| Document Purpose For routine inspection and preliminary fault diagnosis of mechanical structures, joints, bases, columns, lifting points, tooling, and fasteners. | Intended Users On-site operators, team leaders, equipment maintenance personnel, and after-sales service personnel. |
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| Troubleshooting Principle Shut down and unload first, then inspect. Check the structure and connections before assessing wear, deformation, looseness, or interference. | Important Notice This guide provides general maintenance reference information. For equipment-specific requirements, refer to the product nameplate, contract configuration, and dedicated operation manual. |
Jiangsu Aurek Intelligent Technology Co., Ltd.
How to Use This Guide
| 01 Safety Instructions Shut down, unload the workpiece, and confirm that no unexpected movement can occur | 02 Troubleshooting Process Inspect the load, structure, joints, and tooling in sequence | 03 Quick Fault Reference Use the symptom to identify likely causes quickly | 04 Maintenance Intervals Inspect daily, weekly, monthly, and every six months |
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01Security prerequisites
| Non-Negotiable Safety Rules | If a mechanical abnormality occurs, stop operation first, unload or stabilize the workpiece, and lower the tooling to a safe position. Before servicing, dismantling, or adjusting load-bearing components, joints, tooling, lifting points, or end stops, shut off the air supply or electrical power. Only trained personnel may perform this work. It is strictly prohibited to remove tooling, pins, bolts, brakes, or load-bearing connections while a load is suspended. |
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If a structural component is cracked, a weld is abnormal, obvious deformation is present, a load-bearing bolt is loose, a lifting point is worn, or a brake has failed, remove the equipment from service immediately.
After an impact, overload, uncontrolled drop, or abnormal binding, further trial operation is not recommended. Conduct a complete inspection first.
Personnel must not stand beneath the workpiece, main arm, secondary arm, tooling, or lifting points during testing, troubleshooting, or maintenance.
02Mechanical troubleshooting process
Troubleshoot mechanical systems in the following order; do not begin by dismantling load-bearing components. If any abnormality is found in a load-bearing structure, stop operation and contact the manufacturer for assessment.
| Step | Inspection Focus | Description |
|---|---|---|
| 1 | Verify Load and Operating Conditions | Check for overload, eccentric loading, impact, forced pulling, or a change in workpiece dimensions. |
| 2 | Check Mounting and Supports | Check anchors, the baseplate, column, mobile base, and rail suspension components for looseness, cracking, or deformation. |
| 3 | Inspect Arms and Joints | Check the main arm, secondary arm, pins, retaining rings, bearings, bushings, and end stops for wear or interference. |
| 4 | Inspect Brakes and End Stops | Confirm that brakes hold reliably and that end stops, buffers, and stop blocks have not shifted or been damaged. |
| 5 | Inspect Tooling and Lifting Points | Check the tooling flange, quick-change mechanism, hook, sling, locating pin, and anti-drop features for secure and reliable operation. |
| 6 | Cross-Check the Pneumatic System | If no obvious mechanical abnormality is found, inspect the pushbuttons, valves, cylinders, and brake pneumatic circuit. |
03Common Mechanical Failures Cheat Sheet
The following is a general public-edition checklist for preliminary on-site assessment. Customers should not attempt repairs involving load-bearing structures, welds, lifting points, brakes, or joint wear.
A. Arms, Joints, and Brakes
| Symptom | Possible Causes | On-Site Checks and Corrective Action | Action Level |
|---|---|---|---|
| Main/Secondary Arm Is Difficult to Rotate or Binds | Joint bearing or bushing wear; deformed pin; debris in the joint; end-stop interference; air-tubing or cable tension. | After shutdown and unloading, inspect around the joint for debris, impact damage, or interference. Check pins, retaining rings, and bearing housings for looseness or deformation. If necessary, contact the manufacturer to replace bearings, bushings, or pins. | Correct within the specified period / Remove from service if severe |
| Vertical Motion Is Rough or Binds | Eccentric loading of the main-arm mechanism; increased joint friction; misaligned cylinder support or connection; tooling is too heavy or has an offset center of gravity. | Confirm that workpiece and tooling weights are within the design limits. Test vertical motion without a load. Inspect the cylinder support, force-arm support, and joint connections for misalignment or looseness. | Correct within the specified period |
| Noticeable Vibration or Oscillation at the Manipulator End | Loose anchor bolts; insecure column or baseplate; increased joint play; loose arm connection bolts; eccentric load. | Inspect anchor bolts, the baseplate, column, and arm connections. Check joint play and pin wear. If structural looseness or cracking is found, remove the equipment from service and contact the manufacturer. | Remove from service / Manufacturer assessment required |
| Inaccurate Positioning or Rotary Stop-Position Deviation | Loose or worn end stop; increased joint play; unstable brake locking; shifted rail or mobile-base position. | Reconfirm the pickup and placement positions. Check end stops, locating pins, and stop blocks for looseness, and verify brake holding performance. | Correct within the specified period |
| Joint Brake Binds or Fails to Hold | Worn brake pad/friction block; contaminated brake mechanism; binding brake linkage or pin; incorrect brake-position adjustment. | Determine whether the problem is mechanical binding or a pneumatic actuation failure. Remove oil contamination and dust; inspect connectors, pins, and springs. If the brake will not hold, remove the equipment from service immediately. | Remove from service / Manufacturer assessment required |
| End Stop or Stop Block Has Failed or Is Being Struck | Loose end stop; worn buffer; overtravel impact; limit position not recalibrated after installation. | Check whether end stops have shifted, deformed, or detached. Replace worn buffers, reconfirm limit positions, and prevent end stops from sustaining repeated impact. | Correct within the specified period |
B. Base, Fasteners, and Rails
| Symptom | Possible Causes | On-Site Checks and Corrective Action | Action Level |
|---|---|---|---|
| Column, Base, or Mobile Base Moves | Inadequate foundation; loose expansion anchors; deformed baseplate; insufficient mobile-base counterweight; caster lock failure. | Check the floor for voids or cracking; retighten anchor bolts; inspect the baseplate and welds. For mobile equipment, verify casters, leveling feet, and counterweights. | Remove from service / Manufacturer assessment required |
| Connection Bolts Loosen Frequently | Loss of preload due to vibration or impact; settlement of contact surfaces; thread damage; incorrect tightening torque; inadequate locking method. | After shutdown, inspect threads, washers, and contact surfaces. Retighten to the manufacturer's requirements. If necessary, use suitable lock washers, threadlocker, or a mechanical locking feature. | Correct within the specified period |
| Cracked Weld or Deformed Structural Component | Overload, eccentric loading, impact, or fatigue damage; repeated impact loading; on-site welding or cutting that compromises structural strength. | Stop immediately and unload the equipment. Do not field-weld a load-bearing structure. Photograph the crack location and extent of deformation, and contact the manufacturer for repair-or-replacement assessment. | Remove from service immediately |
| Bearing/Bushing Wear or Excessive Joint Play | Poor lubrication; ingress of dust or metal chips; prolonged eccentric loading; incorrect bearing installation; mismatch between actual load and selected capacity. | Check for looseness, abnormal noise, heat, or metallic debris at the joint. Verify dust protection and lubrication. Replace bearings, bushings, or pins if wear is severe. | Correct within the specified period / Manufacturer support |
| Abnormal Pin, Shaft, or Retaining Ring | Worn pin; retaining ring not fully seated or detached; enlarged bore; prolonged impact or eccentric loading; incorrect reassembly after service. | Shut down and inspect pin ends, retaining-ring grooves, retaining rings, and cotter pins. If a retaining ring has detached, a pin has migrated, or a bore is worn, remove the equipment from service. | Remove from service / Manufacturer assessment required |
| Overhead-/Rail-Mounted Unit Travels Roughly or Binds | Rails are not parallel; rollers are worn; rail joints have a step; suspension fittings are loose; debris has entered the rail. | Check rail level and alignment, joints, rollers, and suspension fittings. Remove debris from the rail. If a suspension connection is loose or the rail is deformed, remove the equipment from service. | Correct within the specified period / Remove from service |
C. Tooling, Lifting Points, and Moving Mechanisms
| Symptom | Possible Causes | On-Site Checks and Corrective Action | Action Level |
|---|---|---|---|
| Tooling Opening/Closing Binds or Encounters Mechanical Interference | Contaminated gripper-jaw guide; deformed gripper jaws; displaced locating pin; change in workpiece dimensions; tooling collides with equipment or a rack. | Clean tooling guides and contact surfaces. Check whether gripper jaws are parallel or deformed. Confirm workpiece dimensions and placement. Do not force deformed tooling to operate. | Correct within the specified period |
| Workpiece Is Skewed After Gripping or at Risk of Falling | Incorrect gripping-point selection; worn gripper-jaw pads; oil on the locating surface; offset workpiece center of gravity; anti-drop feature has failed. | Reconfirm the gripping point and center of gravity. Replace worn pads, remove oil contamination, and inspect the anti-drop pin, secondary restraint, and mechanical lock. | Remove from service immediately |
| Worn Hook, Lifting Point, Sling, or Rigging | Long-term wear, corrosion, or impact loading; side pulling or diagonal lifting; incorrect loading direction at the lifting point; damaged hook safety latch. | Inspect the hook for deformation, throat opening, cracks, chips, or corrosion. Check the pin and safety latch. If a clear defect is found, remove the component from service and replace it. | Remove from service immediately |
| Control Handle Is Loose or Pushbutton Enclosure Shakes | Loose control-handle connection bolts; worn mounting holes; repeated push/pull impacts; cable conduit or air tubing under tension. | Inspect the control-handle connection plate, bolts, mounting holes, and support. Improve air-tubing/cable-conduit retention, and do not use the control handle as a load-bearing lever. | Correct within the specified period |
| Mobile Base Is Difficult to Push or Tracks to One Side | Caster binding; uneven floor; debris in caster bearings; brakes not fully released; offset center of gravity of the base. | Clean the casters and remove floor debris. Inspect caster bearings, brake pedals, and locks. Move slowly on a level surface. | Observe / Correct |
| Abnormal Noise, Friction, or Metallic Impact | Dry-running joint; damaged bearing; loose bolt; impact at an end stop; cracked or deformed structural component. | Inspect by section to locate the sound source. Run unloaded at low speed to identify the abnormal location. Continued operation is not recommended when a distinct metallic impact is present. | Correct within the specified period / Remove from service |
| Equipment Operates Abnormally After an Impact | Bent arm; damaged joint; shifted end stop; deformed tooling; impacted leveling feet or base. | Remove the equipment from service immediately and inspect the complete unit. Recheck arm straightness, welds, joint clearances, tooling positioning, end stops, and the base. | Remove from service immediately |
04Key inspection areas
| Inspection Location | Critical Inspection Items | Recommended Action |
|---|---|---|
| Fixed Baseplate / Anchors | Anchor bolts, baseplate deformation, floor cracking, and contact between the baseplate and floor | If looseness, cracking, or obvious movement is found, remove the equipment from service to prevent overturning or displacement. |
| Column / Main Support | Column verticality, welds, connection plates, flanges, and supports | Check for tilt, deformation, failed welds, corrosion, or abnormal movement. |
| Main Arm / Secondary Arm | Arm straightness, connection bolts, welds, end stops, and surface impact marks | The arms carry the principal bending moment. Do not continue operation if deformation or cracking is present. |
| Rotary Joint / Pin | Smoothness of rotation, play, abnormal noise, retaining rings, bearing housing, and snap rings | Inspect if there is looseness, abnormal noise, binding, or pin migration. |
| Brake Device | Brake pads/friction blocks, springs, connection pins, brake cylinder, or linkage | An unreliable brake can allow the load to slip; correct this condition as a priority. |
| Tooling Connection Flange | Flange bolts, locating pins, mating surfaces, and tooling quick-change mechanism | Loose tooling connections directly compromise workpiece safety and require periodic retightening and inspection. |
| Lifting Points / Hooks / Rigging | Deformed lifting points, hook safety latch, pins, sling wear, and broken wire-rope strands | Do not continue using components with obvious damage, chips, deformation, or corrosion. |
| Control Handle | Control-handle support, pushbutton enclosure mounting, connection bolts, and air-tubing/cable retention | Prevent a loose control handle from causing unintended operation or line wear. |
05Maintenance cycle recommendations
| Recommended Interval | Maintenance Item |
|---|---|
| Daily / Every Shift | Check the area around the equipment for obstructions. Inspect the arms, tooling, lifting points, and base for obvious damage. Confirm smooth motion without abnormal noise. |
| Weekly | Inspect load-bearing bolts, anchor bolts, pins, retaining rings, end stops, and tooling connections. Check the brake mechanism, lifting points, hooks, and control handle. |
| Monthly | Inspect rotary-joint play, bearing/bushing wear, arm welds, and base/column connections. Inspect tooling guides, pads, and anti-drop features. |
| Every 6 Months | Conduct a complete inspection of load-bearing structures, joints, lifting points, mobile bases, and rail suspension components. Replace wear parts as necessary. |
| After an Impact/Overload | Stop immediately for inspection; do not wait for the next scheduled interval. Recheck arm deformation, welds, joints, tooling, end stops, and the base. |
06Boundary between customer self-inspection and manufacturer processing
| Checks the Customer May Perform • Check for overload, eccentric loading, or a change in workpiece placement. • Check the base, column, control handle, and tooling for obvious looseness or interference. • Check around joints for debris, tension on lines, or impact against end stops. • Check tooling pads, guides, hook safety latches, casters, and rails for obvious damage. | Contact the Manufacturer for Service When • A weld is cracked, an arm is deformed, the base moves, or an anchor is loose and cannot be retightened. • A load-bearing pin, bearing, bushing, lifting point, hook, or quick-change mechanism is visibly worn. • A brake has failed, a joint slips abnormally, the equipment has sustained an impact, or overload is suspected. • The tooling cannot grip or release reliably, creating a drop hazard. • The installation configuration must be changed, an arm lengthened, the tooling replaced, or the load-bearing structure modified. |
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07Information description
This guide covers common mechanical structures and daily inspection items for Pneumatic Industrial Manipulators, rigid-arm manipulators, Pneumatic Balancers, Articulating Jib Cranes, and custom tooling. It is intended for Resource Center downloads, customer training, and after-sales communication.
Inspection priorities may vary with operating conditions, tooling, and installation configuration. The equipment nameplate, contract configuration, site-specific solution, and manufacturer's technical requirements take precedence.
| Document Name | Common Mechanical-System Faults and Corrective Actions | File Version | V1.0 |
|---|---|---|---|
| Applicable Products | Pneumatic Industrial Manipulator / Pneumatic Balancer / Custom Tooling | Document Type | Maintenance and Troubleshooting |
| Issued By | Jiangsu Aurek Intelligent Technology Co., Ltd. | Official Website | www.aurek.cn |