Ground Rail Intelligent Workstation Equipment Maintenance Manual

Preface

Proper use, maintenance, and care of the equipment play an important role in ensuring normal operation, preventing failures and accidents, extending the equipment’s service life, and maximizing its economic efficiency. Equipment operators must undergo professional training and pass examinations before starting work. During operation, they must strictly comply with safety operation and maintenance procedures, and any violation of these rules is strictly prohibited.

Equipment maintenance should follow the principle of “prevention first,” eliminating potential faults at an early stage. The main tasks are to prevent looseness of connecting parts and abnormal wear, ensure operators use the equipment correctly in accordance with operating regulations, prevent accidents, extend the service life and maintenance cycle, ensure safe operation, and keep the equipment in optimal condition for production.

It is necessary to adhere to the principle of combining operation with maintenance. During daily maintenance, operators should achieve the “Three Goods” (manage well, use well, maintain well); the “Four Skills” (know how to operate, know how to maintain, know how to inspect, know how to troubleshoot); and implement the “Five Fixed Lubrication Rules,” which refer to fixed personnel, fixed schedule, fixed quality, fixed quantity, and fixed point.

Operators of all types of equipment must perform regular and designated maintenance according to these regulations for the equipment they use, including robots, ground rails, cantilevers, gantries, equipment tracks, welding machines, and transmission systems.

Maintenance and Care of the Guide Rail Rack

After long-term use and wear, a large amount of grease and sludge will accumulate on the guide rail rack, as shown in the figure below. This sludge is mainly formed by the mixture and friction of metal dust produced during the welding process and lubricating oil. Since the sludge consists entirely of metal particles, if not cleaned for a long time, it will accelerate the wear of the guide rail and the ball bearings in the slider. Prolonged friction can lead to a loss of guide rail precision.

Solution method: Wipe off the sludge with a clean cloth. For areas with strong adhesion, use fine abrasive cloth to remove it, or soak with kerosene and then wipe clean.
Note: Use special 00# lubricating grease for guide rail lubrication.

Maintenance cycle: After each work shift, wipe the guide rail once with a clean cloth. During summer or humid seasons, when oil adheres to the surface, use a brush to spread it evenly to prevent the guide rail from rusting.

Use of the Oil Injection Lubrication System

The ground rail workstation is equipped with an automatic timed or PLC program–driven lubrication system. Automatic lubrication points are installed at locations such as the gears, sliders, and racks of each moving axis. Grease is stored in grease packs or grease tanks. When using an oil tank for lubrication, the injection amount of lubricating grease should be 1/3 to 1/2 of the cavity volume: for low-speed operation, add grease up to 2/3 of the cavity; for high-speed operation, add grease up to 1/2 of the cavity.

For PLC program–driven oil pumps, grease packs are used for oil supply. Be sure to purchase and use the specified grease grade (00#). Regularly check the grease level in the pack, and replace it promptly when it is nearly exhausted.

When using a timed lubrication system, each piece of equipment should have its oiling time and quantity reasonably set according to actual operating conditions. (Recommended oil pump injection time: 12–18 seconds; interval: once every 2 hours; power the oil pump 1 day per week, and keep it powered off during the remaining time.) This ensures that the guide rails, sliders, racks, and gears receive adequate lubrication without causing excessive oil accumulation or leakage due to over-lubrication.

When using a program-driven lubrication system, run the lubrication program for each moving axis at least once every 7 days. Also, inspect the oil supply and discharge ports for any leakage; if leakage is found, handle it immediately.

The following shows the picture of a timed-type oil pump.

The following shows the picture of a PLC program–driven oil pump

Surface Dust Removal of the Equipment

After long-term use of equipment such as robots, welding machines, and electrical control cabinets, a large amount of dust, oil stains, and sludge will accumulate on the surface due to workshop environmental conditions. This buildup affects the equipment’s appearance, operating accuracy, and normal functionality, and therefore needs to be cleaned regularly.

Solution method: Wipe off the sludge with a clean cloth. For thicker, hardened sludge, use a steel scraper to remove it. Floating dust inside control cabinets can be blown away using an air pump gun.

Maintenance cycle: Wipe surface dust and oil stains once a week with a clean cloth. Floating dust inside closed spaces such as control cabinets should be blown out with an air pump at least once a month.

Cleaning and Maintenance of Equipment Exhaust Fans

The exhaust and cooling system is an important part of the equipment, including the exhaust systems of the welding machine, robot control cabinet, and additional axis cabinet. Whether this system functions properly has a significant impact on the service life and performance of the equipment. Therefore, its maintenance and care are extremely important to ensure the normal operation of the exhaust fan and to keep the exhaust outlet free from dust blockage.

Solution method: Use tools such as a high-pressure air gun to blow away dust from inside the cooling mesh cover.

Maintenance cycle: Determined according to the on-site environment; under normal conditions, clean once a month.

Cleaning and maintenance of the camera

Cameras are precision mechanical components, requiring enhanced lens protection and proper heat dissipation. Lens blur directly impacts light acquisition and point cloud quality, which in turn affects camera positioning accuracy. Excessive camera temperature can affect performance and potentially damage core components.

Solution: Always close the camera cover when welding after scanning. Regularly inspect the protective glass and promptly replace any glass that is damaged or contaminated. Never operate the camera without the protective cover or glass installed. Also, regularly inspect the visual air pipe connector and replace any leaks immediately to prevent poor cooling due to insufficient air pressure and poor opening and closing of the protective cover, which can affect camera operation.

Maintenance cycle: Depends on the site environment and should be checked in a timely manner.

Use and maintenance of the teaching pendant

The robot’s teach pendant is frequently used and is one of the most vulnerable parts. Faults can include touchscreen damage, touchscreen malfunction, cable breakage, and loose cable connections.

Solution: Use the teach pendant properly and avoid pulling or yanking the cable. The teach pendant must be used with a protective film. Check the protective film regularly for damage and replace any damaged film promptly. The teach pendant must be hung on the teach pendant bracket when not in use.

Maintenance and Care of the Welding Machine

Warning! Electric shock can be fatal.
Before opening the equipment:

Turn the main switch to the OFF position.
Disconnect the equipment from the power supply.
Prevent it from being reconnected.
Use appropriate measuring instruments to ensure that live components (such as capacitors) have been discharged.

Principle overview: Under normal operating conditions, the welding machine requires very little maintenance. However, to ensure its service life, the following maintenance procedures must be followed.

Maintenance of the Welding Power Source

The equipment number nameplate must be riveted at the specified position on the machine cover; otherwise, internal components may be damaged.
The connection between the welding cable plug and the output socket must be tight and reliable; otherwise, the plug and socket may burn, causing instability during the welding process.
Avoid short circuits between the welding cable and any metal objects on the ground to prevent output short circuits.
Prevent damage or disconnection of welding cables and control cables.
Avoid impact deformation, and do not place heavy objects on the welding power source.
Ensure smooth ventilation.
Regular inspection and maintenance are required.

Before maintenance, the following checks should be performed:

Check whether the front panel status and welding specification display are correct, and whether the buttons and knobs function normally.

Check whether the line voltage of the three-phase power supply is within the range of 340V–420V and whether there is any phase loss.
Verify that the input cable connections are correct and reliable.
Ensure the welding cable connections are correct and the contacts are good.
Check whether the gas circuit is in good condition and whether the gas regulator or mixer is functioning properly.

Note: The maximum voltage inside the welding power source reaches 600V. To ensure safety, it is strictly forbidden to open the machine cover without authorization. During maintenance, appropriate safety measures must be taken to prevent electric shock. When installing welding cables or replacing welding torch components, the power must be turned off.

Maintenance of the Wire Feeding Mechanism

During use, avoid contact with water or other corrosive liquids. If accidental contact occurs, wipe it off immediately and keep the wire feeder clean at all times.

After long periods of use, the wire feeding rollers and pressure rollers will experience wear. When the wear becomes significant enough to affect feeding stability, they should be replaced promptly.

To ensure smooth wire feeding, the wire feeding system should be cleaned regularly to prevent increased feeding resistance, which can affect feeding stability and welding quality.

Water cooler maintenance

The coolant should be replaced every 12 months. The disposal of waste coolant should refer to the coolant instructions.

How to drain the coolant:

First, drain the coolant from the water tank through the drain port.
Then use an air compressor to pump air into the outlet and return ports respectively, and drain the coolant in the water pump and radiator into the water tank.
Then drain the coolant in the water tank again through the drain port.

The radiator should be cleaned of dust every 6 months. If the welding gun or cutting torch overheats, it may be caused by excessive dust in the radiator and insufficient cooling capacity of the water cooler. It should be cleaned with dry compressed air, as shown in the figure:

The filter should be cleaned every two months. The filter is removable, as shown in the figure. When impurities accumulate, it should be cleaned promptly. Remove the transparent filter cup/filter screen in the order 1-3 in the figure below, clean thoroughly with air from a compressor or running water, and then reinstall in the order 3-1 in the figure below. Improper installation may create gaps and reduce filtering effectiveness.

(Warning! Be sure to clean thoroughly and keep it clean during the cleaning process to ensure it is not contaminated again)

Notes:

Please use coolant according to regulations to avoid radiator damage, water pump leakage and motor damage.
Do not start the water cooler without coolant or with insufficient coolant, as this may damage the water pump or welding gun. (3) Do not use the water cooler in an environment containing silicon, acid, alkali or salt, as this may cause corrosion and leakage of the water cooler.

Coolant Considerations

Ambient temperature＞5℃, water can be used as coolant in the water tank

Warning: The water quality standard is deionized water or distilled water, which must meet the water quality standards. Otherwise, the scale produced may cause water seal leakage, rust and jam of the water pump, and burn the motor.

When the ambient temperature is ≤5℃, antifreeze must be used as the coolant in the water tank.

Warning: You must use an organic antifreeze. Otherwise, the corrosion inhibitors in inorganic antifreeze can cause water pump seal leaks, welding torch overheating, or corrosion of the welding torch cable copper wire. We recommend using antifreeze that meets national standards and is used according to their requirements. Use antifreeze brands that clearly indicate “organic,” “OAT (Organic Acid Technology Antifreeze),” or “all-organic” in the name and ingredient list. Avoid using antifreeze products that clearly indicate the absence of inorganic salts, such as “free of phosphates, borates, silicates, nitrates, nitrites, and amines.” Avoid using antifreeze products that clearly indicate “inorganic” in the name or contain inorganic salts such as silicates in the ingredient list.

Functions of organic antifreeze: antifreeze, anticorrosion, anti-boiling, anti-scaling

The main indicator is the freezing point of the antifreeze.

When choosing antifreeze, its freezing point should be 10℃ lower than the lowest temperature in the area where it is used. For example, if the local temperature is as low as -15℃, choose antifreeze with a freezing point of -25℃ to ensure that the antifreeze will not freeze. If the antifreeze is not used according to regulations, the following consequences will occur:

The radiator inside the machine is very easy to freeze and crack in winter.
The copper wire in the welding gun cable is easily corroded and falls off, which enters the water pump and causes the water pump to wear and leak. (3) Scale is generated, causing waterway blockage or water pump jam.

Recommended manufacturer: Lucent 100 coolant

Model: Lucent 100 100% organic coolant Antifreeze degree: -27℃

Applicable areas: the lowest annual temperature is higher than -17℃ Specifications: 4kg

(Note! Do not mix different coolants. When changing coolant, make sure to replace all of them.)

Welding gun maintenance

In order to ensure the service life and excellent performance of the welding gun equipment, the welding gun system needs to be regularly inspected and maintained:

Daily inspection:

Is there any abnormality in appearance?
Please check the gun neck and integrated cable to see if they are normal before use. If damaged, they need to be repaired before use.
If welding performance deteriorates, necessary cleaning and maintenance work is required.
If the inner hole of the conductive nozzle is deformed or arc striking is difficult, the conductive nozzle should be replaced in time.
If there is any problem with wire feeding, please replace the conductive nozzle and wire feeding tube in time.
When parts are worn, please replace them with original welding materials in time.

Weekly inspection:

Check the installation status of the integrated cable for excessive tension or twisting.
Clean and maintain the gun neck to prevent spatter from bridging the conductive tip and nozzle and causing damage to the welding gun.

Monthly inspection:

Remove the wire feed tube inside the integrated cable and clean it thoroughly with compressed air.
Check hoses for wear.
Check all joints and screws for looseness and pipelines for damage.

Annual inspection:If necessary, inspect and repair the electrical circuit.

Oil change and maintenance of robots

For robots, the lubricating oil must be replaced every 11,000 operating hours or every 3 years (whichever comes first). The required oil quantities for each axis, the orientation of each axis during oil filling, the steps for replacing the lubricating oil, and the procedure for releasing residual pressure in the chamber after refilling must all be carried out according to the instructions in this section. If you have any questions or require technical support, please contact our company’s after-sales service department in time.

Below is the oil quantity table for lubricating oil replacement of the external ER series EFORT robots, along with schematic diagrams showing the oil inlet and outlet positions for each joint.

Table 4-6 Lubricating Oil Replacement Quantities

Supply Location	Filling Quantity	Lubricant Name	Remarks
J1 Reducer	680 cc	MOLYWHITERE No.00 – – – – – – – –	Rapid oil injection will cause an increase in chamber pressure, leading to seal rupture. To avoid this, control the oil injection speed at ≤ 40 cc / 10 sec.
J2 Reducer	700 cc
J3 Reducer	310 cc
J4 Reducer	110 cc
Wrist Component	125 cc

Position of oil filling and drain ports on each joint shaft

The following is a table showing the oil gauge for lubricating oil replacement and the locations of the oil filling and drain ports for each joint of the hollow wrist ARC series EFORT robots

Table 4-6 Lubricant Oil Replacement Gauge
Provide Location	Amount of Refueling	Lubricating Oil Name	Remark
J1 axis reducer	1310±10cc	MOLYWHITERE No.00	Rapid oiling will cause the pressure in the oil tank to rise, causing the sealing ring to crack and resulting in lubricating oil leakage. The oil supply speed should be controlled below 40cc/10 seconds.
J2 axis reducer	870±10cc
J3 axis reducer	370±10cc
J4 axis reducer	480cc	BONNOC AX68	Install quasi-dual time grease filling.

Position of oil filling and drain ports on each joint shaft

After lubrication, the robot should be operated appropriately to release the residual pressure in the lubrication tank. At this time, a recovery bag should be installed under the lubrication oil inlet and outlet to prevent the leaked lubricant from scattering.

To release residual pressure, with the oil drain port open, repeatedly move the J1 axis within the ±30° range, the J2/J3 axis within the ±5° range, and the J4 and J6 axis within the 30° range for more than 20 minutes, controlling the speed to a low-speed motion state. If the above actions cannot be performed due to surrounding conditions, the robot should be operated for the same number of times (if the axis angle can only be half, the robot should be operated for twice the original time).

After completing the above steps, install the sealing plug on the oil drain port (using a combination gasket or wrapping sealing tape). For detailed steps and instructions on how to change the lubricating oil, please refer to the “Robot Oil Change and Maintenance Operation Manual”.

Tightening of connecting bolts

The robot’s base and other components are primarily connected with high-strength bolts. Because the overall structure is dynamically loaded, these bolts inevitably loosen over time, affecting the equipment’s operating accuracy and creating safety hazards. The mounting brackets for the vision system and welding gun are also prone to loosening, causing deviations in visual accuracy.

Solution: Check whether the bolts are dropped or loose, and use an electric wrench or a manual torque wrench (with preset torque values) to tighten the bolts to the preset torque value.

The following is a table of recommended pre-tightening force settings for each bolt connection part of the workstation.

Recommended table for pre-tightening force of bolts for installing smart workstation equipment

Serial number	Installation location	Bolt specifications	Pre-torque wrench specifications	Sleeve specifications	Pre-torque value
1	Welding gun (flange, anti-collision) install	M4	Xiaofei 1/4 1–6N·M	H3 (length 100mm)	3.3N·M
2	Camera flange bracket installation	M6	Dafei 1/2 5–60N·M	H5	8.5N·M
3	Camera box installation	M3	Xiaofei 1/4 1–6N·M	H2.5	1.2N·M
4	Motor fixed installation (less than 3.14KW)	M8	Dafei 1/2 5–60N·M	H6 (length 230mm)	20N·M
5	Motor fixed installation (3.14KW and above)	M12	Dafei 1/2 60–330N·M	H10 (length 230mm)	128N·M
6	Motor shaft fastening installation (1.5KW)	M6	Dafei 1/2 5–60N·M	H5 (length 90mm)	16N·M
7	Motor shaft fastening installation (3.14KW)	M8	Dafei 1/2 5–60N·M	H6 (length 90mm)	30N·M
8	Motor shaft fastening installation (5.5KW)	M20	Dafei 1/2 60–330N·M	H14 (length 100mm)	330N·M
9	Robot base installation	M14	Dafei 1/2 60–330N·M	H12	200N·M
10	Robot base installation	M16	Dafei 1/2 60–330N·M	H14	200N·M
11	Cantilever, gantry column and beam connection	M20	Dafei 1/2 60–330N·M	H14 (length 100mm)	330N·M
12	Connection between cantilever, gantry steel column and slide or trolley	M20	Dafei 1/2 60–330N·M	H14 (length 100mm)	330N·M
13	Connection between cantilever, gantry column beam and support	M20	Dafei 1/2 60–330N·M	H14 (length 100mm)	330N·M

Maintenance cycle: Tighten all bolts thoroughly every three months of use.

Adjustment of walking track

During the long-term movement of the equipment, the ground rail track may experience height changes or straight line tilt, affecting the equipment’s travel speed and positioning accuracy, thereby shortening its service life and affecting the normal function of the equipment.

Solution: Check the track pads for looseness. Use a level or theodolite to measure the track levelness. If any deviation is found, adjust the height. Check that each transmission mechanism is running smoothly and for any abnormal noise. If any problem occurs, address it promptly.

Maintenance cycle: Check the track levelness and straightness every 12 months and make adjustments if any deviation occurs.

Maintenance of electrical systems such as distribution boxes and junction boxes

Floor rail systems are equipped with numerous electrical equipment, including electrical control cabinets, network cabinets, and distribution boxes. These devices require complex wiring. Prolonged use can lead to loose connections, exposed cables, and loose wires. These risks can easily cause short circuits and power outages, impacting the normal operation of the equipment and posing safety risks. This area requires regular inspection and maintenance.

Solution: Check the switch wiring for loose cables and exposed wires. Check the neutral, live, and ground wires for proper connection, proper cable routing, and proper current and voltage. Any abnormalities should be addressed promptly. Always turn off the power and exercise caution when checking.

Maintenance cycle: Every 12 months of use, conduct a comprehensive inspection and overhaul of the distribution box, junction box, network cabinet wiring cables and power switches.

October 11, 2025
10:55 pm