left lower front side. There
are two sensors at this position displaying numbers. The pressure sensor is the sensor
farthest from the front of the module.
Module pressure sensor

(PS6-103G-PWM-019)
Module vacuum sensor
(PS6-102V-PWM-020) 01MEC-0304Ea
3. Change the MODE switch to S1 using a precision minus screwdriver.
4. Use the screwdriver to adjust the SET1 switch until the value 0.40 displays.
Note: Changing the MODE switch only changes the display. If SET1 or SET2 are adjusted when
the value for that item is not being displayed, the value will still change.
5. Change the MODE switch to S2 with the screwdriver.
6. Use the screwdriver to adjust the SET2 switch until the value 0.0 displays.
7. Change the MODE switch back to ME to display the current pressure value.
Note: If any of the switches are changed while the value for that switch is not being displayed, be
sure to adjust that value to be correct after displaying it.
8. If the side cover was removed, replace it and then return the module to its original
position. (Refer to section 5.1 "Pulling Out/Returning a Module".)

9.5 Base Vacuum Sensor

1. Locate the base vacuum sensor. It is positioned on the front left side and is the right
display of the two displays.
2. Push and hold the SET button until "LoC" displays.
3. Continue pushing one of the arrow keys until "UnL" displays and then push SET.
4. Push and hold SET for longer than two (2) seconds. The display will change to display
"SOG", "Sor", "rED", or "Grn".
5. Push an arrow key repeatedly until SoG displays.
6. Push SET and the characters "HYS" or "Ynd" display.
7. Push an arrow key repeatedly until HYS displays.
8. Push SET and the characters "no" or "nC" will display.
9. Push an arrow key repeatedly until “nC” displays.
10.Push SET and a value will display.
11.Push an arrow key repeatedly until 2.5 displays.
12.Push SET and characters will display.
13.Push an arrow key repeatedly until the characters like "nAn" display.
14.Push SET to complete the sensor initial settings.
15.Push SET and "n_1" flashes on the display alternating with the value.
16.Push the up key to display the value for n_1.
17.Use the arrow keys to change the blinking value to "0".

Note: If no actions are performed within ten seconds, the display changes back to the alternating
display. Push one of the arrow keys to change the display back.
18.Push SET to change to the second digit.
19.Use the arrow keys to change the second digit to "9".
20.Push SET to change to the third digit.
21.Use the arrow keys to change the third digit to "5".
22.Push SET to change to the sign position.
23.Use the arrow keys to change the sign to the " " shape. This indicates that the minus
sign is selected.
24.Do not push any keys once the correct value of -59.0 has been entered. Automatically
the display will begin to alternate between "n_1" and the value.
25.Push SET and then push SET again to display to the current measured value.
26.Push and hold SET until "UnL" displays.
27.Use the arrow keys to change the display to "LoC" and then push SET to complete the
setting procedure.

9.6 Base Pressure Sensor

1. Locate the base pressure sensor. It is positioned on the front left side and is the left
display of the two displays.
2. Push and hold the SET button until "LoC" displays.
3. Continue pushing one of the arrow keys until "UnL" displays and then push SET.
4. Push and hold SET for longer than two (2) seconds. The display will change to display
"SOG", "Sor", "rED", or "Grn".
5. Push an arrow key repeatedly until SoG displays.
6. Push SET and the characters "HYS" or "Ynd" display.
7. Push an arrow key repeatedly until HYS displays.
8. Push SET and the characters "no" or "nC" will display.
9. Push an arrow key repeatedly until “no” displays.
10.Push SET and a value will display.
11.Push an arrow key repeatedly until 2.5 displays.
12.Push SET and characters will display.
13.Push an arrow key repeatedly until the characters like "nAn" display.
14.Push SET to complete the sensor initial settings.
15.Push SET and "P_1" flashes on the display alternating with the value.
16.Push the up key to display the value for P_1.
17.Use the arrow keys to change the blinking value to "0".

Note: If no actions are performed within ten seconds, the display automatically changes back to
the alternating display. Push an arrow key to change the display back.
18.Push SET to change to the second digit.
19.Use the arrow keys to change the second digit to "0".
20.Push SET to change to the third digit.
21.Use the arrow keys to change the third digit to "4".
22.Push SET to change to the sign position.
23.Use the arrow keys to change the sign to the “ “shape. This indicates that the positive
sign is selected.
24.Do not push any keys once the correct value of 0.40 has been entered. Automatically
the display will begin to alternate between "P_1" and the value after a short time.
25.Push SET and then push SET again to display to the current measured value.
26.Push and hold SET until "UnL" displays.
27.Use the arrow keys to change the display to "LoC" and then push SET to complete the
setting procedure.

MEMO:

QD144-17 10. Supplementary Information
10. Supplementary Information

10.1 Noise Levels
10.1.1 Measured noise levels
The following table shows the measured noise levels for the machine during operation.
Measurement Points (in the figure) Maximum Noise Level (dB)
(1) Distance from the front side of the machine: 1m 73.5
(2) Distance from the right side of the machine: 1m 72.0
(3) Distance from the left side of the machine: 1m 71.6
(4) Distance from the rear side of the machine: 1m 70.4
M3-2 x 2 (H01) - M6-2 (H01+Tray unit-LT)
(4)
(3) NXT-2 (2)
(1) 01MEC-0368
WARNING
Operators should use hearing protection such as ear plugs in

operating environments where noise levels are high enough to
cause hearing damage (80 dB or higher).

10. Supplementary Information QD144-17
MEMO:

QD144-17 Index
Index
Numerics Base CPU box
2M-2 base Functions ............................................. 53
Functions ............................................ 47 Replacing .......................................... 532
4M-2 base Base pressure sensor
Functions ............................................ 47 Adjusting ........................................... 629
A Base support
Adjusting Lubricating ......................................... 266
Base pressure sensor ....................... 629 Base vacuum sensor
Base vacuum sensor ........................ 628 Adjusting ........................................... 628
Conveyor panel pass sensor sensitivity Boards in the Base CPU Box
........................................................... 623 Replacing .......................................... 536
Module pressure sensor ................... 627 Boards in the Module CPU Box
Module vacuum sensor ..................... 626 Replacing .......................................... 522
Tray unit-L belt tension ..................... 344 Body
Tray unit-LT belt tension ................... 350 Components ........................................ 23
Tray unit-LTC belt tension ................. 357 Brush on the station type brush unit
Tray unit-M belt tension .................... 366 Replacing .......................................... 307
Air regulator Brush unit filter
Cleaning ............................................ 299 Cleaning ............................................ 298
Attaching C
Module side covers ........................... 555
Checking
Nozzle station ................................... 187
Conveyor belt tension ............... 339, 388
Placing head ..................................... 175
Conveyor motor belt tension ............. 394
Tray unit-M ........................................ 197
CZ-axis belt tension .......................... 391
B H04(S) head mechanical valve O-rings
Backup plates ........................................................... 265
Exchanging ....................................... 191 H08 head mechanical valve O-rings . 265
Base H08M head mechanical valve O-rings

........................................................... 265
Functions ............................................ 47
H12(S) head mechanical valve O-rings
Machine configuration ......................... 45 .......................................................... 265
Sensor position ............................. 56, 69 H12HS head mechanical valve O-rings
........................................................... 265
Base control box 1
Tray unit-L belt tension ...................... 344
Replacing .......................................... 526
Tray unit-L tray drawer bottom surface
Base control box 2 sheet ................................................. 347
Replacing .......................................... 529 Tray unit-LT belt tension ................... 350
Base CPU battery Tray unit-LT tray drawer bottom surface
sheet ................................................. 354
Replacing .......................................... 434

Index QD144-17
Tray unit-LTC belt tension ................. 357 Reject parts conveyor belt ................. 243
Tray unit-LTC tray drawer bottom surface Soft backup pins ................................ 390
sheet ................................................. 361
Tray unit-L conveyor belts ................. 243
Tray unit-M belt tension .................... 366
Tray unit-L fan filter ........................... 311
V12 head mechanical valve O-rings . 265
Tray unit-L shuttle belts ..................... 243
Cleaning
Tray unit-LT conveyor belts ............... 244
Air regulator ...................................... 299
Tray unit-LT feeder slots and connectors
Brush unit filter .................................. 298 .......................................................... 235
Conveyor belt cleaner ....................... 389 Tray unit-LT reject parts box ............. 228
Conveyor belts .................................. 389 Tray unit-LT shuttle belts ................... 244
Feeder pallet ..................................... 230 Tray unit-LTC conveyor belts ............ 244
Feeder pallet and part supply base Tray unit-LTC feeder slots and
connector .......................................... 388 connectors ......................................... 235
H01 head flange filter ........................ 251 Tray unit-LTC shuttle belts ................ 244
H01 head sleeve assembly ............... 278 Tray unit-M ........................................ 282
H02 head flange filter ........................ 251 V12 head mirrors ............................... 236
H04(S) head syringes ....................... 252 V12 head prism glass ........................ 238
H04(S) nozzles with filters ................ 378 V12 head syringes ............................ 252
H08 head syringes ............................ 252 Vacuum pump filter ........................... 309
H08M head syringes ......................... 252 Waste tape box ................................. 227
H08M nozzles with filters .................. 385 Waste tape cutter .............................. 398
H12(S) head syringes ....................... 252 Waste tape processing unit duct ....... 398
H12HS head syringes ....................... 252 Components
Hybrid calibration jig parts ................. 373 Body .................................................... 23
Hybrid calibration marks ................... 373 Feeder pallet ....................................... 30
Linear motor cooling fan filter ............ 267 Mark camera ....................................... 29
Mark camera light half mirror ............ 300 Mark camera light ................................ 29
Mark camera light source .................. 300 MCU (Module Change Unit) ................ 41
Mist separator filter ........................... 308 Nozzle changer ................................... 36
Module (inside) ................................. 233 Panel height detection function ........... 38
Module Top Cover ............................ 372 Parts camera ....................................... 28
Nozzle pick-up surface ...................... 249 PCU (Pallet Change Unit) ................... 39
Nozzle station ................................... 229 PCU-2 (Pallet Change Unit) ................ 40
Nozzles ............................................. 374 Placing head ....................................... 24
Parts camera glass cover ................. 231 Reject parts conveyor ......................... 35
Parts camera glass cover inside light unit Tray unit-L ........................................... 31
........................................................... 232
Tray unit-LT ......................................... 32
Parts camera lens ............................. 301
Tray unit-LTC ...................................... 33
Placing head vacuum filters .............. 245
Tray unit-M .......................................... 34
Reject parts box ................................ 228

QD144-17 Index
Waste tape processing unit ................. 37 E

Consumable Parts Empty trays
About Consumable Parts .................. 409 Removing empty trays ...................... 371
Control system Equipment Check
Functions ............................................ 53 How to check I/Os ............................... 55
Conveyer controller Exchanging
Replacing .......................................... 545 Backup plates .................................... 191
Conveyor F
Checking belt tension ................ 339, 388 Feeder pallet
Cleaning belt cleaner ........................ 389 Cleaning ............................................ 230
Cleaning belts ................................... 389 Components ........................................ 30
Lubricating ........................................ 335 Functions ............................................. 52
Conveyor belt cleaner Loading ..................................... 118, 125
Replacing .......................................... 414 Removing .................................. 118, 125
Conveyor belts Sensor position ................................... 73
Replacing .......................................... 409 Feeder pallet and part supply base connector
Conveyor motor Cleaning ............................................ 388
Checking belt tension ........................ 394 Feeder pallet and parts supply base
Conveyor panel pass sensor connector
Adjusting sensitivity ........................... 623 Replacing .......................................... 563
Cooling fan Feeder pallet DC power supply unit
Replacing .......................................... 556 Replacing .......................................... 542
Cover attachment Functions
M6-2 extended conveyor module ...... 591 2M-2 base ........................................... 47
Tray unit-L ......................................... 566 4M-2 base ........................................... 47
Tray unit-LT ....................................... 574 Base .................................................... 47
Tray unit-LTC .................................... 583 Base CPU box ..................................... 53
Cover detachment Control system .................................... 53
extended conveyor module ............... 591 Double conveyor ................................. 53
Tray unit-L ......................................... 566 Feeder pallet ....................................... 52
Tray unit-LT ....................................... 574 H01 head ............................................. 50
Tray unit-LTC .................................... 583 H02 head ............................................. 50
CZ-axis H04(S) head ........................................ 50
Checking belt tension ........................ 391 H08 head ............................................. 50
D H08M head .......................................... 50

H12(S) head ........................................ 50
Double conveyor
H12HS head ........................................ 50
Functions ............................................ 53
M3-2 module ....................................... 48
Sensor position ................................... 77
M6-2 extended conveyor ..................... 53

Index QD144-17
M6-2 module ....................................... 48 H02 head flange filter

M6-2SP module .................................. 48 Cleaning ............................................ 251
Mark camera ....................................... 52 H04 head
Module ................................................ 48 Lubricating ......................................... 315
Module CPU box ................................. 53 H04(S) head
Module servo box ................................ 53 Functions ............................................. 50
Nozzle changer ................................... 51 Lubricating ................................. 256, 283
Operation panel .................................. 53 H04(S) head mechanical valve O-rings
Panel conveyance ............................... 53 Checking ........................................... 265
Panel height detection function ........... 54 Replacing .......................................... 327
Parts camera ....................................... 52 H04(S) head syringes
Parts supply system ............................ 52 Cleaning ............................................ 252
Placing head ....................................... 49 H04(S) head vacuum filters
Single conveyor .................................. 53 Replacing .......................................... 307
Tray unit-L ........................................... 52 H04(S) nozzle filters
Tray unit-LT ......................................... 52 Replacing .......................................... 378
Tray unit-LTC ...................................... 52 H04(S) nozzles with filters
Tray unit-M .......................................... 52 Cleaning ............................................ 378
V12 head ............................................. 50 H04S head
Vision system ...................................... 52 Lubricating ......................................... 317
Fuse on a base control I/F board H08 head
Replacing .......................................... 448 Functions ............................................. 50
Fuse on base remote I/O boards Lubricating ......................... 256, 283, 319
Replacing .......................................... 444 H08 head mechanical valve O-rings
Fuse on boards inside a module Checking ........................................... 265
Replacing .......................................... 441 Replacing .......................................... 327
H H08 head syringes
H01 head Cleaning ............................................ 252
Functions ............................................ 50 H08 head vacuum filters
Lubricating ........................................ 312 Replacing .......................................... 307
H01 head flange filter H08M head
Cleaning ............................................ 251 Functions ............................................. 50
H01 head sleeve assembly Lubricating ......... 242, 256, 283, 286, 325
Cleaning ............................................ 278 H08M head mechanical valve O-rings
H02 head Checking ........................................... 265
Lubricating ........................................ 313 H08M head syringes
Cleaning ............................................ 252

QD144-17 Index
H08M head vacuum filters L

Replacing .......................................... 307 Linear motor cooling fan
H08M nozzle filters Cleaning filter .................................... 267
Replacing .......................................... 385 Replacing filter .................................. 307
H08M nozzles with filters Loading
Cleaning ............................................ 385 Feeder pallet ............................. 118, 125
H12(S) head Lubricating
Functions ............................................ 50 Base support ..................................... 266
Lubricating ........................ 256, 283, 319 Conveyor ........................................... 335
H12(S) head mechanical valve O-rings H01 head ........................................... 312
Checking ........................................... 265 H02 head ........................................... 313
Replacing .......................................... 327 H04 head ........................................... 315
H12(S) head syringes H04(S) head .............................. 256, 283
Cleaning ............................................ 252 H04S head ........................................ 317
H12(S) head vacuum filters H08 head ........................... 256, 283, 319
Replacing .......................................... 307 H08M head ........ 242, 256, 283, 286, 325
H12HS head H12(S) head ...................... 256, 283, 319
Functions ............................................ 50 H12HS head .............. 256, 283, 284, 321
Lubricating ................ 256, 283, 284, 321 Module support ................................. 266
H12HS head mechanical valve O-rings Nozzle changer up/down shafts ........ 304
Checking ........................................... 265 PCU (Pallet Change Unit) ................. 401
Replacing .......................................... 327 PCU-2 (Pallet Change Unit) .............. 405
H12HS head syringes Tray unit-L ......................................... 342
Cleaning ............................................ 252 Tray unit-LT ....................................... 348
H12HS head vacuum filters Tray unit-LTC .................................... 355
Replacing .......................................... 307 Tray unit-M (tray stoppers) ................ 364
Hybrid calibration jig parts Tray unit-M (TY-axis clutches) .......... 362
Cleaning ............................................ 373 V12 head ........... 239, 256, 283, 285, 323
Hybrid calibration marks Waste tape processing unit ............... 341
Cleaning ............................................ 373 X-axis gears ...................................... 269
Hybrid calibration unit XY-robot ............................................ 287
Sensor position ................................... 81 XY-robot flat cables ........................... 294
I Y-axis flat cables ............................... 274
Inserting Y-axis rollers ..................................... 274
Tray unit-L ......................................... 144 M
Tray unit-LT ....................................... 150 M3-2 module
Tray unit-LTC .................................... 164 Functions ............................................. 48
Machine configuration ......................... 42

Index QD144-17
M6-2 extended conveyor Module CPU battery

Sensor position ................................... 80 Module CPU box
M6-2 extended conveyor module Functions ............................................. 53
Cover attachment .............................. 591 Replacing .......................................... 519
Cover detachment ............................. 591 Module pressure sensor
M6-2 module Adjusting ........................................... 627
Functions ............................................ 48 Module servo amplifier
M6-2/M6-2SP module Replacing battery .............................. 417
Machine configuration ......................... 43 Module servo box
M6-2SP module Functions ............................................. 53
Functions ............................................ 48 Module side covers
Machine configuration .............................. 42 Attaching ........................................... 555
Base .................................................... 45 Removing .......................................... 555
M3-2 module ....................................... 42 Module support
M6-2/M6-2SP module ......................... 43 Lubricating ......................................... 266
Mark camera Module Top Cover
Components ........................................ 29 Cleaning ............................................ 372
Functions ............................................ 52 Module top cover
Replacing .......................................... 508 Removing .......................................... 554
Mark camera light Module vacuum sensor
Components ........................................ 29 Adjusting ........................................... 626
Mark camera light half mirror Movable blades on waste tape processing
unit
Cleaning ............................................ 300
Replacing .......................................... 490
Mark camera light source
Cleaning ............................................ 300
N
MCU (Module Change Unit) Nozzle changer
Components ........................................ 36
Components ........................................ 41
Mist separator filter Functions ............................................. 51
Cleaning ............................................ 308 Sensor position ................................... 72

Nozzle changer up/down shafts
Module
Cleaning inside module ..................... 233 Lubricating ......................................... 304
Nozzle clamp pins
Functions ............................................ 48
Inserting ............................................ 103 Replacing .......................................... 249
Pulling out ........................................... 99 Nozzle pick-up surface

Cleaning ............................................ 249
Removing .......................................... 103
Returning ............................................ 99 Nozzle station
Module control box Attaching ........................................... 187

Cleaning ............................................ 229
Replacing .......................................... 516

QD144-17 Index
Removing .......................................... 187 Placing head

Nozzle station fluorescent stickers Attaching ........................................... 175
Replacing .......................................... 438 Components ........................................ 24
Nozzles Functions ............................................. 49
Cleaning ............................................ 374 Removing .......................................... 175
O Replacing battery .............................. 419
Operation panel Sensor position ................................... 59
Functions ............................................ 53 Placing head vacuum filters
P Cleaning ............................................ 245
PAM Placing head vacuum filters

<H01/H02 heads>
On machine PAM (Placement accuracy
measurement) ................................... 593 Replacing .......................................... 388
Panel clamper stoper bolts Preventive maintenance
Replacing .......................................... 415 12000 hrs maintenance ..................... 308
Panel conveyance 2 weekly maintenance (every 320 hrs)

........................................................... 239
Functions ............................................ 53
3 Monthly maintenance (every 2000 hrs)
Panel height detection function ........................................................... 266
Components ........................................ 38 6 Monthly maintenance (every 4000 hrs)
........................................................... 278
Functions ............................................ 54
About preventive maintenance .......... 211
Sensor position ................................... 82
Applying grease ................................ 217
Parts camera
Daily maintenance (every 24 hrs) ..... 227
Components ........................................ 28
Irregular maintenance ....................... 370
Functions ............................................ 52
Maintenance checklist ....................... 218
Replacing .......................................... 503
Maintenance frequency ..................... 211
Parts camera glass cover
Monthly maintenance (every 700 hrs)
Cleaning ............................................ 231 .......................................................... 243
Parts camera glass cover inside light unit Points of caution ................................ 212
Cleaning ............................................ 232 Required equipment .......................... 213
Parts camera lens Weekly maintenance (every 160 hrs)
.......................................................... 229
Cleaning ............................................ 301
Yearly maintenance (every 8000 hrs)
Parts supply system ........................................................... 299
Functions ............................................ 52
R
PCU (Pallet Change Unit)
Reject parts box
Components ........................................ 39
Cleaning ............................................ 228
Lubricating ........................................ 401
PCU-2 (Pallet Change Unit)
Components ........................................ 35
Components ........................................ 40
Remove rejected parts ...................... 370
Lubricating ........................................ 405

Index QD144-17
Reject parts conveyor belt H04(S) head vacuum filters ............... 307
Cleaning ............................................ 243 H04(S) nozzle filters .......................... 378
Reject parts unit H08 head mechanical valve O-rings . 327
Replacing .......................................... 511 H08 head vacuum filters ................... 307
Remove rejected parts H08M head mechanical valve O-rings 332
Reject parts conveyor ....................... 370 H08M head vacuum filters ................ 307
Removing H08M nozzle filters ............................ 385
Feeder pallet ............................. 118, 125 H12(S) head mechanical valve O-rings
........................................................... 327
Module side covers ........................... 555
H12(S) head vacuum filters ............... 307
Module top cover .............................. 554
H12HS head mechanical valve O-rings
Nozzle station ................................... 187 ........................................................... 327
Placing head ..................................... 175 H12HS head vacuum filters .............. 307
Tray unit-L ......................................... 144 Linear motor cooling fan filter ............ 307
Tray unit-LT ....................................... 150 Mark camera ..................................... 508
Tray unit-LTC .................................... 164 Module control box ............................ 516
Tray unit-M ........................................ 197 Module CPU battery .......................... 425
Waste tape processing unit ............... 513 Module CPU box ............................... 519
Removing rejected parts Module servo amplifier battery .......... 417
Tray unit-L ......................................... 370 Movable blades on waste tape processing
Replacing unit .................................................... 490
Base control box 1 ............................ 526 Nozzle clamp pins ............................. 249
Base control box 2 ............................ 529 Nozzle station fluorescent stickers .... 438
Base CPU battery ............................. 434 Panel clamper stopper bolts .............. 415
Base CPU box .................................. 532 Parts camera ..................................... 503
Boards in the Base CPU Box ............ 536 Placing head battery ......................... 419
Boards in the Module CPU Box ........ 522 Placing head vacuum filters <H01/H02
heads> .............................................. 388
Brush on the station type brush unit . 307
Reject parts unit ................................ 511
Conveyer controller ........................... 545
Tray unit-L and parts supply base
Conveyor belt cleaner ....................... 414 connector .......................................... 565
Conveyor belts .................................. 409 Tray unit-L control board fuse ........... 456
Cooling fan ........................................ 556 Tray unit-L remover sponge pad ....... 457
Feeder pallet and parts supply base Tray unit-L servo axis amplifier battery
connector .......................................... 563 ........................................................... 455
Feeder pallet DC power supply unit .. 542 Tray unit-L servo controller battery ... 453
Fuse on a base control I/F board ...... 448 Tray unit-L tray drawer bottom surface
sheet ................................................. 347
Fuse on base remote I/O boards ...... 444
Tray unit-LT and parts supply base
Fuse on boards inside a module ....... 441 connector .......................................... 573
H04(S) head mechanical valve O-rings Tray unit-LT control board fuse ......... 461
........................................................... 327

QD144-17 Index
Tray unit-LT servo axis amplifier battery Panel height detection function ........... 82
........................................................... 460
Placing head ....................................... 59
Tray unit-LT servo controller battery . 458
Single conveyor ................................... 75
Tray unit-LT tray drawer bottom surface
sheet ................................................. 354 Tray unit-L ........................................... 83
Tray unit-LTC and parts supply base Tray unit-LT ......................................... 88

connector .......................................... 582 Tray unit-LTC ...................................... 92
Tray unit-LTC interface board fuse ... 466 Tray unit-M .......................................... 96
Tray unit-LTC servo axis amplifier battery Triple conveyor .................................... 79
.......................................................... 464
Waste tape processing unit ................. 74
Tray unit-LTC servo controller battery
........................................................... 462 XY-robot .............................................. 70
Tray unit-LTC tray drawer bottom surface Single conveyor
sheet ................................................. 361
Functions ............................................. 53
Tray unit-M control board fuses ........ 467
Sensor position ................................... 75
V12 head mechanical valve O-rings . 329
Soft backup pins
V12 head stickers ............................. 440
Cleaning ............................................ 390
V12 head vacuum filters ................... 307
Supplementary information
Vacuum pump control box ................ 540
Noise levels ....................................... 631
Vacuum pump gaskets ............. 468, 480
T
Vacuum pump inlet valves/outlet valves
.......................................................... 480 Tray unit-L
Vacuum pump inlet valves/outlet valves & Adjusting belt tension ........................ 344
gaskets ............................................. 468
Checking belt tension ........................ 344
Vacuum pump thermofuse ................ 452
Checking tray drawer bottom surface
Waste tape processing unit brush ..... 399 sheet ................................................. 347
S Cleaning fan filter .............................. 311
Safety Components ........................................ 31
About Symbols ...................................... 1 Control board fuse replacement ........ 456
EMERGENCY STOP button ............... 18 Cover attachment .............................. 566
Locking system ................................... 19 Cover detachment ............................. 566
Safety guideline .................................... 1 Functions ............................................. 52
Safety labels ....................................... 14 Inserting ............................................ 144
Safety rules for all machine types ......... 2 Lubricating ......................................... 342
Safety rules for NXT-2 .......................... 6 Removing .......................................... 144
Sensor position Removing rejected parts ................... 370
Base .............................................. 56, 69 Replacing tray drawer bottom surface
sheet ................................................. 347
Double conveyor ................................. 77
Sensor position ................................... 83
Feeder pallet ....................................... 73
Servo axis amplifier battery replacement
Hybrid calibration unit ......................... 81 ........................................................... 455
M6-2 extended conveyor .................... 80 Servo controller battery replacement
........................................................... 453
Nozzle changer ................................... 72

Index QD144-17
Tray unit-L and parts supply base connector Checking belt tension ........................ 357
Replacing .......................................... 565 Checking tray drawer bottom surface
sheet ................................................. 361
Tray unit-L conveyor belts
Components ........................................ 33
Cleaning ............................................ 243
Cover attachment .............................. 583
Tray unit-L remover
Cover detachment ............................. 583
Sponge pad replacement .................. 457
Functions ............................................. 52
Tray unit-L shuttle belts
Inserting ............................................ 164
Cleaning ............................................ 243
Interface board fuse replacement ..... 466
Tray unit-LT
Lubricating ......................................... 355
Adjusting belt tension ........................ 350
Removing .......................................... 164
Replacing tray drawer bottom surface
Checking tray drawer bottom surface sheet ................................................. 361
sheet ................................................. 354
Sensor position ................................... 92
Components ........................................ 32
Servo axis amplifier battery replacement
Control board fuse replacement ........ 461 } .......................................................... 464
Cover attachment .............................. 574 Servo controller battery replacement
Cover detachment ............................. 574 ........................................................... 462
Functions ............................................ 52 Tray unit-LTC and parts supply base

connector
Inserting ............................................ 150
Replacing .......................................... 582
Lubricating ........................................ 348
Tray unit-LTC conveyor belts
Removing .......................................... 150
Cleaning ............................................ 244
Replacing tray drawer bottom surface
sheet ................................................. 354 Tray unit-LTC feeder slots and connectors
Sensor position ................................... 88 Cleaning ............................................ 235
Servo axis amplifier battery replacement Tray unit-LTC shuttle belts

........................................................... 460 Cleaning ............................................ 244
Servo controller battery replacement Tray unit-M
........................................................... 458
Tray unit-LT and parts supply base connector
Attaching ........................................... 197
Replacing .......................................... 573
Tray unit-LT conveyor belts
Cleaning ............................................ 282
Cleaning ............................................ 244
Components ........................................ 34
Tray unit-LT feeder slots and connectors
Control board fuses replacement ...... 467
Cleaning ............................................ 235
Functions ............................................. 52
Tray unit-LT reject parts box
Removing .......................................... 197
Cleaning ............................................ 228
Sensor position ................................... 96
Tray unit-LT shuttle belts
Tray unit-M (tray stoppers)
Cleaning ............................................ 244
Lubricating ......................................... 364
Tray unit-LTC
Tray unit-M (TY-axis clutches)
Lubricating ......................................... 362

QD144-17 Index
Triple conveyor W
Sensor position ................................... 79 Waste tape box
V Cleaning ............................................ 227
V12 head Waste tape cutter
Functions ............................................ 50 Cleaning ............................................ 398
Lubricating ........ 239, 256, 283, 285, 323 Waste tape processing unit
V12 head mechanical valve O-rings Cleaning duct .................................... 398
Checking ........................................... 265 Components ........................................ 37
Replacing .......................................... 329 Lubricating ......................................... 341
V12 head mirrors Removing .......................................... 513
Cleaning ............................................ 236 Replacing Brush ................................ 399
V12 head prism glass Sensor position ................................... 74
Cleaning ............................................ 238 X
V12 head stickers X-axis gears
Replacing .......................................... 440 Lubricating ......................................... 269
V12 head syringes XY-robot
Cleaning ............................................ 252 Lubricating ......................................... 287
V12 head vacuum filters Sensor position ................................... 70
Replacing .......................................... 307 XY-robot flat cables
Vacuum pump Lubricating ......................................... 294
Cleaning filter .................................... 309 Y
Gaskets replacement ................ 468, 480 Y-axis flat cables
Inlet valves/outlet valves & gaskets Lubricating ......................................... 274
replacement ...................................... 468
Y-axis rollers
Inlet valves/outlet valves replacement 480
Lubricating ......................................... 274
Replacing thermofuse ....................... 452
Vacuum pump control box
Replacing .......................................... 540
Vision system
Functions ............................................ 52

Index QD144-17
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Management No. Date Notes
MEC-NXTII-1.0E February 15, 2008 -

QD144-00 April 25, 2008 -
QD144-01 July 17, 2008 -
QD144-02 October 14, 2008 -
QD144-03 May 15, 2009 V5.11
QD144-04 August 26, 2009 V5.12
QD144-05 December 10,2009 V5.15
QD144-06 January 29, 2010 -
QD144-07 March 5, 2010 -
QD144-08 May 18, 2010 V5.17
QD144-09 June 18, 2010 -
QD144-10 July 16, 2010 -
QD144-11 October 18, 2010 V5.19
QD144-12 February 28, 2011 -
QD144-13 May 20, 2011 V5.30
QD144-14 July 13, 2011 -
QD144-15 November 28, 2011 V5.40
QD144-16 February 29, 2012 -
QD144-17 March 30, 2012
FUJI MACHINE MFG CO., LTD.

19 Chausuyama, Yamamachi, Chiryu,
Aichi Prefecture, 472-8686 Japan
 2012 FUJI MACHINE MFG. CO., LTD. All Rights Reserved.

Printed in Japan
This manual is printed on recycled paper.

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Manual Update Notice

The following manual has been revised and released:

Manual title: NXT II Mechanical Reference

Chapter, Section Summary of changes

FUJI MACHINE MFG. CO., LTD.

Warranty and Liability

NXT II Mechanical Reference i

2.12 Waste Tape Processing Unit Components ... 37

ii NXT II Mechanical Reference

3.5.5 Tray unit-M.............................................................52

NXT II Mechanical Reference iii

4.4 Module Base Sensors..................................... 69

iv NXT II Mechanical Reference

4.17.4 Reject parts conveyor ..........................................95

NXT II Mechanical Reference v

5.7.2 Inserting a tray unit-LTC into the module ............ 173

vi NXT II Mechanical Reference

6.2.1 Maintenance performed by operators when the

NXT II Mechanical Reference vii

6.6.8 Cleaning the placing head syringes .................... 252

viii NXT II Mechanical Reference

6.10 12000 Hr Maintenance................................ 308

NXT II Mechanical Reference ix

6.10.29 Checking and adjusting the tray unit-M belt tension

x NXT II Mechanical Reference

7.4 Replacing Panel Clamper Stopper Bolts....... 415

NXT II Mechanical Reference xi

7.11.1 Module remote I/O boards ................................ 441

xii NXT II Mechanical Reference

7.20 Replacing the Tray Unit-LT Servo Axis Amplifier

NXT II Mechanical Reference xiii

7.28.3 Procedure for A type ......................................... 492

xiv NXT II Mechanical Reference

8.8 Replacing the Base Control Box 1 ................ 526

NXT II Mechanical Reference xv

8.16 Attaching/Removing the Module Side Covers

xvi NXT II Mechanical Reference

8.23.1 Required tools....................................................582

NXT II Mechanical Reference xvii

9.5 Base Vacuum Sensor ................................... 628

xviii NXT II Mechanical Reference

• NXT II Setup Manual

• NXT II System Reference

• NXT II Mechanical Reference

• NXT II Programming Manual

NXT II Setup Manual

NXT II System Reference

NXT II Mechanical Reference

NXT II Programming Manual

Formal name Names used in this manual

M3 II module M3-2 module

M6 II module M6-2 module

M6 IISP module M6-2SP module

2M II base 2M-2 base

4M II base 4M-2 base

NXT II Mechanical Reference xix

xx NXT II Mechanical Reference

1.1 About Symbols

1.1.1 Degree of Hazards

Failure to observe this hazard warning may lead to severe

Failure to observe this hazard warning may lead to

1.1.2 Examples of the Symbols

A circle with an exclamation mark is used to draw your attention to a