It’s 2026—the start of a new year! As you ease back into your standard work routine and ramp up production, don’t skip these five critical maintenance checks before hitting ‘Start’ on your HMI screen. A little preventative maintenance now can save you from costly downtime later.
1. Air Supply
Start with your compressed air supply. While shutting off compressed air before closing shop is standard practice, moisture can build up in the air lines when the system is powered back on. This moisture creates critical issues in your coating delivery system—hurting paint performance—and can get into robot motors, leading to system failure. Over time, moisture also causes corrosion and rust, damaging both parts and finish quality.
2. Encoder and CPU Batteries
Battery power is critical for keeping robot controller function and mastering data. Neglecting battery replacement means risking controller failure and losing mastering. We recommend annual battery replacement—check your robot controller unit’s maintenance sticker for service dates.
Encoder Batteries can be replaced while the robot controller unit is powered on. The process is simple, but proper procedure is key.
CPU Batteries require more care due to their location and connectors. Carefully unlatch and disconnect the old battery before installing the new one. If the battery is poorly connected or disconnected for too long, you may experience memory backup interruption or loss.
3. Mastering
Your loaded paths depend on proper mastering to function correctly. Accurate coating application requires the robot to maintain its true zero position across all axes. Use the teach pendant and witness marks on each joint to jog the robot to its zero position, then save these positions.
Before mastering, verify that both the robot and its rail system are in their zero positions. The rail system reaches zero when aligned with the mastering hole location.
4. Connections—Cables, Hoses, and Wires
Connections degrade with repeated use. Have your robot operator and a second technician carefully inspect all exposed cables, hoses, and wires. Look for:
- Cracks or abrasions
- Faded color (indicates thinning or UV damage)
- Loose or corroded connections
- Shortened or stretched connections
Catching these issues early prevents loss of pulse, power, and encoder functions—failures that can halt production.
5. Grease
Smooth operation depends on properly lubricated joints and linear axes. We recommend greasing your gear rack, felt pinion, and bearing trucks every three months. Refer to your equipment manual for proper greasing procedures, torque specifications, and recommended lubricants. Regular lubrication prevents premature wear and ensures consistent robot movement throughout its operational life.
Start 2026 Right
These five maintenance checks take minimal time but deliver maximum protection against unexpected downtime. Build them into your post-holiday restart routine, and your robotic paint system will reward you with reliable performance all year long.
