Preface
Proper use, maintenance, and care of equipment play a vital role in ensuring normal operation, preventing malfunctions and accidents, extending the service life, and maximizing the economic efficiency of the equipment. Operators must receive professional training and pass examinations before taking up their positions. During operation, they must strictly follow the safety and maintenance procedures—any violation of operational regulations is strictly prohibited.
Equipment maintenance should follow the principle of “prevention first,” eliminating potential faults at an early stage. The main objectives are to prevent loosened connections and abnormal wear, to ensure that operators use the equipment correctly in accordance with the operation manual, to prevent equipment accidents, to extend the service life and maintenance intervals, and to guarantee safe operation and optimal production performance.
Operators must adhere to the principle of combining use and maintenance, achieving the “Three Goods” (manage well, use well, and maintain well) and the “Four Skills” (know how to operate, maintain, inspect, and troubleshoot). The “Five Fixed Lubrication Rules” refer to fixed personnel, fixed schedule, fixed quality, fixed quantity, and fixed location.
All types of equipment operators must perform regular and designated maintenance in accordance with this regulation, including robots, ground rails, cantilevers, gantries, welding machines, and transmission systems.
Surface Dust Treatment
For equipment such as robots, welding machines, and electrical control cabinets that operate for extended periods, a large amount of dust, oil stains, and sludge may accumulate on their surfaces due to workshop environmental conditions. These contaminants can affect the equipment’s appearance, operational accuracy, and functional performance, making regular cleaning necessary.
Solution Method: Wipe off oil and sludge with a clean cloth. For thick deposits, use a steel scraper to remove them. Use an air gun to blow off dust inside the control cabinet.
Maintenance Cycle: Wipe the surface dust and oil stains with a clean cloth once a week. Use an air gun to remove dust inside enclosed spaces such as control cabinets at least once a month.
Cleaning and Maintenance of the Equipment Exhaust Fan
The exhaust and cooling system is an essential component of the equipment. It includes 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 upkeep are extremely important. It is necessary to ensure that the exhaust fan operates normally and that the exhaust outlet is free from dust blockage.
Solution Method:
Use tools such as a high-pressure air gun to blow away the dust inside the cooling mesh cover.
Maintenance Cycle:
Depending on the working environment, clean once a month under normal conditions.
Cleaning and Maintenance of the Camera
The camera is a precision mechanical component, and special attention must be given to protecting the camera lens and ensuring proper heat dissipation. A blurred lens directly affects light capture and point cloud quality, which in turn impacts the accuracy of photo positioning. Excessive camera temperature can affect performance and may damage core components.
Treatment Method:
After the equipment completes scanning and starts welding, always close the camera protective cover. Regularly inspect the protective glass, and promptly replace it if it becomes damaged or heavily contaminated. It is strictly prohibited to operate the camera without closing the protective cover or installing the protective glass. Additionally, the visual air pipe fittings should be checked frequently—if air leakage is detected, replace them immediately to prevent insufficient air pressure from reducing cooling efficiency and causing poor operation of the protective cover, which could affect camera performance.
Maintenance Cycle:
Check regularly according to the site environment.
Teaching Pendant Usage and Maintenance
The robot’s teaching pendant is used frequently and is one of the main wear-prone components. Common faults include touchscreen damage, unresponsive touch, cable damage or breakage, and loose connections.
Soltuion Method:
Use the teaching pendant properly—strictly prohibit pulling or yanking the cable. The teaching pendant must always be used with a protective film, and the film should be checked frequently for damage and replaced immediately if torn. When not in use, the teaching pendant must be hung securely on its designated holder.
Teaching Pendant Usage and Maintenance
The robot’s teaching pendant is used frequently and is one of the main wear-prone components. Common faults include touchscreen damage, unresponsive touch, cable damage or breakage, and loose connections.
Soltuion Method:
Use the teaching pendant properly—strictly prohibit pulling or yanking the cable. The teaching pendant must always be used with a protective film, and the film should be checked frequently for damage and replaced immediately if torn. When not in use, the teaching pendant must be hung securely on its designated holder.
Welding Machine Maintenance
WARNING! Electric shock can be fatal. Before opening the device
- Turn the main switch to the off position
- Disconnect the device from the grid
- Prevent reconnection
- Use suitable measuring instruments to ensure that live parts (e.g. capacitors) are discharged.
Brief description of the principle: The welding machine only requires very little maintenance and care under normal operating conditions, but in order to ensure its service life, the following maintenance methods must be followed.
Welding Power Source Maintenance
- The equipment identification plate must be riveted at the designated position on the casing; otherwise, internal components may be damaged.
- The connection between the welding cable plug and the output socket must be tight and secure; otherwise, the plug and socket may burn, causing instability during welding.
- Avoid short circuits between the welding cable and any grounded metal objects to prevent output shorting.
- Prevent damage or breakage to the welding and control cables.
- Avoid impacts or deformation, and do not place heavy objects on the welding power source.
- Ensure proper ventilation.
- Regular inspection and maintenance are required.
Before maintenance, please do the following checks:
- Check whether the front panel status and welding specifications are displayed correctly, and whether the buttons and knobs are working properly.
- Check whether the line voltage of the three-phase power supply is within the range of 340V-420V and whether there is any phase missing.
- Check whether the input cable is connected correctly and reliably.
- Check whether the welding cable is connected correctly and has good contact.
- Is the gas line in good condition? Is the gas regulator or proportioner normal?
Note: The maximum voltage in the welding power supply is 600V. To ensure safety, it is strictly forbidden to open the casing at will. Safety precautions such as preventing electric shock should be taken during maintenance. The power should be turned off when installing welding cables or replacing welding gun accessories.
Wire Feeding Mechanism Maintenance
During use, avoid contact with water or other corrosive liquids. If accidentally exposed, wipe it clean immediately and keep the wire feeder clean at all times.
After long-term use, the wire feeding wheel and pressure wheel may become worn. When the wear affects the stability of wire feeding, they should be replaced promptly.
To ensure smooth wire feeding, regularly clean the wire feeding system to prevent increased feeding resistance, which could affect stability and welding quality.
Water Cooler Maintenance
The coolant should be replaced every 12 months. Disposal of used coolant must follow the coolant’s usage instructions.
Coolant Drainage Method:
- First, drain the coolant in the tank through the drain port.
- Then, use an air compressor to blow air into the outlet and return ports separately, discharging the coolant from the water pump and radiator into the tank.
- Finally, drain the remaining coolant in the tank again through the drain port.
The radiator should be cleaned of dust every 6 months.
If the welding torch or cutting torch overheats, it may be due to excessive dust on the radiator or insufficient cooling capacity of the water cooler. Use dry compressed air to blow and clean the radiator, 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.
- 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.
Notes on Coolant
When ambient temperature ＞5℃, water can be used as the coolant in the tank.
Warning: The water quality standard must be deionized water or distilled water, and it must meet the required quality standard. Otherwise, the scale produced may cause water seal leakage, pump rusting, seizure, and motor burnout.
When ambient temperature ≤5℃, antifreeze must be used as the coolant in the tank.
Warning: Organic antifreeze must be used; otherwise, the corrosion inhibitors in inorganic antifreeze may cause water pump seal leakage, welding torch overheating, or corrosion of the copper wire in the welding torch cable. It is recommended to use antifreeze that meets national standards and follow its requirements. Use antifreeze whose name and ingredient list clearly indicate “organic,” “OAT (Organic Acid Technology),” or “fully organic.” The ingredient list must clearly indicate that it does not contain inorganic salts, such as phosphates, borates, silicates, nitrates, nitrites, or amines. The use of antifreeze products whose names clearly indicate “inorganic” or whose ingredient lists clearly indicate the presence of silicates or other inorganic salts is strictly prohibited.
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.
- 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.
Maintenance and Servicing of the Robot Body
KUKA robot maintenance and servicing include tightening anchor nuts and fastening bolts, lubricating the A1 cable assembly, changing the oil in the A1 reducer, A2 reducer, and A3 reducer, replacing the timing belts of A4, A5, and A6, and cleaning the robot. For maintenance intervals, refer to the following maintenance schedule.
KUKA Robot Maintenance Locations and Schedule Table
| Interval | Item | Task | Auxiliary substances and consumables |
| Once only, after 100 h | 6 | Check the tightening torque for anchor nuts and holding-down bolts. | |
| 5,000 h or 1 year at the latest | – | Carry out a visual inspection of visible flexible tubes for damage. In the case of damage and/or cracks, have the cable set exchanged by KUKA Service. | |
| 5,000 h or 1 year at the latest | 2 | Grease cable set A1 (See section 8.2 “Greasing cable set A1”, Page 164) | Lubricating grease Optitemp RB2, 200 cm³ |
| 5,000 h or 1 year at the latest | 1 | Exchange toothed belt A5 (See section 8.3 “Exchanging the toothed belt on A5”, Page 167) | |
| 20,000 h or 5 years at the latest | 4 | Oil change, gear unit A3 (See section 8.6 “Oil change in A3”, Page 185) | Optigear Synt. ALR 150, Initial filling quantity: 0.26 l |
| 20,000 h or 5 years at the latest | 3 | Oil change, gear unit A2 (See section 8.5 “Oil change in A2”, Page 181) | Optigear Synt. ALR 150, Initial filling quantity: 0.43 l |
| 20,000 h or 5 years at the latest | 5 | Oil change, gear unit A2 (See section 8.4 “Oil change in A2”, Page 173) | Optigear Synt. ALR 150, Initial filling quantity: 0.43 l |
Tightening of Connecting Bolts
The base of the robot and other parts are mainly connected by high-strength bolts. Since the overall structure belongs to a dynamic load connection, after a period of use, the bolts may inevitably loosen, which can affect the operational accuracy of the equipment and create safety hazards. The mounting frames of the vision system and welding torch are also prone to loosening, which may cause deviations in visual accuracy.
Solution method:
Check whether any bolts have fallen off or become loose. Use an electric wrench or a manual torque wrench (with preset torque value) to tighten the bolts to the specified torque value.
The following table provides the recommended pre-tightening torque settings for each bolt connection point of the smart workstation equipment.
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) installation | M4 | Small fly 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 | Small fly 1/4 1-6N.M | H2.5 | 1.2N.M |
| 4 | Robot base installation | M14 | Dafei 1/2 60-330N.M | H12 | 200N.M |
| 5 | Robot base installation | M16 | Dafei 1/2 60-330N.M | H14 | 200N.M |
Maintenance cycle: Tighten all bolts thoroughly every three months of use.
Maintenance of electrical systems such as distribution boxes and junction boxes
Workstations are equipped with numerous electrical devices, 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 normal equipment operation 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.
![Real Welding Expertise That Solves Real Problems]([{"73":"https:\/\/scontent-lax3-1.xx.fbcdn.net\/v\/t15.5256-10\/626109569_2796549544021430_5955185383492330472_n.jpg?stp=dst-jpg_s130x130_tt6&_nc_cat=108&ccb=1-7&_nc_sid=5fad0e&_nc_ohc=jnlq2B2mXCoQ7kNvwE4qx25&_nc_oc=Adk-JMpO4M3MXqFDsTqNNGP61pc589vKYoZYU9-D8CF_FRsF78MGdPquGjdLNxyfH4k&_nc_zt=23&_nc_ht=scontent-lax3-1.xx&edm=AKIiGfEEAAAA&_nc_gid=bveNqZgLYnmU78H7fT0ZJQ&_nc_tpa=Q5bMBQGpW3nuPIJ63rwublWKKePzr3W-R-evLMS4bsl9oXzQMEFiHbjTcpJxROU2-uoPHg6l_xdWvQ32QQ&oh=00_AfueYc32x6fAYN2hUCihOqPmce3HszGIlPZHkt6PcAfRUg&oe=69896FD5","407":"https:\/\/scontent-lax3-1.xx.fbcdn.net\/v\/t15.5256-10\/626109569_2796549544021430_5955185383492330472_n.jpg?_nc_cat=108&ccb=1-7&_nc_sid=5fad0e&_nc_ohc=jnlq2B2mXCoQ7kNvwE4qx25&_nc_oc=Adk-JMpO4M3MXqFDsTqNNGP61pc589vKYoZYU9-D8CF_FRsF78MGdPquGjdLNxyfH4k&_nc_zt=23&_nc_ht=scontent-lax3-1.xx&edm=AKIiGfEEAAAA&_nc_gid=bveNqZgLYnmU78H7fT0ZJQ&_nc_tpa=Q5bMBQE_UbUJAioTeLeaGz5YFLNwRzolLm5kiUV7BeyK0dpBgSUJAYd-ptN07J6HMnXvC64EuQAXGVYwBw&oh=00_AfvCVYjAuZ3RQHaf6INtglzd7xE1J6a7gVu95wn2R3cFAw&oe=69896FD5"}])
![Committed to making meaningful contributions to the field of intelligent welding.]([{"73":"https:\/\/scontent-lax3-1.xx.fbcdn.net\/v\/t15.5256-10\/625953028_1983522555917538_6973877136670326768_n.jpg?stp=dst-jpg_s130x130_tt6&_nc_cat=108&ccb=1-7&_nc_sid=5fad0e&_nc_ohc=B3sUiw1OUqEQ7kNvwFSRUhF&_nc_oc=AdmLUiDh_735TFUQmqBG7TbY8JQJOY1szUFFsojU6xrXuMdJN57UUvDcRBtRZJl-7D8&_nc_zt=23&_nc_ht=scontent-lax3-1.xx&edm=AKIiGfEEAAAA&_nc_gid=bveNqZgLYnmU78H7fT0ZJQ&_nc_tpa=Q5bMBQEHXYCkTapCSLcF_Fpa1aXzwybuIVmiOz14loui9qbcfiPoPoLG8MLc-uF5q8KktQh1F-DCOtrCkg&oh=00_Afs37aQcD6GfPoWe1LL17m6h35DBQFTJXYkIKxx4IzFfoA&oe=69896F6A","405":"https:\/\/scontent-lax3-1.xx.fbcdn.net\/v\/t15.5256-10\/625953028_1983522555917538_6973877136670326768_n.jpg?_nc_cat=108&ccb=1-7&_nc_sid=5fad0e&_nc_ohc=B3sUiw1OUqEQ7kNvwFSRUhF&_nc_oc=AdmLUiDh_735TFUQmqBG7TbY8JQJOY1szUFFsojU6xrXuMdJN57UUvDcRBtRZJl-7D8&_nc_zt=23&_nc_ht=scontent-lax3-1.xx&edm=AKIiGfEEAAAA&_nc_gid=bveNqZgLYnmU78H7fT0ZJQ&_nc_tpa=Q5bMBQGAyr6-kS3fwKfoPXRjwR_3pyxlqvux48cHkx-DK0ebc_xf5PdlB2rTyqSU_DzoZP-rQlT0r4WvEw&oh=00_AftD4I-iLRQjFR_mZdtQsnV_RM8Jo7sxQwH-IpWVIkxb0g&oe=69896F6A"}])
![Intelligent Assembly & Welding Work Island]([{"73":"https:\/\/scontent-lax3-2.xx.fbcdn.net\/v\/t15.5256-10\/626005470_1441542640913051_2836992346395485824_n.jpg?stp=dst-jpg_s130x130_tt6&_nc_cat=107&ccb=1-7&_nc_sid=5fad0e&_nc_ohc=ChMQZI1qmscQ7kNvwGXnRc0&_nc_oc=Admh_qWjVnw_cFQKgKfEdisFilGETPIgcwA5s3vfVBz_gz4X7FkwUWo0qZ6Au0iRWtA&_nc_zt=23&_nc_ht=scontent-lax3-2.xx&edm=AKIiGfEEAAAA&_nc_gid=bveNqZgLYnmU78H7fT0ZJQ&_nc_tpa=Q5bMBQHBg_PCoTmvFRTzNbfhhozxInXy87R4_6cmnM6tTx0kHMuvX3wUweeLCcoQ8QLvhtkKdXYE8Sw6Ag&oh=00_Afsw9_rH_6mfzxLexxBfK5fss7tkHZBqxf2UHQDsTb9u2g&oe=698996B5","405":"https:\/\/scontent-lax3-2.xx.fbcdn.net\/v\/t15.5256-10\/626005470_1441542640913051_2836992346395485824_n.jpg?_nc_cat=107&ccb=1-7&_nc_sid=5fad0e&_nc_ohc=ChMQZI1qmscQ7kNvwGXnRc0&_nc_oc=Admh_qWjVnw_cFQKgKfEdisFilGETPIgcwA5s3vfVBz_gz4X7FkwUWo0qZ6Au0iRWtA&_nc_zt=23&_nc_ht=scontent-lax3-2.xx&edm=AKIiGfEEAAAA&_nc_gid=bveNqZgLYnmU78H7fT0ZJQ&_nc_tpa=Q5bMBQHAP-tbhLIgqQRJA4owhJTDfOJuoVc8gMjdYTOzK1Z7-uHnxcn8Nfklb2dDaPTAOynT9pfAOZEsDA&oh=00_AfvEQYc2CBwZTe_mHQVWBZdZpiUJQMH0W6cUdujacHxSsQ&oe=698996B5"}])
![Sample Production in Progress with Intelligent Welding Robots]([{"130":"https:\/\/scontent-lax3-1.xx.fbcdn.net\/v\/t15.5256-10\/622741177_920944680510007_6479334267822552756_n.jpg?stp=dst-jpg_s130x130_tt6&_nc_cat=102&ccb=1-7&_nc_sid=5fad0e&_nc_ohc=3IoZKZgtTkYQ7kNvwGC0if-&_nc_oc=Adnt6n2jTrR1yomx2u-z_nDFF3d1HIEh_03-BYp9Owj2KS0Uzdj47LzvToiVVpNtm9I&_nc_zt=23&_nc_ht=scontent-lax3-1.xx&edm=AKIiGfEEAAAA&_nc_gid=bveNqZgLYnmU78H7fT0ZJQ&_nc_tpa=Q5bMBQE431kSp5tB_hf35VOtQYxMkon1jWS5VIc3g_PRvcm4Y7eJGXesaRYBhByTqZva8fAo9kQRax8ylA&oh=00_AfuR54d8B61AlcaPvp56hYo-O6R1oZJdzqKt6oLhjjoF8A&oe=69899CB9","720":"https:\/\/scontent-lax3-1.xx.fbcdn.net\/v\/t15.5256-10\/622741177_920944680510007_6479334267822552756_n.jpg?_nc_cat=102&ccb=1-7&_nc_sid=5fad0e&_nc_ohc=3IoZKZgtTkYQ7kNvwGC0if-&_nc_oc=Adnt6n2jTrR1yomx2u-z_nDFF3d1HIEh_03-BYp9Owj2KS0Uzdj47LzvToiVVpNtm9I&_nc_zt=23&_nc_ht=scontent-lax3-1.xx&edm=AKIiGfEEAAAA&_nc_gid=bveNqZgLYnmU78H7fT0ZJQ&_nc_tpa=Q5bMBQGn1xXhd7tCWIF8kqc_yy7FJPoYwl5oBkI0hNLFrAVjAwJRdsHH3W4QwRACYFQC_jig_wje2MRfbA&oh=00_Afs3KXl4RhAeE7vh7x7Lrr6aJAu2Dm2JiTeF76CJyDOvNQ&oe=69899CB9"}])