Eml1127110 Ys100

Maintenance Manual
EML1127110
Safety instructions
Safety instructions
w
Be sure to read these safety instructions before using YAMAHA surface mounters or related products.
Contents
CE marking i
1. Safety ii
1.1 To ensure safety ii
1.1.1 Defining safety ii
1.1.2 Causes of injuries and accidents ii
1.2 Using safety gear ii
1.3 Restrictions on machine use iii
1.3.1 Defining the operator and service personnel iii
1.3.2 Restricting machine operation with passwords iii
1.4 Cautions during machine operation iii
1.5 Cautions during power outages iii
1.6 Cautions regarding ferromagnetic fields iii
1.7 Handling the internal tape cutter iii
1.8 Keeping hands away from moving parts iv
1.9 Handling solvents vi
1.10 Handling the X-ray unit vi
2. Safety message vii

2.1 Safety message and categories in this manual vii
2.2 Typical warning text found in manual viii
2.2.1 Safety instruction viii
2.2.2 Operation and handling precautions ix
2.2.3 Facilities and environmental condition x
3. Warning labels xi
3.1 Warning label format and mark description xi
3.1.1 Warning label format xi
3.1.2 Meaning of marks xi
3.2 Warning labels xii
3.2.1 Handling safety covers xii
3.2.2 Pinching or crushing injury xiii
3.2.3 Effects on human body xiv
3.2.4 Handling each section xv
3.3 Caution labels xvii
3.3.1 Effects on human body xvii
3.3.2 Machine damage xix
3.4 Label positions xxii
SF_SMT_EP124-410
CE marking
This equipment conforms to the EU Machinery Directive 2006/42/EC (description A1 below) and EMC
Directive 2004/108/EC (description A2 below).
However, this equipment does not bear CE marking if a custom order item was installed.
Safety instructions
A1.
Cautions regarding the official language of EU countries and the language used in operation
manuals, CE declarations, operation screen characters, and warning labels when this equipment is
installed in an EU countr y.
• All materials except warning labels are written in English only.
n NOTE
Warning labels only have pictograms or else include warning messages in English, Chinese, Korean and Japanese
language.
A2.
EMC description
• Electromagnetic immunity (Immunity)
Complies with test standards as specified by EN 61000-6-2.
• Electromagnetic emissions (Emission)
Complies with test standards for ISM category: Group 1, Class A, as specified by EN 55011.
n NOTE
Class A equipment is intended for use in industrial environments. If used in other environments, ensuring
electromagnetic compatibility (EMC) might be difficult. Refer to EN 55011 standards for detailed information.
i
1. Safety
To ensure that the machine you purchased is used safely and correctly, always comply with the instructions
and rules in this manual regarding safety. However this manual cannot cover all items regarding safety in
detail. So it is extremely important that the operator or person handling the machine make correct decisions
Safety instructions
regarding safety.
1.1 To ensure safety

To maintain the safety of the operator or person working with this machine, it is essential that it (including
external parts feeders) be installed correctly in compliance with the safety standards and conditions of that
country.
Complying with the safety regulations and laws of that country is the responsibility of the customer who
purchased this machine. The supervisor of this machine must take responsibility to ensure all measures have
been taken for machine safety.
1.1.1 Defining safety

1. Safety has priority over all other operations.
2. Safety is more important than any other task.
3. Safety is the foundation for work efficiency.
4. Safety begins with maintaining (keeping it neat and orderly) the work environment.
1.1.2 Causes of injuries and accidents

Most accidents are not something that occurs but something that are caused. So it is important to make an
effort NOT to cause accidents.
n Hazardous actions
• Ignoring causes of accidents
• Working or operating equipment in cramped locations
• Working in locations or positions where safety cannot be ensured
• Unsafe machine operation and using equipment whose safety cannot be ensured
• Working or operating equipment at speeds where safety cannot be ensured
• Working or operating machines with safety equipment removed
• Performing work or tasks on top of a machine currently in operation
• Playing around or goofing off during work
• Performing maintenance or inspections without wearing safety gear
1.2 Using safety gear

Always wear safety gear when operating or servicing equipment.
Helmet : Use during maintenance work
Safety glasses or goggles : Use around light harmful to eyes and when applying lubricant, etc.
Respiratory gear : Use when handling organic solvents
Safety gloves : Use when applying lubricant, etc.
n Precautions when applying lubricant (grease)
w WARNING
• Inflammation may occur if grease or lubricant gets in the eyes. Before handling the grease or
lubricant, wear safety goggles to ensure it will not come in contact with the eyes.
• Inflammation may occur if the grease or lubricant comes into contact with skin. Be sure to wear
protective gloves to prevent contact with skin.
• Do not take orally or eat the grease or lubricant. Eating will cause diarrhea and vomiting.
ii
1.3 Restrictions on machine use
1.3.1 Defining the operator and ser vice personnel
c CAUTION
Only the operator and service personnel having sufficient knowledge of this machine should handle this machine.
Safety instructions
Operator:
The operator is someone who has been trained by us in machine operation, has a thorough knowledge of the machine
operation manual and demonstrates adequate knowledge of machine operation and safety.
Main tasks of the operator include pre-operation checks, operation (component mounting) and making setups
(changeovers). The machine is only used in normal operating mode.
Ser vice personnel:
The service personnel are those trained by us in machine maintenance as well as safety instruction and demonstrate a
thorough knowledge of safe handling of the machine according to the type and location of machine operation. They must
also understand hazardous sections of the machine and residual risks.
Main tasks of the service personnel include machine maintenance, repair, adjustment and management of the system.
The service personnel may make changes to the machine settings and operation in factory adjustment mode.
1.3.2 Restricting machine operation with passwords

Machine operating levels usable by the operator and service personnel (mentioned above) must be restricted
by password. This prevents the operator and service personnel from using the machine at a higher level than
allowed.
1.4 Cautions during machine operation

• Always make pre-operation checks before turning on the main power switch.
• Do not use an air blow tool when cleaning the machine. (Airborne dust will badly affect machine operation.)
• Stop all machine operation before cleaning around the machine.
• Do not turn off the compressed air during operation.
• Always make periodic inspections to prevent unexpected machine breakdowns.
• Allow only properly trained, experienced workers to perform repair and adjustment.
1.5 Cautions during power outages

If a power outage (blackout) occurs during automatic machine operation, always turn the main power switch
off to prevent faulty operation and equipment damage after power has been restored. Remove items such as
boards that remain inside the machine.
1.6 Cautions regarding ferromagnetic fields

Some YG series machines contain parts generating strong magnetic fields which may cause bodily injury, death,
or device malfunction. Always comply with the following instructions.
• Persons wearing electronic medical devices such as hearing aids and/or cardiac pacemakers must keep away
from the linear motor.
• Persons wearing ID cards, purses, and/or wristwatches must keep away from the linear motor.
• Do not attempt to disassemble the linear motor (including surrounding covers).
• Do not bring tools close to the linear motor.
• Do not bring tools close to the magnetic scale.
• Do not put magnetic materials or objects close to the linear motor.
• Do not touch a portion close to the linear motor during operation or immediately after the operation has been
finished since such part is hot.
1.7 Handling the internal tape cutter

• Never supply electrical power and compressed air to the machine while the covers for the tape cutter are removed.
• Tape cutter maintenance tasks must be performed by YAMAHA service personnel.
iii
1.8 Keeping hands away from moving parts
During use of this machine, the customer’s equipment and operating conditions might allow the operator’s
hands to come into contact with moving parts.
Use the following safety measure options to avoid possible danger where openings or gaps are found on the
machine.
Safety instructions
■ Dummy feeder
Use dummy feeders as safety measures to fill a gap between tape feeders. Install dummy feeders on the feeder plate the
same way as normal feeders in order to prevent hands from entering.
Prevention of hand entry

Dummy feeder
YS series YG series
Clamp lever
Dummy feeder (Wide-size)
Dummy feeder (8mm-size)

91203-L0-10
c CAUTION
To install or remove a dummy feeder, be sure to first press the emergency button and then open the cover. T he
machine has a structure that does not allow installing or removing a dummy feeder when the machine is in operation.
However, inserting a dummy feeder inside the cover during operation may cause serious accidents, so be careful not
to attempt it.
■ One-stop cover (For feeder exchange carriage)

If not using a feeder exchange carriage in the machine that is to be used with feeder exchange carriages, install a
one-stop cover in the position where a feeder exchange carriage is to be installed.
Prevention of hand entry

One-stop cover
One-stop cover
91204-L0-10
n NOTE
One-stop covers cannot be installed or removed during operation. The machine must be in a stopped state because
the section where a feeder exchange carriage is to be installed will move up and down for the installation or removal
of the feeder exchange carriage.
iv
■ Muzzle plate
Use these plates as a safety measure for the board conveyor entrance and exit openings. Each plate is movable, so adjust
the mounting position to match the boards to be produced.
Muzzle plate
Safety instructions
Upper muzzle plate
Board conveyance plane
Lower muzzle plate
91205-L0-00
Upper clearance Lower clearance Remarks
YS100/YS88 8.0 to 38.5mm 1.0 to 31.0mm
YS12, YS12P, YS12F, YS24, YS24X 5.0 to 20.0mm 4.2 to 39.2mm

From board conveyor plane
YC8 13.4 to 80.4mm 4.6 to 39.2mm
YSP 0 to 6.6mm 0 to 26.4mm
v
1.9 Handling solvents
Take the following precautions when handling cleaning solvents during solder printing or preparation.
Hazards when handling solvents

Safety instructions
1. Hazards to human health

Organic solvents constantly vaporize and contaminate the surrounding atmosphere. Inhaling or coming in contact with
organic solvent vapor may cause serious damage to human health.
2. Flammability
Organic solvents are highly flammable substances and can easily catch fire if handled improperly.
3. Adverse effects on machines
Some solvent types will damage the cleaning unit, electrical wire sheath and various units used in the solder paste
printer.
To avoid hazards of solvents

1. Be careful not to inhale toxic vapors of solvents for extended periods.
2. Do not use solvents near fire or flame. Keep solvents away from flame or fire.
3. Use only the specified solvent in the correct manner. Do not reuse any solvent repeatedly, and do not mix with other
solvents or chemicals.
1.10 Handling the X-ray unit

Some YS series inspection equipment models contain an X-ray unit. Take the following precautions when using
with an X-ray unit.
1. The X-ray output window of the X-ray source is made of ver y thin ber yllium foil.
· Beryllium in the form of dust particles can cause acute toxicity or chronic toxicity, and may induce respiratory
problems if inhaled.
· To ensure safety, the X-ray unit is designed so that the X-ray window cannot be touched. However, should the X-ray
output window be broken for some reason, immediately turn off the power switch and use extreme care not to inhale
the dust particles.
· Chlorine gas can corrode the beryllium window of the X-ray tube, causing permanent damage to the X-ray tube. Do
not use the X-ray unit in environments where chlorine gases are generated. Take special care when handling samples
such as vinyl chloride materials which may generate chlorine gases.
2. Lead is used in the covers of machines equipped with an X-ray unit.
Although lead is sealed within the covers so that the lead portions cannot be directly touched, use caution since lead is
known as heavy metal having harmful effects.
3. A safety key is provided for machines equipped with an X-ray unit.
The safety key must be managed by the supervisor of the machine.
vi
2. Safety message
This section describes information you should always comply with to prevent unforeseen accidents that might
lead to injury of the operator and others or damage the machine. Hazards and injuries that might result from
ignoring safety instructions and operating the machine incorrectly are categorized as follows.
Safety instructions
2.1 Safety message and categories in this manual
This manual uses the following safety alert symbols, signal words, and format styles according to the degree of
hazard.
n Safety alert symbols and signal words
w WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
These are points most essential for protecting the safety of the machine operator, inspector and service
personnel.
c CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor injury, or material loss or damage
to the machine. These points are important for protecting the safety of the machine and data, etc.
n NOTE
Gives helpful information or key points when operating the machine, in a simple and clear manner.
e EMERGENCY STOP
This mark indicates the emergency stop button must first be pressed before continuing the procedure.
vii
2.2 Typical warning text found in manual
The following are typical warning message text found in the YAMAHA surface mounter or related product
manual.
2.2.1 Safety instruction

Safety instructions
When you see the following cautions or warnings, always read them thoroughly and make sure you fully
understand them.
n Warnings
w WARNING
The signal light (signal tower) installed on the top of the machine is an important device that shows the
operating status of the machine. BEFORE OPERATING THE MACHINE, MAKE SURE THAT EACH LAMP OF THE SIGNAL
TOWER LIGHTS UP CORRECTLY (GREEN DURING OPERATION, YELLOW WHEN ERROR OCCURS OR INTERLOCK IS DETECTED,
AND RED DURING EMERGENCY STOP). NEVER PLACE ANY PART OF THE BODY IN THE HEAD MOVEMENT RANGE WHILE THE
GREEN LIGHT IS ON. (On machines designed to meet EU specifications, green/white/blue lamps are used
instead of green/red/yellow lamps.)
w WARNING
Never allow any part of your body (hands, head) to enter within the machine movement range during
operation.
w WARNING
Be careful when using isopropyl alcohol, since inhaling its fumes over long periods can be hazardous
to health.
n Cautions
c CAUTION
The person operating the machine must have been trained in correct machine operation and safety.
c CAUTION
This machine contains parts generating strong magnetic fields. G reat care should be taken when a part of your body
is put inside the machine for the maintenance work. C autions regarding ferromagnetic fields are described in the
section, “Safety Instructions”, at the beginning of this document. A lways thoroughly read this section to fully
understand its contents.
c CAUTION
The exhaust air blow might strike your face, so be sure to wear safety goggles.
viii
2.2.2 Operation and handling precautions
understand them.
n Warnings
Safety instructions
w WARNING
Inflammation may occur if grease or lubricant gets in the eyes. Before handling the grease, wear safety
goggles to ensure the grease will not come in contact with the eyes.
w WARNING
Inflammation may occur if the grease or lubricant comes into contact with skin. Be sure to wear
protective gloves to prevent contact with skin.
w WARNING
Do not take orally or eat the grease or lubricant. Eating will cause diarrhea and vomiting.
n Cautions
c CAUTION
Always stop the machine before installing the parts feeder into the machine. Hands or other parts of your body might
otherwise be caught in the moving parts.
c CAUTION
During operation only press the emergency stop button in cases of emergency.
c CAUTION
Always turn off the power with the correct procedure. Using hasty or incorrect procedures to turn off power might
damage the flash disk in the machine.
c CAUTION
When installing push-up pins on the push-up plate, set them in positions where they will not interfere with the conveyor
rails or other parts when the push-up plate is raised.
c CAUTION
When the machine you are using is not equipped with a nozzle station, you must change the nozzle by hand if it is not
a specified nozzle. In this case, always first press the emergency stop button.
c CAUTION
If an abnormality occurs during warm-up, immediately stop the machine, find the cause of the problem and eliminate it.
c CAUTION
When storing the grease after use, tightly close the cap of the grease tube or container to prevent dust and moisture
from entering inside. S tore it in a dark place to avoid direct sunlight, and keep away from fire and heating sources.
c CAUTION
After copying board data or system data into a USB flash memory, do not leave that data in the USB flash memory for
a long time. U se the USB flash memory just as a copy medium for backup data. P repare other backup media
(CD , DVD , MO , etc.) to store backup data more safely.
c CAUTION
You can also clean and grease the ball screw after removing the push-up plate. H owever, the push-up plate is heavy.
S o, take great care during handling.
c CAUTION
A strong air flow is exhausted during the cleaning blow. Always remove all nozzles attached to the heads before
starting the cleaning blow. Starting the cleaning blow while the nozzles are still attached may blow the nozzles away
from the heads causing the nozzles to break or become lost.
ix
2.2.3 Facilities and environmental condition
understand them.
n Warnings
Safety instructions
w WARNING
Always shut off the power and air supply before replacing parts or performing repairs.
w WARNING
During teaching or when making machine adjustments, always keep alert so that you can stop the
machine whenever needed.
w WARNING
Safety devices (safety interlocks) that stop machine operation should always be in good operating
condition.
w WARNING
The machine should never be used in locations with inflammable gas or in extremely dirty or polluted
environments.
w WARNING
• Persons wearing electro-medical devices such as cardiac pacemakers must be kept away from the
head assembly.
• Persons with implanted magnetic metals must be kept away from the head assembly.
• Do not bring ferrous objects such as metal tools and screws close to the parts where a strong
magnetic field warning is indicated.
• Do not bring magnetic cards or objects vulnerable to magnetic fields close to the head assembly.
w WARNING
To avoid the risk of electrical shock, make sure that the power source i s off before connecting the
power cable. A lso make sure that the ground cable i s securely connected to the machine.
n Cautions
c CAUTION
When disconnecting the air hose, be careful not to allow oil, water or impurities to splash outwards. A dditionally, take
great care since a large air exhaust sound is produced when disconnecting the coupler.
c CAUTION
Use a power cable whose conductor cross-section area is greater than 3.5mm2.
x
3. Warning labels
To use the YAMAHA machines safely and correctly, warning labels are attached to the machine body and
peripheral equipment. Check that the information on each warning label is clearly legible and comply with
the instructions.
Safety instructions
3.1 Warning label format and mark description
3.1.1 Warning label format

As shown below, a warning label indicates the degree of hazard by means of a signal word and the color of the
signal word panel. A mark and a pictogram are also used to emphasize the message. Basically, labels attached
to the outside of machines are in 4 languages (English, Chinese, Korean and Japanese) while labels attached to
the inside of the machines are only a pictogram.
Warning label format

Warning message and mark (pictogram) example
Safety alert symbol Signal word
WARNING Signal word panel

Danger : Red
Pinch or crush hazard. Warning : Orange
Caution : Yellow
Mark and pictogram
Message
90K41-000380
91206-L0-00
3.1.2 Meaning of marks

The following 3 types of marks are used on warning labels. Each mark has its own meaning and is typically
used with a pictogram to emphasize the message.
Mark and pictogram

Marks and examples used with pictogram
Warning mark Prohibition mark Instruction mark
WARNING WARNING WARNING
Usage examples
91207-L0-00
Meaning of the above

Definition Shape/Color
examples
Indicates a hazard, how to Yellow triangle with black Risk of electrical shock
avoid the hazard, and potential border. Pictogram is black on
Warning
consequences of ignoring the yellow.
warning.
Indicates a prohibited action to Red circle with slash. Pictogram Do not modify or disassemble
Prohibition avoid the potential hazard. is black and located behind safety cover switch.
slash.
Indicated an action that must Blue circle. Pictogram is white Read the manual to understand
Instruction be taken to avoid the potential on blue. procedure before starting
hazard. operation.
xi
3.2 Warning labels
Safety instructions
3.2.1 Handling safety covers

Potential
Injury from touching moving parts during machine operation
hazard
To avoid Do not touch or tamper with safety cover switches and do not operate machine if any safety cover
hazard switches were deactivated.
Applicable
All YS series machines, tray changers, etc. Case All case
machines
Potential
Unexpected accidents may occur if safety mechanisms are disabled.
hazard
To avoid Do not remove or disassemble any specified safety mechanism (protective cover, safety cover,
hazard etc.).
Applicable
YS24, YS24X, YSH20, etc. Case All case
machines
xii
3.2.2 Pinching or crushing injur y
Potential · Hands or fingers might be caught between moving parts and covers, causing injury.
Safety instructions
hazard · Hands or fingers might be pinched by moving parts, causing injury.
To avoid
Never place hands or fingers in machine during operation such as when handling tray magazines.
hazard
Applicable
All YS series machines, tray changers, etc. Case All case
machines
Potential
Hands or fingers might be pinched or crushed by clamp plate, causing injury.
hazard
To avoid
Never place hands or fingers in the machine when clamping a mask.
hazard
Applicable • Setup
YSP Case
• Maintenance
machines
Potential
Injury from tape cutter
hazard
To avoid
Do not put hands into cutter unit while power or compressed air is supplied.
hazard
Applicable
YS series (machines equipped with tape cutter) Case Maintenance
machines
xiii
3.2.3 Effects on human body
Potential
Safety instructions
Electrical shock hazard

hazard
To avoid
Do not touch and disassemble ionizer discharge needles. Keep them away from water.
hazard
Applicable
Machines equipped with ionizer (option) Case All case
machines
To prevent the electric shock or damage.

Do not touch electrodes.
WARNING Do not disassemble this unit.
Keep unit away from water and high
humidity
可造成触电和故障的原因。
别用手触摸电极部位。
警告不可私自拆分部件。
请避免部件接触水分并远离极度潮湿环境。
感電や故障の原因になります。
放電針に手を触れないで下さい。
警告分解はしないで下さい。
電気部に水をかけないで下さい。
Potential
Death, serious injury or equipment malfunction
hazard
To avoid
Observe precautions necessary due to strong magnetic fields.
hazard
Applicable
YS12, YS12P, YS12F, YS24, YS24X, YSH20, etc. Case All case
machines
Potential
hazard
To avoid
Do not touch power supply inside cover.
hazard
Applicable
All machines Case All case
machines
xiv
3.2.4 Handling each section
Potential
Safety instructions
Solvent may catch fire.
hazard
To avoid
Keep solvents such as alcohol away from fire or flame.
hazard
All solder paste printers Case
• Maintenance
machines
Potential
hazard
To avoid
Before opening covers wait at least 100 seconds after turning power off.
hazard
Applicable
All machines Case Maintenance
machines
Potential
Possible skidding or slipping causing injury
hazard
To avoid
Do not step on base section.
hazard
Applicable
YS24X (machines equipped with sATS II) Case All case
machines
xv
Potential
Damage to machine or injury to person
hazard
Safety instructions
To avoid Before handling the product (equipment) always read manuals and make sure you fully understand
hazard the contents.
Applicable
All YS series machines Case All case
machines
Potential
Exposure to radiation
hazard
To avoid
Keep covers closed during operation.
hazard
Applicable
YSi-X Case All case
machines
Potential
Risk of injury
hazard
To avoid
Do not open any cover without permission from YAMAMA service personnel.
hazard
Applicable
Maintenance parts for linear motors (strong magnetic fields) Case Maintenance
machines
xvi
3.3 Caution labels
Safety instructions
3.3.1 Effects on human body
Potential
Burn hazard
hazard
To avoid
Heater becomes very hot during and shortly after operation, so do not touch it.
hazard
YSH20 machines equipped with heater (option) Case
• Maintenance
machines
Potential
hazard
To avoid
Do not touch while power is supplied.
hazard
Applicable All YS series machines (controller unit) except for inspection
Case Maintenance
machines equipment
Potential
Loss of eyesight
hazard
To avoid
Do not directly look into laser beam.
hazard
Applicable IT options such as barcode readers (Class 2 laser)
Case All case
machines YS series machines (Class 1 laser)
xvii
Potential
Electrical shock
hazard
Safety instructions
To avoid
Keep the ionizer away from eyes. Do not disassemble or touch the discharge needles.
hazard
Applicable
Machines equipped with ionizer (option) Case All case
machines
Potential
Electrical shock
hazard
To avoid
Always turn off UPS switch when performing maintenance work.
hazard
Applicable
Machines equipped with UPS (option) Case Maintenance
machines
Potential
Electrical shock
hazard
To avoid
Always turn off UPS switch when performing maintenance work.
hazard
Applicable
machines
xviii
3.3.2 Machine damage
Potential
Safety instructions
Adverse effects on component mounting accuracy
hazard
To avoid
Do not touch camera unit or apply impacts to it.
hazard
All machines Case
• Maintenance
machines
Potential
Risk of damage
hazard
To avoid
Remove shipping bolts and clamps before using machine.
hazard
Applicable
Feeder exchange carriage (option) Case Installation
machines
Potential
Machine damage or malfunction
hazard
To avoid
Connect power only at the specified voltage.
hazard
Applicable
All machines Case Installation
machines
Example for machines that must be connected to 200 VAC
xix
Potential
Machine damage
hazard
Safety instructions
To avoid
Make sure push-up pins are arranged within specified area.
hazard
Applicable
YS24, YS24X Case Setup
machines
Potential
Machine damage or fire
hazard
To avoid
Do not use other than specified solvent.
hazard
• Maintenance
machines
Potential
Machine damage
hazard
To avoid
Always use gauze rolls of proper size.
hazard
• Maintenance
machines
xx
Potential
Machine damage
hazard
Safety instructions
To avoid If machine is not to be used for 6 months or more, block off the solvent path to protect solvent
hazard pump.
Applicable
All solder paste printers Case Maintenance
machines
Potential
Might disable machine functions
hazard
To avoid
Periodically replace USP battery since it has a limited service life.
hazard
Applicable
machines
Potential
Machine damage
hazard
To avoid
Read manuals and use correct procedure to operate machine.
hazard
Applicable
YS24X (machines equipped with sATS II) Case All case
machines
xxi
3.4 Label positions
The following warning/caution labels are attached to the YAMAHA products to ensure safe and correct use.
Check that the information on each label is clearly legible and comply with the instructions.
For safety precautions other than those on the labels shown in this section, see the instructions in "1. Safety".
n
Safety instructions
NOTE
Basically, labels are attached to the positions shown below, although they may differ slightly depending on the
machine model.
n NOTE
When connecting power to this equipment, refer to "Power connection terminals" described in the appendix of the
maintenance manual or user's manual.
Warning/caution labels
Front
N Main switch
N Open/close cover inner side
N Open/close cover
N Conveyor opening
N Feeder setup section
N Cutter section
N Side
N Cutter inner side N Panel inner side
N Lower panels
93201-L1-10
xxii
n Label positions
Rear
N Open/close cover inner side
Safety instructions
N Conveyor opening
N Open/close cover
N Feeder setup section
N Lower panels
N Cutter section
N Cutter inner side
93202-L1-10
xxiii
n Label positions
N Head assembly
Safety instructions
N Camera unit
N Controller
N Top of controller
N Controller front panel
93204-L1-10
xxiv
General Contents
Introduction
1. About this manual i
2. Maintenance list ii
Chapter 1 Maintenance
1. Maintaining machine performance 1-1
1.1 Essential conditions and working environment 1-1
1.2 Importance of periodic inspections and cleaning 1-2
2. Preparing for maintenance tasks 1-3

2.1 Consumable parts and replaceable parts (for repairs) 1-3
2.1.1 Consumable parts 1-3
2.1.2 Replaceable parts (for repairs) 1-6
2.2 Maintenance tools 1-7
2.2.1 Cleaning tools 1-7
2.2.2 Lubricating tools and grease 1-9
2.3 Required tools 1-11
Chapter 2 Daily maintenance items

Before beginning work 2-1
1. Checking the nozzle 2-2

1.1 Check with software 2-2
1.2 Checking the nozzles visually 2-4
2. Cleaning the feeder plate 2-5
3. Cleaning the camera protective glass 2-6
Chapter 3 Periodic maintenance items

1. Weekly inspection 3-1
1.1 Checking and cleaning the nozzles 3-1
1.1.1 Checking and cleaning the spring-action parts 3-1
1.1.2 Checking the nozzle leaf springs 3-3
1.1.3 Cleaning the nozzle top end 3-3
1.2 Checking the conveyor sensor condition and operation 3-4
1.3 Checking the board clamp condition and operation 3-5
1.3.1 Checking the board clamp condition 3-5
1.3.2 Checking the board clamp operation 3-5
EML1127110
2. Monthly or bimonthly inspection 3-6
2.1 Cleaning the nozzle air path 3-6
2.2 Cleaning Type F nozzles 3-7
2.2.1 Removing FNC nozzle assembly 3-7
2.2.2 Cleaning the FNC nozzle assembly 3-9
2.2.3 Cleaning the FNC lock pin 3-13
2.2.4 Reassembling the FNC nozzle assembly 3-14
2.3 Inspecting ball screws and guides of each axis 3-17
2.4 Cleaning and greasing the X, Y and W axes 3-18
2.4.1 Cleaning and greasing the X, Y and W axis ball screws 3-18
2.4.2 Cleaning and greasing the X, Y and W axes guides 3-21
2.5 Inspecting, cleaning and greasing the push-up shaft 3-22
2.6 Inspecting the board conveyor unit 3-24
2.6.1 Inspecting and cleaning the conveyor belt 3-24
3. Three-month inspection 3-25

3.1 Cleaning and replacing the ejector filter 3-25
3.1.1 Checking the ejector vacuum pressure 3-26
3.1.2 Checking the blow valve operation (each head) 3-27
3.1.3 Checking the cleaning blow valve operation (for all heads) 3-27
3.2 Cleaning and lubricating the inside of the spline shaft 3-28
3.2.1 Cleaning the inside of the spline shaft 3-28
3.2.2 Checking the negative pressure when the spline shaft is open 3-30
3.3 Checking the spline shaft movement and lubricating the slide section 3-31
3.4 Inspecting and cleaning the air/mist filters 3-32
4. Six-month or one-year inspection 3-34

4.1 Cleaning the camera lighting unit (6-month inspection) 3-34
4.2 Cleaning and replacing the blow station filter (1 year) 3-35
4.3 Checking the nozzle station sensor condition (1 year) … option 3-36
Chapter 4 How to replace consumable parts

1. Replacing the nozzle leaf springs 4-1
1.1 Replacing the nozzle leaf springs of standard heads 4-1
2. Ejector unit 4-2

2.1 Replacing an ejector bit 4-2
2.2 Replacing a valve (solenoid coil) 4-3

2.3 Replacing a cleaning blow valve 4-6
3. Cleaning and replacing the conveyor belts 4-7
4. Lubrication points 4-9

4.1 X-axis guide and ball screw 4-9
4.2 Y1 and Y2 axis guide and ball screw 4-10
4.3 PU-axis ball guide and ball screw 4-10
4.4 Conveyor W-axis guide and ball screw 4-11
4.5 Z-axis spline shaft 4-11
Appendix
1. Specifications A-1
1.1 Air regulator unit A-1
1.2 Power connection terminals A-2
2. Warranty A-3
Introduction
Contents
1. About this manual i
2. Maintenance list ii
1. About this manual
Descriptions in this manual stress important maintenance items that are essential for maintaining equipment
performance. Information given here mainly describes making inspections, cleaning and greasing as well as
procedures for replacing consumable parts in each location given in a step-by-step format. This manual is
Introduction
comprised of the following chapters.
Describes conditions and environments to use for maintaining equipment performance. The importance of making daily
checks and performing cleaning tasks is explained. Setups to make before starting maintenance work, consumable parts
and maintenance tools as well as the necessary tools are also described.

Making checks and cleaning the machine are essential daily maintenance tasks for maintaining equipment performance.
Performing these tasks prevents unforeseen trouble and allows using the machine in an optimum state.

Describes maintenance tasks that should be performed periodically to maintain equipment performance. Includes
periodic maintenance intervals such as for "weekly", "monthly or bimonthly", "3-month", "6-month" and "1-year"
maintenance tasks.

Describes methods for replacing parts subject to constant wear such as nozzle leaf springs and ejector valves.
w WARNING
ALWAYS THOROUGHLY READ “SAFETY INSTRUCTIONS” STATED AT THE BEGINNING OF THIS DOCUMENT BEFORE STARTING
THE MAINTENANCE WORK.
i
2. Maintenance list
n Maintenance list
: Perform maintenance. : Perform if necessary after inspection.

Introduction
Inspection interval Maintenance work

and interval
Section Unit name Check items
Weekly Monthly 3 Mon. 6 Mon. 1 year Clean- Lubri-
ing cation
Air path Bimonthly
Nozzle Spring action
Pick-up condition
Leaf spring Holding condition
Air path
Nozzle holder
Buffing (spring
Head action)
assembly
Filter
parts
Vacuum pressure
Ejector unit
(BIT)
Blow pressure
Main & spline

Air path
shaft
Lock pin Air path
Z-axis spline 3 Mon.
Ball screw Bimonthly

X-axis
Guide Bimonthly
X and Y
axes
Ball screw Bimonthly
Y-axis
Guide Bimonthly
Condition and
Board sensor
operation
Condition and
Board clamp & operation
stop
Pneumatic valve
Conveyor PU axis (push-up
units Ball screw, guide Bimonthly
axis)
W axis (conveyor Ball screw 6 Mon.

width auto
adjustment) Guide 6 Mon.
Board transport
Conveyor belt
conveyor
Vision Fiducial camera
Vision systems
system
Camera lighting
Lighting Multi-vision camera
unit
unit Protective glass
Vision systems
Camera lighting Side-view camera
unit
Option Blow station Filter

units
ANC sensor
Nozzle station
board
Tape cutter Filter 1 year
Others Air/mist filter Filter
ii
n Replacement and adjustment list
: By user : .By YAMAHA or sales representative
Replace- Adjust-
Section Unit name Check items Symptom ment ment
Head
Performance
assembly Ejector unit Solenoid coil
Introduction
dropped
parts
Ball screw Abnormal noise

X-axis
Guide Abnormal noise
X and Y axes
Ball screw Abnormal noise
Y-axis
Guide Abnormal noise
Board sensor Condition and operation Operation failure
Condition and operation Operation failure

Board clamp & stop
Pneumatic valve Operation failure
Conveyor
units
PU axis (push-up axis) Ball screw and guide Unusual noise
Ball screw Unusual noise

W axis (conveyor width
auto adjustment)
Guide Unusual noise
Fiducial camera Breakdown

Vision
system Camera & lighting unit Multi-vision camera Breakdown
Lighting unit
Side-view camera Breakdown
Nozzle station ANC sensor board Operation failure

Option units
Tape cutter Condition and operation Operation failure
iii
Contents
1. Maintaining machine per formance 1-1

1.1 Essential conditions and working environment 1-1
1.2 Importance of periodic inspections and cleaning 1-2
2. Preparing for maintenance tasks 1-3

2.1 Consumable parts and replaceable parts (for repairs) 1-3
2.1.1 Consumable parts 1-3
2.1.2 Replaceable parts (for repairs) 1-6
2.2 Maintenance tools 1-7
2.2.1 Cleaning tools 1-7
2.2.2 Lubricating tools and grease 1-9
2.3 Required tools 1-11
1. Maintaining machine performance
The most important condition essential for maintaining the performance of the machine you purchased is
using it under good environmental conditions. Performing daily maintenance and periodic inspections is also
absolutely essential.
1
1.1 Essential conditions and working environment
Maintenance
n Air
• Use a supply air pressure of at least 0.45MPa.
• Use an air hose with an inner diameter (I.D.) of at least 8mm.
• Use clean air obtained via an air dryer and air filter.
n Power
Power supply : 200/208/220/240/380/400/416VAC (±10%), 3-phase AC line
Frequency : 50 Hz or 60 Hz
Power supply capacity : 6.1KVA (main unit only)
Average power consumption : 0.75KW (main unit only)
Power supply connection : Power cable conductor cross-section area: 2.5 mm2 minimum
n Environment
Noise : Complies with EN61000-6-2 standard.
Humidity : 20 to 90% (no condensation), optimal range: 50 to 60%
Temperature : Functions guaranteed within 15 to 35°C. Machine precision guaranteed within 20 to 28°C.
Atmosphere : No dust or powder. No significant noise generation.
Installation : Flat level location sturdy enough so no vibration occurs during operation.
Wooden floors in particular are unsuitable.
Required floor flatness : When using feeder exchange carriages on the front and rear sides of the machine, the
flatness of the floor must be within 10mm, including the area directly under the machine.
Floor load-bearing strength : 850kg/m 2 or more
n NOTE
Keep the humidity at 40% or higher to prevent electrostatic charges. When using an industrial humidifier, use water
that is equal to pure water.
1-1
1.2 Importance of periodic inspections and cleaning
Periodic inspections and cleaning are extremely important maintenance tasks. Failure to perform inspections
1 and cleaning will prevent the machine from delivering full performance and may lead to component mounting
problems or equipment breakdowns.
Examples:
• Dirty nozzles might cause mistakes in component recognition and cause mounting errors.
Maintenance
• Dirty air paths may cause numerous pickup and mounting errors.
• Inadequate feeder and feeder plate inspections may cause pickup errors.
• Dirty optical system (camera, lighting, etc.) may cause recognition errors.
• Poor greasing of axes may cause abnormal noises.
• Poor inspections such as of valves may cause errors in PCB clamping and conveying.
As these examples show, failure to make inspections may lead to equipment problems. We strongly recommend
you perform periodic inspections and cleaning to ensure the machine is used under optimal conditions.
1-2
2. Preparing for maintenance tasks
Tasks described in this section focus mainly on replacing parts (consumable parts) that might cause a gradual
loss of machine functions during use. This section also describes how the user can easily replace parts when
a breakdown occurs.
1
c CAUTION
Maintenance
Parts (part numbers) listed in this manual are current as of the time this manual was issued.
When placing an order, always contact us to obtain the latest information.
2.1 Consumable parts and replaceable parts (for repairs)
2.1.1 Consumable parts

The term "consumable parts" in this manual indicates parts subject to continual wear during use causing
gradual loss of functions. The following parts are classified in this manual as consumable parts and should be
replaced as needed during maintenance.
Consumable parts
Parts supplied with machine
Washer for locking nozzle leaf spring

Filter for ejector
O-ring for Type 304A/315A nozzles
Nozzle leaf spring
O-ring for ejector Leaf spring for improving

nozzle gripping force
Nozzle leaf mounting screw
Nozzle bracket mounting screw Bolt for FNC block
Spring for FNC locate pin
FNC cam stopper Spring for FNC nozzle

53100-L1-00
n Consumable parts (supplied with YS100 FNC)
Product Name Parts List Designation Parts No. Note
Nozzle leaf spring LEAF SPRING KG7-M7137-A0X
Leaf spring for improving nozzle

PLATE,SPRING KGS-M714W-03X
gripping force
Nozzle leaf spring mounting screw SCREW 90990-28J024 M2xL3
Washer for locking nozzle leaf spring WASHER PLAIN 90990-28J002
Filter for ejector FILTER K46-M8527-C0X
O-ring for ejector O-RING 90990-17J010 T0.8, Φ 7.5(Inner)
Nozzle bracket mounting screw SCREW,PAN HEAD 90990-08J012 M1.4xL2.5
O-ring for Type 304A/315A nozzles O-RING 90990-17J013 T1.9, Φ 3.8(Inner)
Spring for FNC nozzle SPRING KV8-M71U7-00X
Spring for FNC locate pin SPG.LOCATE KV8-M71X1-00X
Bolt for FNC block BOLT HEX.SOCKET HEAD 90990-01J031 M1.6xL4
FNC cam stopper SCREW SET 90990-02J009 M1.6xL5
c CAUTION
Part numbers are subject to change without notice. Please contact our sales representative before ordering.
1-3
Consumable parts
1
O-ring for Type 304A/315A nozzles O-ring for Type 305A/316A nozzles
Washer for locking nozzle leaf spring
Nozzle leaf spring

Maintenance
Nozzle leaf mounting screw
Filter for ejector

gripping force
O-ring for ejector

53101-L1-00
n Consumable parts (supplied with YS100SF)
Nozzle leaf spring LEAF SPRING KG7-M7137-A0X

PLATE,SPRING KGS-M714W-03X
gripping force
Nozzle leaf spring mounting screw SCREW KG7-M7169-00X M2xL3
Washer for locking nozzle leaf spring WASHER PLAIN 90990-28J002
Filter for ejector FILTER K46-M8527-C0X
O-ring for ejector O-RING 90990-17J010 T0.8, Φ 7.5(Inner)
O-ring for Type 304A/315A nozzles O-RING 90990-17J013 T1.9, Φ 3.8(Inner)
O-ring for Type 305A/316A nozzles O-RING 90990-17J015 T1.9, Φ 8.8 (Inner)
c CAUTION
1-4
Consumable parts
Optional parts
1
Conveyor belt
Maintenance
53102-L1-00
n Consumable parts (optional parts)
Conveyor belt BELT 1, CONVEYOR KHW-M9129-00X For board transport
NOZZLE 71F ASSY. KV8-M71N1-A1X 301F on software

FNC nozzle
(compatible with conventional NOZZLE 72F ASSY. KV8-M71N2-A1X 302F on software
type 30X)
NOZZLE 73F/93F ASSY. KV8-M71N3-A0X 303F on software
NOZZLE 301A ASSY. KHN-M7710-A1X
NOZZLE 302A ASSY. KHN-M7720-A1X
ANC nozzle NOZZLE 303A/314A ASSY. KHY-M7740-A0X

(compatible with conventional
type 30X) NOZZLE 304A/315A ASSY. KHY-M7750-A0X
NOZZLE 305A/316A ASSY. KHY-M7760-A0X For SF type head
NOZZLE 311F ASSY. KJJ-M71N1-A0X
FNC nozzle NOZZLE 312F ASSY. KJJ-M71N2-A0X

(compatible with conventional
type 31X) NOZZLE 92F ASSY. KV8-M772F-A0X 313F on software
NOZZLE 73F/93F ASSY. KV8-M71N3-A0X 314F on software
NOZZLE 311A ASSY. KHY-M7710-A0X

ANC nozzle
(compatible with narrow NOZZLE 303A/314A ASSY. KHY-M7740-A0X
adjacent type 31X)
NOZZLE 304A/315A ASSY. KHY-M7750-A0X
c CAUTION
1-5
2.1.2 Replaceable parts (for repairs)
The term "Replaceable parts" in this manual indicates parts that might cause a machine stoppage as these parts
1
lose their functions but do not require machine adjustment after replacement work. Methods for replacing the
following parts are described in this manual.
Replaceable parts
Replace if broken
Maintenance
Solenoid valve
BIT (Cap + BIT)
Valve for shaft blow
Valve for conveyor unit
53103-L1-00
n Replaceable parts list
Solenoid valve VALVE KJJ-M717B-00X
Bit BIT KHY-M7154-01X Bit for ejector
Valve for shaft blow VALVE (SPARE PARTS) KGB-M37P1-00X Exhaust shutoff valve
Valve for conveyor unit VALVE (SPARE PARTS) KHW-M8582-40X For main stopper etc.
c CAUTION
1-6
2.2 Maintenance tools
1
2.2.1 Cleaning tools
Cleaning tools
Nozzle cleaning wire
Maintenance
Nozzle tip cleaning tape
53104-L1-00
n Cleaning tools
Nozzle cleaning wire NEEDLE ASSY KV8-M8883-A0X
Double-sided adhesive
Nozzle tip cleaning tape TAPE, CLEANER KGT-M8895-00X
tape
c CAUTION
n NOTE
Before cleaning nozzle tips with nozzle tip cleaning tape (double-sided adhesive tape), always clean the nozzles with
an ultrasonic cleaner (option) or IPA.
1-7
Cleaning tools
Optional parts
1 Nozzle cleaning wire handle

CLEANER, VISION SET
Lens blower brush
Maintenance
Lens cleaner
Spline shaft cleaning kit
Cotton swab sticks
Vacuum ASSY Air blow tool
53105-L1-10
n Cleaning tools
Optional parts
Nozzle cleaning wire handle NEEDLE CLEANER ASSY KV8-M8881-A0X Special Tool
Air blow tool AIR BLOW TOOL KU4-M8590-00X
Cotton swab sticks SWAB KGA-M3802-00X

CLEANER, VISION
Lens blower brush BLOWER KGA-M3803-00X SET
(KHW-M3801-A0X)
Lens cleaner CLEANER, LENS KGA-M3801-00X
Spline shaft cleaning kit CLEANING KIT KHN-M8860-00X
Vacuum ASSY VACUUM ASSY KHY-M88V0-A0X For cleaning (vacuum)
c CAUTION
1-8
2.2.2 Lubricating tools and grease
1
Lubricating and greasing tools
Lithium-based grease NSL
Maintenance
Oil syringe for nozzle holder
53106-L1-00
n Lubricating and greasing tools

Lithium-based grease GREASE PACK K48-M3856-00X NSL 80g
Oil syringe for nozzle holder SYRING, OIL KV8-M8870-00X Turbine oil VG32
c CAUTION
n Precautions when handling grease
w WARNING
Inflammation may occur if grease or lubricant gets into the eyes. Before handling the grease or
lubricant, wear safety goggles to ensure the grease or lubricant does not get into the eyes.
w WARNING
Inflammation may occur if grease or lubricant comes into contact with skin. Be sure to wear protective
gloves to prevent contact with skin.
w WARNING
Do not take orally or eat grease or lubricant. Eating will cause diarrhea and vomiting.
c CAUTION
After use, tightly cap the grease tube to ensure dust, debris and moisture do not enter inside. Store the grease in a
dark location not exposed to direct sunlight and keep it away from fire and heating sources.
1-9
Lubricating and greasing tools
Optional parts
1 Grease gun set
Standard nozzle
Maintenance
Grease gun
Grease gun nozzle

(flexible type)
Grease gun nozzle

(bent type)
Cleaning wiper
53107-L1-00
n Lubricating and greasing tools

Optional parts
Grease gun (with standard nozzle) GREASE GUN K48-M3852-00X
GREASE GUN SET

Nozzle (flexible type) GREASE NOZZLE K48-M3857-00X
KHW-M3852-A0X
Nozzle (bent type) GREASE NOZZLE K48-M3854-00X
Cleaning wiper WIPER KGS-M3840-00X
c CAUTION
1-10
2.3 Required tools
Prepare the following tools and items necessary for maintenance.
n Tool list
: Supplied with machine, : Options

1
Name Description Remarks
Maintenance
Oil syringe for nozzle holder Used to supply turbine oil (VG32).
Nozzle cleaning wire Used to clean nozzle holes and spline holes.
Phillips screwdriver Large, small D-2
Slotted (flat-blade) screwdriver Large, small
Hex wrench set 1 set HEX, WRENCH SET
Grease gun Used to supply grease
Air blow tool Used for cleaning
Ultrasonic cleaner Used to clean nozzles.
Precision wrench set Used for maintenance of spline shafts.
#0, #1 (Used to replace nozzle leaf springs and air

Phillips precision screwdriver
valves.)
Vacuum ASSY Used to clean top surface of feeder plate.
Cleaning wire Used for cleaning nozzle block. KM4-M3801-40X
n Other tool list

: Supplied with machine, : Options
Name Description
Grease (lithium-based grease: NSL) Used to lubricate X, Y and W axes.
Turbine oil (VG32) Used to lubricate nozzles.
Cotton swab stick Used to clean camera lens, half mirror and lighting unit.
Lens cleaner Used to clean camera lens and lighting unit.
Lens blower brush Used to clean camera lens and lighting unit.
Cleaning kit Used for cleaning spline shaft.
Cleaning paper Use lint-free cleaning paper or cloth that does not leave dust or residue.
Cleaning alcohol Use IPA (isopropyl alcohol) or ethanol.
Paper cup or tray Used for cleaning spline shaft.
Marker pen Used for marking when replacing conveyor belt.
n Safety goggles and mask
Name Description
Dust-proof goggles
Always wear these goggles and mask when using an air blow tool or IPA.
Dust-proof mask
1-11
Contents
Before beginning work 2-1
1. Checking the nozzle 2-2

1.1 Check with software 2-2
1.2 Checking the nozzles visually 2-4
2. Cleaning the feeder plate 2-5
3. Cleaning the camera protective glass 2-6

Before beginning work
In most cases, maintenance should be performed with the main power turned off.
However, some maintenance tasks are performed under emergency stop conditions with the power turned on.
In such cases, ensure adequate safety and press the emergency stop before beginning the maintenance.
The power is turned on during maintenance where any servo-axis must be operated or machine operation
checked. In this case, also ensure adequate safety before beginning the maintenance.
When operating the machine, make sure the following conditions are met.
■ Operating conditions
2
1. Supply air pressure is kept at correct pressure.
2. All safety covers are closed.
Daily maintenance items

3. All feeder exchange carriages are securely clamped when they are used with the machine.
4. Nozzles and other units are attached in place.
2-1
1. Checking the nozzle
Solder sticking to the nozzle tip or a clogged nozzle hole can cause component pickup errors and
recognition errors. Poor nozzle spring action can also cause pickup and mounting errors. To prevent such
problems periodically inspect and clean each nozzle.
1.1 Check with software
2
n How to check for a dirty nozzle (with the [Check Nozzle] button)
The term "dirty nozzle" as used here indicates shiny material such as solder adhering to the nozzle tip. This
shiny portion might be mistaken for a component and cause recognition errors. To check for this problem,
press the [Check Nozzles] button on the [Setup] screen while the nozzle tip picks up no components. The
camera finds the extent of grime or dirt on the nozzle tip.
1 Press the [Check Nozzles] button as Step 1 Pressing the [Check Nozzles] button
follows.
Open the [Setup] screen and press the
[Check Nozzles] button in "Utilities".
54200-L1-00
2 Select the item to be executed.

After checking the displayed message,
select the desired button.
■ When [Yes] was selected

Performs auto nozzle change and checks all nozzles
that can be changed. To make this check, "Nozzle
Check" items under "Schedule Specification" in [Check Nozzles] button
machine setting must be set.
54201-L1-00 Step 2 Selecting the item to be executed
n NOTE
If no setting is made for "Schedule Specification", nozzle
check will be made by automatically changing the
nozzles to Type 302.
■ When [No] was selected

Checks the nozzle currently attached to each head. If
you want to check any particular nozzle, that nozzle
must be attached to a head in advance.
When [No] was selected

3 Check the message.
Clean the nozzle if the check shows it is dirty.
2-2
n How to check for clogged nozzles (on the [Unit]-[Head] tab screen)
The term "clogged nozzle" used here indicates that material such as solder is adhering to the nozzle hole,
causing a rise in negative pressure even if no component is being picked up by the nozzle. This state might
cause problems such as component mounting errors. Check for clogged nozzles with the following procedure,
which is described using Type 302 (313) nozzles as an example.
e1 Attach the nozzle.

Press the emergency stop button and attach
Type 302 (313) nozzles to all heads. When
Step 1 to 3 Negative pressure generation
the machine has a nozzle station, press the
2
[Nozzle Change] button to change the
nozzles.
54204-L1-00
2 Reset the numerical figure.

Open the [Unit] - [Head] tab screen. Then

press the [Reset] button on the lower right of
the screen to reset the pickup level values.
3 Generate negative pressure.

On the [Unit] - [Head] tab screen, set the
[Vacuum] buttons for all heads to ON. When [Vacuum] button [Nozzle Change] button [Reset] button
this value starts rising, wait 5 to 10 seconds
and set to OFF. Step 4 Negative pressure check
4 Check the vacuum levels.

Read the "Max" value shown in red on the
[Head] tab screen. If this value is 110 (90) or
less then it is in normal range. If higher than
110 (90), then the nozzle hole might be dirty
and probably needs cleaning.
54205-L1-00
Max value
n NOTE
The above example is for Type 302 (313) nozzles so the values shown will be different for other types of nozzles.
n NOTE
If a correct value cannot be obtained after cleaning even after performing steps 1 to 4, then the interior of the spline
shaft might be dirty. To check it, refer to the table on the right.
n Vacuum level in spline shaft air path
n NOTE
The vacuum level in the spline shaft air path might sometimes differ slightly depending on the air source and operating
conditions. Use the above criteria values for reference during maintenance.
Nozzle Typical criteria when open Typical criteria when sealed
Type 303F/314F 100 or less

190 or higher
ANC head with no nozzle 70 or less
2-3
1.2 Checking the nozzles visually
Use either of the following two methods to check the nozzle tip visually.
n Remove the nozzle and check with a magnifying glass or similar tool.
Nozzle state
Normal condition
2 Nozzle tip
Nozzle hole
Clogged nozzle Shiny material on tip
Solder is adhering to nozzle hole Solder is adhering to nozzle tip
53200-L1-00
n Leave the nozzle installed and check with a hand mirror and flashlight.
Check with a hand mirror.
Hand mirror
Flashlight Multi-vision camera
53201-L1-00
c CAUTION
If the above check reveals a dirty or a clogged nozzle, promptly clean the nozzle by referring to sections 1. "Checking
the nozzle", in this chapter.
2-4
2. Cleaning the feeder plate
Chips or foreign matter falling on the feeder plate might bite into the surface during feeder setting and cause
the pickup position to deviate. Periodic inspection and cleaning are recommended to prevent this problem.
■ Cleaning with the accessor y brush

Clean the feeder plate with the accessory brush as shown below.
Cleaning the feeder plate (bank)

2

Dustpan Cleaning brush
53202-L1-00
■ Cleaning with the vacuum ASSY (option)

Connect the optional vacuum ASSY (KHY M88V0 A0X) to the air connector on the front of the machine and suck in fine
dust particles to clean the feeder plate.
Cleaning the feeder plate

Use the vacuum ASSY
Vacuum ASSY
53205-L1-00
2-5
3. Cleaning the camera protective glass
Dirt or dust particles sticking to the protective glass of the Multi-view camera can cause recognition errors.
Periodic inspection and cleaning are recommended to prevent this problem.
e
To ensure safety, make sure that the machine power switch is off or the emergency stop button is pressed
before starting work.
2 1 Remove dust on the protective glass

with the lens blower brush.
53203-L1-00
Step 1 Blowing off dust with blower brush
Reference
A lens blower brush is available as an option.
2 Wipe the protective glass with a

lint-free cloth.
Apply a few drops of lens cleaner to a
lint-free cleaning cloth or paper towel and
wipe the protective glass.
53204-L1-00
n NOTE
Use a lint-free cleaning cloth or paper wiper. Lens blower brush
A lens cleaner is supplied with the machine. Do not use
other type of cleaner.
Step 2 Wiping the protective glass
Lent-free cleaning cloth or paper wiper
2-6
Contents
1. Weekly inspection 3-1

1.1 Checking and cleaning the nozzles 3-1
1.1.1 Checking and cleaning the spring-action parts 3-1
1.1.2 Checking the nozzle leaf springs 3-3
1.1.3 Cleaning the nozzle top end 3-3
1.2 Checking the conveyor sensor condition and operation 3-4
1.3 Checking the board clamp condition and operation 3-5
1.3.1 Checking the board clamp condition 3-5
1.3.2 Checking the board clamp operation 3-5
2. Monthly or bimonthly inspection 3-6

2.1 Cleaning the nozzle air path 3-6
2.2 Cleaning Type F nozzles 3-7
2.2.1 Removing FNC nozzle assembly 3-7
2.2.2 Cleaning the FNC nozzle assembly 3-9
2.2.3 Cleaning the FNC lock pin 3-13
2.2.4 Reassembling the FNC nozzle assembly 3-14
2.3 Inspecting ball screws and guides of each axis 3-17
2.4 Cleaning and greasing the X, Y and W axes 3-18
2.4.1 Cleaning and greasing the X, Y and W axis ball screws 3-18
2.4.2 Cleaning and greasing the X, Y and W axes guides 3-21
2.5 Inspecting, cleaning and greasing the push-up shaft 3-22
2.6 Inspecting the board conveyor unit 3-24
2.6.1 Inspecting and cleaning the conveyor belt 3-24
3. Three-month inspection 3-25

3.1 Cleaning and replacing the ejector filter 3-25
3.1.1 Checking the ejector vacuum pressure 3-26
3.1.2 Checking the blow valve operation (each head) 3-27
3.1.3 Checking the cleaning blow valve operation (for all heads) 3-27
3.2 Cleaning and lubricating the inside of the spline shaft 3-28
3.2.1 Cleaning the inside of the spline shaft 3-28
3.2.2 Checking the negative pressure when the spline shaft is open 3-30
3.3 Checking the spline shaft movement and lubricating the slide section 3-31
3.4 Inspecting and cleaning the air/mist filters 3-32
4. Six-month or one-year inspection 3-34
4.1 Cleaning the camera lighting unit (6-month inspection) 3-34
4.2 Cleaning and replacing the blow station filter (1 year) 3-35
4.3 Checking the nozzle station sensor condition (1 year) … option 3-36
1. Weekly inspection
This section mainly describes weekly inspection and cleaning.
1.1 Checking and cleaning the nozzles

If buffing action (spring action) is poor, component pickup errors may occur. To prevent such problems,
periodically check and clean each nozzle.
1.1.1 Checking and cleaning the spring-action parts
■ Checking the spring action

Check the spring action of the nozzles. Press on a nozzle and if it returns normally there is no problem.
However, if the return action is poor (sluggish) then pickup errors and recognition errors will occur.
Checking the nozzle spring action

3
Periodic maintenance items

Press on the nozzle tip with your hand.
OK No good
Returns to original Returns sluggishly

position or does not return.
53300-L1-00
3-1
n Cleaning the slide section Step 3 Lubricating the slide section
1 Remove the nozzle from the head.

e Always first press the emergency stop button
and then remove the nozzle from the head.
The machine must be in emergency stop to
ensure safety during work.
c CAUTION
Do not take apart the removed nozzle.
2 Clean the slide section.

Apply IPA (isoprophyl alcohol) or ethanol to
the slide section. Push the nozzle tip several
times to repeat the buffing action (spring
action) to clean the slide section. After
cleaning, blow sufficient air to remove IPA or Nozzle
ethanol. Precision screwdriver
(with a small amount of turbine oil applied)
3
3 Lubricate the slide section.
Using a precision screwdriver or similar tool
Step 4 Checking the spring action
with a pointed tip, apply a small amount of
turbine oil (just enough so that it sinks in) to
the slide section.
53301-L1-00
4 Check the buffing action (spring

action).
Push the nozzle tip several times to repeat
the buffing action and spread turbine oil.
Use a lint-free cleaning cloth to wipe away
excess oil from around the nozzle.
53302-L1-00
5 Remove excess oil remaining in the

nozzle.
Using an Air blow tool, blow air for about 5 Spring action at nozzle tip
seconds from the nozzle tip, and for about 5
seconds from the nozzle attachment side.
Repeat this process a few times to remove
excess turbine oil remaining in the nozzle.
n NOTE
A thin coat of oil is enough to lubricate the slide section.
6 Check that the oil was removed. Step 6 Checking for residual oil
Blow air through the nozzle again while
placing commercially-available oil blotting Oil blotting paper
paper over the opposite end of the nozzle, Oil will appear after blowing air (first
and check for residual oil in the nozzle. time) for about 5 seconds from the
nozzle tip.
n NOTE
Performing step 5 is usually sufficient to remove oil Repeat the air blow for about 5
remaining in the nozzle. However, if oil still remains then seconds each from the nozzle tip
blow air through the nozzle once again. and from the attachment side.
53303-L1-00
This task is finished when oil no

7 Reinstall the nozzle. longer appears.
After checking one more time that there is
no oil remaining in the nozzle, reinstall the
nozzle back onto the head (when the
machine is not equipped with a nozzle
station).
c CAUTION
When the machine is equipped with a nozzle station,
return the nozzles to the nozzle station after cleaning.
3-2
1.1.2 Checking the nozzle leaf springs
If nozzle leaf springs cannot hold a nozzle securely, this adversely affects pickup, recognition and mounting
operations. Periodically check the leaf springs for nozzle holding status.
n Leaf spring inspection points

Check the following points by removing the nozzle and reattaching it to the nozzle holder.
• The leaf spring has enough gripping force.
• There is no gap between the leaf springs and the nozzle.
• The leaf spring is not warped or deformed.
• The gripping part of the leaf spring is not frayed.
Checking the leaf spring condition
Screw should Leaf spring should not be

be tightened. warped or deformed.
3
There should be
no gap.

Leaf spring should
not be frayed.
53304-L1-00
c CAUTION
If any of the above points is found to be a problem, remove the nozzle and replace the leaf springs as a pair, by
referring section 1, "Nozzle leaf springs" in Chapter 4.
c CAUTION
When the machine is equipped with a nozzle station, return the removed nozzles to the nozzle station.
1.1.3 Cleaning the nozzle top end

Clean the contamination of the nozzle top end with a nozzle top end cleaning tape supplied with the machine.
n NOTE
An ultrasonic cleaning unit (option) is effective to remove the contamination of the nozzle which has not been
removed with the nozzle top end cleaning tape.
■ Cleaning procedure
Stick the adhesive surface of the nozzle top end cleaning tape to the nozzle top end and peel it off to remove the
contamination.
3-3
1.2 Checking the conveyor sensor condition and operation
This machine uses a transmission mode fiber sensor as the conveyor sensor.
Check whether the sensor operates correctly even when the conveyor rail width is changed.
Checking the conveyor sensor condition and operation
Light emitter
Light
sensor
3
53305-L1-00
1 Open the [Unit] – [Conveyor] tab. Step 1-3 Checking the conveyor sensor
2 Press the [Width] button to change

the conveyor width.
In the "Conveyor Width" dialog box that

appears, enter a conveyor width and press
[OK].
The conveyor is changed to the width that
was just entered.
3 Check whether an error has

occurred.
The conveyor sensor is operating properly
unless an error message appears when the
conveyor width is changed. No further
check is necessary.
If an error message appears, then adjust the
sensor with the procedure below.
54300-L1-00
■ Adjusting the conveyor sensor Conveyor sensor tuning

If an error occurred when the conveyor width was 2 3
changed, check the output status of the conveyor
sensor.
1. Open the [Unit] – [I/O] tab.
2. From the "Output" drop-down list, select
"CONVEYOR".
3. Select "CONV SENSOR TUNING" (T01000E0) in the
output I/O list.
4. Press the [ON/OFF] button to switch the I/O status
from "0" (OFF) → "1" (ON) → "0" (OFF) to perform
auto tuning.
5. On the [Unit] – [Conveyor] tab, press the [Axis]
button again and change the conveyor width. The
sensor is operating properly unless an error message 4
appears.
54301-L1-00
3-4
1.3 Checking the board clamp condition and operation
1.3.1 Checking the board clamp condition

Check the following points to see the board clamp condition.
1. The board is clamped without play when the board
Checking the clamp condition
clamp is raised.
2. There is no clearance between the board and the
board hold plate when the board clamp is raised.
3. The board is flush with the upper surface of the
conveyor rails when the board clamp is raised.
4. The board clamp unit moves smoothly.
53306-L1-00
3
Check that there is no clearance Clamp and unclamp the
between the board and board hold board to check the
plate and also that the board is flush movement.

with the conveyor rails.
1.3.2 Checking the board clamp operation
1 Open the [Unit] – [Conveyor] tab.

2 Press the [Width] button to set the
conveyor width. Step 2-5 Checking the clamp operation
In the "Target Width" box in the "Conveyor
Width" dialog box that appears, enter the
board width and press [OK].
The conveyor is changed to the width that
was just entered.
3 Press the [Push Up] button to enter

the board thickness.
In the dialog box that appears, enter the
board thickness and press [OK].
4 Press the [Board Clamp] button to

clamp the board.
5 Press the [Board Clamp] button Step4, Step5 Step2
again to unclamp the board.
54302-L1-00
Repeat steps 4 and 5 to clamp and unclamp the Step3
board to make sure the clamp unit operates

smoothly.
3-5
2. Monthly or bimonthly inspection
This section mainly explains the cleaning and lubrication procedures after inspection.
2.1 Cleaning the nozzle air path
e1 Remove the nozzle from the head.

Always first press the emergency stop button
and then remove the nozzle from the head.
Step 2 Air blow
Air tube (black)

The machine must be in emergency stop to Insert the
ensure safety during work. nozzle tip into
the air tube and
c
blow air.
CAUTION
When the machine is equipped with a nozzle station
(option), make sure that the nozzles are returned to the
3
nozzle station after cleaning.
Air blow tool
(option)
2 Blow air through the nozzle. Blow air from the

Using an Air blow tool, blow air through the nozzle attachment
nozzle from the nozzle tip and then from the side.
other end.
Air tube (orange) connected to

53307-L1-00 air supply port
Step 3
n NOTE Cleaning a nozzle
If there are dust deposits in the nozzle, perform steps 3
and 4.
3 Clean the nozzle hole.

Pass the nozzle cleaning wire through the
nozzle hole and clean the nozzle hole. While
holding both ends of the wire with fingers as
shown or using a custom handle (option),
gently move the nozzle back and forth.
53308-L1-00
Custom
handle
4 Blow air onto the nozzle tip again. (option)
After removing the cleaning wire, blow air
through the nozzle with the Air blow tool, just
as in step 2.
Nozzle cleaning wire
53309-L1-00
Nozzle
Following the nozzle cleaning above, check and
clean the spring-action parts. (See 1.1.1, "Checking Step 4 Air blow
and cleaning the spring-action parts" described
earlier in this chapter.)
Air blow tool (option) Nozzle
3-6
2.2 Cleaning Type F nozzles
2.2.1 Removing FNC nozzle assembly

This section explains how to clean Type F nozzles used with the FNC heads.
1 Perform return-to-origin.
Check safety and press the [Origin] button Step 4-1 Loosening the bolt securing the stopper block
on the Setup screen.
Stopper block
2 Select "Type 302F nozzle" for the

FNC heads.
On the [Unit]-[Head] tab screen, press the
[Nozzle Change] button and select "Type-
302F" for the FNC heads (Heads 2, 4, 6 and
8).
e3 Press the emergency stop button.

The machine must be in emergency stop for
safe maintenance work. 3
4 Slide the stopper block outward.
1. Loosen the bolt securing the stopper
Hex wrench (1.5)
block with the M1.5 hex wrench.

2. Slide the stopper block by pushing on Step 4-2 Sliding the stopper block outward
one end of it.
53310-L1-00
53311-L1-00
5 Pull out the FNC nozzle shaft.

While gripping the nozzle assembly, pull out
the FNC nozzle shaft horizontally along with
the bevel gear.
53312-L1-00
Slide the stopper block outward.
Step 5 Pulling out the FNC nozzle shaft
Pull the bevel gear and shaft.
3-7
6 Remove the FNC nozzle assembly. Step 6 Removing the FNC nozzle assembly
Pull the FNC nozzle assembly down to
remove it from the head.
53313-L1-00
c CAUTION
Do not mix up the nozzle assemblies, bevel gears, and
shafts of the different heads. Keep them as the original
set for each FNC head.
7 Remove the FNC lock pin.

1. Using the M0.7 dedicated hex wrench,
loosen the set screw used to prevent one
of the lock pin cam from being released.
FNC nozzle assembly
(Stop loosening the set screw at a
position where the cam is retracted in
Step 7-1 Loosening the set screw
3
the shaft.)
2. Retract the lock pin cams fully in the Dedicated hex wrench
spline shaft while placing your hand
under the lock pin so that it will not be
pushed out by the internal spring. The
lock pin and spring then come out, so
take them out of the spline shaft.

53314-L1-00
53315-L1-00
Step 7-2 Removing the lock pin and spring
Remove the lock pin and spring.
3-8
2.2.2 Cleaning the FNC nozzle assembly
1 Disassemble the FNC nozzle Step 1 Disassembled FNC parts

assembly. Spring
Use the Phillips screwdriver (No.0 or No.00) to Nozzle block
Nozzle tip
remove the nozzle mounting screws, and
remove the nozzles and springs from the FNC
nozzle assembly.
53316-L1-00
c CAUTION
The screwdriver bit size may slightly differ between
manufacturers. Use the screwdriver that matches the
recessed pattern on the screw head.
Take care not to lose the small spring inserted in the Type 213F Type 211F
spring-action nozzle.
Type 212F
2 Clean the parts with alcohol.

Immerse the nozzles, springs, nozzle brackets,
nozzle block, bevel gear and shaft and
Nozzle bracket
Step 3-1 Cleaning the index holder nozzle shaft hole

3
standard nozzles in alcohol. Leave these
Cotton swab moistened with alcohol
parts immersed in alcohol for about 3 to 5
minutes. In the meantime, clean the nozzle

shaft hole as explained in step 3.
c CAUTION
Do not put the O-ring of the nozzle into alcohol. The
O-ring may stretch and become unusable when
immersed in alcohol.
3 Clean the nozzle shaft hole of the

FNC assembly.
While the parts are immersed in alcohol in
step 2, clean the index holder nozzle shaft
hole of the FNC heads as follows.
Index holder
1. Clean the nozzle shaft hole with a cotton
swab moistened with alcohol and blow Step 3-2 Cleaning the index holder nozzle shaft hole
air with an Air blow tool (KU4-M8590-00X).
2. Brush the bevel gear of the index holder
with a toothbrush moistened with alcohol
and blow air with the Air blow tool
(KU4-8590-00X).
53317-L1-00
53318-L1-00
c CAUTION
Use lint-free cotton swabs that do not leave residue.
Clean the bevel gear with

a toothbrush moistened with alcohol
3-9
4 Blow air into the spline shaft. Step 4 Blowing airinto spline shaft
Press the [Blow] button for each head on the
[Unit]-[Head] tab screen. The inside of the
spline shaft is then blown with air.
54303-L1-00
5 Take the parts out of the alcohol

container and clean them.
1. Clean the hole of the nozzle block by
passing the cleaning wire through it.
2. Clean the bevel gear, hole and surface
with a cleaning cloth, toothbrush and
cotton swab.
3. Clean the inside of the pinhole (air path) [Blow] button
in the middle of the bevel shaft by

Step 5-1 Cleaning the nozzle block
passing the cleaning wire through it and
3
also wipe the shaft surface with a Cleaning wire
cleaning cloth.
4. Clean other parts with cloth.
53320-L1-00
53321-L1-00
53322-L1-00
6 Blow air onto the cleaned parts.

Use the Air blow tool (KU4-M8590-00X) to Nozzle block
blow air sufficiently onto the cleaned parts.
Step 5-2 Cleaning the bevel gear
7 Check that the nozzles were Bevel gear
cleaned.
• If the nozzle tip is still clogged, reclean it
with alcohol or cleaning wire (KV8-
M8883-A0X).
• If the nozzle tip is nicked or foreign
matter cannot be removed, replace the
nozzle with a new one.
Clean the bevel bear hole

8 Reassemble the FNC nozzles. with cotton swab
Put the nozzle parts back together.
Step 5-3 Cleaning the bevel gear shaft
c CAUTION
Do not forget to insert the spring back in place.
Clean the air path hole
in the middle of shaft.
Bevel gear shaft
3-10
9 Clean the slide section. Step 10 Lubricating the slide section
Apply IPA (isoprophyl alcohol) or ethanol to
the slide section. Push the nozzle tip several
times to repeat the buffing action (spring
action) to clean the slide section. After
cleaning, blow sufficient air to remove IPA or
ethanol.
0 Lubricate the slide section.

Using a precision screwdriver or similar tool
with a pointed tip, apply a small amount of
turbine oil (just enough so that it sinks in) to
the slide section.
53323-L1-00
q Check the buffing action (spring

action). Nozzle
Push the nozzle tip several times to repeat Precision screwdriver
3
the buffing action and spread turbine oil. (with a small amount of turbine oil applied)
Use a lint-free cleaning cloth to wipe away
excess oil from around the nozzle.
Step 11 Checking the spring action
53324-L1-00
w Remove excess oil remaining in the

nozzle.

Using an Air blow tool, blow air for about 5
seconds from the nozzle tip, and for about 5
seconds from the nozzle attachment side.
Repeat this process a few times to remove
excess turbine oil remaining in the nozzle.
n NOTE
A thin coat of oil is enough to lubricate the slide section.
e Check that the oil was removed.

Blow air through the nozzle again while Spring action at nozzle tip
placing commercially-available oil blotting
paper over the opposite end of the nozzle,
Step 13 Checking for residual oil
and check for residual oil in the nozzle.
Oil blotting paper
n NOTE
Performing step 12 is usually sufficient to remove oil
Oil will appear after blowing air (first
time) for about 5 seconds from the
remaining in the nozzle. However, if oil still remains then nozzle tip.
blow air through the nozzle once again.
Repeat the air blow for about 5
53325-L1-00 seconds each from the nozzle tip
and from the attachment side.
This task is finished when oil no

longer appears.
3-11
r Lubricate the bevel gear and shaft. Step 14 Lubrication syringe
Using the lubrication syringe (KV8-M8870-
00X) and turbine oil (VG32), apply one drop
of oil at each of the bevel gear inner sides
and shaft, and then spread it with your
finger.
53326-L1-10
53327-L1-10
c CAUTION
Do not lubricate the bevel gear section, as foreign
matter may get caught in the gear.
Turbine oil (VG32)

t Reassemble the FNC nozzle
assembly. Step 14 Lubrication points on bevel gear
Use the Phillips screwdriver to reassemble
3
the nozzles onto the nozzle block.
c CAUTION
The screwdriver bit size may slightly differ between
manufacturers. Use the screwdriver that matches the
recessed pattern on the screw head.
Take care not to lose the small spring inserted in the
spring-action nozzle.
Lubricate with one drop of oil.
Shaft
n Precautions when replacing the bevel gear shaft (SHAFT_1)

Caution is required when replacing only the bevel gear shaft (SHAFT_1) during maintenance since a nozzle assembly and
SHAFT_1 must be used in the correct combination. There are 3 grades each of nozzle assemblies and SHAFT_1
depending on the hole inner diameter and shaft outer diameter. They are identified by marks ( , , etc.) as shown
below. Always use the correct combination of a nozzle assembly and SHAFT_1 which have the same mark.
c CAUTION
If the nozzle assembly and SHAFT_1 combination is incorrect, the nozzles may operate erroneously or vacuum leaks
may occur during component pickup.
Nozzle assembly and SHAFT_1 combination
NOZZLE ASSY (nozzle assembly) SHAFT_1

There are 3 grades depending on the hole inner diameter. There are 3 grades depending on the outer diameter.
ID mark
4mm
4mm
4mm
ID mark
KV8-M71R1-10X mm
KV8-M71R1-20X 4mm
KV8-M71R1-30X 4mm
53328-L1-00
3-12
2.2.3 Cleaning the FNC lock pin
Inside the spline shaft of each FNC head, a lock pin (or locate pin) is used to lock the rotation of the FNC
nozzle assembly when the selected nozzle points downwards. If dust or grime adheres to this lock pin,
component pickup or mount errors tend to occur. Although depending on the operation time, we recommend
cleaning the lock pin at the time when you take apart and clean the FNC nozzle assembly.
1 Clean the FNC lock pin parts.

Wipe the FNC lock pin and spring with a Step 1 FNC lock pin and spring removed from head
lint-free cleaning cloth moistened with
alcohol.
53329-L1-00
Spring
2 Clean the FNC lock pin insertion

hole.
1. Blow air into the air path of the FNC lock
pin insertion section of the spline shaft.
3
2. Wipe inside the FNC lock pin insertion
section thoroughly with a lint-free cotton FNC lock pin
swab moistened with alcohol.

53330-L1-00
TIP
Use spiral-tip cotton swabs (thickness: 4mm or less) that Step 2 Cleaning the FNC lock pin insertion section

are commercially available.
3 Lubricate the FNC lock pin.

Using the lubrication syringe (KV8-M8870-
00X) and turbine oil (VG32), apply one or
two drops of oil to the FNC lock pin and then
spread it with your finger.
4 Reinstall the FNC lock pin and

spring.
Advance to the next section 1.2.4,
"Reassembling the FNC nozzle assembly".
Wipe with cotton swab/bud moistened with alcohol.
3-13
2.2.4 Reassembling the FNC nozzle assembly
When finished cleaning the FNC nozzle assembly and FNC lock pin, reassemble them as explained below.
1 Rotate the spline shaft so the mark Step 1 Positioning so the mark faces the front
in the middle of the index holder
This mark should face the front.
faces the front.
53331-L1-00
2 Reassemble the FNC nozzle

assembly.
Insert, in order, the spring, FNC lock pin and
FNC nozzle assembly into the holder. At this
point, hold the FNC nozzle assembly with the
cutout facing towards the front and Type
302F nozzle pointing downwards, and insert
each part up into the index holder.
3
53332-L1-00
n NOTE
Before inserting the FNC lock pin, make sure that the
small cams above the index holder are retracted Step 2 Inserting the FNC nozzle assembly
upwards.
Index holder
3 Insert the bevel gear and shaft into

the center of the FNC nozzle
assembly.
While slightly pressing the FNC nozzle
assembly up, insert the bevel gear and shaft
into the center hole of the FNC nozzle
assembly from the front, and align the mark
on the bevel gear with the mark on the
index holder.
53333-L1-00
c CAUTION
Reassemble the nozzle assembly, bevel gear and shaft Type 302F nozzle should be pointed downwards. Cutout
in their original combination for each FNC head, without
mixing them with parts for other heads. If this Step 3 Inserting the bevel gear and shaft
combination is changed, the bevel gear may not rotate Insert the shaft.
smoothly or the pickup vacuum level may drop.
Align marks with each other.
3-14
4 Secure the FNC nozzle assembly. Step 4-2 Securing the FNC nozzle assembly
1. Turn the index holder so that the bevel Position the flat face of shaft horizontally.
gear faces the opposite side.
2. Align the surface of the bevel gear shaft
horizontally and slide the stopper block
back to the original position. Then tighten
the bolt with the M1.5 hex wrench to
secure the stopper block.
3. Rotate the spline shaft so the bevel gear
faces the front. With the spline shaft
lowered, use the dedicated hex wrench
(0.7) to tighten the set screw that
prevents one of the lock pin cams from
being retracted in the shaft.
53334-L1-00
53335-L1-00

Secure the stopper block with the hex wrench.
Step 4-3 Tightening the set screw for lock pin cam
Dedicated hex wrench
3-15
5 Check the movement after Step 5-2 Releasing the FNC lock pin
reassembly.
1. After reassembling the FNC nozzle
assembly, press the [Head] button on the
[Unit]-[Head] tab screen to lower the
reassembled head.
2. Lower the FNC lock pin cam.
Lowering this cam releases the FNC lock
pin, allowing you to rotate the bevel
gear by hand.
3. With the cam still lowered, check that
rotating the larger bevel gear also
Lower the cam.
rotates the smaller bevel gear smoothly.
53336-L1-00
Step 5-3 Checking the bevel gear movement
53337-L1-00
Rotate the larger bevel gear to check movement.
3 6 Check the nozzle change

movement.
On the [Unit]-[Head] tab screen, press the
[Nozzle Change] button to check that each
nozzle changes normally.
c CAUTION
On machines with an optional nozzle station, cancel
emergency stop and check safety before performing
nozzle change.
3-16
2.3 Inspecting ball screws and guides of each axis
Inspect the ball screws and the guides on the X, Y and W axes. Checkpoints are listed below.
A ball screw cover is installed to the X and Y axes. Remove these covers when inspecting the ball screw and
guide.
TIP
For instructions on how to detach or attach the ball screw covers, refer to sections 2.4.1 and 2.4.2 described later on.
Checkpoints
1. Any foreign matter adhering to the ball screws and guides?
Check if any fallen chips have adhered to the X and Y axis ball screws and/or X, Y and W axis guides.
2. Do the ball screws and guides have the correct amount of grease?
Check if grease has flowed off or splattered in the air failing to adhere. Also check if grease has discolored or hardened.
3. Any abnormal sounds from the ball screws?
3
Press the emergency stop button. Then check for any abnormal sounds while pressing the head assembly or conveyor
table by hand along the X-axis or Y-axis back and forth.
Countermeasures
1. Ball screws and guides may be damaged when chips and other material bite into them. If chips are adhering, wipe

them off along with the grease or remove with tweezers, etc.
2. Apply grease while referring section 2.4, "Cleaning and greasing the X, Y and W axes" explained in this chapter.
3. Consult your YAMAHA sales office or representative when abnormal sounds occur even after trying the
countermeasures in the above steps 1 and 2.
3-17
2.4 Cleaning and greasing the X, Y and W axes
To clean and grease the ball screws and guides of the X, Y and W axes, follow the steps below. Prepare a
grease gun and specified grease (NSL).
c CAUTION
When handling grease or lubricant, read and follow the precautions listed in section 2.2.2, "Lubricating tools and
grease" in Chapter 1.
c CAUTION
If abnormal noise is emitted from the X, Y or W axis ball screw or guide, then contact our sales representative for
assistance. Disassembly and cleaning of the ball screw or guide by the user will void the warranty.
2.4.1 Cleaning and greasing the X, Y and W axis ball screws
3
The machine must be in emergency stop to Step 2 Removing the X-axis ball screw cover
Phillips screwdriver
2 Remove the ball screw covers.
Remove the X, Y1 and Y2 axis ball screw
covers.
X-axis
1. Use a Phillips screwdriver to remove the
screws securing the left side of the ball
screw cover.
2. Move the head all the way to the left
side and remove the screws securing the
right side of the ball screw cover.
3. Remove the ball screw cover by pulling it
to the right.
53338-L1-00 X-axis ball screw cover
TIP
When reattaching the X-axis ball screw cover, use the
reverse order of the above procedure.
Step 2 Removing the Y-axis ball screw cover
Y1 and Y2 axes
1. Use a Phillips screwdriver to remove the
screws securing the rear side of the ball
screw cover.
2. Move the head all the way to the rear Y-axis motor
side and remove the screws securing the
front side of the ball screw cover.
3. Remove the ball screw cover by pulling it
to the front.
53339-L1-00
TIP
When reattaching the Y-axis ball screw covers, use the
reverse order of the above procedure.
Y-axis ball screw cover Y-axis ball screw cover
mounting cover
3-18
3 Clean the ball screws. Step 3 Cleaning the ball screws
1. Using the handle, move the head to one
end of each axis.
2. Wipe away the old grease and dirt from
the ball screw with a lint-free cloth or
paper towel (for clean room use).
3. Move the head to the opposite end of
each axis (X, Y and W axes) and wipe
the ball screw clean.
53340-L1-00
c CAUTION
Wipe away the old grease and dirt in the lead groove
of the ball screw. Also check that no debris or residue
X-axis ball screw
remains in the lead groove.

Y-axis ball screw
W-axis ball screw
3-19
4 Apply grease to the ball screws. Step 4 Greasing the ball screws
1. X-axis, Y-axis Grease nipple
Use the grease gun to supply the X-axis
specified grease (NSL) to the grease
nipples.
Then move the head back and forth by
hand along each axis and wipe away
excess grease.
2. W-axis
Apply the specified grease (NSL) by hand
uniformly over the surface and lead
groove of the ball screw.
53341-L1-00
Grease gun
5 Reattach the covers. Y-axis
Reattach the ball screw covers in the
3
reverse order of the removal procedures.
Grease gun
W-axis
n Grease list
For ball screws
No. Axis Grease name Grease type How to grease
Use a grease gun. (bent

1 X and Y axes NSL Lithium-based grease
nozzle type)
2 W axis NSL Lithium-based grease Apply grease by hand.
3-20
2.4.2 Cleaning and greasing the X, Y and W axes guides

2 Clean the guides. Step 2 Cleaning the guides

1. Move the head (or conveyor rails) to one
end of its axis, and wipe away the old
grease and dirt from the guides with a
lint-free cloth or paper towel.
2. Move the head (or conveyor rails) to the
opposite side of its axis and wipe the
guides. (X, Y and W axes)
53342-L1-00
c
3
CAUTION
Wipe away thoroughly the old grease in the grooves of
the guide rails.
Guide rail Wipe with cleaning cloth or paper towel.

3 Apply new grease to the guide rails.
1. X axis
Step 3

Greasing the guide
Use the grease gun to supply the
specified grease (NSL) to the X-axis guide
grease nipples.
The grease nipples are located behind
the head assembly, two each on the
right and left at the positions (heights) of
the upper and lower guides (total of 4
places).
2. Y1 and Y2 axes
Use the grease gun to supply the
specified grease (NSL) to the Y-axis guide
grease nipples. The grease nipples are
located on the front and back sides of
the slider on each Y-axis guide (total of 4
X-axis guide Grease gun Grease nipple
places).
3. W axis
Apply grease (NSL) by hand uniformly
over the surface and groove of the
guide rails.
53343-L1-00
4 Remove excess grease.

After moving the head (or conveyor rails)
back and forth a few times along their axes,
wipe away excess grease.
Grease gun Y-axis guide
n Grease list
For guides
No. Axis Grease name Grease type How to grease
Use a grease gun. (bent nozzle type

1 X and Y axes NSL Lithium-based grease for X axis; standard nozzle type for Y
axis)
2 W axis NSL Lithium-based grease Apply grease by hand.
3-21
2.5 Inspecting, cleaning and greasing the push-up shaft
The push-up shaft is designed to prevent flexing or warping of the board during clamping and is important
because it prevents depressing of the board during component mounting.
The push-up shaft also prevents deviations in the component mounting accuracy due to the board depressing
during component mounting, so it is important to regularly clean and inspect the push-up shaft to ensure it
operates correctly.
c CAUTION
If trouble occurs with the push-up shaft, then contact our sales representative for assistance. Disassembly and
cleaning of the push-up shaft by the user will void the warranty.
1 Set the conveyor width to Step 1 Setting the conveyor width

maximum.
Press the [Width] button to display the
"Conveyor Width" dialog. Enter the maximum
conveyor width from the specifications and
3
press [OK]. The conveyor is changed to the
width that was just entered.
54304-L1-00
e2 Remove the push-up plate.

Press the emergency stop button and then
remove the push-up plate using a hex

wrench.
c CAUTION
The push-up plate is heavy so use plenty of caution
during handling.
3 Raise the push-up unit.

Cancel emergency stop and raise the
push-up unit manually.
e4 Remove the old grease by hand.

After pressing the emergency stop button,
thoroughly remove the old grease from the
two ball screws and the two ball guides by
hand.
5 Apply the new grease by hand. Step 5 Applying the grease

Ball screw
Apply as much as 2 cm of new grease to Ball screws (2 places)
your finger, and rub it evenly into the ball
screw grooves.
Ball guide
Apply as much as 2 cm of new grease to
your finger, and coat it evenly on the ball
guides.
53346-L1-00
Ball guides (2 places)
3-22
6 Raise and lower the push-up unit
manually.
After cancel emergency stop, raise and
lower the push-up unit several times
manually to spread the grease evenly. After
the grease is well spread, raise the push-up
unit and leave it in that state.
e7 Wipe away excess grease by hand.

After pressing the emergency stop button,
wipe away excess grease by hand.
Again raise and lower the push-up unit
several times manually and if there is no
problem then lower the push-up unit.
8 Reinstall the pushup plate to its

original position.
Reinstall in the reverse procedure of step 2.
c CAUTION
The push-up plate is heavy so use plenty of caution
3
during handling.
3-23
2.6 Inspecting the board conveyor unit
2.6.1 Inspecting and cleaning the conveyor belt
As the belt wears away, slippages may occur that prevent securely conveying the boards. It is therefore
necessary to make periodic checks for wear of the conveyor belt.
Belt wear may also cause trouble such as erroneous detection of the conveyor sensor due to dust from belt
wear accumulating on the sensor surface, or dust from belt wear accumulating in the belt guide grooves may
cause the belt to stick, etc.
1 Change the conveyor width to a

convenient width for maintenance Step 1 Changing the conveyor width
work.
1. Press the [Width] button to display the
"Conveyor Width" dialog.
2. In the "Target Width" box, enter a width
large enough for maintenance work
3
(space where you can use a slotted
screwdriver) and press [OK].
The conveyor is changed to the width
that was just entered.
54305-L1-00
e2
Loosen the tension on the conveyor

belt.
Press the emergency stop button and then
use a 4mm and 5mm hex wrenches to Step 2 Loosening the tension on the belt
loosen the belt tension.
53319-L1-00
3 Remove the conveyor belt.

Remove the conveyor belt from the pulley
and the belt groove of the board guide.
4 Check for wear on the board

conveying side of the conveyor belt.
After removing the belt in step 3, check for
wear on the board conveying side of that
conveyor belt.
TIP
About half (3 to 4 mm) the belt width is used for board
conveying. If the board conveying side of the conveyor Tensioner bolt
belt is worn, then you can still reuse the belt by
switching the used side with the opposite side. However,
this will cause errors after long-term use, so early belt
replacement is recommended.
5 Clean the pulley and the belt

groove on the board guide.
Using a vacuum cleaner or similar device,
suction up the belt wear dust deposited in
the belt groove or on the sensor surface.
Also use a vacuum cleaner while brushing
debris away with the brush supplied with the
machine.
Also clean the pulley and other parts for the
conveyor belt.
c CAUTION
Though it rarely occurs, dust from belt wear might
sometimes adhere to and darken the outer
circumference of the pulley. If that happens, then
remove it with a metallic spatula, etc.
3-24
3. Three-month inspection
3.1 Cleaning and replacing the ejector filter
Although depending on the air supply conditions and operating time, ejectors should be inspected once every
3 months. Use an Air blow tool to remove dust buildups when small. We recommend replacing the air filter if
heavy dust deposits are found.
1 Move the head all the way to the Step 3 Removing the filter cap
front end of the Y axis.
On the [Unit]-[Head] tab (or [conveyor] tab)
screen, press the [Axis] button to open the
"Move Axis" screen. Then move the head
assembly all the way to the front of the Y
axis (front of machine).
3
TIP
The ejector unit is located at the top of the head
assembly. It is easier to inspect the ejector filters when
the head assembly is positioned to the front side of the
Y axis. (Inspect the ejector filters from the front of the
machine.)

The machine should be in emergency stop
to ensure safety during work.
Ejector unit Ejector filter
Step 5 Cleaning the filter

3 Remove the filter cap.
Loosen the filter cap by turning it to the left Filter Air blow tool
with a slotted screwdriver, and remove it.
53347-L1-00
4 Clean the filter.

Take the filter out of the ejector. When there
is only a little dust in the filter, use an Air
blow tool to blow it away and return the
filter back to the original position.
53348-L1-00
n NOTE
If there are heavy dust deposits in the filter or the filter
has discolored, replace it with a new filter (K46-M8527-
C0X). As a general guide, filters should be replaced
once every 3 months, although this depends on the
actual operating time.
5 Reattach the filter cap.

1. Fit the filter into the filter cap and insert it
into the ejector.
2. Turn the filter cap to the right until it locks
and clicks.
c CAUTION
When attaching the filter, be careful to make sure the
O-ring does not come out from between the manifold
and the filter cap.
3-25
3.1.1 Checking the ejector vacuum pressure
Check the vacuum level of each ejector of the ejector unit to see if it is working correctly.

Step 2 Disconnecting the air hoses
Ejector
2 Disconnect the air hose from the

air joint.
Disconnect all air hoses from the air joints (air
couplings) at the top of the spline shafts.
53349-L1-00
3 Check the ejector vacuum level.

1. Open the [Unit]-[Head] tab.
2. Press the [Vacuum] button while blocking
3
the end of each air hose with your finger.
Make the same check for all heads.
3. Make a note of the "Max" reading of Ejector unit Air joint Transparent air hose
each head while the air hose is blocked,
and check that the reading is higher Step 3 Checking the vacuum levels
than the criterion value below.
54306-L1-00
■ Criterion of ejector vacuum level

When air joint is blocked: 190 or more
TIP
If the vacuum level of any head does not reach the
criterion value, then check the air path in the head
(interior of the spline shaft or air hose between the
ejector and spline shaft). Clean or replace it if
necessary.
Press the [Vacuum] button for each head.
Check "Max" vacuum levels

(with air joint blocked).
3-26
3.1.2 Checking the blow valve operation (each head)
Check the blow level of each ejector of the ejector unit to see if it is working correctly.
1 Check that the blow air is being Step 1 Checking the blow air exhaust
exhausted correctly.
To check if the blow air is being uniformly
exhausted from each air joint on the lower
part of the ejector unit, open the [Unit]-
[Head] tab and press the [Blow] button for
each head.
54307-L1-00
Press the [Blow] button for each head.

3
3.1.3 Checking the cleaning blow valve operation (for all heads)
Check that the cleaning blow function for the spline shafts is working correctly.

1 Remove the nozzles from all heads.
c CAUTION
A strong air flow is exhausted during the cleaning blow.
Step 2 Operating the cleaning blow valves.
Select a head.
Always remove all nozzles attached to the heads
before starting the cleaning blow. Starting the cleaning
blow while the nozzles are still attached may blow the
nozzles away from the heads causing the nozzles to
break or become lost.
2 Operate the cleaning blow valves.

1. Open the [Unit]-[I/O] tab.
2. Select [Head] from the Output dropdown
list and select the address for the head
shaft blow (T003C000).
3. Press the [ON/OFF] button to operate the
cleaning valves of all heads. Press the [ON/OFF] button. Select an address.
54313-L1-00 Step 3 Checking the blow air
3 Check the exhaust blow air of each

head.
Open the [Unit]-[Head] tab. Press the [Blow]
button of each head to check the exhaust
blow air from each head.
54308-L1-00
4 Turn OFF the cleaning blow valves.

c CAUTION
The cleaning air blow or exhaust air blow might strike
your face, so be sure to wear safety goggles.
Press the [Blow] button for each head.
3-27
3.2 Cleaning and lubricating the inside of the spline shaft
Although depending on the air supply conditions and operating time, dust or grime adheres to the air path of
the spline shaft and may cause component pickup or mounting errors. The inside of the spline shaft should be
cleaned once every 6 months.
c CAUTION
If spline shaft movement becomes unstable or abnormal noise is emitted from a spline shaft, then contact our sales
representative for assistance. Disassembly and cleaning of the spline shaft by the user will void the warranty.
3.2.1 Cleaning the inside of the spline shaft
1 Remove the nozzles from all heads. Step 2 Disconnecting the air hoses
After making sure that the emergency stop
button is pressed, remove all nozzles. Air joint for spline hose
On FNC heads, remove the FNC nozzle
3
assemblies by referring to section 1.2.1,
"Removing FNC nozzle assembly" earlier in
this chapter.
2 Disconnect the air hose from each

spline shaft.
As shown in the photo, disconnect the air
hose inserted into the top of each spline

shaft.
53350-L1-00
3 Prepare the cleaning kit (KV8-

M8860-00X). Air hoses Spline shaft
1. Pour IPA (isopropyl alcohol) into the
container of the cleaning kit. (Never pour
Step 3 Cleaning tool
other solvent into the container.)
2. Slide the stopper on the nozzle tube of
the cleaning kit so it is positioned 185 to
200mm away from the nozzle tip.
3. Place a paper cup or tray under the
spline shaft to be cleaned. (This prevents
IPA from flowing out downwards in step
4.)
53351-L1-00
4 Clean the inside of each spline

shaft.
1. Insert the nozzle of the cleaning kit into
Stopper Nozzle
the spline shaft until the stopper on the Set the stopper at a position
185 to 200mm away from the nozzle tip.
nozzle tube makes contact with the top
of the spline shaft. Step 4 Cleaning the spline shaft
2. Pour alcohol (IPA) into the spline shaft air
path to clean away dust and grime.
53352-L1-00
Cleaning tool
3-28
5 Blow air into the spline air path. Step 5 Blowing airinto spline shaft
1. Insert the air hose into the fitting at the Spring
top of the spline shaft to be cleaned.
2. Open the [Unit]-[Head] tab on the
operation display.
3. Press the [Blow] button on the operation
display to blow air into the spline air path
while placing cloth under the lower end
of the spline shaft.
54312-L1-00
6 Repeat the above procedure.

Disconnect the air hose and repeat step 4
and then step 5. [Blow] button
When the IPA flowing out from the spline
shaft becomes clean, blow air through the
3
spline air path as the last cleaning step. Use
the same procedure to clean all other
heads.
7 Reconnect the air hose to each

spline shaft.
After connecting the air hoses, check the

negative pressure by referring to the next
section.
3-29
3.2.2 Checking the negative pressure when the spline shaft is open
After cleaning the spline shafts, check the negative pressure (vacuum level) generated in each head without
nozzle.
Step 1 Checking the vacuum level
1 After cleaning, check the vacuum
levels.
1. Leave nozzles detached from the heads.
2. Open the [Unit]-[Head] tab screen and
press the [Vacuum] button to generate a
negative pressure. Read the "Max" values
shown on the screen and check whether
the vacuum levels are appropriate by
referring to the criteria below.
■ Vacuum level criteria in spline air path
When spline shaft is open: 70 or less
54309-L1-00
3 2 Reattach the nozzles.

Return the ANC nozzles to the nozzle
station, and attach the FNC nozzles back to
Read "Max" values. [Vacuum] button
the heads by referring to 2.2.4,

"Reassembling the FNC nozzle assembly".
n NOTE
The vacuum level in the spline shaft air path might sometimes differ slightly depending on the air source and operating
conditions. Use the above criteria for reference during maintenance.
3-30
3.3 Checking the spline shaft movement and lubricating the slide section
After cleaning the spline shafts, check the spline shaft movement and lubricate the slide section.
c CAUTION
If the up/down movement of a spline shaft is unstable or a spline shaft does not move, then contact our sales
representative for assistance. Disassembly and cleaning of the spline shaft by the user will void the warranty.
1 Turn off the machine power switch.

Quit the software and turn off the machine
power switch.
2 Move each spline shaft by hand to

check for abnormal movement.
Move each spline shaft up and down by
hand and make sure that all spline shafts
move smoothly without hanging up and
3
unusual noise.
c CAUTION
If the machine is operated while movement of any
spline shaft is awkward, this may cause serious trouble.
Do not operate the machine and contact us for

assistance.
3 Clean the outside of each spline

shaft.
Use a lint-free cleaning wiper or cotton swab
to wipe the outside of each spline shaft.
4 Apply grease to the outside of each Step 4 Applying grease to spline shaft
spline shaft.
Apply a thin, uniform coat of grease by
hand to the outside of each spline shaft.
53357-L1-00
5 Wipe away excess grease.

Move each spline shaft by hand several
times and wipe away excess grease.
Grease
Spline shaft
3-31
3.4 Inspecting and cleaning the air/mist filters
Air/mist filters are used to prevent oil, mist and other impurities in the air compressor from penetrating into the
machine. These filters should be inspected and cleaned periodically as instructed below. (The filter closer to
the air coupler is the air filter and the other one is the mist filter.)
n Cleaning the filter cup
1 Check the inside of the filer cup. Step 3 Removing the filter cup
Check for oil or water deposits in the filter
cup through the window. If the window is
dirty, follow the steps below to clean the
filter cup.
TIP
The drain cock at the bottom of the filter cup is an
auto-drain type. It automatically drains the oil or water
when deposited in the cup. We recommend
3
connecting a hose to this drain cock.
2 Disconnect the air hose from the

air coupler.
c CAUTION
Filter cup Button

When disconnecting the air hose, be careful not to
allow oil, water or impurities to splash outwards.
Step 4 Cleaning the filter cup
3 Remove the filter cup.

While pressing the button on the side of the
filter cup, turn it clockwise, and pull the filter
cup downwards.
53358-L1-00
4 Clean the inside of the filter cup.

1. Lightly clean the filter cup with water.
2. Then, pour water-diluted neutral
detergent into the filter cup and clean
the inside while shaking it.
3. Air blow the filter cup and wipe away
any moisture with clean cloth or paper. Filter cup Water-diluted
neutral detergent
53359-L1-00
5 Reattach the filter cup.

1. Align the button on the side of the cup
with the attach/detach position and
push the cup upwards.
2. Turn the cup counterclockwise until you
hear a click.
n NOTE
Leave the filter cup removed to clean the air filter as
explained in the next procedure.
6 Reconnect the air hose to the air

coupler.
After connecting the air hose, check that no
air is leaking.
3-32
n Cleaning the air filter
1 Remove the filter cup.

See the previous procedure in "Cleaning the
filter cup".
2 Remove the air filter. Step 2 Removing the air filter

Rotate the white disk clockwise as viewed
from the top and take out the air filter.
53360-L1-00
3 Clean the air filter.

Use an Air blow tool to blow away dust and
impurities trapped by the air filter. If the filter
is excessively dirty and cannot be cleaned,
replace it with a new filter.
3
4 Reattach the air filter.
Screw the white disk back in to attach the
air filter to the original position.
53361-L1-00
Loosen and remove the white disk.
5 Reattach the filter cup. Step 4 Reattaching the air filter

n NOTE
When cleaning the mist filter, use the same procedure.
Air filter
3-33
4. Six-month or one-year inspection
4.1 Cleaning the camera lighting unit (6-month inspection)
The lighting unit may become dirty due to dust and dirt. We recommend periodic cleaning as explained below.
To ensure safety, make sure that the machine power switch is off or the emergency button is pressed before
starting work.
c CAUTION
Do not apply strong force or shock to the camera unit and lighting unit during cleaning. Optical axis adjustment might
become unreliable.
c CAUTION
If trouble occurs with the lighting unit, then contact our sales representative for assistance. Disassembly and cleaning
of the lighting unit by the user will void the warranty.
3 n Fiducial mark recognition camera

The fiducial mark recognition camera is mounted on the right of the head assembly. Clean the lighting unit for
this camera as explained below.
• Cleaning method Wipe with cleaning cloth.
Apply a few drops of lens cleaner to a lint-free

cleaning cloth and wipe the diffuser plate on the
bottom of the lighting unit.
53362-L1-00
Lighting unit for fiducial mark camera
3-34
4.2 Cleaning and replacing the blow station filter (1 year)
To clean or replace the blow station filter, follow the steps below.
c CAUTION
If trouble occurs with the blow station, then contact our sales representative for assistance. Disassembly and cleaning
of the blow station by the user will void the warranty.
1 Turn off the air supply and the Step 1 Shutting off the air supply
power to the machine.
1. Quit the software and turn off the
machine power switch.
2. Turn the air supply/shutoff valve inside
the machine lower left panel to the right,
to stop the air supply.
53364-L1-00
2 Cut the cable ties on the filter.

Using a wire cutter or similar tool, cut the
cable ties that hold the filter unit inside the
3
blow station stand.
53365-L1-00

Air supply/shutoff valve
3 Disconnect the air hose from one Step 2 Cutting the cable tie
end of the filter unit and take out
the filter. Cable tie
1. Disconnect the air hose from one end of
the in-line filter unit.
2. Remove the filter joint caps on both sides
of the filter by rotating them 90 degrees.
3. Pull the transparent case to remove it
and take out the filter.
53366-L1-00
4 Clean the filter.

Use an Air blow tool to blow air through the
filter from the inside and from the outside. If
the filter is excessively dirty and cannot be
cleaned, replace it with a new filter.
Wire cutter In-line filter unit
Step 3 Taking out the filter

Air hose
In-line filter unit

Filter joint caps
Filter Transparent filter case
3-35
4.3 Checking the nozzle station sensor condition (1 year) … option
When the machine is equipped with a nozzle station (option), check the nozzle station sensors to see if they
are working correctly.
c CAUTION
If a nozzle station sensor fails to detect a nozzle, the nozzle change cannot be performed correctly and the machine
operation may be interrupted due to a nozzle detection error.

2 Open the nozzle station shutter. Step 2 Opening the shutter

1. Open the [Unit]-[Head] tab.
2. Press the [Nozzle Stn Shutter] button to
3
open the nozzle station shutter.
54310-L1-00
3 Check the detection status of the

nozzle station sensors.
Check to see if the nozzle station sensors
detect the presence or absence of nozzles.

1. Open the [Unit]-[I/O] tab.
2. From the "Input" drop-down list, select
"NZL STATION".
3. While extracting a nozzle from the nozzle
station and returning it to the same
position, check whether the Step 3 Checking the nozzle detection status
corresponding sensor detects the nozzle Select "NZL STATION".
correctly.
The detection status on the screen should
read "1" when the nozzle is extracted
from the nozzle station, and should read
"0" when the nozzle is in the nozzle
station.
54311-L1-00
TIP
The nozzle station position No. where a nozzle was
extracted or inserted is displayed on the lower part of
the "Input" status screen.
4 Close the nozzle station shutter. Nozzle station position No. is Shows the presence or absence
On the [Unit]-[Head] tab, press the [Nozzle displayed here. of nozzles detected by sensors.
Stn Shutter] button to close the nozzle station
shutter.
c CAUTION
If the detection status of a nozzle station sensor is
unstable or a senor fails to detect a nozzle, then contact
our sales representative for assistance. Disassembly
and cleaning of the nozzle station sensors by the user
will void the warranty.
3-36
Contents
1. Replacing the nozzle leaf springs 4-1

1.1 Replacing the nozzle leaf springs of standard heads 4-1
2. Ejector unit 4-2

2.1 Replacing an ejector bit 4-2
2.2 Replacing a valve (solenoid coil) 4-3

2.3 Replacing a cleaning blow valve 4-6
3. Cleaning and replacing the conveyor belts 4-7
4. Lubrication points 4-9

4.1 X-axis guide and ball screw 4-9
4.2 Y1 and Y2 axis guide and ball screw 4-10
4.3 PU-axis ball guide and ball screw 4-10
4.4 Conveyor W-axis guide and ball screw 4-11
4.5 Z-axis spline shaft 4-11
1. Replacing the nozzle leaf springs
1.1 Replacing the nozzle leaf springs of standard heads
If an abnormal condition (deformation, wear, etc.) is found by inspecting the leaf springs, replace the leaf
springs using the following procedure.
Step 3 Removing leaf springs

Nozzle leaf spring
mounting washer
2 Remove the nozzle.
Remove the nozzle attached to the leaf Nozzle leaf spring
springs to be replaced, by pulling it mounting screw
downwards by hand.
3 Remove the leaf springs.

Use a Phillips precision screwdriver to loosen
the screws securing the defective leaf
Nozzle holder
springs and remove the leaf springs along
with the reinforcing springs from the nozzle
Step 4 Attaching leaf springs
arm assembly.
53402-L1-00
c CAUTION
The nozzle arm also comes off by removing the
mounting screws. Be careful not to drop it.
4
4 Attach new leaf springs.
How to replace consumable parts

While placing the new leaf spring and
reinforcing spring against the nozzle arm,
tighten the mounting screw with the Phillips
screwdriver. At this point, do not forget to fit
the washer.
53403-L1-00
Precision Phillips screwdriver
5 Reattach the nozzle.

6 Check that the nozzle is held
securely.
1. Check that there is no gap between the
leaf springs and nozzle.
2. Attempt detaching and attaching the
nozzle several times to check that there
is no looseness.
4-1
2. Ejector unit
2.1 Replacing an ejector bit
1 Shut off the air supply. Step 1 Shutting off the air supply
Turn the air supply/shutoff valve inside the
machine lower left panel to the right, to stop
the air supply.
53417-L1-00
2 Move the head to a convenient

position for replacement work.
3 Pull out the ejector bit by hand.
Remove the cap by turning it to the left with
a hex wrench. The end of the bit is seen
sticking out of the ejector unit. Pull out the
bit by hand.
53418-L1-00
c CAUTION
The removed bit cannot be reused. Reuse may cause
Step 3 Removing the bit
4
component pickup errors.
4 Clean the bit installation hole.

Remove dust or grime in the installation hole
using an Air blow tool (available as an
option), lint-free cotton swab, etc.
5 Install a new bit.

Fit an O-ring to the new bit and install one
end of the bit into the cap. Then insert the
bit into the installation hole and close the
cap by turning it to the right.
53419-L1-00
Bit installation hole
c CAUTION
If the bit is not installed in place, it may fly out when
vacuum is turned on. Always make sure that the bit is
securely installed.
c
BIT O-ring Cap
CAUTION
When closing the cap after inserting the bit, be careful
Step 5 Installing the bit
not to let the O-ring come out.
Not installed in place
6 Supply air to the machine.

Turn the air supply/shutoff valve inside the
machine lower left panel to the left, to start
the air supply.
4-2
2.2 Replacing a valve (solenoid coil)
1 Turn off the air supply and the Step 1 Shutting off the air supply
power switch. Then turn the air supply/
shutoff valve inside the machine lower left
panel to the right, to stop the air supply.
53417-L1-00
2 Unplug the connectors on the head

valve unit.
1. Unplug all connectors attached to the
head valve unit.
2. Unplug the connector attached to the
vacuum sensor board.
53405-L1-00
c CAUTION
A harness of thin wires is attached to the connector
Step 2 Unplugging the connector
Connector
housing. Use extreme caution not to break the wires. Do
not pull the harness to unplug the connector. Always
grip the connector body when unplugging.
3 Disconnect the air hoses.

Disconnect the air hose inserted in each
4
ejector unit.
53406-L1-00

Vacuum sensor board connector
Step 3 Disconnecting the air hose
4-3
4 Disconnect the air hoses on the Step 4 Disconnecting the air hose
right side of the valve unit.
Disconnect the two air hoses located on the
right side of the valve unit.
53407-L1-00
5 Remove the valve unit from the

head assembly.
1. Use the M5 hex wrench to remove the
four bolts securing the valve unit (two
bolts each on the right and left of the
base).
2. Remove the valve unit from the head
assemble while slightly lifting it up.
Air hose
53408-L1-00
Step 5 Removing the valve unit
4
Remove the bolt with

the hex wrench.
Valve unit removed from head assembly
4-4
6 Remove the valve (solenoid coil). Step 6 Removing the valve (solenoid coil)
Use a precision Phillips screwdriver to loosen
Valve (solenoid coil)
the two screws securing the valve (solenoid
coil) to be replaced, and then remove the
valve (solenoid coil) .
53410-L1-00
c CAUTION
Be careful not to drop the gasket which is fitted to the
back of the solenoid coil.
7 Attach a new valve (solenoid coil).

Use a precision Phillips screwdriver to tighten
the two screws to secure the new valve
(solenoid coil) .
53411-L1-00 Solenoid coil mounting screw
c CAUTION
Be careful not to lose the gasket, or not to fit it inside out
Step 7 Attaching a valve (solenoid coil)
or pinch it. New valve (solenoid coil)
8 Reinstall the valve unit in the

reverse of the above procedure.
4
Also reconnect the air hoses and connectors
back to their original positions.
9 Check the operation.

After installing the valve unit in its original
position, supply air to the machine and turn

on the machine power. Then generate a
negative pressure (vacuum) with the same
procedure described in 3.2.2, "Checking the
negative pressure when the spline shaft is
open" in Chapter 3, and check that no
abnormal values appear.
4-5
2.3 Replacing a cleaning blow valve
1 Turn off the air supply and the Step 3 Disconnecting the connector
power switch. Then turn the air supply/
shutoff valve inside the machine lower left
panel to the right, to stop the air supply.
2 Remove the head valve unit.

Remove the head valve unit using the same
procedure described in steps 2 to 5 in the
previous section 2.2, "Replacing a solenoid
coil".
3 Remove the cleaning blow valve.

Use a precision Phillips screwdriver to loosen
the two screws securing the cleaning blow
valve to be replaced, and then remove the Blow valve connector Blow valve
cleaning blow valve.
53420-L1-00
Step 4 Removing the cleaning blow valve
c CAUTION
Be careful not to drop the gasket which is fitted to the
4
back of the cleaning blow valve.
4 Attach a new cleaning blow valve.

Use a precision Phillips screwdriver to tighten
the two screws to secure the new cleaning
blow valve.
53421-L1-00
c CAUTION
Be careful not to lose the gasket, or not to fit it inside out
Blow valve Precision Phillips screwdriver
or pinch it.
5 Reinstall the valve unit in the

reverse of the above procedure.
Also reconnect the air hoses and connectors
back to their original positions.
6 Check the operation.

After installing the valve unit in its original
position, supply air to the machine and turn
on the machine power. Then generate a
negative pressure (vacuum) with the same
procedure described in 3.2.2, "Checking the
negative pressure when the spline shaft is
open" in Chapter 3, and check that no
abnormal values appear.
4-6
3. Cleaning and replacing the conveyor belts
The conveyor belts are used in three conveyors: board carry-in conveyor, board clamp conveyor and board
carry-out conveyor.
The following explains the procedure for replacing the belts in the board clamp and carry-out conveyors.
When replacing the belt in the board carry-in conveyor, skip steps 4, 5 and 8.
1 Press the emergency stop button. Step 2 Loosening the belt tensioner bolt
2 Slacken the belt.

Loosen the belt tensioner bolt with the M4
hex wrench and slide the bolt fully along the
elongate hole (in the direction of slackening
the belt).
53412-L1-00
3 Detach the belt.

Using the M3 hex wrench, loosen the bolt
securing the belt drive pulley and pull out
the shaft in the direction of arrow (shown in
photo). Then detach the belt from the pulley Tensioner bolt
4
and take it out through the space between
the pulley and the shaft.
Step 3 Removing the shaft
53413-L1-00
Drive pulley
4 Remove the board clamp assembly.

Single type:

Using the M3 hex wrench, remove the two
bolts securing each board clamp assembly
and remove the board clamp assembly (one
assembly per belt).
Double type:
Using the M3 hex wrench, remove the two
bolts securing each board clamp assembly
and remove the board clamp assemblies
(two assemblies per belt).
53414-L1-00
Shaft
Step 4 Removing the board clamp assembly
Board clamp assembly Board clamp assembly mounting bolt
4-7
5 Detach the belt from the conveyor. Step 5 Detaching the belt from the conveyor
53415-L1-00
6 Clean the conveyor rail.

Use a fine brush or cleaning cloth to clean
the gap between the conveyor rail and
board guide.
7 Attach a new belt.

1. Temporarily fit a new belt onto the pulley.
2. Reconnect the shaft to the pulley and
tighten the bolt.
3. Move the belt tensioner bolt to apply a
proper tension to the belt. Then tighten
the belt tensioner bolt. Pull out the belt.
8 Reattach the board clamp assembly. Step 8 Installing the board clamp assembly
1. Install the board clamp assembly in the
original position and temporarily tighten
the bolts to secure the board clamp
assembly.
2. On the [Unit] – [Conveyor] tab screen,
press the [Board Clamp] button to raise
4
the board clamp assembly and tighten
the bolts securely.
53416-L1-00
c CAUTION
Compressed air must be supplied during adjustment to
actuate the board clamp assembly. Secure the board

clamp assembly while it is in the raised position. Board clamp assembly
9 Check the belt rotating condition.

1. Open the [Unit]-[Conveyor] tab screen,
and press the [Board Clamp] button
again to unclamp. At this point, make
sure that the top of the board clamp
assembly is 0.5mm lower than the upper
surface of the belt.
2. On the [Unit]-[Conveyor] tab screen, 0.5 mm
press the [Conveyor In] button or

[Conveyor Out] button to turn on the
conveyor motor and check the belt
rotation. Board clamp
3. If the rotation speed fluctuates or there is

slack in the belt, adjust the position of
the tensioner bolt and then check the
rotation again.
4-8
4. Lubrication points
This section describes lubrication points, intervals and procedures.
■ Grease
Use the following specified grease.
Grease name : NSL
Part No. : K48-M3856-00X
4.1 X-axis guide and ball screw
X-axis lubrication points
X-axis guide X-axis ball screw
Grease nipple (upper side)
Grease nipple
Grease nipple (lower side)
53435-L1-00
Lubrication section Lubrication point Interval Procedure
Guide 4
Bimonthly (once
Use a grease gun (bent nozzle type)
per 2 months)
Ball screw 1
4-9
4.2 Y1 and Y2 axis guide and ball screw
Y-axis lubrication points
X-axis ball screw X-axis guide
Grease nipple Grease nipples

(front and rear)
4
53436-L1-00
Guide 4 Use a grease gun with a flexible nozzle for

Bimonthly (once
ball screws and a grease gun with a standard
per 2 months)
Ball screw 2 nozzle for guide.
4.3 PU-axis ball guide and ball screw
PU-axis lubrication points
Ball guide
Ball screw Ball guide
Ball screw
53437-L1-00
Ball guide 2 (4 for twin type)

Bimonthly (once
Apply grease by hand.
per 2 months)
Ball screw 2 (4 for twin type)
4-10
4.4 Conveyor W-axis guide and ball screw
W-axis lubrication points
Hexagonal spline
W-axis guide
W-axis guide
W-axis ball screw
W-axis ball screw
53438-L1-00
4
Guide 2
Ball screw 2 6 months. Apply grease by hand.
Hexagonal spline 1
4.5 Z-axis spline shaft

Z-axis lubrication points
Z-axis spline shaft (upper side)
Z-axis spline shaft (lower side)
53439-L1-00
Z-axis spline shaft 8 3 months Apply a thin coat of grease by hand.
4-11
Appendix
Appendix
Contents
1. Specifications A-1
1.1 Air regulator unit A-1
1.2 Power connection terminals A-2
2. Warranty A-3
1. Specifications
1.1 Air regulator unit
Appendix
The air regulator for controlling the air pressure to the pneumatic units of the machine is located behind the
front lower left panel. A digital pressure gauge is provided on the front left of the machine. The air pressure
must be set to the optimum level.
Air pressure regulator and pressure gauge
Air pressure setting for machine
Air pressure
regulator
Air release valve

Air supply/shutoff (for tape cutter)
valve
Pressure-drop detection level
53500-L1-00
■ Supply air pressure

This is the pressure of the source air supplied to the machine. Before setting the air pressure with the air regulator, make
sure that this supply air pressure is in the following optimal range.
0.45MPa to 0.7MPa
■ Digital pressure gauge

Shows the supply air pressure (upper reading) and pressure-drop detection level (lower reading). A normal pressure value
is shown in green, and a pressure value lower than the pressure-drop detection level is shown in red.
■ Air pressure setting and pressure-drop detection level

Air pressure setting for machine (upper reading) : 0.40MPa to 0.41MPa
Pressure-drop detection level (lower reading) : 0.33MPa
■ Air supply/shutoff valve

Turning this valve to the right shuts off air supply and also discharges the air remaining in the air path.
■ Air release valve (for tape cutter)

Turning this valve to the right shuts off air supply to the tape cutter and also discharges the air remaining in the air path.
■ Source air connector

Prepare an air hose with an inner diameter of at least 8mm having a 40SH socket (Nitto Koki, or equivalent), and connect
it to this connector. Use dry, clean air passed through an air filter.
A-1
1.2 Power connection terminals
The power connection terminals are located inside the lower right panel on the front of the machine. Connect
the power cable leads as shown below to the L1, L2, L3 and ground terminal (PE) on the power terminal block.
■ Power supply specifications
Appendix
Model name Power Frequency Power capacity
YS100 3-phase AC 200/208/220/240/380/400/416V (±10%) 50/60Hz 6.1KVA
Power connection terminals
Power input terminals

(L1, L2, L3) and ground terminal
Main breaker
53501-L1-00
Power cable example
L=100mm L1 Ring-tongue crimp terminal

L2
L3 PE
Fork-tongue crimp terminal
53502-L1-00
c CAUTION
Use a power cable whose conductor cross-section area is greater than 2.5mm2.
w WARNING
To avoid the risk of electrical shock, make sure that the power source is off before connecting the
power cable. Also make sure that the ground cable is securely connected to the machine.
A-2
2. Warranty
The machine you have purchased is warranted against malfunctions as described below.
n Warranty description:
Appendix
If a failure or breakdown occurs due to defects in workmanship or materials used to manufacture this machine within
one year or 5,000 hours of operation (whichever comes first) after the incoming inspection is complete, then YAMAHA
will repair the defective parts free of charge.
n Warranty period
The warranty period ends when any of the following applies:
1. After one year has elapsed from the time of installation.
2. After 5,000 hours of operation.
n Items not covered by the warranty
The warranty does not cover any of the following conditions:
1. Damage as a result of deterioration due to age or wear (e.g., normal discoloration of painted or plated surfaces, wear
of replaceable parts, etc.).
2. Incidents associated with sensory perceptions which have no bearing on the quality or function of the machine (e.g.,
signal sounds emitted by the controller, rotating sounds of the motor, etc.).
3. Damage caused by the user environment (e.g., impurities in the air supply, dust, debris and oil mist in the machine).
n Exception to warranty repairs
Warranty repairs will not be made if damage is caused by the following:
1. Earthquakes, typhoons, floods, lightning, accidents or fires, other natural or man-made disaster.
2. Modifications or conversions not approved by YAMAHA or its dealers.
3. Use of non-genuine parts, greases or lubricants.
4. Lack of proper maintenance and inspection procedures.
5. Maintenance handled by someone other than the approved dealers.
6. Damage or malfunction due to changes in the machine installation level that may be caused by changes in the
foundation or surrounding environment.
7. The machine was modified or changed in specifications after the incoming inspection is complete.
8. When defective parts replaced free of charge were not returned to the location specified by YAMAHA or YAMAHA
sales representatives within 30 days.
n Note on network connections
A precondition for network connections with the YAMAHA surface mounters and related machines is that such
connections will be used in closed networks comprised of a YAMAMHA surface mounter (or related machine) and an
off-line PC. The customer must take responsibility for connections to company in-house networks and to external
networks. Please acknowledge that YAMAHA can bear absolutely no responsibility for networks configured by other than
just a YAMAMHA surface mounter (or related machine) and off-line PC nor can accept responsibility for problems
occurring due to network settings and connections.
n About USB memor y devices

• Use the USB memory device (supplied with the machine or purchased from YAMAHA sales reps) specified by YAMAHA
Motors Co., Ltd. Do not use any other type of USB memory device with YAMAHA surface mounters and related
machines. Any problems arising from using other than the specified USB memory device are not covered by our
warranty.
• Do not connect any USB device other than the specified USB memory device to the USB port on the machine. If a
device driver for a wrong device is installed, then the machine might not work correctly. We take no responsibility for
any problems caused by connecting a wrong or inappropriate device.
A-3
MAINTENANCE MANUAL
Jul. 2012
Version 1.10
© YAMAHA MOTOR CO., LTD. IM Operations
All rights reserved. No part of this publication may be
reproduced in any form without the permission of
YAMAHA MOTOR CO., LTD.
Information furnished by YAMAHA in this manual is believed to
be reliable. However, no responsibility is assumed for possible
inaccuracies or omissions. If you find any part unclear in this manual,
please contact YAMAHA or YAMAHA sales representatives.

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Maintenance Manual

2. Safety message vii

1.1 To ensure safety

1.1.1 Defining safety

1.1.2 Causes of injuries and accidents

1.2 Using safety gear

n Precautions when applying lubricant (grease)

1.3.2 Restricting machine operation with passwords

1.4 Cautions during machine operation

1.5 Cautions during power outages

1.6 Cautions regarding ferromagnetic fields

1.7 Handling the internal tape cutter

Prevention of hand entry

Dummy feeder (Wide-size)

Dummy feeder (8mm-size)

■ One-stop cover (For feeder exchange carriage)

Prevention of hand entry

Board conveyance plane

Lower muzzle plate

Upper clearance Lower clearance Remarks

YS100/YS88 8.0 to 38.5mm 1.0 to 31.0mm

YS12, YS12P, YS12F, YS24, YS24X 5.0 to 20.0mm 4.2 to 39.2mm

YSP 0 to 6.6mm 0 to 26.4mm

Hazards when handling solvents

1. Hazards to human health

To avoid hazards of solvents

1.10 Handling the X-ray unit

n Safety alert symbols and signal words

2.2.1 Safety instruction

3.1.1 Warning label format

Warning label format

WARNING Signal word panel

Mark and pictogram

3.1.2 Meaning of marks

Mark and pictogram

Warning mark Prohibition mark Instruction mark

WARNING WARNING WARNING

Meaning of the above

3.2.1 Handling safety covers

Electrical shock hazard

To prevent the electric shock or damage.

Example for machines that must be connected to 200 VAC

N Feeder setup section

N Cutter inner side N Panel inner side

N Feeder setup section

N Cutter inner side

N Controller front panel

2. Preparing for maintenance tasks 1-3

Chapter 2 Daily maintenance items

1. Checking the nozzle 2-2

2. Cleaning the feeder plate 2-5

3. Cleaning the camera protective glass 2-6

Chapter 3 Periodic maintenance items

3. Three-month inspection 3-25

4. Six-month or one-year inspection 3-34

Chapter 4 How to replace consumable parts

2. Ejector unit 4-2

2.2 Replacing a valve (solenoid coil) 4-3

3. Cleaning and replacing the conveyor belts 4-7

4. Lubrication points 4-9

1. About this manual i

Chapter 2 Daily maintenance items

Chapter 3 Periodic maintenance items